Afag CR 16-D Quick reference guide

Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0 1–55
Assembly & Operating Instructions
Compact Rotary Modules
CR 16-D ICR 16-ZA-D
CR 20-D ICR 20-ZA-D
Translation of the Original Assembly Instructions EN
◼CR 16-D Order no.: 50433054
◼CR 16-ZA-D Order no.: 50433057
◼CR 20-D Order no.: 50433055
◼CR 20-ZA-D Order no.: 50433058

2 –55 Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0
Dear Customer,
Thank you for choosing our products and placing your trust and confidence in
our company!
These assembly and operating instructions contain all essential information you
need about your product. Our aim is to provide the required information as
concisely and clearly as possible. If, however, you still have any questions on
the contents or suggestions, please do not hesitate to contact us. We are always
grateful for any feedback.
Our team will also be glad to answer any further question you may have
regarding the rotary module or other options.
We wish you every success with our products!
With kind regards
Your Afag team
© Subject to modifications
The rotary modules have been designed by Afag Automation AG according to
the state of the art. Due to the constant technical development and improvement
of our products, we reserve the right to make technical changes at any time.
Updates of our documentations
Unlike the printed documents, our digital instructions manuals, product data
sheets and catalogues are being continuously updated on our website.
Please keep in mind that the digital documents on our website are always the
latest versions.
© Copyright 2021 Afag Automation AG
All contents of the present assembly and operating instructions, in particular the
texts, photographs and graphics, are protected by copyright. All rights reserved.
No part of these assembly and operating instructions may be reproduced,
distributed (made available to third parties), or transmitted in any form or by any
means, including photocopying, recording, or other electronic or mechanical
methods, without the prior written permission of Afag Automation AG.
Afag Automation AG
Luzernstrasse 32
CH-6144 Zell (Switzerland)
Tel.: [phone]
e-mail: [email protected]
Internet: www.afag.com

Table of contents
Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0 3–55
Table of contents
1General....................................................................................................................6
1.1 Contents and purpose of these assembly instructions.................................6
1.2 Explanation of symbols.................................................................................6
1.3 Additional symbols........................................................................................7
1.4 Applicable documents ..................................................................................8
1.5 Warranty.......................................................................................................8
1.6 Liability..........................................................................................................8
2Safety instructions.................................................................................................9
2.1 General.........................................................................................................9
2.2 Intended use.................................................................................................9
2.3 Foreseeable misuse...................................................................................10
2.4 Obligations of the operator and the personnel...........................................10
2.4.1 Observe the assembly instructions......................................................10
2.4.2 Obligations of the operating company..................................................11
2.4.3 Obligations of the personnel ................................................................11
2.5 Personnel requirements .............................................................................12
2.5.1 Personnel qualification.........................................................................12
2.6 Personal protective equipment (PPE)........................................................13
2.7 Changes and modifications........................................................................13
2.8 General hazards / Residual Risks..............................................................14
2.8.1 General hazards at the workplace .......................................................14
2.8.2 Danger due to electricity ......................................................................15
2.8.3 Mechanical hazards .............................................................................16
2.8.4Danger due to pneumatics...................................................................16
2.8.5 Danger caused by omitting maintenance work....................................16
3Technical data ......................................................................................................17
3.1 Rotary module CR 16-D.............................................................................17
3.1.1 Dimensional drawing CR 16-D.............................................................17
3.1.2 Technical data CR 16-D.......................................................................18
3.1.1 Preferred combinations CR 16-D.........................................................19
3.1.2 Module loads CR 16-D.........................................................................20
3.1.3 Load diagrams CR 16-D ......................................................................21
3.2 Rotary module CR 20-D.............................................................................22
3.2.1 Dimensional drawing CR 20-D.............................................................22
3.2.2 Technical data CR 20-D.......................................................................23
3.2.3 Preferred combinations CR 20-D.........................................................24
3.2.4 Module loads CR 20-D.........................................................................25
3.2.5 Load diagrams CR 20-D ......................................................................26
4Transport, Packaging and Storage ....................................................................27
4.1 Safety instructions for transport..................................................................27

4 –55 Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0
4.2 Scope of supply..........................................................................................27
4.3 Transport ....................................................................................................28
4.4 Packaging...................................................................................................28
4.5 Storage.......................................................................................................29
5Structure and description ...................................................................................30
5.1 Construction rotary modules ......................................................................30
5.2 Product description.....................................................................................30
5.3 Accessories ................................................................................................31
5.3.1 Accessories CR 16-D, CR 20-D...........................................................31
5.3.2 Other accessories CR 16-D, CR 20-D.................................................32
5.4 Fields of application....................................................................................32
6Installation, assembly & setting .........................................................................34
6.1 Safety instructions for installation & assembly...........................................34
6.2 Installation and assembly...........................................................................35
6.2.1 Assembly and attachment....................................................................35
6.2.2 Tightening torques for screws..............................................................36
6.2.3 Connection to the pneumatic system...................................................36
6.2.4 Assembling, monitoring, replacement of the sensors..........................38
6.3 Settings.......................................................................................................40
6.3.1 Safety notes for settings.......................................................................40
6.3.2 Adjusting the angle of rotation..............................................................41
6.3.3 Setting of the end positions..................................................................42
6.3.4 Setting of the end position damping.....................................................42
6.3.5 Adjusting the shock absorber...............................................................43
6.3.6 Setting of intermediate positions..........................................................44
6.3.7 Approaching the intermediate positions...............................................45
7Commissioning ....................................................................................................46
7.1 Safety instructions for commissioning........................................................46
7.2 Commissioning of the modules ..................................................................46
8Fault elimination...................................................................................................47
8.1 General notes.............................................................................................47
8.2 Safety instructions for troubleshooting .......................................................47
8.3 Table Fault causes and remedy.................................................................47
8.3.1 Troubleshooting table...........................................................................47
9Maintenance and repair.......................................................................................48
9.1 General notes.............................................................................................48
9.2 Safety instructions for maintenance and repair..........................................48
9.3 Maintenance activities and maintenance intervals.....................................49
9.3.1 Overview of the maintenance points....................................................49
9.3.2 Compressed air specifications .............................................................50
9.3.3 Further maintenance............................................................................51
9.4 Spare parts and repair work.......................................................................51

Table of contents
Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0 5–55
10 Decommissioning, disassembly, disposal........................................................52
10.1 Safety instructions for decommissioning, disassembling and disposal......52
10.2 Decommissioning .......................................................................................52
10.3 Disassembly ...............................................................................................52
10.4 Disposal......................................................................................................53
11 Declaration of incorporation...............................................................................54

General
6 –55 Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0
1 General
1.1 Contents and purpose of these assembly instructions
These assembly instructions contain important information on assembly,
commissioning, functioning and maintenance of the rotary modules CR 16-D,
CR 16-ZA-D, CR 20-D, CR 20-ZA-D to ensure safe and efficient handling and
operation.
Consistent compliance with these assembly instructions will ensure:
▪permanent operational reliability of the rotary module,
▪optimal functioning of the rotary module,
▪timely detection and elimination of defects (thereby reducing maintenance
and repair costs),
▪prolongation of the rotary module service life.
The illustrations in this manual shall provide you with a basic understanding of
the module and may vary from the actual design of your module.
1.2 Explanation of symbols
The safety notes are marked by a pictogram and a signal word. The safety notes
describe the extent of the hazard.
DANGER
Danger!
This safety note indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
Warning!
This safety note points out a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Caution!
This safety note points out a potentially dangerous situation which, if not
avoided, can result in minor or slight injuries.
NOTICE
This safety note points out a potentially dangerous situation which, if not
avoided, can cause substantial damage to property and the environment.

General
Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0 7–55
This note contains important additional information as well as useful tips for
safe, efficient and trouble-free operation of the module.
Further warning signs:
Where applicable, the following standardised symbols are used in this manual
to point out the various potential health risks.
Warning - Dangerous electrical voltage.
Warning - Risk of injury from contact with hot surfaces.
Warning - Risk of hand and finger injury due to uncontrolled
movements of components.
Warning - Magnetic field.
Warning - back injury due to heavy lifting.
Warning - Risk of injury as a result of parts being flung out!
Warning - high noise levels.
1.3 Additional symbols
In these assembly instructions the following symbols are used to highlight
instructions, results, references, etc.
Symbol
Description
1.
Instructions (steps ...)

Results of actions

References to sections
◼
Enumerations not ordered

General
8 –55 Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0
1.4 Applicable documents
In addition to the assembly instructions, the following documents must be
observed:
▪Safety data sheets etc.
▪Instructions for integrated components (supplier documentation)
Each rotary module is accompanied by a safety information sheet. This
information sheet must be read carefully by every person who carries out work
on and with the rotary module.
1.5 Warranty
The warranty terms for Afag handling components and handling systems are
the following:
▪24 months from initial operation and up to a maximum of 27 months from
delivery.
▪Wear parts (e.g. shock absorbers) are excluded from the warranty.*
The warranty covers the replacement or repair of defective Afag parts. Further
claims are excluded.
* However, a customer has a right to a defect-free product. This does also
apply to defective accessories and wear parts. Normal wear and tear is
excluded from the warranty.
The warranty shall expire in the following cases:
▪Improper use of the module
▪Non-observance of the instructions regarding assembly, commissioning,
operation and maintenance of the module
▪Improper assembly, commissioning, operation and maintenance
▪Repairs and design changes carried out without prior technical instructions
of Afag Automation AG
▪Removing the serial number from the product
▪Using the module without shock absorbers or with defective shock absorbers
▪Inadequate checking of wear parts
▪Non-observance of the EC Machinery Directive, the Accident Prevention
Regulations, the Standards of the German Electrotechnology Association
(VDE) and these safety and assembly instructions
1.6 Liability
No changes shall be made to the rotary modules CR 16-D, CR 16-ZA-D, CR 20-
D, CR 20-ZA-D unless described in this instructions manual or approved in
writing by Afag Automation AG.
Afag Automation AG accepts no liability for unauthorized changes or improper
assembly, installation, commissioning, operation, maintenance or repair work.

Safety instructions
Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0 9–55
2 Safety instructions
2.1 General
This chapter provides an overview of all important safety aspects to ensure safe
and proper use of the rotary module and optimal protection of personnel.
Failure to follow the directions and safety instructions given in this instructions
manual may result in serious hazards.
2.2 Intended use
The CR 16-D, CR 16-ZA-D, CR 20-D, CR 20-ZA-D rotary modules are used for
shock-free gripping/rotating of loads in non-hazardous atmospheres under the
ambient and operating conditions defined for these modules.
The rotary modules are designed exclusively for gripping payloads that do not
pose any danger to persons, property or the environment during manipulation.
In combination with other modules the rotary modules can be used as a pick &
place Station.
In the chemical industry and in potentially explosive areas, the use of rotary
modules is not permitted without additional safety measures. In such cases,
please consult with the Afag technical department.
The intended use of the module also includes:
▪observance of all instructions given in this instructions manual,
▪compliance with the inspection and maintenance work and the
specifications in the data sheets,
▪using only original spare parts.

Safety instructions
10 –55 Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0
2.3 Foreseeable misuse
Any use other than or beyond the intended use described above is considered
a misuse of the rotary module.
Especially the following use is considered a misuse:
▪Use in potentially explosive atmospheres
Risks can occur if the module is not used as intended. In the event of
damages caused by improper use the following shall apply:
▪the operating company shall be solely responsible for such damage, and
▪Afag does not accept any liability for damages caused by improper use.
2.4 Obligations of the operator and the personnel
2.4.1 Observe the assembly instructions
A basic prerequisite for safe and proper handling of the rotary modules is a good
knowledge of the basic safety instructions.
These assembly instructions, in particular the safety instructions contained
therein, must be observed by all persons working with the rotary modules.
WARNING
Risk of injury if the module is not used as intended!
The improper use of the rotary modules poses a potential hazard to the
personnel.
▪The rotary module may only be used in a technically perfect condition in
accordance with its intended use and the instructions in this manual and in
compliance with the safety requirements!
▪Any malfunctions, particularly those that could impair safety, must be
eliminated immediately!

Safety instructions
Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0 11–55
2.4.2 Obligations of the operating company
In addition to the safety instructions given in this manual, the operating company
must comply with the safety, accident prevention and environmental protection
regulations valid for the field of application of the rotary modules.
The operating company is required to use only personnel who:
▪have the necessary professional qualifications and experience,
▪are familiar with the basic rules regarding occupational safety and accident
prevention,
▪have been instructed in the correct handling of the rotary modules,
▪have read and understood these assembly instructions.
The operating company is also required to:
▪monitor on an ongoing basis that the personnel work safely considering any
potential hazard involved and the assembly instructions are observed,
▪ensure that the assembly instructions are always kept at hand at the
installation in which the modules are mounted,
▪observe and communicate universally applicable laws and regulations
regarding accident prevention and environmental protection,
▪provide the necessary personal protective equipment (e.g. protective gloves)
and instruct the personnel to wear it
▪update the related safety data sheets.
2.4.3 Obligations of the personnel
All personnel working with the rotary modules are required to:
▪read and observe these assembly instructions, especially the chapter on
safety,
▪observe the occupational safety and accident prevention regulations,
▪observe all safety and warning signs on the rotary modules,
▪refrain from any activity that might compromise safety and health.
In addition, the personnel must wear the personal protective equipment
required for carrying out their work. (Chapter 0).

Safety instructions
12 –55 Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0
2.5 Personnel requirements
2.5.1 Personnel qualification
The activities described in the assembly instructions require specific requisites
at the level of professional qualifications of the personnel.
Personnel not having the required qualification will not be able to asses the risks
that may arise from the use of the rotary modules thus exposing himself and
others to the risk of serious injury. Therefore, only qualified personnel may be
permitted to carry out the described activities on the rotary modules.
Persons whose ability to react is restricted due to the intake of medication or the
like must not interact with the rotary modules.
These installation instructions are intended for skilled personnel (installers,
system integrators, maintenance personnel, technicians), electricians and
operating personnel.
The following is a description of the professional skills (qualifications) required
for carrying out the different activities:
Qualified personnel:
Qualified personnel with appropriate training who are qualified due to their
special know-how and fully familiar with the machine and who have been given
instructions on how to carry out the task entrusted to them safely.
Qualified electrician:
Persons who have obtained their electrical qualifications through appropriate
professional training and complementary courses that enables them to identify
risks and prevent possible hazards resulting from electricity.
Operator (trained personnel):
Authorized persons who due to their specialized professional training,
expertise and experience are capable of identifying risks and preventing
possible hazards arising from the use of the machine.

Safety instructions
Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0 13–55
2.6 Personal protective equipment (PPE)
The personal protective equipment serves to protect the personnel from hazards
affecting their safety and health at work.
When working on/with the rotary modules, the personnel must wear the
personal protective equipment assigned by the safety officer of the operating
company or as required by safety regulations. In addition, the personnel is
required to:
▪wear the personal protective equipment provided by the operating company
(employer),
▪check the personal protective equipment for proper condition, and
▪immediately notify the person responsible on site of any defects found on the
personal protective equipment.
Personal protective equipment and the respective mandatory signs:
Protective clothing is a close-fitting clothing specifically
designed to protect personnel from hazards during work.
Protective gloves are specifically designed to protect the
personnel against hand injuries (such as cuts, abrasion,
burns).
Safety shoes are specifically designed to protect the
personnel against foot injuries from crushing, falling objects or
slipping on slippery surfaces.
Hearing protectors are required to protect the personnel
against excessive noise levels to prevent noise-induced
hearing loss.
2.7 Changes and modifications
No changes may be made to the rotary modules which have not been described
in these assembly instructions or approved in writing by Afag Automation AG.
Afag Automation AG accepts no liability for unauthorised changes or improper
assembly, installation, commissioning, maintenance or repair work.
The rotary modules may not be changed or modified in any way, except with
the prior written consent of Afag Automation AG.

Safety instructions
14 –55 Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0
2.8 General hazards / Residual Risks
Despite the safe design of the machine and the technical protective measures
taken, there still remain residual risks that cannot be avoided, and which present
a non-obvious residual risk when operating the rotary modules.
Observe the safety instructions in this chapter and in the other sections of this
manual to avoid damage to property and dangerous situations for the personnel,
.
2.8.1 General hazards at the workplace
The rotary module has been built according to the state-of-the-art and the
applicable health and safety requirements. However, improper use of the rotary
modules may cause the following hazards to the personnel:
▪danger to life and limb of the operator or third parties,
▪on the rotation modules themselves,
▪Property damage.
Always keep the assembly instructions ready at hand at the workplace!
Please, also observe:
▪the general and local regulations on accident prevention and environmental
protection.
▪the safety information sheet for the rotary modules.
WARNING
Danger - Do not use in unsuitable environment!
The rotary modules are designed for use in non explosive atmospheres.
▪Do not use the rotary modules in potentially explosive atmospheres!
CAUTION
Danger of injury in the working area of the rotary modules!
Due to the decentralised control system, the operator of the rotary modules
must not necessarily stand next to the rotary modules during operation so
that he may not have a complete view of the working area. Persons in the
working area may be injured.
▪When operating the rotary modules, ensure a good overview of the entire
working area.
▪Unauthorized persons must not stay within the working area during
operation.

Safety instructions
Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0 15–55
2.8.2 Danger due to electricity
CAUTION
Risk of injuries due to uncontrolled parts movements!
When operating the rotary modules uncontrolled movements may occur
which can cause personal injury or property damage.
▪Only qualified personnel may work with or on the rotary modules.
▪Read the assembly instructions carefully before carrying out any work on
or with the rotary modules.
CAUTION
Risk of noise-induced hearing loss!
When the rotary modules are installed in a machine or plant, the permissible
noise level may be exceeded depending on the various components, the
environment and the resonance.
▪The operating company is responsible for ensuring that the permissible
noise levels are observed.
▪If the noise level exceeds 85 dB(A) in normal operation, the operator must
wear hearing protectors at the workplace.
WARNING
Danger! Risk of electric shock!
If work on electrical components is required, ensure that the work is carried
out properly, failure to do so will cause serious or fatal injuries.
▪Work on the machine's electrical equipment may only be performed by
skilled electrician or trained personnel under the supervision of a skilled
electrician in accordance with all relevant electrical regulations.

Safety instructions
16 –55 Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0
2.8.3 Mechanical hazards
2.8.4 Danger due to pneumatics
2.8.5 Danger caused by omitting maintenance work
CAUTION
Danger of injury by moving components!
Limbs can be crushed by moving components!
▪Work on and with the rotary modules may only be carried out by qualified
personnel.
WARNING
Risk of injury - Do not reach into the system during operation!
There is a risk of injury if the personnel reach into the system during normal
operation.
▪Never reach into the system during normal operation!
WARNING
Risks by the pneumatic system!
The pneumatic system can pose various hazards that can cause serious or
fatal injuries if the work is carried out improperly.
▪Only qualified personnel may work with or on the pneumatic system!
▪The necessary personal protective equipment must be provided and used.
CAUTION
Danger of injury!
Poor or not regularly performed maintenance work may cause malfunction of
the components which may result in injuries.
▪The due diligence obligations of the operating company include ensuring
that the personnel carrying out maintenance work is appropriately trained
and qualified.

Technical data
Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0 17–55
3 Technical data
3.1 Rotary module CR 16-D
3.1.1 Dimensional drawing CR 16-D
Fig. 1 Dimensional drawing - Rotary module CR 16-D

Technical data
18 –55 Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0
3.1.2 Technical data CR 16-D
Fig. 2 Table technical data CR 16-D
* In the end position, only half the torque is achieved, since in this position the
pressure is exerted by one piston only (  chapter 0 ).

Technical data
Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0 19–55
3.1.1 Preferred combinations CR 16-D

Technical data
20 –55 Assembly instructions EN ◼CR 16-D I CR 20-D ◼10.05.2023 ◼V4.0
3.1.2 Module loads CR 16-D
Fig. 3 Table module loads CR 16-D