Afag EPS mini YZ User manual

Assembly instructions DE EPS Handling systems Date 08.09.2021 Version 2.0 1–112
Assembly and operating instructions
EPS Handling Systems (electrical)
EPS mini YZ EPS midi YZ EPS maxi YZ EPS giga YZ EPS tera YZ
EPS mini XZ EPS midi XZ EPS maxi XZ
EPS mini XYZ EPS midi XYZ EPS maxi XYZ
EPS mini gantry XXYZ EPS midi gantry XXYZ EPS maxi gantry XXYZ
EPS mini gantry s EPS midi gantry s EPS maxi gantry s
EPS mini gantry h EPS midi gantry h EPS maxi gantry h
Translation of the Original Assembly Instructions EN

2 – 112 Assembly instructions EN EPS Handling systems Date 08.09.2021 Version 2.0
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 EPS handling system or other options.
We wish you every success with our products!
With kind regards
Your Afag team
© Subject to modifications
The EPS handling systems have been designed by Afag 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 Fa. Afag
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.
Afag Engineering GmbH
Gewerbestraße 11
D-78739 Hardt (Germany)
Tel.: [phone]
e-mail: [email protected]
Internet: www.afag.com

Table of contents
Assembly instructions DE EPS Handling systems Date 08.09.2021 Version 2.0 3–112
Table of contents
1General.................................................................................................................... 7
1.1 Contents and purpose of these assembly instructions................................. 7
1.2 Explanation of symbols................................................................................. 7
1.3 Additional symbols........................................................................................ 8
1.4 Applicable documents .................................................................................. 9
1.5 Warranty ....................................................................................................... 9
1.6 Liability.......................................................................................................... 9
2Safety instructions............................................................................................... 10
2.1 General....................................................................................................... 10
2.2 Intended use............................................................................................... 10
2.3 Foreseeable misuse ................................................................................... 10
2.4 Obligations of the operator and the personnel ........................................... 11
2.4.1 Observe the assembly instructions ...................................................... 11
2.4.2 Obligations of the operating company.................................................. 11
2.4.3 Obligations of the personnel ................................................................ 12
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 ...................................................................... 14
2.8.3 Danger due to strong magnetic fields .................................................. 15
2.8.4 Danger due to pneumatics................................................................... 15
2.8.5 Danger due to high temperatures ........................................................ 15
2.8.6 Mechanical hazards ............................................................................. 15
3Technical data ...................................................................................................... 16
3.1 EPS System mini YZ .................................................................................. 16
3.1.1 Dimensioned drawing EPS mini YZ ..................................................... 16
3.1.2 Technical data EPS mini YZ ................................................................ 17
3.1.3 Module loads EPS mini YZ .................................................................. 18
3.2 EPS System midi YZ .................................................................................. 19
3.2.1 Dimensioned drawing EPS midi YZ ..................................................... 19
3.2.2 Technical data EPS midi YZ ................................................................ 20
3.2.3 Module loads EPS midi YZ .................................................................. 21
3.3 EPS System maxi YZ ................................................................................. 22
3.3.1 Dimensioned drawing EPS maxi YZ .................................................... 22
3.3.2 Technical data EPS maxi YZ ............................................................... 23
3.3.3 Module loads EPS maxi YZ ................................................................. 24
3.4 EPS System giga YZ .................................................................................. 25
3.4.1 Dimensioned drawing EPS giga YZ..................................................... 25

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4 – 112 Assembly instructions EN EPS Handling systems Date 08.09.2021 Version 2.0
3.4.2 Technical data EPS giga YZ ................................................................ 26
3.4.3 Module loads EPS giga YZ .................................................................. 27
3.5 EPS System tera YZ................................................................................... 28
3.5.1 Dimensioned drawing EPS tera YZ...................................................... 28
3.5.2 Technical data EPS tera YZ................................................................. 29
3.5.3 Module loads EPS tera YZ................................................................... 30
3.6 EPS System mini XZ .................................................................................. 31
3.6.1 Dimensioned drawing EPS mini XZ ..................................................... 31
3.6.2 Technical data EPS mini XZ ................................................................ 32
3.6.3 Module loads EPS mini XZ .................................................................. 33
3.7 EPS System midi XZ .................................................................................. 34
3.7.1 Dimensioned drawing EPS midi XZ ..................................................... 34
3.7.2 Technical data EPS midi XZ ................................................................ 35
3.7.3 Module loads EPS midi XZ .................................................................. 36
3.8 EPS System maxi XZ ................................................................................. 37
3.8.1 Dimensioned drawing EPS maxi XZ .................................................... 37
3.8.2 Technical data EPS maxi XZ ............................................................... 38
3.8.3 Module loads EPS maxi XZ ................................................................. 39
3.9 EPS System mini XYZ................................................................................ 40
3.9.1 Dimensioned drawing EPS mini XYZ................................................... 40
3.9.2 Technical data EPS mini XYZ .............................................................. 41
3.9.3 Module loads EPS mini XYZ ................................................................ 42
3.10 EPS System midi XYZ................................................................................ 43
3.10.1 Dimensioned drawing EPS midi XYZ................................................... 43
3.10.2 Technical data EPS midi XYZ .............................................................. 44
3.10.3 Module loads EPS midi XYZ ................................................................ 45
3.11 EPS System maxi XYZ............................................................................... 46
3.11.1 Dimensioned drawing EPS maxi XYZ.................................................. 46
3.11.2 Technical data EPS maxi XYZ ............................................................. 47
3.11.3 Module loads EPS maxi XYZ ............................................................... 48
3.12 EPS mini gantry XXYZ ............................................................................... 49
3.12.1 Dimensioned drawing EPS mini gantry XXYZ ..................................... 49
3.12.2 Technical data EPS mini gantry XXYZ................................................. 50
3.12.3 Module loads EPS mini gantry XXYZ................................................... 51
3.13 EPS midi gantry XXYZ ............................................................................... 52
3.13.1 Dimensioned drawing EPS midi gantry XXYZ ..................................... 52
3.13.2 Technical data EPS midi gantry XXYZ................................................. 53
3.13.3 Module loads EPS midi gantry XXYZ................................................... 54
3.14 EPS maxy gantry XXYZ ............................................................................. 55
3.14.1 Dimensioned drawing EPS maxi gantry XXYZ .................................... 55
3.14.2 Technical data EPS maxi XYZ ............................................................. 56
3.14.3 Module loads EPS maxi gantry XXYZ.................................................. 57
3.15 EPS mini gantry s ....................................................................................... 58
3.15.1 Dimensioned drawing EPS mini gantry s............................................. 58

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Assembly instructions DE EPS Handling systems Date 08.09.2021 Version 2.0 5–112
3.15.2 Technical data EPS mini gantry s ........................................................ 59
3.15.3 Module loads EPS mini gantry s .......................................................... 60
3.16 EPS midi gantry s ....................................................................................... 61
3.16.1 Dimensioned drawing EPS midi gantry s............................................. 61
3.16.2 Technical data EPS midi gantry s ........................................................ 62
3.16.3 Module loads EPS midi gantry s .......................................................... 63
3.17 EPS maxi gantry s ...................................................................................... 64
3.17.1 Dimensioned drawing EPS maxi gantry s............................................ 64
3.17.2 Technical data EPS maxi gantry s ....................................................... 65
3.17.3 Module loads EPS maxi gantry s ......................................................... 66
3.18 EPS mini gantry h....................................................................................... 67
3.18.1 Dimensioned drawing EPS mini gantry h............................................. 67
3.18.2 Technical data EPS mini gantry h........................................................ 68
3.18.3 Module loads EPS mini gantry h .......................................................... 69
3.19 EPS midi gantry h....................................................................................... 70
3.19.1 Dimensioned drawing EPS midi gantry h............................................. 70
3.19.2 Technical data EPS midi gantry h........................................................ 71
3.19.3 Module loads EPS midi gantry h .......................................................... 72
3.20 EPS maxi gantry h...................................................................................... 73
3.20.1 Dimensioned drawing EPS maxi gantry h............................................ 73
3.20.2 Technical data EPS maxi gantry h....................................................... 74
3.20.3 Module loads EPS maxi gantry h ......................................................... 75
3.21 Overview of power supplies ....................................................................... 76
4Transport, packaging and storage ..................................................................... 77
4.1 Safety instructions for transport.................................................................. 77
4.2 Transport .................................................................................................... 77
4.3 Packaging................................................................................................... 77
4.4 Storage ....................................................................................................... 78
5Installation, assembly and setting ..................................................................... 79
5.1 Safety instructions for installation and assembly ....................................... 79
5.2 Required mounting material ....................................................................... 80
5.3 Weight compensation................................................................................. 81
5.3.1 Weight compensation with MagSpring................................................. 81
5.3.2 Weight compensation with pneumatic cylinder .................................... 81
5.4 Interfaces of the axis controllers................................................................. 81
5.4.1 Axis controller C11xx............................................................................ 82
5.4.2 Axis controller C12xx............................................................................ 83
5.4.3 Axis controller E12xx............................................................................ 85
5.5 Pin assignment and electrical connection data of the motors.................... 87
5.6 Connector assignment encoder on the controller ...................................... 88
5.7 Connector strip ........................................................................................... 89
6Commissioning .................................................................................................... 90
6.1 Safety instructions for commissioning ........................................................ 90

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6.2 Preparatory activities for commissioning.................................................... 91
6.3 Commissioning of the modules .................................................................. 91
6.4 Settings....................................................................................................... 92
6.4.1 Set speeds on electric axes ................................................................. 92
6.4.2 Teaching the positions on electric axes ............................................... 96
6.4.3 Adjusting damping and speeds on pneumatic modules....................... 97
6.4.4 External position measuring system .................................................... 97
7Fault elimination................................................................................................... 99
7.1 Safety instructions for troubleshooting ....................................................... 99
7.2 Fault causes and remedy ........................................................................... 99
8Maintenance and repair..................................................................................... 100
8.1 General notes ........................................................................................... 100
8.2 Safety instructions for Maintenance and Repair ...................................... 100
8.3 Maintenance activities and maintenance intervals................................... 101
8.3.1 Overview of the maintenance points.................................................. 101
8.3.2 Further maintenance .......................................................................... 101
8.4 Spare parts ............................................................................................... 102
8.4.1 Motor cable - Designation - Axes - Controller - Application ............... 102
8.4.2 Motor cable......................................................................................... 103
8.4.3 Servo controller .................................................................................. 104
8.4.4 Position measuring system ................................................................ 104
8.4.5 MagSpring .......................................................................................... 105
9Decommissioning and disposal....................................................................... 106
9.1 Safety instructions for decommissioning and disposal............................. 106
9.2 Decommissioning ..................................................................................... 106
9.3 Disposal.................................................................................................... 106
10 Declaration of incorporation............................................................................. 107

General
Assembly instructions DE EPS Handling systems Date 08.09.2021 Version 2.0 7–112
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 EPS handling system to
ensure safe and efficient handling and operation.
Consistent compliance with these assembly instructions will ensure:
permanent operational reliability of the EPS handling system,
optimal functioning of the EPS handling system,
timely detection and elimination of defects (thereby reducing maintenance
and repair costs),
Extension of the service life of the EPS handling system.
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
8 – 112 Assembly instructions EN EPS Handling systems Date 08.09.2021 Version 2.0
This note contains important additional information as well as useful tips for
safe, efficient and trouble-free operation of the EPS handling system.
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: hot surfaces can cause burns upon contact.
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
Assembly instructions DE EPS Handling systems Date 08.09.2021 Version 2.0 9–112
1.4 Applicable documents
Each EPS handling system 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 EPS handling system.
Please also observe the installation instructions for the integrated modules!
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 are excluded from the warranty (The customer is entitled to a
product free of defects. This does also apply to defective accessories and
wear parts. Normal wear and tear are excluded from the warranty.
The warranty covers the replacement or repair of defective Afag parts. Further
claims are excluded.
The warranty shall expire in the following cases:
Improper use of the handling system.
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.
Removing the serial number from the product.
Using the EPS handling system 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.
Disasters caused by foreign bodies and force majeure.
1.6 Liability
No changes shall be made to the EPS handling system unless described in this
instructions manual or approved in writing by Afag.
Afag accepts no liability for unauthorized changes or improper assembly,
installation, commissioning, operation, maintenance or repair work.

Safety instructions
10 – 112 Assembly instructions EN EPS Handling systems Date 08.09.2021 Version 2.0
2 Safety instructions
2.1 General
This chapter provides an overview of all important safety aspects to ensure safe
and proper use of the EPS handling system and optimal protection of personnel.
Safe handling and trouble-free operation of the EPS handling system requires
knowledge of the basic safety regulations.
Every person carrying out installation, commissioning, maintenance work or
operating the EPS handling system must have read and understood the
complete user manual, especially the chapter on safety instructions.
Beyond this, there are rules and regulations regarding accident prevention that
are applicable to the place of installation which must be observed.
Improper use may result in danger to life and limb of the user or third parties or
in damage to the automation system or other material assets.
Failure to follow the directions and safety instructions given in this instructions
manual may result in serious hazards.
2.2 Intended use
EPS handling systems are designed for use in automation systems and are
used exclusively for moving workpieces.
The pneumatic modules are exclusively intended for operation by means of
compressed air (4-7 bar). The electric axes are designed exclusively for
operation with original LinMot components (controller, cables...).
EPS handling systems may only be used in the ambient and operating
conditions defined for these modules (Chapter 3 Technical data).
Any use beyond the described purpose is considered to be not in accordance
with the intended use.
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.
2.3 Foreseeable misuse
Any use other than or beyond the intended use described above is considered
a misuse of the EPS handling system.
Especially the following use is considered a misuse:
Use to move parts for which the EPS handling system is not designed.
Use in unsuitable ambient and operating conditions.