Afag ES40 User manual

Assembly Instructions EN ◼ES40 ◼01.06.2023 ◼V1.2 1–59
Assembly and operating instructions
Electric slide
ES40 IES40-HP
Translation of the Original Assembly Instructions EN
◼ES40-100-SL  Order no.: 50465218 ◼ES40-100-HP-SL  Order no.: 50465225
◼ES40-100  Order no.: 50465219 ◼ES40-100-HP  Order no.: 50465226
◼ES40-200  Order no.: 50465220 ◼ES40-200-HP  Order no.: 50465227
◼ES40-300  Order no.: 50465221 ◼ES40-300-HP  Order no.: 50465228
◼ES40-400  Order no.: 50465222 ◼ES40-400-HP  Order no.: 50465229
◼ES40-500  Order no.: 50465223 ◼ES40-500-HP  Order no.: 50465230

2 –59 Assembly instructions EN ◼ES40 ◼01.06.2023 ◼V1.2
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 electric slide or other options.
We wish you every success with our products!
With kind regards
Your Afag team
© Subject to modifications
The electric slides 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 ◼ES40 ◼01.06.2023 ◼V1.2 3–59
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.....................................................................................9
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..................................................10
2.4.3 Obligations of the personnel ................................................................11
2.5 Personnel requirements .............................................................................11
2.5.1 Personnel qualification.........................................................................11
2.6 Personal protective equipment (PPE) ........................................................12
2.7 Changes & modifications............................................................................12
2.8 General hazards / residual risks.................................................................13
2.8.1 General hazards at the workplace .......................................................13
2.8.2 Danger due to electricity ......................................................................14
2.8.3 Danger due to strong magnetic fields ..................................................14
2.8.4 Danger due to high temperatures ........................................................14
2.8.5 Mechanical hazards .............................................................................14
3Technical data ......................................................................................................15
3.1 Electric slide ES40......................................................................................15
3.1.1 Dimension drawing ES40.....................................................................15
3.1.2 Technical data ES40............................................................................16
3.1.3 Preferred combinations ES40..............................................................17
3.1.4 Module loads ES40..............................................................................18
3.1.5 Motor overview ES40...........................................................................19
3.2 Electric slide ES40-HP ...............................................................................20
3.2.1 Dimensional drawing ES40-HP............................................................20
3.2.2 Technical data ES40-HP......................................................................21
3.2.3 Preferred combinations ES40-HP........................................................22
3.2.4 Module loads ES40-HP........................................................................23
4Transport, packaging and storage.....................................................................24
4.1 Safety instructions for transport..................................................................24
4.2 Scope of supply..........................................................................................24

Table of contents
4 –59 Assembly instructions EN ◼ES40 ◼01.06.2023 ◼V1.2
4.3 Transport ....................................................................................................25
4.4 Packaging...................................................................................................25
4.5 Storage.......................................................................................................25
5Structure and description ...................................................................................26
5.1 Design electric slides..................................................................................26
5.2 Product description.....................................................................................26
5.3 Accessories ................................................................................................27
5.3.1 MagSpring............................................................................................27
5.3.2 External position measuring system for ES40 and ES40-HP..............32
5.3.3 Servo controller....................................................................................34
5.3.4 Controllers, cables, plugs.....................................................................38
5.3.5 Transformers and power supplies........................................................42
6Installation, assembly & setting .........................................................................44
6.1 Safety Instructions for installation & assembly...........................................44
6.2 Assembly & attachment..............................................................................45
6.2.1 Mounting holes.....................................................................................45
6.2.2 Centering bushing................................................................................46
6.2.3 Tightening torques................................................................................47
6.2.4 Mounting ES40 (slide)..........................................................................47
6.2.5 Mounting ES40 (basic element)...........................................................47
6.2.6 Rotatability of C motor connector (ES40) ............................................48
6.3 Programming of the electric slides .............................................................49
6.3.1 Safety instructions for programming ....................................................49
6.3.2 Programming........................................................................................49
7Commissioning ....................................................................................................50
7.1 Safety instructions for commissioning........................................................50
7.2 Preparatory activities for commissioning....................................................51
7.3 Commissioning of the modules ..................................................................51
7.4 Setting up & retrofitting...............................................................................52
8Fault elimination...................................................................................................53
8.1 Safety instructions for troubleshooting .......................................................53
8.2 Fault causes and remedy...........................................................................53
9Maintenance and repair.......................................................................................54
9.1 General notes.............................................................................................54
9.2 Safety instructions for maintenance and repair..........................................54
9.3 Maintenance activities and maintenance intervals.....................................55
9.3.1 Overview of the maintenance points....................................................55
9.3.2 Further maintenance............................................................................56
9.4 Spare parts and repair work.......................................................................56
10 Decommissioning and disposal.........................................................................57
10.1 Safety instructions for decommissioning and disposal...............................57

Table of contents
Assembly Instructions EN ◼ES40 ◼01.06.2023 ◼V1.2 5–59
10.2 Decommissioning .......................................................................................57
10.3 Disposal......................................................................................................57
11 Declaration of incorporation...............................................................................58

General
6 –59 Assembly instructions EN ◼ES40 ◼01.06.2023 ◼V1.2
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 electric slide to ensure safe
and efficient handling of the electric slide ES40 and ES40-HP.
Consistent compliance with these assembly instructions will ensure:
▪permanent operational reliability of the electric slide,
▪optimal functioning of the electric slide,
▪timely detection and elimination of defects (thereby reducing maintenance
and repair costs),
▪prolongation of the electric slide’s 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.
This note contains important additional information as well as useful tips for
safe, efficient and trouble-free operation of the electric slide.
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 ◼ES40 ◼01.06.2023 ◼V1.2 7–59
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 –59 Assembly instructions EN ◼ES40 ◼01.06.2023 ◼V1.2
1.4 Applicable documents
Each electric slide 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 electric slides.
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 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
▪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 electric slides 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 ◼ES40 ◼01.06.2023 ◼V1.2 9–59
2 Safety instructions
2.1 General
This chapter provides an overview of all important safety aspects to ensure safe
and proper use of the electric slide and optimal protection of personnel.
Safe handling and trouble-free operation of the electric slides requires
knowledge of the basic safety regulations.
Every person carrying out installation, commissioning, maintenance work or
operating the ES modules must have read and understood the complete user
manual, especially the chapter on safety instructions.
Also observe all rules and regulations regarding accident prevention applicable
to the place of installation of the modules.
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
The ES electric slides series is designed for the shock-free linear movement of
permanently mounted loads in non-explosive environments and in the ambient
and operating specially conditions defined for these modules.
The electric slides are used in automation systems.
The electric slides are exclusively intended for operation with original LinMot
components (controller, cables ...).
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/improper use of the electric slides.
Especially the following use is considered a misuse:
▪Use in potentially explosive atmospheres

Safety instructions
10 –59 Assembly instructions EN ◼ES40 ◼01.06.2023 ◼V1.2
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 parallel gripper 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 electric slides.
2.4.2 Obligations of the operating company
In addition to the safety instructions given in this manual, the operating company
must also comply with the safety, accident prevention and environmental
protection regulations valid for the field of application of the electric slides.
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 electric slides,
▪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
automation system in which the electric slides have been integrated,
▪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.
WARNING
Risk of injury if the module is not used as intended!
The improper use of the electric slides poses a potential hazard to the
personnel.
▪The electric slides may only be used in a technically perfect condition in
accordance with their intended use and instructions in this manual as well
as in compliance with the safety requirements!
▪Any malfunctions, particularly those that could impair safety, must be
eliminated immediately!

Safety instructions
Assembly Instructions EN ◼ES40 ◼01.06.2023 ◼V1.2 11–59
2.4.3 Obligations of the personnel
All personnel working with the electric slides 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 electric slides,
▪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 2.6).
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 assess the
risks that may arise from the use of the electric slides 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 electric slides.
Persons whose ability to react is restricted due to the intake of medication or the
like must not interact with the electric slides.
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
12 –59 Assembly instructions EN ◼ES40 ◼01.06.2023 ◼V1.2
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 electric slides, 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 are 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 & modifications
No changes may be made to the electric slides 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 electric slides may not be changed or modified in any way, except with
the prior written consent of AFAG Automation AG.

Safety instructions
Assembly Instructions EN ◼ES40 ◼01.06.2023 ◼V1.2 13–59
2.8 General hazards / residual risks
Despite the safe design of the electric slides 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 electric slides.
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 electric slides have been built according to the state-of-the-art and the
applicable health and safety requirements. Nevertheless, improper use of the
electric slides may cause the following hazards to the personnel:
▪danger to life and limb of the operator or third parties,
▪on the electric slides 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.
▪Observe the safety information sheet for the electric slide.
WARNING
Danger - Do not use in unsuitable environment!
The electric slides are designed for use in non-explosive atmospheres.
▪Do not use the electric slides in potentially explosive atmospheres!
CAUTION
Risk of injuries due to uncontrolled parts movements!
When connecting the electric slides to the control unit or when operating the
electric slides sudden, unexpected movements may occur which can cause
personal injury or property damage.
▪Only qualified personnel may work with or on the electric slides.
▪Read the assembly instructions carefully before carrying out any work on
or with the electric slides.

Safety instructions
14 –59 Assembly instructions EN ◼ES40 ◼01.06.2023 ◼V1.2
2.8.2 Danger due to electricity
2.8.3 Danger due to strong magnetic fields
2.8.4 Danger due to high temperatures
2.8.5 Mechanical hazards
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.
DANGER
Danger due to magnetic fields!
Due to the strong magnetic fields, electronic devices such as pacemakers
can be disturbed or their function impaired.
Persons with a pacemaker must keep a safety distance of at least 50 cm.
CAUTION
Danger of injury from hot surfaces!
During continuous operation of the electric slide, the surface of the slide heats
up.
▪Before touching hot surfaces without protective gloves, make sure they
have cooled down to ambient temperature.
CAUTION
Danger of injury from moving components!
Limbs can be crushed by moving components!
▪Work on and with the electric slides may only be carried out by qualified
personnel.
▪Never reach into the system during normal operation!

Technical data
Assembly Instructions EN ◼ES40 ◼01.06.2023 ◼V1.2 15–59
3 Technical data
3.1 Electric slide ES40
3.1.1 Dimension drawing ES40
Fig. 1 Dimensional drawing of electric slide ES40

Technical data
16 –59 Assembly instructions EN ◼ES40 ◼01.06.2023 ◼V1.2
3.1.2 Technical data ES40

Technical data
Assembly Instructions EN ◼ES40 ◼01.06.2023 ◼V1.2 17–59
3.1.3 Preferred combinations ES40

Technical data
18 –59 Assembly instructions EN ◼ES40 ◼01.06.2023 ◼V1.2
3.1.4 Module loads ES40

Technical data
Assembly Instructions EN ◼ES40 ◼01.06.2023 ◼V1.2 19–59
3.1.5 Motor overview ES40
Module
Stroke
Motor
Stator
Stator no
Rotor
Rotor no.
ES40-100-SL
100
P01-48x240F/90x240-C
PS01-48x240F
50467386
PL01-28x410/330
50467392
ES40-100
100
P01-48x240F/90x240-C
PS01-48x240F
50467386
PL01-28x410/330
50467392
ES40-200
200
P01-48x240F/180x330-C
PS01-48x240F
50467386
PL01-28x500/420
50467396
ES40-300
300
P01-48x240F/300x450-C
PS01-48x240F
50467386
PL01-28x620/540
50467397
ES40-400
400
P01-48x240F/390x540-C
PS01-48x240F
50467386
PL01-28x710/630
50467398
ES40-500
500
P01-48x240F/480x630-C
PS01-48x240F
50467386
PL01-28x800/720
50467399
ES40-100-SL-HP
100
P01-48x360F/60x210-C
PS01-48x360F
50467389
PL01-28x500/420
50467396
ES40-100-HP
100
P01-48x360F/60x210-C
PS01-48x360F
50467389
PL01-28x500/420
50467396
ES40-200-HP
200
P01-48x360F/180x330-C
PS01-48x360F
50467389
PL01-28x620/540
50467397
ES40-300-HP
300
P01-48x360F/270x420-C
PS01-48x360F
50467389
PL01-28x710/630
50467398
ES40-400-HP
400
P01-48x360F/360x510-C
PS01-48x360F
50467389
PL01-28x800/720
50467399

Technical data
20 –59 Assembly instructions EN ◼ES40 ◼01.06.2023 ◼V1.2
3.2 Electric slide ES40-HP
3.2.1 Dimensional drawing ES40-HP
Fig. 2 Dimensional drawing of electric slide ES40-HP