Afag PDZ-128 User manual

Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼12.04.2023 ◼V4.1 1–62
Assembly and operating instructions
Portal axes
PDZ-128 IPDZ-160
PDZ-200
Translation of the Original Assembly Instructions EN
◼PDZ-128 Order no.: 50394896
◼PDZ-160 Order no.: 50245033
◼PDZ-200 Order no.: 50228209

2 –62 Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼Date 12.04.2023 ◼V4.1
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 portal axis or other options.
We wish you every success with our products!
With kind regards
Your Afag team
© Subject to modifications
The modules 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 2022 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 ◼PDZ-128 I PDZ-160 I PDZ-200 ◼12.04.2023 ◼V4.1 3–62
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..................................................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 and modifications........................................................................13
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 high temperatures ........................................................15
2.8.4 Mechanical hazards .............................................................................15
3Technical data ......................................................................................................16
3.1 Portal axis PDZ-128 ...................................................................................16
3.1.1 Dimensional drawing PDZ - 128-D.......................................................16
3.1.2 Technical data PDZ -128 .....................................................................17
3.1.3 Preferred combinations PDZ -128-D....................................................18
3.1.4 Slide loads PDZ-128 ............................................................................19
3.2 Portal axis PDZ-160 ...................................................................................20
3.2.1 Dimensional drawing PDZ -160-D........................................................20
3.2.2 Technical data PDZ-160 ......................................................................21
3.2.3 Preferred combinations PDZ-160.........................................................22
3.2.4 Slide loads PDZ-160 ............................................................................23
3.3 Portal axis PDZ-200 ...................................................................................24
3.3.1 Dimensional drawing PDZ -200-D........................................................24
3.3.2 Technical data PDZ-200 ......................................................................25
3.3.3 Preferred combinations PDZ-200.........................................................26
3.3.4 Slide loads PDZ-200 ............................................................................27
3.4 SE Power Control.......................................................................................28

Table of contents
4 –62 Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼Date 12.04.2023 ◼V4.1
3.4.1 Dimension drawing SE-Power .............................................................28
3.4.2 Technical data SE-Power.....................................................................29
4Transport, packaging and storage.....................................................................30
4.1 Safety instructions for transport..................................................................30
4.2 Scope of supply..........................................................................................31
4.3 Transport ....................................................................................................32
4.4 Packaging...................................................................................................32
4.5 Storage.......................................................................................................32
5Design and description .......................................................................................33
5.1 Structure of portal axis................................................................................33
5.2 Product description.....................................................................................33
5.3 Accessories ................................................................................................34
6Installation, assembly & setting .........................................................................36
6.1 Safety Instructions for Installation & Assembly ..........................................36
6.2 Assembly & attachment..............................................................................37
6.2.1 Overview of individual parts of the PDZ...............................................37
6.2.2 Mounting surfaces................................................................................37
6.2.3 Mounting options on the axle slide.......................................................38
6.2.4 Attachment grid and centering bushings..............................................38
6.2.5 Tightening torques................................................................................39
6.3 Installation in an assembly system.............................................................40
6.4 Motor gearbox combination........................................................................40
6.4.1 Electrical interfaces of the portal axis...................................................41
6.4.2 Changing the gearbox mounting side ..................................................42
6.4.3 Attachment of other gearboxes............................................................44
6.5 Programming the portal axis ......................................................................45
6.6 Add-on modules .........................................................................................45
6.6.1 Servo motor..........................................................................................46
6.6.2 Mounting the transmission unit ............................................................47
6.6.3 Superstructures for portal axes............................................................48
6.6.1 Stroke limiter ........................................................................................48
6.6.2 Portal axis with double slide (special version) .....................................50
7Commissioning ....................................................................................................51
7.1 Safety instructions for commissioning........................................................51
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...........................................................................54
8.2.1 A) Malfunctions during reference travel ...............................................54
8.2.2 Malfunction during operation................................................................55

Table of contents
Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼12.04.2023 ◼V4.1 5–62
9Maintenance and repair.......................................................................................56
9.1 General notes.............................................................................................56
9.2 Safety instructions for Maintenance and Repair ........................................56
9.3 Maintenance activities and maintenance intervals.....................................56
9.3.1 Overview of the maintenance points....................................................57
9.3.2 Lubrication of the linear guide..............................................................58
9.3.3 Further maintenance............................................................................58
9.4 Spare parts and repair work.......................................................................59
10 Decommissioning, disassembly, disposal........................................................60
10.1 Safety instructions for decommissioning and disposal...............................60
10.2 Decommissioning .......................................................................................60
10.3 Disposal......................................................................................................60
11 Declaration of incorporation...............................................................................61

General
6 –62 Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼Date 12.04.2023 ◼V4.1
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 portal axes PDZ-128, PDZ-
160 and PDZ-200 to ensure safe and efficient handling and operation.
Consistent compliance with these assembly instructions will ensure:
▪permanent operational reliability of the PDZ,
▪optimal functioning of the PDZ,
▪timely detection and elimination of defects (thereby reducing maintenance
and repair costs)
▪prolongation of the PDZ 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 severe injury.
WARNING
Warning!
This safety note points out a potentially hazardous situation which, if not
avoided, could result in death or severe 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 ◼PDZ-128 I PDZ-160 I PDZ-200 ◼12.04.2023 ◼V4.1 7–62
This note contains important additional information as well as useful tips for
safe, efficient and trouble-free operation of the portal axis.
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 –62 Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼Date 12.04.2023 ◼V4.1
1.4 Applicable documents
Each portal axis 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 portal axis.
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 portal axis 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
Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼12.04.2023 ◼V4.1 9–62
2 Safety instructions
2.1 General
This chapter provides an overview of all important safety aspects to ensure safe
and proper use of the portal axis and optimal protection of personnel.
Safe handling and trouble-free operation of the portal axis requires knowledge
of the basic safety regulations.
Every person carrying out installation, commissioning, maintenance work or
operating the module 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
The portal axis is used for shock- linear movement of fixed loads in non-
hazardous environments and in the ambient and operating conditions defined
for this axis (Chap. 3 “Technical data” & data sheet in the catalogue).
The portal axes are specially designed for horizontal operation.
Typical areas of application are e.g.:
▪Moving module assemblies over longer distances.
▪Use as portal modules.
▪In combination with OZ modules for fast and flexible pick & place
applications.
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.

Safety instructions
10 –62 Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼Date 12.04.2023 ◼V4.1
2.3 Foreseeable misuse
Any use other than or beyond the intended use described is considered a
misuse of the stroke PDZ.
Especially the following use is considered a misuse:
▪The use for the transport of people and animals,
▪the use as pressing or bending device for cold working of metals.
▪Use in potentially explosive atmospheres without additional measures.
Please consult AFAG in this regard!
▪Use in the chemical and food industry without additional measures. Please
consult AFAG in this regard!
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 damage 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 PDZ 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 portal axis.
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 portal axis.
Only persons may work on the PDZ axes 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 portal axis,
WARNING
Risk of injury if the module is not used as intended!
The improper use of the portal axis poses a potential hazard to the personnel.
▪The portal axes may only be used in a technically perfect condition in
accordance with its intended use and the 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!