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!

Safety instructions
Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼12.04.2023 ◼V4.1 11–62
▪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.
2.4.3 Obligations of the personnel
All personnel working with the 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 PDZ,
▪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 asses the risks
that may arise from the use of the portal axis 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 portal axes.
Persons whose ability to react is restricted due to the intake of medication or the
like must not interact with the portal axis.
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.

Safety instructions
12 –62 Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼Date 12.04.2023 ◼V4.1
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.
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 portal axis, 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.

Safety instructions
Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼12.04.2023 ◼V4.1 13–62
2.7 Changes and modifications
No changes may be made to the portal axes 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 portal axes may not be changed or modified in any way, except with the
prior written consent of AFAG.
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 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 portal axis has been built according to thestate-of-the-art and the applicable
health and safety requirements. However, improper use of the portal axis may
cause the following hazards to the personnel:
▪danger to life and limb of the operator or third parties,
▪on the portal axes 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 portal axis.
WARNING
Danger - Do not use in unsuitable environment !
The portal axes are designed for use in non explosive atmospheres.
▪Do not use the portal axis in potentially hazardous atmospheres!

Safety instructions
14 –62 Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼Date 12.04.2023 ◼V4.1
2.8.2 Danger due to electricity
WARNING
Risk of injuries due to uncontrolled parts movements!
When connecting and operating the portal axes, unexpected movements can
lead to serious injuries and/or damage to property.
▪Only qualified personnel may work with or on the portal axis.
CAUTION
Risk of injury due to high noise exposure!
the portal axis generates 78 dB(A) during full-load operation. Depending on
the add-ons, the environment and the resonance of the protective device
theses values may be exceeded and expose the operator to a higher noise
level.
▪The operating company is responsible for ensuring that the permissible
noise levels are observed.
▪If the permissible noise levels are exceeded, the operating company shall
ensure that the operator uses a suitable hearing protection.
CAUTION
Risk of injury when lifting the portal axis!
Depending on the type, the weight of the portal axis can be between 11.8 kg
and 55 kg. Back injuries can occur when packing and unpacking as well as
when handling the portal axes.
▪To lift the modules, we recommend attaching the axes to straps and lifting
the portal axis out of the transport box with a lifting device.
DANGER
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
Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼12.04.2023 ◼V4.1 15–62
2.8.3 Danger due to high temperatures
2.8.4 Mechanical hazards
CAUTION
Danger of injury from hot surfaces.
During continuous operation of the portal axes, the surface on the motor heats
up to 100°C.
▪Wear protective gloves!
▪Before touching hot surfaces without protective gloves, make sure they
have cooled down to ambient temperature.
CAUTION
Danger of injury by moving components!
Limbs can be crushed by moving components!
▪Work on and with the portal axis may only be carried out by qualified
personnel.
▪Never reach into the system during normal operation!

Technical data
16 –62 Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼Date 12.04.2023 ◼V4.1
3 Technical data
3.1 Portal axis PDZ-128
3.1.1 Dimensional drawing PDZ - 128-D
Fig. 1 Dimensional drawing portal axis PDZ -128

Technical data
Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼12.04.2023 ◼V4.1 17–62
3.1.2 Technical data PDZ -128

Technical data
18 –62 Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼Date 12.04.2023 ◼V4.1
3.1.3 Preferred combinations PDZ -128-D
AFAG accepts no liability where third-party modules have been attached to portal
axes.
Add-on modules must be able to absorb forces (accelerations) occurring when
the portal axis is running at full capacity.

Technical data
Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼12.04.2023 ◼V4.1 19–62
3.1.4 Slide loads PDZ-128
The values given are guide values that can be specified more precisely
depending on the intended use!

Technical data
20 –62 Assembly instructions EN ◼PDZ-128 I PDZ-160 I PDZ-200 ◼Date 12.04.2023 ◼V4.1
3.2 Portal axis PDZ-160
3.2.1 Dimensional drawing PDZ -160-D
Fig. 2 Dimensional drawing portal axis PDZ -160