Afag KLF 5 Product guide

Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0 1–44
Operating & Installation Instructions
Linear Feeder
KLF5 / KLF7 / KLF15 / KLF25
Translation of the Original Assembly Instructions EN
Linear feeder KLF5 (230 V/50 Hz) Order no.: 15044649 (complete) 15152773 (basic unit)
Linear feeder KLF5 (115 V/60 Hz) Order no.: 15052019 (complete) 15087298 (basic unit)
Linear feeder KLF7 (230 V/50 Hz) Order no.: 15150973 (complete) 15059714 (basic unit)
Linear feeder KLF7 (115 V/60 Hz) Order no.: 15173186 (complete) 15125060 (basic unit)
Linear feeder KLF15 (230 V/50 Hz) Order no.: 15021614 (complete) 15132435 (basic unit)
Linear feeder KLF15 (115 V/60 Hz) Order no.: 15014508 (complete) 15165339 (basic unit)
Linear feeder KLF25 (230 V/50 Hz) Order no.: 15048476 (complete) 15185736 (basic unit)
Linear feeder KLF25 (115 V/60 Hz) Order no.: 15169958 (complete) 15006002 (basic unit)

2 – 44 Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0
Dear Customer
Thank you for choosing our products and placing your trust and confidence in
our company!
These operating and installation 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 linear feeder or other options.
We wish you every success with our products!
With kind regards
Your Afag team
© Subject to modifications
The linear feeders 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 2023 Afag Automation AG
All contents of the present operating and installation 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
Wernher-von-Braun Street 1
D-92224 Amberg (Germany)
Tel.: [phone]
e-mail: [e-mail]
Internet: www.afag.com
Afag Automation AG
Luzernstrasse 32
CH-6144 Zell (Switzerland)
Tel.: [phone]
e-mail: [e-mail]
Internet: www.afag.com

Table of contents
Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0 3–44
Table of contents
1General .................................................................................................................... 5
1.1 Contents and purpose of this manual........................................................... 5
1.2 Explanation of symbols................................................................................. 5
1.3 Additional symbols........................................................................................ 6
1.4 Warranty ....................................................................................................... 7
1.5 Liability.......................................................................................................... 7
2Safety instructions................................................................................................. 8
2.1 General ......................................................................................................... 8
2.2 Intended use ................................................................................................. 8
2.3 Foreseeable misuse ..................................................................................... 9
2.4 Obligations of the operator and the personnel ............................................. 9
2.4.1 Follow these instructions........................................................................ 9
2.4.2 Obligations of the operating company.................................................... 9
2.4.3 Obligations of the personnel ................................................................ 10
2.5 Personnel requirements ............................................................................. 10
2.5.1 Personnel qualification ......................................................................... 10
2.6 Personal protective equipment (PPE) ........................................................ 11
2.7 Changes & Modifications............................................................................ 11
2.8 General hazards / residual risks................................................................. 11
2.8.1 General hazards at the workplace ....................................................... 11
2.8.2 Danger due to electricity ...................................................................... 12
2.8.3 Hazards due to strong alternating magnetic fields............................... 12
2.8.4 Mechanical hazards ............................................................................. 13
3Technical data ...................................................................................................... 14
3.1 Dimensional drawing KLF .......................................................................... 14
3.1.1 Dimensional drawing KLF5 .................................................................. 14
3.1.2 Dimensional drawing KLF7-KLF25 ...................................................... 15
3.2 Technical data KLF..................................................................................... 16
3.2.1 Technical data KLF5 ............................................................................ 16
3.2.2 Technical data KLF7-KLF25 ................................................................ 17
3.3 Accessories ................................................................................................ 18
3.3.1 Mounting parts...................................................................................... 18
3.3.2 Controller.............................................................................................. 18
4Transport, packaging and storage ..................................................................... 19
4.1 Safety instructions ...................................................................................... 19
4.2 Scope of supply .......................................................................................... 20
4.3 Transport .................................................................................................... 21
4.4 Packaging ................................................................................................... 21
4.5 Storage ....................................................................................................... 21

Table of contents
4 – 44 Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0
5Design and description ....................................................................................... 22
5.1 Structure of the KLF ................................................................................... 22
5.2 Description of the KLF ................................................................................ 22
6Installation, assembly and setting ..................................................................... 23
6.1 Safety instructions ...................................................................................... 23
6.2 Assembly .................................................................................................... 24
6.2.1 Tightening torques................................................................................ 24
6.2.2 Fastening the module........................................................................... 24
6.2.3 Assembly of the conveyor rail .............................................................. 25
6.2.4 Assembly of two conveyor rails............................................................ 26
6.2.5 Assembly of divided conveyor rails ...................................................... 27
6.3 Electrical connection................................................................................... 28
6.4 Settings....................................................................................................... 29
6.4.1 Design of the conveyor rails................................................................. 29
6.4.2 Adjust balance of weights .................................................................... 30
6.4.3 Natural frequency fine adjustment ....................................................... 32
6.4.4 Adjust air gap ....................................................................................... 34
7Operation .............................................................................................................. 35
7.1 Safety instructions for commissioning ........................................................ 35
7.2 Preparatory activities for commissioning.................................................... 35
7.3 Commissioning of the modules .................................................................. 35
8Fault elimination................................................................................................... 36
8.1 Safety instructions ...................................................................................... 36
8.2 Fault causes and remedy ........................................................................... 36
9Maintenance and repair....................................................................................... 39
9.1 General notes ............................................................................................. 39
9.2 Safety instructions ...................................................................................... 39
9.3 Maintenance activities and maintenance intervals..................................... 40
9.3.1Overview of the maintenance points .................................................... 40
9.3.2 Check leaf springs for wear and oxidation ........................................... 40
9.3.3 Check spring setting behaviour............................................................ 41
9.3.4 Remove leaf springs ............................................................................ 41
9.3.5 Further maintenance ............................................................................ 41
9.4 Spare and wear parts lists, repairs............................................................. 42
9.4.1 Spare parts........................................................................................... 42
9.4.2 Wear parts............................................................................................ 42
10 Decommissioning and disposal ......................................................................... 43
10.1 Safety instructions ...................................................................................... 43
10.2 Decommissioning ....................................................................................... 43
10.3 Disposal...................................................................................................... 43

General
Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0 5–44
1 General
1.1 Contents and purpose of this manual
These operating and installation instructions contain important information on
assembly, commissioning, functioning and maintenance of the linear feeder KLF
to ensure safe and efficient handling and operation.
Consistent compliance with these operating instructions will ensure:
permanent operational reliability of the linear feeders,
optimal functioning of the linear feeders,
timely detection and elimination of defects (thereby reducing maintenance
and repair costs),
prolongation of the linear feeder’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.
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
6 – 44 Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0
This note contains important additional information as well as useful tips for
safe, efficient and trouble-free operation of the linear feeders.
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 hand
and finger injury due to uncontrolled
movements of components.
Warning
- Magnetic field
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
Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0 7–44
1.4 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 installation, commissioning,
operation and maintenance.
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
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.
1.5 Liability
No changes shall be made to the linear feeders unless described in this 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
8 – 44 Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0
2 Safety instructions
2.1 General
This chapter provides an overview of all important safety aspects to ensure safe
and proper use of the linear feeders and optimal protection of personnel.
Safe handling and trouble-free operation of the controllers requires knowledge
of the basic safety regulations.
Every person carrying out installation, commissioning, maintenance work or
operating the linear feeders 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.
Failure to follow the directions and safety instructions given in this instructions
manual may result in serious hazards.
2.2 Intended use
The linear feeder KLF may only be used for transporting, buffering and arranging
parts. With regard to the maximum permissible dimensions and weights of add-
on parts, the notes in chapter 3 "Technical data" must be observed.
The following uses of the HLF are considered as improper use :
Use in damp and wet areas
Use at temperatures below 10°C or above 45°C
Use in areas with highly flammable media
Use in areas with explosive media
Use in heavily polluted or dusty environments
Use in aggressive environment (e.g. salty atmosphere)
The intended use of the module also includes:
observance of all instructions given in this manual.
compliance with the inspection and maintenance work and the
specifications in the data sheets,
using only original spare parts.

Safety instructions
Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0 9–44
2.3 Foreseeable misuse
Any use other than or beyond the intended use described above is considered
a misuse of the linear feeder.
2.4 Obligations of the operator and the personnel
2.4.1 Follow these instructions
A basic prerequisite for safe and proper handling of the linear feeders is a good
knowledge of the basic safety instructions.
This manual, in particular the safety instructions contained therein, must be
observed by all persons working with the linear feeder.
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 linear feeder.
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 linear feeder,
have read and understood these operating 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 linear feeder is 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.
WARNING
Risk of injury if the KLF is not used for its intended purpose or if it is
foreseeable used incorrectly!
The improper use of the KLF poses a potential hazard to the personnel.
The linear feeders 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!

Safety instructions
10 – 44 Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0
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 controllers,
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. (chap. 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 linear feeder 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 linear feeders.
These operating 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 can identify
risks and preventing possible hazards
arising from the use of the machine.

Safety instructions
Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0 11–44
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 linear feeder, 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.
2.7 Changes & Modifications
No changes may be made to the linear feeders which have not been described
in these operating instructions or approved in writing Afag Automation AG.
Excluded from this are the rails stated in chap. 6.4.1 and chap. 6.2.3, as
well as the accessories specified in chap. 3.3.
Afag Automation AG accepts no liability for unauthorised changes or improper
assembly, installation, commissioning, maintenance or repair work.
The linear feeders 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 KLF and the technical protective measures taken,
there still remain residual risks that cannot be avoided, and which present a non-
obvious residual risk when operating the rotary modules.
Observe the safety instructions in this chapter and in the other sections of this
manual to avoid damage to property and dangerous situations for the personnel.
2.8.1 General hazards at the workplace
The KLF linear feeder has been built according to the state-of-the-art and the
applicable health and safety requirements. However, improper use of the linear
feeder may cause the following hazards to the personnel:
danger to life and limb of the operator or third parties,
on the KLF themselves,
property damage.

Safety instructions
12 – 44 Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0
Always keep the operating 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 linear feeder.
2.8.2 Danger due to electricity
2.8.3 Hazards due to strong alternating magnetic fields
WARNING
Danger - Do not use in unsuitable environment !
The KLF are designed for use in non-explosive atmospheres.
Do not use the KLF modules in potentially explosive atmospheres!
CAUTION
Risk of injuries due to uncontrolled parts movements!
When operating the KLF uncontrolled movements may occur which can
cause personal injury or property damage.
Only qualified personnel may work with or on the KLF.
Read this manual carefully before carrying out any work on or with the KLF.
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 alternating magnetic fields!
The alternating magnetic fields occurring in the immediate vicinity of the KLF
can affect the proper functioning of e.g., pacemakers and defibrillators.
Persons with a pacemaker must keep a safety distance of at least 10 cm.

Safety instructions
Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0 13–44
2.8.4 Mechanical hazards
CAUTION
Danger of injury by moving components!
Limbs can be crushed by moving components!
Work on and with the KLF may only be carried out by qualified personnel.
Never reach into the system during normal operation!

Technical data
14 – 44 Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0
3 Technical data
3.1 Dimensional drawing KLF
3.1.1 Dimensional drawing KLF5
Fig. 1 Dimensional drawing - KLF5

Technical data
Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0 15–44
3.1.2 Dimensional drawing KLF7-KLF25
Fig. 2 Dimensioned drawing KLF7-KLF25

Technical data
16 – 44 Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0
3.2 Technical data KLF
3.2.1 Technical data KLF5

Technical data
Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0 17–44
3.2.2 Technical data KLF7-KLF25

Technical data
18 – 44 Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0
3.3 Accessories
3.3.1 Mounting parts
Tab. 1 Attachment parts and ordering data
3.3.2 Controller
Tab. 2 control units for KLF
For more information on the controller, see chap. 6.3 and the controller
manufacturer's instructions.
Type Designation Weight [g] Order Number
KLF5 Trimming weight NM07 25 [g] 15183426
KLF7
Trimming weight 100 [g]
50 [g]
15148404
15209275
Angle 47 [g] 15032942
Side plate 70 [g] 15157317
KLF15
Trimming weight 200 [g]
100 [g]
15081054
15192548
Angle 133 [g] 15026423
Side plate 190 [g] 15107163
KLF25
Trimming weight 400 [g]
800 [g]
Angle 350 [g] 152088257
Side plate 550 [g] 15010882
Type Power supply Order Number Note
IRG1-S 230V/50Hz 50360105 Control without timer function
External setpoint setting
115V/60Hz 50360106
MSG801
230V/50Hz -
115V/60Hz
50391818
Sensor feed, timer function,
valve and interface outputs
MSG802
230V/50Hz -
115V/60Hz
50391819 Sensor feed

Transport, packaging and storage
Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0 19–44
4 Transport, packaging and storage
4.1 Safety instructions
The linear feeders are packed in the original packaging (cardboard box).
Carefully remove the linear feeder from the original packaging.
CAUTION
Danger of injury due to improper transport equipment!
The improper use of transport equipment such as industrial trucks, overhead
cranes, slings can lead to injuries (e.g., crushing)!
Observe transport and assembly instructions.
Use the means of transport properly!
NOTICE
Damage to property due to improper lifting!
The linear feeder must not be lifted at the conveyor rail! Using the conveyor
rail as a lifting point can damage the linear feeder!
Lift the linear feeder by the base only!

Transport, packaging and storage
20 – 44 Operating & Installation Instructions EN KLF5/KLF7/KLF15/KLF25 Date 24.08.2023 Version 7.0
4.2 Scope of supply
The corresponding documentation is supplied with each linear feeder (e.g.,
operating and installation instructions, etc.).
Fig. 3 Scope of delivery KLF
[Unt] Designation
1 x Linear feeder KLF
1 x Operating and installation instructions