flexfactory flexfeeder X Series User manual

Source le name: Assembly Instructions X-Series B.afpub
Path: /Users/felix.buechi/Documents/Montage Anleitung E
Revision: A unreleased/preliminary
Save Date: 19.01.2023
Document P/N: 700-000-002
Assembly Instructions
exfeeder X-Series

Table of contents
l Chapter 1 l Regulatory and Legal 5
1.1 Obligation to read First 5
1.2 Copyright 5
1.3 Manufacturer 5
1.4 Declaration of Incorporation 6
l Chapter 2 l General Information 7
About this Manual 7
Danger Level Indicators used in this Manual 8
l Chapter 3 l Safety 10
3.1 Introduction 10
3.2 Responsibility of the operating company 10
3.3 Personnell Requirements 11
3.4 Personal protective equipment 12
3.5 Intended use 13
3.6 Residual risks 14
3.7 Safety Equipment 16
3.8 Unrecognizable symbols and labels on the machine 17
3.9 Securing against reconnection to electrical power 17
3.10 Shutdown in case of emergency machine 18
3.11 Environmental protection 18
l Chapter 4 l Transportation & Storage 19
4.1. Safety instructions for transportation 19
l Chapter 5 l Assembly and Installation 22
5.1 Safety 22
5.2 Overview of exfeeder X shipping congurations options 23
5.3 Scope of supply 26
5.4 Functional parts and assemblies of the exfeeder X 29
5.5 Installing the Feeder 31
5.5 Installing the exfeeder X on the machine base 33
5.6 Electrical installation 36

l Appendix A0 l Controls Schematic 40
l Appendix A1 l exfeeder X250 feeder-unit 41
l Appendix A2 l Dimensions exfeed X250 with tower 42
l Appendix A3 l X250 work envelopes 43
l Appendix A4 l X250 Base plate mounting pattern 44
Table of contents

l Chapter 1 l Regulatory and Legal
Assembly Instructions exfeeder X 5
Assembly Instructions exfeeder X
Before you start working with the product described
here, you must have read and understood the contents
Of this documentation in full.
1.1 Obligation to read First
This manual is protected by copyright and is intended exclusively
for internal purposes. Transfer of this manual to third parties,
reproductions in any manner and form – in full or in part – as well
as exploitation and/ or communication of content without written
permission from the manufacturer, except for internal purposes,
is prohibited.
1.2 Copyright
exfactory ag
Giessenstrasse 15
CH-8953 Dietikon
Switzerland
Tel: [phone]
Fax: [phone]
www.exfactory.com
info@exfactory.com
1.3 Manufacturer

l Chapter 1 l Regulatory and Legal
Assembly Instructions exfeeder X 6
1.4 Declaration of Incorporation
Manufacturer exfactory ag
Giessenstrasse 15
8953 Dietikon, Switzerland
Phone: [phone]
Homepage: www.exfactory.com
Email: info@exfactory.com
We hereby declare that, based on its conception, design and construction, the product
named below, in the version placed on the market by us, complies with
the essential safety requirements of the Machinery Directive, including the
amendments applicable at the time of the declaration, up to the interfaces described in
the enclosed technical documentation. The basic safety requirements according to the
appendix of this declaration of incorporation have been complied with.
Product designation exfeeder X-Series
Machine models X185, X250, X350
Relevant EC directives Machinery directive 2006/42/EC
EMC 2014/30/EC
Applied harmonised
standards
EN ISO 12100:2010 Safety of machines
EN ISO 13857:2020 Safety distances to prevent reaching hazardous areas
EN 61000-6-2:2019 EMC generic standards - immunity standards for industrial
environments
EN 61000-6-4:2011 EMC generic standards - emission standards for industrial
environments
Obligation The manufacturer undertakes to transmit the documentation electronically to the
competent national authority upon justied request. The special technical documents
belonging to the machine according to Annex VII Part B have been prepared.
Authorised
representative for
compiling the technical
documentation
Peter Ulrich, exfactory ag, Giessenstrasse 15, 8953 Dietikon, Switzerland
Obligation The manufacturer undertakes to transmit the documentation electronically to the
competent national authority upon justied request. The special technical documents
belonging to the machine according to Annex VII Part B have been prepared.
Intended product use The exfeeder X models are intended for installation in complete production systems.
Their commissioning is prohibited until it has been ensured that the entire machine in
which the mentioned partly completed machinery is installed complies with the
provisions of the Machinery Directive.
Disclaimer This declaration does not contain any guarantees. The safety instructions in the
product documentation must be observed. If a change to the listed products is not
agreed upon with the manufacturer, this declaration loses its validity.
Dietikon, May 2022; Felix Büchi, CEO
in accordance with EC Machinery
Directive 2006/42/EC, Annex II B

l Chapter 2 l General Information
Assembly Instructions exfeeder X 7
2.1.1 Using the Assembly
Instructions
These assembly instructions enable the operator to take over, assemble and
commission the exfeeder within the framework of the instructions described
here. The basic prerequisite for safe working is compliance with all the
warnings and instructions given in these assembly instructions.
2.1.2 Reading Obligation Personnel are required to carefully read and understand these installation
instructions before beginning any work.
2.1.3 Reselling, Handover If the exeeder is passed on to third parties, these assembly instructions must
also be handed over.
2.1.4 Additional applicable
documentation
In addition to these assembly instructions, the exfeeder instructions, notes
and signs in the appendix also apply.
2.1.5 Regulations In addition, the local accident prevention regulations and general safety
regulations for the area of application of the machine apply.
2.1.6 Figures, Illustrations Illustrations in these assembly instructions are for basic understanding and
may deviate from the actual design of the machine.
2.1.7 Loss of the
instructions
If the assembly instructions are lost, request a replacement immediately. For
contact details, see imprint (page 2).
2.1.8 Online
Documentation
The operating instructions available online apply in addition to these assembly
instructions. The operating instructions enable safe and efcient handling of
the exfeeder throughout all phases of the machine's life. Among other things,
the operating instructions provide the necessary information on operation,
maintenance, and troubleshooting.
About this Manual

l Chapter 2 l General Information
Assembly Instructions exfeeder X 8
Danger Level Symbol, Information, Explanation, Colors
2.2.1 Risk of Death
A warning at this danger level indicates an imminent dangerous situation.
Failure to avoid the dangerous situation will result in death or serious injury.
Follow the instructions in this warning to avoid the risk of death or serious
personal injury.
DANGER RISK OF DEATH
Consequences in case of noncompliance
_________
Notes on avoidance
2.2.2 Risk of Injury
A warning at this danger level indicates a potentially dangerous situation.
Failure to avoid the dangerous situation may result in death or serious injury.
Follow the instructions in this warning to avoid the potential risk of death or
serious personal injury.
WARNING RISK OF INJURY
Consequences in case of noncompliance
_________
Notes on avoidance
2.2.3 Caution
A warning at this danger level indicates a potentially dangerous situation.
Failure to avoid the dangerous situation may result in minor or moderate injury.
Follow the instructions in this warning to avoid personal injury.
CAUTION RISK OF INJURY
Consequences in case of noncompliance
_________
Notes on avoidance
Danger Level Indicators used in this Manual

l Chapter 2 l General Information
Assembly Instructions exfeeder X 9
Danger Level Symbol, Information, Explanation, Colors
2.2.4 Damage to Equipment Possible Damage to Equipment
Consequences in case of noncompliance
_________
Notes on avoidance
2.2.5 Safety Instructions Safety Instructions
Place here your instructions for carrying out work
safely.
2.2.6 Useful Information
Instructions
Tips and Notes
Place here additional information that is important to
simplify
a task or better understand a situation.

l Chapter 3 l Safety
Assembly Instructions exfeeder X 10
3.1 Introduction This section provides an overview of all important safety aspects for the
optimum protection of personnel and for safe and smooth operation.
Noncompliance with the handling instructions and warnings provided in these
instructions can result in signicant dangers. In these instructions, only those
risks can be considered that have beenidentied based on a risk assessment.
Risks resulting from the working conditions, the location of use and interfaces
to external components must be identied and warnings must be
supplemented accordingly.
3.2 Responsibility of
the operating
company
The operating company is generally subject to the legal requirements for
occupational safety, since the machine is intended for use in the commercial
sector. In addition to the warnings in these instructions, the applicable safety,
accident prevention and environmental protection regulations for the area in
which the machine is used must therefore also be observed.
3.2.1 Risk assessment The operating company must, by means of a risk assessment, inform itself
about the applicable occupational health and safety regulations and identify
additional dangers resulting from the specic working conditions at the
machine's place of use.
3.2.2 Operating instructions According to the results of the risk assessment at the workplace, the operating
company must issue, implement and document a set of operating instructions.
During the entire operating time of the machine, the operator is responsible for
ensuring that the operating instructions that it has prepared comply with the
current legal requirements.
3.2.3 Responsibilities The operating company must regulate the responsibilities for work on or with
the machine and designate a person responsible for ensuring the safe
operation of the machine and the coordination of all activities.
3.2.4 Information ow The operating company must ensure that all personnel who perform work on
or with the machine have read and understood these instructions and other
operating instructions. In addition, it must train the assigned personnel at
regular intervals and inform them about the relevant hazards.
3.2.5 Personal protective
equipment
The operating company must provide the relevant personnel with the required
personal protective equipment.
3.2.6 Safety material The operating company must provide all necessary safety materials, such as
a padlock to secure the main switch, during maintenance.
3.2.7 Safety requirements If necessary, the operating company must ensure that the machine into which
this product is to be integrated or of which it is a component complies with the
essential safety requirements and provisions of all relevant directives prior to
commissioning.
3.2.8 Technically perfect
condition
To keep the machine in a technically perfect condition at all times, the
operating company must ensure that the maintenance intervals specied in
these instructions are observed. In addition, the operating company must
ensure that all necessary safety devices are properly installed on the
machine. It must regularly check them for completeness and functionality.

l Chapter 3 l Safety
Assembly Instructions exfeeder X 11
3.3.1 Generall personell
requirements
Only persons who reliably carry out their work and whose ability to react is not
impaired by the inuence of, for example, drugs, alcohol or medication, may
be assigned as operating personnel.
When selecting personnel, the job-specic age specications applicable at the
location where the machine is operated must be observed.
3.3.2 Qualications Improper handling due to insufcient qualication can result in signicant
injuries.
- Have all activities carried out by qualied personnel only
- Keep unqualied personnel away from the danger zones
The following qualications for different areas of activity are specied in the
instructions:
3.3.3 Qualied personell
3.3.4 Qualied electrician
3.3.5 Manufacturer
3.3.6 Forklift driver
3.3.7 Instructed person
Qualied personnel are able to perform the work assigned to them due to their
technical training, knowledge and experience as well as their knowledge of the
relevant standards and regulations, and to independently identify and avoid
possible dangers.
Qualied electricians are able to perform the work assigned to them due to their
technical training, knowledge and experience as well as their knowledge of the
relevant standards and regulations, and to independently identify and avoid
possible dangers.
Qualied electricians are trained for the specic location in which they work and
know the relevant directives, standards and regulations.
Some work may only be carried out by the manufacturer's qualied personnel.
Other personnel are not authorised to carry out this work. Contact the
manufacturer's service department to arrange for the necessary work to be
carried out (see the imprint on page 2).
A forklift driver is at least 18 years of age and is capable of driving industrial
trucks equipped with a driver's seat or driver's platform due to his or her
physical, mental and character traits.
In addition, the forklift driver has been trained to drive industrial trucks equipped
with a driver's seat or driver's platform.
The forklift driver has demonstrated to the operating company that he or she is
capable of driving industrial trucks equipped with a driver's seat or a driver's
platform and has subsequently been instructed in writing by the operating
company to perform this task.
The instructed person has been informed by the operating company about the
tasks assigned to him or her and about possible dangers in case of improper
behaviour.
3.3 Personnell Requirements

l Chapter 3 l Safety
Assembly Instructions exfeeder X 12
3.3.8 Unauthorised
personnel
Unauthorised personnel who do not satisfy the requirements described here
are not aware of the dangers in the work area.
- Keep unauthorised personnel away from the work area.
- In case of doubt, approach the people concerned and direct them away
from the work area.
- Stop work as long as unauthorised personnel are present in the work area.
3.4 Personal
protective equipment
Some work requires personnel to use personal protective equipment in order
minimise health hazards. In addition to the personal protective equipment
specied in these instructions, the notes posted in the work area must be
observed. The following personal protective equipment must be worn
accordingly before beginning the respective tasks:
3.4.1 Appropriate work clothing
is tight-tting work clothing with low tear resistance, tight sleeves
and no protruding parts. It is primarily used for protection
against entrapment by moving machine parts. Do not wear rings, chains or
other jewellery.
3.4.2 Safety shoes
are used to protect against heavy falling parts and slipping on
slippery surfaces.
3.4.3 Protective gloves
are used to protect the hands from friction, abrasions, punctures
or deeper injuries as well as from contact with hot surfaces.
3.4.4 Safety goggles
are used to protect the eyes from ying particles and parts.

l Chapter 3 l Safety
Assembly Instructions exfeeder X 13
3.5 Intended use The machine is designed and built exclusively for the intended use described
here and must only bnbe operated accordingly:
3.5.1 Functional description
of the exfeeder
The exfeeder is a exible feeding system for bulk parts. It consists of a stock
parts hopper with a retaining ap and a vibrating table with discharge function.
This enables the rejection of NIO parts and a quick product change on the
line. The bulk parts are poured from the hopper onto the conveyor platform
where they are distributed as best as possible. The kinematics of the drive
allows different movement patterns. Through these, the parts can be moved
back and forth, redistributed or turned. The servo drives allow the movement
of light as well as heavy parts.
The exfeeder is equipped with a Linux-based/embedded controller. The
communication between exfeeder and robot or plant control is done via
Ethernet TCP/IP.
The exfeeder is set up via a browser-based user interface. With only two
parameters - intensity and duration of the movement - the conveying behavior
can be individually adjusted to the different parts.
3.5.2 Intended use The exfeeder is designed and constructed exclusively for the intended use
described here and may only be operated accordingly:
The exfeeder
- serves exclusively as a exible feeding system for bulk material parts for, for
example, assembly, testing or packaging machines.
- is intended exclusively for installation in a complete system.
- may only be operated in accordance with the operating and ambient
conditions specied in the chapter Technical data p.31.
- may only be operated in accordance with the requirements of the locally
applicable accident prevention regulations.
- may only be operated with additional protective measures (e.g. machine
guarding) during automatic removal of parts from the vibrating table. Together
with a collaborative robot, the formwork can be dispensed with, provided that
this is permitted by the risk analysis of the higher-level machine/plant.
- May only be operated with additional protective measures (e.g. safety light
grid) when parts are removed manually.
3.5.3 Improper use There is a risk of serious injury or death if the exfeeder is not used as
intended due to:
- Operation in potentially explosive atmospheres
- feeding of unpacked foodstuffs
- operation without lateral xation on the table
3.5.4 Misuse Folgenden Fehlgebrauch dringend vermeiden:
Zuführung von nassen, stark verschmutzten und stark öligen Teilen.
Ansprüche jeglicher Art wegen Schäden aufgrund nicht bestimmungsmässiger
Verwendung sind ausgeschlossen.

l Chapter 3 l Safety
Assembly Instructions exfeeder X 14
3.6 Residual risks
The following section lists residual risks that have been identied on the basis
of a risk assessment.
3.6.1 Dangers from electrical energy
In case of contact with electrically live parts, damage to the insulation or
individual components, there is a danger to life due to electric current.
• To be ensured by the operator: The electrical connection of the machine
in which the exfeeder is installed must comply with the electrotechnical
regulations.
• Work on the electrical system may only be carried out by qualied
electricians
• In case of damage to the insulation, switch off the power supply
immediately and arrange for repair.
• Before connecting the machine to the power supply, compare the data in
the "Technical data" with the data of the power supply system and
connect only if there is a match.
• Before starting work on active parts of electrical systems and equipment,
ensure that they are de-energized for the duration of the work.
• Never bridge fuses or put them out of operation. When replacing fuses,
observe the correct current rating.
• Keep moisture away from electrically live parts. This can lead to a short
circuit.
3.6.2 Mechanical dangers
• Moving assemblies harbor the potential for injury from crushing, shearing
and impact.
• In automatic mode, only operate the machine with installed and
functioning protective covers.
• Before maintenance work and troubleshooting, switch off the machine
and secure it against being switched on again.
• Operator responsibility: Manual operation of the machine within the
machine enclosure is the responsibility of the operator and is subject to
the safety concept of the relevant machine or its control system.
Safety Instructions
Failure to observe the safety instructions, warnings and handling
instructions given in these assembly instructions may result in
considerable danger.
• It is essential to observe the listed safety and warning notes
and instructions for action!
• Also observe the safety instructions contained in the
applicable documents.

l Chapter 3 l Safety
Assembly Instructions exfeeder X 15
3.6.3 Dangers due noise
Depending on the material being conveyed, high noise levels may occur
which can cause hearing damage.
• Depending on the material conveyed, wear hearing protection if
necessary.
• Operator responsibility: It is the operator's responsibility to take additional
measures to protect against noise emissions, if necessary. Possible
measures include, for example, the use of special conveyor plates, lining
the hopper and the return container, and adjustments to the machine
casing (to improve sound insulation).
3.6.4 Dangers at the place of use
Safety deciencies caused by incorrectly performed work due to insufent
lighting
• Ensure sufcient lighting at the workplace. Have defective lamps replaced
immediately.
• Sharp edges, corners, and sharp-edged materials can cause abrasions
and cuts on the skin.
• Exercise caution when working near sharp edges and corners and when
handling sharp-edged materials.
• If in doubt, wear protective gloves (e.g. when cleaning the machine).
• Dirt and objects lying around are sources of slipping and tripping:
• Always keep the work area clean
• Remove objects that are no longer needed
• Mark tripping hazards with yellow-black marking tape

l Chapter 3 l Safety
Assembly Instructions exfeeder X 16
3.7.1 General
3.7 Safety Equipment
3.7.2 Protective measures at the feeder
Danger due to non-functioning safety devices!
Before starting work, ensure that the safety devices are functional and
correctly installed.
Never disable safety devices.
Ensure that safety devices such as the EMERGENCY STOP button are
always accessible.
The cell protection device is mounted on the machine itself.
Instru
ctions
Tips and Notes
The exfeeder must be integrated into the emergency stop
concept of the entire plant
Moving components, such as drive units, are either fully enclosed,
or protective measures have been applied.
The exfeeder is intended for operation within a safety fence. In case of other
use, as described e.g. on page "Intended use", the manufacturer must assess
the overall system according to the risks and take suitable measures .
The protective covers attached to the exfeeder must not be modied,
dismantled or put out of operation.
Protective covers removed during maintenance/repair work must be retted
before recommissioning.
Protective covers must always be in place when the feeder is powered on.

l Chapter 3 l Safety
Assembly Instructions exfeeder X 17
3.8 Unrecognizable symbols and labels on
3.9 Securing against reconnection to electrical power
Risk of injury from unrecognizable symbols or pictograms on the machine:
Ensure that all safety, warning and operating instructions are always in
clearly legible condition.
Replace damaged symbols and pictograms immediately.
Never cover, block or remove symbols and pictograms.
Pictograms may be located on the machine. They refer to the immediate
environment in which they are located and indicate hazards or measures
to be taken.
Risk of serious injury or death due to unauthorized or uncontrolled restarting
(e.g. during troubleshooting or maintenance work):
Before restarting, make sure that all enclosures and protective covers are
mounted and in working order and that there is no danger to persons.
Always follow the procedure described below for securing against
restarting.
Disconnect the machine from the power supply.
Secure the main switch (of the complete system) with a lock or other
adequate measures. Observe the information in the operating instructions
for the complete system.
After all work has been carried out, ensure that there is no danger to
persons.
Ensure that all safety and protective devices are installed and in working
order.
Only remove the lock from the main switch, after complying with all the
points above.

l Chapter 3 l Safety
Assembly Instructions exfeeder X 18
3.10 Shutdown in case of emergency
3.11 Environmental protection
In case of accidents and in case of danger, the machine must be stopped
immediately.
The emergency stop circuits of the exfeeder and the higher-level overall
system must be connected to each other. When the emergency stop button on
the overall system is pressed, the exfeeder therefore also goes into
emergency stop.
Pressing the emergency stop button triggers an emergency stop.
Risk of serious injury or death due to uncontrolled restart:
Before restarting, make sure that the cause of the emergency stop has
been eliminated and that all safety devices are mounted and functionall.
Den Not-Halt-Taster erst entriegeln, wenn keine Gefahr mehr besteht.
Danger to the environment due to incorrect handling of environmentally
hazardous substances, in particular incorrect disposal, is posed by the
following substances used in the exfeeder:
Lubricants such as greases and oils (e.g. In ball bearings) may contain
toxic substances. They must not be released into the environment.
Disposal must be carried out by a specialist disposal company in
accordance with the locally applicable regulations.
Replaced machine parts may be contaminated by greases and oils and
thus contain toxic substances and must be disposed of professionally.
All materials used in the exfeeder can be disposed of in the usual
channels such as: Scrap metal, plastics, electronic components

l Chapter 4 l Transportation & Storage
Assembly Instructions exfeeder X 19
Safety Instructions
Safe working during the transport of the machine!
Perform all work in compliance with the following
safety instructions listed below
1Observe the regulations listed in chapter Safety $? for all work
on / with the machine..
2Observe the instructions and personnel requirements
according to chapter Personnel requirements.
3Provide suitable forklift trucks for transport.
4Do not step under heavy loads. Instruct unauthorized
persons from danger areas.
4.1. Safety
instructions for
transportation
4.2.1 Packaging crate
Crate with feeder-unit only
Crate with feeder and camera tower
Contruction of
packaging crate
1 Pallet (wood)
2 Crate (wood)
3 Fixation tape
4 Feeder
5 Camera Tower

l Chapter 4 l Transportation & Storage
Assembly Instructions exfeeder X 20
4.2.2 Lifting & Moving with a forklift
Prerequisites
The feeders and accessories packed on a wooden pallet can be transported
with a forklift under the following conditions:
Center of gravitiy
Licensed fork lift driver
• The center of gravity of the transport unit must be taken into account. This
is +/- 200mm below the middle beam of the wooden pallet.
• The transport locks of the individual components (screws in wooden pallet)
may only be removed at the destination.
• The forklift may only be operated by a licensed forklift driver
Transportation
Fork alignment
Center align forks
1. Make sure the forks are
600-800mm apart
2. Center the fork pair
sideways under the pallet
and make sure the fork tips
protrude from unterneath
the pallet.
3. Start lifting the pallet slowly.
Lift it only as high as
needed.

l Chapter 4 l Transportation & Storage
Assembly Instructions exfeeder X 21
Level pallet with machine base 1. Position the pallet in front of the machine base and level the top of the pallet
slightly above the machine base
2. Remove the screws which secure the feeder on the pallet
3. Carefully push the feeder onto the machine base
Center of gravitiy
Licensed fork lift driver
m: Center of gravitiy
Prerequisites The exfeeder can be transported with a crane in compliance with the
company's internal regulations:
1. Screw the enclosed 4 eyebolts M6x13 (ISO3266) into the side plate.
2. Thread the belts into eyebolts or hang them with additional hooks. So that
the eyebolts and the threads are not overloaded laterally, the hanger must
have a minimum distance to the crane hook of 1m.
3. Ensure that ropes, belts, etc. are not twisted and that the transport pieces
are securely fastened.
4.2.3 Transport with crane
CAUTION
Personal injury due to overloading
when lifting loads: If the exfeeder is
lifted manually from the transport
pallet, the operator's internal safety
regulations must be observed (see
weight specications page 21)