Conveyor FB30 / FB60 / FB90

Translation of original operating instructio n

Copyright by Afag Automation AG

Release: 4.1 2010-01-29 Seite 2

Release: 4.1 2010-01-29 Seite 3

This operation instruction applies to:

Type Order number

Conveyor

FB30

Pro

ject

-spe

cific

FB30 with brake-clutch unit

FB60

FB60 with brake-clutch unit

FB90

FB90 with brake-clutch unit

Version of Documentation: BA_FB30-90_R4.1_E.docx

Release: 4.1

Date: 2010-01-29

Release: 4.1 2010-01-29 Seite 4

Release: 4.1 2010-01-29 Seite 5

Table of contents:

1 Declaration of incorporation for the incomplete mac hine ............................. 7

2 Safety instructions ............................... ............................................................. 8

2.1 Notes on symbols and instructions ........................................................................................................... 8

2.2 Basic safety instructions ........................................................................................................................... 9

2.3 Appropriate use ........................................................................................................................................ 9

2.4 Reasonably foreseeable misoperation ...................................................................................................... 9

3 Description of the device ......................... ....................................................... 11

3.1 General ................................................................................................................................................... 11

3.2 Functional description ............................................................................................................................. 11

3.3 Technical data FB30/60/90 ..................................................................................................................... 15

3.4 Technical data FB30/60/90 with break-clutch unit................................................................................. 17

4 Assembly instructions ............................. ....................................................... 18

4.1 Transport ................................................................................................................................................ 18

4.2 Installing the unit .................................................................................................................................... 18

4.3 Power supply ........................................................................................................................................... 18

4.4 Wiring diagram ....................................................................................................................................... 19 4.4.1 Conveyor 230V / 400V .................................................................................................................. 20 4.4.2 Conveyor with brake-clutch unit 230V .......................................................................................... 21 4.4.3 Conveyor with brake-clutch unit 400V .......................................................................................... 23

5 Operating instructions ............................ ........................................................ 25

5.1 Standard operation ................................................................................................................................. 25

6 Maintenance instructions .......................... ..................................................... 25

6.1 Troubleshooting and fault repair ............................................................................................................ 25

6.2 Cleaning .................................................................................................................................................. 27

6.3 Replacing the drive belt .......................................................................................................................... 29

6.4 Replacing the conveyor belt .................................................................................................................... 29

6.5 Replacing the drive belt (with break-clutch unit) .................................................................................... 31

6.6 Replacing the conveyor belt (with break-clutch unit) ............................................................................. 31

6.7 Aligning the transport belt ...................................................................................................................... 33

6.8 Drive unit................................................................................................................................................. 33

6.9 Bearing .................................................................................................................................................... 33

7 Accessories ....................................... .............................................................. 33

7.1 Control device ......................................................................................................................................... 33

7.2 Spare parts .............................................................................................................................................. 34 7.2.1 FB30/60/90 ................................................................................................................................... 35 7.2.2 FB30/60/90 with break-clutch unit ............................................................................................... 37

7.3 Address for orders ................................................................................................................................... 39

8 Disposal .......................................... ................................................................. 39

Release: 4.1 2010-01-29 Seite 6

Release: 4.1

1 Declaration of incorporation for the incomplete mac hine

Declaration of incorporation according to the ECAnnex II B

The manufacturer: Afag Automa

www.afag.com

hereby declares, that the incomplete machine:

Designation: FB30 / FB60 / FB90

Complies with the basic safety and health requirements of the Machinery Directive Annex I .

The incomplete machine also complies with the following:

Relevant EC Directives:

Machinery

Low Voltage Directive 2006/95/EC

EMC-

Applied harmonised standards:

EN ISO 12100

The technical documentation for this incomplete machine was prepared in accordance with Annex VII, Part B. Upon request, the manufacturer undertakes to transmit these tecelectronically to national authorities, if requested.

Authorised representative for the compilation of the technical documentation:

The start- up of the incomplete machine icomplies with the regulations of the EC Machinery D irective and until the EC Declaration of Conformity according to Annex II A is available.

City, Date:

Company:

Address:

Authorised representative (signature)

Name

Position

2010-01-29

Declaration of incorporation for the incomplete mac hine

Declaration of incorporation according to the EC -Machinery- Directive 2006/42/EC,

Afag Automation AG, Fiechtenstrasse 32, CH-4950 Huttwil

www.afag.com – Tel.:+41 (0)62 / 959 87 05

hereby declares, that the incomplete machine: Conveyor

FB30 / FB60 / FB90 – all with or without break- clutch unit

es with the basic safety and health requirements of the Machinery Directive

The incomplete machine also complies with the following:

Machinery-Directive 2006/42/EC

Low Voltage Directive 2006/95/EC

- Directive 2004/108/EC

Applied harmonised standards:

EN ISO 12100-1; EN ISO 12100-2

The technical documentation for this incomplete machine was prepared in accordance with Annex VII, Part B. Upon request, the manufacturer undertakes to transmit these tecelectronically to national authorities, if requested.

Authorised representative for the compilation of the technical documentation: Marc ZinggAfag Automation AGProduct ManagerCH

up of the incomplete machine i s prohibited until installed in a complete machine that complies with the regulations of the EC Machinery D irective and until the EC Declaration of Conformity according to Annex II A is available.

Huttwil, 2009-12-23

Afag Automation AG

Fiechtenstrasse 32

CH-4950 Huttwil

Authorised representative (signature)

Dr. Ing. Martin Daniel Marc Zingg

Managing Director Product Manager

Seite 7

Declaration of incorporation for the incomplete mac hine

Directive 2006/42/EC,

4950 Huttwil

clutch unit

es with the basic safety and health requirements of the Machinery Directive 2006. /42/EC

The technical documentation for this incomplete machine was prepared in accordance with Annex VII, Part B. Upon request, the manufacturer undertakes to transmit these technical documents

Marc Zingg Afag Automation AG Product Manager CH-4950 Huttwil

s prohibited until installed in a complete machine that complies with the regulations of the EC Machinery D irective and until the EC Declaration of

Marc Zingg

Product Manager

Release: 4.1 2010-01-29 Seite 8

2 Safety instructions

2.1 Notes on symbols and instructions

Symbols: Assembly and commissioning must be carried out by qualified personnel only and according to these operating instructions.

Please observe the meaning of the following symbols and notes. They are grouped into risk levels and classified according to ISO 3864-2.

DANGER

Indicates an immediate threatening danger.

Non-compliance with this information can result in death or serious personal injuries (invalidity).

WARNING

Indicates a possible dangerous situation.

Non-compliance with this information can result in death or serious personal injuries (invalidity).

CAUTION

Indicates a possibly dangerous situation.

Non-compliance with this information can result in damage to property or light to medium personal injuries.

NOTE

Indicates general notes, useful operator tips and o perating recommendations which don’t affect safety and healt h of the personnel.

Release: 4.1 2010-01-29 Seite 9

2.2 Basic safety instructions

This operating manual provides the basis for the safe use and operation of the conveyor belt. This operating manual and, in particular, the included safety instructions have to be observed by all individuals working with and on the conveyor belt. In addition, all rules and regulations regarding accident prevention that are applicable for the site of operation are to be complied with.

The operating manual must always be kept at the site of operation of the conveyor belt.

2.3 Appropriate use

The conveyors are intended for storing, transporting, separating and arranging component parts of different sizes, forms and materials.

The workpieces must meet the following requirements in order to ensure a problem-free operation:

- they must be free of oil, grease and burrs

- they must not be sticky

- they must not be statically charged

- they must not be magnetic (no self-magnetism)

- they must be free of dirt and not be mixed with foreign parts

- rubber parts can be powdered with talcum

2.4 Reasonably foreseeable misoperation

The conveyor belt is exclusively designed for parts conveyance. Any other use or use exceeding this is considered as non-conforming and leads to the expiration of any guarantee claims.

The conveyor belt is not approved for explosion-hazardous areas.

Release: 4.1 2010-01-29 Seite 10

Fig. 1

Release: 4.1 2010-01-29 Seite 11

3 Description of the device

3.1 General

The conveyor has been designed for the transportation of oriented small components

3.2 Functional description

The conveyor FB 15 has been designed for the transportation of oriented small components over a specific distance. The conveyor is executed in different lengths.

Min. length 400mm

Max. length 2500mm

The basic construction of a conveyor comprises the following elements. (See Fig. 1)

FB30/60/90

1 Drive motor

2 Condenser (only 230V)

3 Drive pulley

4 Tensioning pulley

5 Pulley set with drive belt

6 Deflection pulley with adjusting screw

7 Large protection cover

8 Conveyor belt

9 Slide

10 Conveyor belt guide

11 Clamp set

12 Fixing bracket

13 Column

14 Single column support

Release: 4.1 2010-01-29 Seite 12

Fig. 2

Release: 4.1 2010-01-29 Seite 13

FB30/60/90 with Brake-clutch unit

(See Fig. 2)

1 Drive motor

2 Condenser (only 230V)

3 Drive pulley

4 Tensioning pulley

5 Pulley set with drive belt

6 Deflection pulley with adjusting screw

7 Large protection cover

8 Conveyor belt

9 Slide

10 Conveyor belt guide

11 Clamp set

12 Fixing bracket

13 Column

14 Single column support

15 Clutch

16 Brake

17 Terminal box

18 Small protection cover

Release: 4.1 2010-01-29 Seite 14

Release: 4.1 2010-01-29 Seite 15

Fig.3

3.3 Technical data FB30/60/90 (See Fig. 3)

Single -phase

A.C.

Threephase A.C. motor

Belt width 30 60 90

Dimensions [mm] A=182

[mm] B=38

[mm] C=15

[mm] D=55 D=85 D=115

[mm] E=30 E=60 E=90

[mm] F=3 F=18 F=33

[mm] G=75 G=90 G=105

[mm] H=198

[mm] I=150

Operating voltage [VAC] 230 400

Power frequency [Hz] 50 50

Current consumption [mA] 250 190

Capacitor [µF-450V] 4 -

Capacity [W] 34 35

Motor speed [rpm] 2675 2675

Torque at i=75 [Nm] 5.6

Torque at i=71 [Nm] 10.5

Torque at i=36.5 [Nm] 10.5

Protection class [IP] 44 Environmental conditions operation: temperature range

[C°] -10 to +40

Relative humidity (without capacitor) [%] 0 - 95

Environmental conditions storage: temperature range

[C°] -25 to +60

Relative humidity (without capacitor) [%] 0 – 95

Noise emission: Continuous noise pressure level (without transported material)

[dB] <70

Measuring height/measuring distance

[m] 1,6 / 1

Measurement direction with respect to the noise source

[°] 90

Measurement method - A evaluation

Release: 4.1 2010-01-29 Seite 16

Fig. 4

Release: 4.1 2010-01-29 Seite 17

3.4 Technical data FB30/60/90 with break-clutch uni t (See Fig. 4)

Single-phase A.C. motor

Threephase A.C. motor

Belt width 30 60 90

Dimensions [mm] A=182

[mm] B=38

[mm] C=15

[mm] D=55 D=85 D=115

[mm] E=30 E=60 E=90

[mm] F=3 F=18 F=33

[mm] G=75 G=90 G=105

[mm] H=198

[mm] I=150

Operating voltage [VAC] 230 400

Power frequency [Hz] 50 50

Current consumption [mA] 250 190

Capacitor [µF-450V] 4 -

Capacity [W] 34 35

Motor speed [rpm] 2675 2675

Torque at i=75 [Nm] 5.6

Torque at i=71 [Nm] 10.5

Torque at i=36.5 [Nm] 10.5

Protection class [IP] 44

Brake/clutch unit [VDC] 24 Environmental conditions operation: temperature range

[C°] -10 to +40

Relative humidity (without capacitor) [%] 0 - 95

Environmental conditions storage: temperature range

[C°] -25 to +60

Relative humidity (without capacitor) [%] 0 – 95

Noise emission: Continuous noise pressure level (without transported material)

[dB] <70

Measuring height/measuring distance

[m] 1,6 / 1

Measurement direction with respect to the noise source

[°] 90

Measurement method - A evaluation

Release: 4.1 2010-01-29 Seite 18

4 Assembly instructions

4.1 Transport

WARNING

Improper use of transport means (industrial trucks, cranes, technical aids, sling gear etc.) may lead to bruise s and other injuries. Required behaviour:

� Observe and follow the transport and maintenance instructions

� Proper use of transport means

4.2 Installing the unit

For the operation, the conveyor belt must always be mounted on a sufficiently dimensioned substructure. It has to be fastened with at least two supports and single legs.

4.3 Power supply

WARNING

Any work on the electrical supply may only be perfo rmed by trained, authorised, qualified personnel!

WARNING

The power supply must be protected by an FI switch (provided by the customer).

WARNING

The conveyor belt may only be operated with the pow er supply specified on the name plate.

When operating at 400VAC, the conveyor belt is directly connected inside the control cabinet and switched on and off by a contactor. The conveyor belt must be protected against overload by means of a protective motor switch.

Release: 4.1 2010-01-29 Seite 19

When operating at 230VAC, the capacitor 11006497 (4.5µF) must be used (see chapter 4.4).

When operating at 230VAC, the conveyor belt can be connected to the belt motor control SE621 (see figure 5).

Fig.5

4.4 Wiring diagram

NOTE

If the direction of rotation of the drive motor has to change, it is necessary to rotate the conveyor belt as well! (See Fig. 6)

Fig.6

Release: 4.1 2010-01-29 Seite 20

4.4.1 Conveyor 230V / 400V

Fig.7

Release: 4.1 2010-01-29 Seite 21

4.4.2 Conveyor with brake-clutch unit 230V

Fig.8

Release: 4.1 2010-01-29 Seite 22

Release: 4.1 2010-01-29 Seite 23

4.4.3 Conveyor with brake-clutch unit 400V

Fig.9

Release: 4.1 2010-01-29 Seite 24

Release: 4.1 2010-01-29 Seite 25

5 Operating instructions

5.1 Standard operation

No further settings are required for standard operation mode once the controller is switched on.

6 Maintenance instructions

WARNING

Certain preventive checks should however be carried out: A damaged mains cable should be replace immediately!

NOTE

Check all visible screws are tightness!

6.1 Troubleshooting and fault repair

WARNING

� Electrical work must only be carried out by trained personnel!

� Before removing the casing, unplug the power cable!

Interruptions caused by defective components must be repaired by replacing the defective component, only.

NOTE

Defective components must only be replaced by Afag original spare parts.

Release: 4.1 2010-01-29 Seite 26

Release: 4.1 2010-01-29 Seite 27

Conveyor does not operate after being switched on.

Troubleshooting: Fault repair

Supply cable to drive unit broken / defective

Replace supply cable

Transport belt slips on drive roll Tension transport belt (see chapter 6.7)

Defective drive unit (worm gear motor)

Replace drive unit

Strong noise emissions of the conveyor belt

Troubleshooting: Fault repair

Transport belt touches the side guides Align transport belt (see chapter 6.7)

6.2 Cleaning

Conveyor belt Detergent: Cleaning method:

HNI-5P Spirit clean with a damp cloth, let it dry

F-0 Spirit clean with a damp cloth, let it dry

CNB-5E Spirit clean with a damp cloth, let it dry

CAUTION

If other cleaning agents or cleaning methods than t hose mentioned above are used, the components can get pe rmanently damaged so that the proper function of the conveyor is no longer guaranteed.

WARNING

The following requirements must be met during the c leaning:

� Wear safety goggles

� Provide sufficient ventilation when cleaning with v olatile substances

Release: 4.1 2010-01-29 Seite 28

Fig.10

Release: 4.1 2010-01-29 Seite 29

6.3 Replacing the drive belt (See Fig.10)

1. Loosen the screws (1) and remove the protection cover (2).

2. Loosen the grub screw (3)

3. Remove the pulley (4) and the drive belt (5).

4. Fit the new drive belt and mount the components in reverse order.

6.4 Replacing the conveyor belt (See Fig. 10)

1. Loosen the screws (6) and remove the protection cover (7).

2. Loosen the tensioning screw (8) and remove the tensioning screw (9).

3. Remove the condenser (10) (if installed).

4. Remove the circlip (11) and the plate (12).

5. Remove the conveyor belt (13).

6. Fit the new transport belt and mount the components in reverse order. Note the running direction of the transport belt (see Fig. 11).

7. Align transport belt (see chapter 6.7)

Fig. 11

Release: 4.1 2010-01-29 Seite 30

Fig.12

Release: 4.1 2010-01-29 Seite 31

6.5 Replacing the drive belt (with break-clutch uni t) (See Fig. 12)

1. Loosen the screws (1) and remove the protection cover (2).

2. Loosen the grub screw (3)

3. Remove the pulley (4) and the drive belt (5).

4. Fit the new toothed belt and mount the components in reverse order.

6.6 Replacing the conveyor belt (with break-clutch unit) (See Fig. 12)

1. Loosen the screws (6) and remove the protection cover (7).

2. Loosen the tensioning screw (8) and remove the tensioning screw (9) completely.

3. Remove the condenser (10) (if installed).

4. Remove the protection cover (11) (the terminal box (12) must not be dismantled)

5. Loosen the grub screw (13) and remove the brake disk (14).

6. Remove the circlip (15) and the plate (16).

7. Remove the conveyor belt (17).

8. Fit the new transport belt and mount the components in reverse order. Note the running direction of the transport belt (see Fig. 13).

9. Align transport belt (see chapter 6.7)

Fig. 13

Release: 4.1 2010-01-29 Seite 32

Release: 4.1 2010-01-29 Seite 33

6.7 Aligning the transport belt (See Fig.14)

The tension and the centric position of the conveyor belt are to be checked on a weekly basis. In case the tension of the belt is not sufficient or the belt is off-center, the tension and the centricity of the belt is then to be corrected by using the setscrews (1 and 2) at the inner and the two outer deflection rollers. It is important that the belt is not too tight as this may affect the service life of the bearings. A soiling of the conveyor belt is to be avoided by regular cleaning (see chapter 6.2). This will ensure a long service life of the overall system.

Fig. 14

6.8 Drive unit

No maintenance is required for the worm gear motor.

6.9 Bearing

No maintenance is required for the bearings of the drive- and deflection rollers.

7 Accessories

7.1 Control device

Type Power supply AFAG Art.-Nr.

SE 621

Belt motor control SE 621 230V/50Hz 50000396

2

2

1

Release: 4.1 2010-01-29 Seite 34

7.2 Spare parts

Fig.15

Release: 4.1 2010-01-29 Seite 35

7.2.1 FB30/60/90 (See Fig. 15)

Pos Dimensions Qty AFAG Art.-Nr.

1 Worm gear motor KD842 Z8/3-K4 i=36.5 1 11017139 2 Worm gear motor KD842 Z8/3-K4 i=71 1 11017140 3 Drive belt 350-5M-9 1 11006558 4 Drive shaft FB30 Ø10x103.5 1 11006521 Drive shaft FB60 Ø10x133.5 1 11006535 Drive shaft FB90 Ø10x163.5 1 11006548 5 Tapped axle FB30 Ø10h6x71 1 11006530 Tapped axle FB60 Ø10h6x101 1 11006544 Tapped axle FB90 Ø10h6x131 1 11006555 6 Non-tapped axle FB30 Ø10h6x71 1 11006528 Non-tapped axle FB60 Ø10h6x101 1 11006542 Non-tapped axle FB90 Ø10h6x131 1 11006554 7 Grooved ball bearing 6000-2Z 10 11006564 9 Alignment axle FB30 Ø10h6x50 2 11006526 Alignment axle FB60 Ø10h6x80 2 11006540 Alignment axle FB90 Ø10h6x110 2 11006553 10 Condenser 4.0 uF/450V 1 11006497

Release: 4.1 2010-01-29 Seite 36

Fig.16

Release: 4.1 2010-01-29 Seite 37

7.2.2 FB30/60/90 with break-clutch unit (See Fig. 16)

Pos. Dimensions Qty AFAG Art.-Nr. 1 Worm gear motor KD842 Z8/3-K4 i=36.5 1 11017139 2 Worm gear motor KD842 Z8/3-K4 i=71 1 11017140 3 Drive belt 350-5M-9 1 11006558 4 Drive shaft FB30 Ø10x135 1 11012178 Drive shaft FB60 Ø10x165 1 11012179 Drive shaft FB90 Ø10x195 1 11012180 5 Tapped axle FB30 Ø10h6x71 1 11006530 Tapped axle FB60 Ø10h6x101 1 11006544 Tapped axle FB90 Ø10h6x131 1 11006555 6 Non-tapped axle FB30 Ø10h6x71 1 11006528 Non-tapped axle FB60 Ø10h6x101 1 11006542 Non-tapped axle FB90 Ø10h6x131 1 11006554 7 Grooved ball bearing 6000-2Z 10 11006564 9 Alignment axle FB30 Ø10h6x50 2 11006526 Alignment axle FB60 Ø10h6x80 2 11006540 Alignment axle FB90 Ø10h6x110 2 11006553 10 Ball bearing 16004 1 11006591 11 Electro-magnetic clutch 86011-07E00-24V20 1 11006588 12 Electro-magnetic brake 86111-07E00-24V 1 11006590 13 Segmented anchor plate 86000-07B200 2 11006589

Release: 4.1 2010-01-29 Seite 38

Release: 4.1 2010-01-29 Seite 39

7.3 Address for orders

Schweiz: Afag Automation AG Zuführtechnik Fiechtenstrasse 32 CH-4950 Huttwil Tel.:+41 (0)62 / 959 87 05 Fax:+41 (0)62 / 959 87 76

Deutschland: Afag GmbH Wernher-von-Braun-Strasse 5a D-92224 Amberg Tel.:+49 (0)96 21 / 65 0 27-0 Fax:+49 (0)96 21 / 65 0 27-390 Sales: Afag GmbH Hertichstrasse 70 D-71229 Leonberg Tel.:+49(0)71 52 / 60 08-0 Fax:+49 (0)71 52 / 60 08-10

sales@afag.com www.afag.com

8 Disposal

Conveyors that are no longer in use should not be disposed of as complete units but dismantled into separate materials and recycled. Non-recyclable components must be disposed of correctly.

Release: 4.1 2010-01-29 Seite 40