Afag aflex 150 qc Operating Or Assembly Instructions
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Afag aflex 150 qc Operating Or Assembly Instructions

Flexible feeding system
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Flexible feeding system
aflex 150 qc / aflex 200 qc
Operating or assembly instructions
Copyright by Afag GmbH

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  • Page 1 Flexible feeding system aflex 150 qc / aflex 200 qc Operating or assembly instructions Copyright by Afag GmbH...
  • Page 2 Type Order number Basis with red back light 50473402 Basis with white back light 50473403 aflex 150 qc White POM FDA plate for transported material 50473406 Black POM FDA plate for transported material 50473407 Basis with red back light 50473404...
  • Page 3 Date: 22.10.2019 History version changes R01.2 Documentation of aflex 150 qc and aflex 200 qc. Documentation of the EtherCAT inter- face R01.3 Documentation of the Profinet interface Documentation of ControlUnit Firmware v1.40. Improved “direction” control when using R01.4 digital inputs.

  • Page 4: Table Of Contents

    Content: Safety instructions .................... 6 Explanation of symbols and instructions ....................6 Basic safety instructions ........................... 7 1.2.1 Electrical Connection ........................7 1.2.2 Danger zones ........................... 8 Intended use ............................. 8 Obligations of the operator ........................8 Description of the device ................11 General ..............................
  • Page 5 4.5.2 Aflex configurations ........................44 4.5.3 Backlight ............................46 4.5.4 Simulation of the external control ....................47 Sub menu controller ..........................50 Sub menu clients ............................. 56 4.7.1 Client Nodes Functions........................59 4.7.2 T4X Client Node ..........................61 4.7.3 Backlight Node ..........................64 4.7.4 Profibus Module ..........................

  • Page 6: Safety Instructions

    1 Safety instructions Explanation of symbols and instructions Symbols: Installation and commissioning shall be done only by qualified personnel according to operating manual. Please observe the importance of following explanation symbols and instructions. They are divided and classified in danger levels according to ISO 3864-2. DANGER Indicates a direct potential danger.

  • Page 7: Basic Safety Instructions

    Basic safety instructions This operating manual serves as the base to start the flexible feeding device aflex and to operate it. This operating manual, in particular the safety instructions must be ob- served which work on or with aflex. Furthermore, the respective valid rules and regu- lations for accident prevention must be observed for the operation site.

  • Page 8: Danger Zones

    1.2.2 Danger zones INSTRUCTION The flexible feeding devices from Afag are built according to EG machine guidelines, state of the art and the recognized technical safety regulations. Nevertheless during use, danger to life and limb of the operators or third parties or impairments to aflex or other material assets can arise.
  • Page 9 Prescribe appropriate personal protective equipment (PPE) for activities with in- creased risk of injury. Pinpoint the responsibilities according to the various tasks, installation, commission- ing and operation. You must immediately notify your supervisor personally of any occurring and recog- nizable malfunctions. R01.43 22.10.2018 Page 9...
  • Page 10 INSTRUCTION All persons working at the aflex as well as persons who are em- ployed under the Temporary Employment Act have a duty to co- operate for safety and health protection at the workplace. You must be instructed about using the aflex. INSTRUCTION Reasonably foreseeable misuse, the dangers for the user, third parties or for the...

  • Page 11: Description Of The Device

    2 Description of the device General The aflex system consists of an aflex and an external control system. This consists of individual control modules. A ControlUnit and two drive modules are used in the stand- ard configuration. Optionally, the control can be extended with additional field bus in- terfaces.

  • Page 12: Technical Data

    Technical data Figure 1: Dimension sheet aflex Table 1: Technical data aflex qc Description Unit aflex150 qc aflex200 qc [mm] [mm] [mm] [mm] [mm] 83,3 106,8 [mm] Dimensions 18 18 [mm] 12 12 [mm] [mm] [mm] [mm] Max. size of the parts & Max. weight of the parts See 2.3.1 &...
  • Page 13 0…45°C 0…45°C Surrounding temperature [°C] Weight [kg] 10,2 Integrated background lighting optional optional Protective type in closed condition IP51 IP51 Figure 2: Dimension sheet plate for transported material Table 2 : technical data of plate for transported material Description Unit aflex150 qc aflex200 qc [mm]...
  • Page 14 Table 4: Technical data of the control unit Evaluation Description Symbol Unit Min. Type Max. 23.0 24.0 25.0 Working voltage DC smoothed Input current control unit 0.064 0.080 Reverse polarity protection Voltage supply – Signal voltage "1" Digital output Signal voltage "0" Digital output 0,002 Output current Digital output [mA]...
  • Page 15 – Output voltage Output + 0.5 Output current Output Pulse width Output Frequency output [Hz] Reverse polarity protection Power output Operation/Storage temperature [°C] +-0 - +40 °C / +-0 - + 85.+°C max. 40% without condensa- Relative humidity tion Protection class IP 30 Table 6: Technical data of the Profibus module PB node Evaluation...

  • Page 16: Maximum Size Of The Parts

    2.3.1 Maximum size of the parts A fixed specification of the maximum part size can not be given. The maximum part size depends on the optimum part number for the process. This number of parts is to be determined empirically, depending on the orientation behaviour and the accessible process.

  • Page 17: Electrical/Control Components

    Electrical/Control Components INSTRUCTION Work on the electrical supply can only be done by qualified per- sonnel. Figure 3: Overview of electrical components Control Unit: Intelligence and memory of the aflex controller Driver units: Outputs for controlling the aflex actuators PB-Node: Optional field bus interface EtherCAT Node: Optional field bus interface Profinet Node: Optional field bus interface All control modules communicate via a BackSideBus which is mounted in a standard...

  • Page 18: Installation Instructions

    3 Installation instructions Transport The aflex qc may only be transported with the quick-change plate installed. If control modules are transported individually, the bus contacts must not be damaged. When transporting the control unit in the assembled state, care must be taken to en- sure a free of play packaging.

  • Page 19: Assembly Of The Device

    Assembly of the device To enable the aflex to work with reliable functionality, follow the steps below. In case of non-observance a fault-free operation can not be guaranteed. 3.2.1 Drilling picture for assembly Figure 4: Drilling picture in assembly level Table 8: Size for drilling picture Description aflex150 qc...

  • Page 20: Assembly On Base Plate

    3.2.3 Assembly on base plate Insert the aflex with the four Flex bushings into the holes of the system base plate. Observe the orientation of the device with regard to the subsequent cable connection. Figure 6: Assembly on base plate 3.2.4 Dismantling the funnel plate In order to fix the aflex on the base plate, the flex bushings must be tightened.

  • Page 21: Tighten Flex Sockets

    Figure 7: Motion sequence dismantling funnel plate with assembly wedges Figure 6: Remove funnel plate 3.2.5 Tighten Flex sockets The Flex sockets should have been tightened using the supplied 5mm wrench socket, a torque wrench and corresponding to the sequence shown below. Figure 7: Tighten Flex sockets 4.

  • Page 22: Remove Transport Safety

    INSTRUCTION Observe the following: Maximum torque 0.9Nm Mounting level realized as plate >17 mm 3.2.6 Remove transport safety Remove the transport safety using a metallic object. Figure 8: Remove transport safety 3.2.7 Install funnel plate Re-install the funnel plate from top of the aflex. Observe the different openings on the funnel plate or on the aflex itself during this.

  • Page 23: Connection Of The Device

    Connection of the device The aflex qc is supplied via the 26 poles D-Subs plug connector of the supplied con- necting cables. The allocation pin can be found in the supplied circuit plan. The aflex qc can be connector either sideways or from below. The non-connected side must be covered since it could lead to short circuits.

  • Page 24: Power Supply

    Power supply WARNING ▪ Work on the electrical supply may only be carried out by trained, authorized qualified personnel! ▪ The grid feed must take place on the customer's side via a residual current circuit breaker! ▪ The aflex may only be driven with 24V DC. The energy feed of aflex takes place with 24V DC low-voltage.

  • Page 25: Building The Control Module

    3.5.1 Building the control module ❶ Mount the profile rail in the control cabinet, the screw head height must not exceed 3.8 mm. ❷ Fasten the bus circuit board using the corresponding circuit board cover. ❸ Now place the individual control modules on the profile rail. Make sure that the housings are not jammed and the con- tacts to the BackSideBus are not bent.

  • Page 26: Electrical Connection

    3.5.2 Electrical Connection INSTRUCTION It is possible to separate the screw terminals of the modules from the housing via the clip lock in order to connect the lines. How- ever, do not interchange the individual terminals. Open the delivered circuit plan with USB stick. The ❶...
  • Page 27 Optional: Connect optional fieldbus interfaces according to the circuit diagram. ❺ Connect the aflex via one of the two connectors. ❻ Cover the unused of the two connectors with the sup- plied cover plate. The cover plate is mounted in the delivery condition on the side.

  • Page 28: Software Description

    4 Software description INSTRUCTION This operating manual describes the software "aflexConfigura- tor" as from version v2.0 The following section describes the "aflexConfigurator" in detail. The control is set up and preconfigured to the desired application via this Windows application. The aflexConfigurator is used to set the aflex on the components to be fed. Figure 11: aflexConfigurator Start page Installation of the Software Install the software included in the scope of delivery.
  • Page 29 To enable easier operation for the standard user, complex functions are distributed to different user levels. The current user group is displayed in the upper right of the aflex- Configurator. Figure 12: Display the current user Clicking on this button changes the user group. Figure 13: User switching User: "Standard"...
  • Page 30 User: "Admin" Has full access rights in the aflexConfigurator. Can parametrize aflex modules and change basic settings. This user is only to be used when exchanging modules. The "admin" user is password-protected. The password should be determined from the manufacturer. INSTRUCTION The user "admin"...

  • Page 31: Start Page

    Start page When the program is started, the start page opens, this is shown in the following figure. ➔ Start the "aflexConfigurator". Figure 14: Overview window (1) User switching (2) Help page (3) Search for devices in the network (4) Display the control unit In order to establish a connection to the control unit of the aflex controller, this must be connected to the computer via Ethernet interface.

  • Page 32: Control Unit States

    Search Devices (3) The aflexConfigurator searches for existing control units using the "Search Devices" button in the network Display the control units (4) This field lists the control units found on the network. Also stored control units are displayed from previous program starts. 4.3.1 Control unit States The control units found or stored in the network have different device status properties.
  • Page 33 Series number (4) The series number of the Controlunit. This can also be found on the housing, in the side inscription field. Network status, Subnet (5) To establish a connection to the control unit, the two participants must be found in the same subnet.
  • Page 34 Figure 17: missing ping response The control unit and computers are located in the same subnet and the ping process is started. However, a valid response is missing. This can have the following causes: The control unit is switched off The network connection has been interrupted.

  • Page 35: Advanced Display For Advanced And Administrator User

    4.3.2 Advanced display for Advanced and Administrator user If the user "admin" or “advanced” are activated, further displays and options are visible on the start page. These are described below. Figure 19: Start page display advanced In advanced mode, the computer's local Ethernet endpoints are displayed. This is used to search the devices in the network via UDP Broadcast.
  • Page 36 Page 36 22.10.2019 R01.43...

  • Page 37: Connection Set-Up

    4.3.3 Connection set-up After pressing the "connect" button the TCP/IP connection is established and the data of the control unit is read out. Figure 22: Connection set-up If another aflexConfigurator is already connected to the control unit, no TCP/IP con- nection is established.
  • Page 38 Figure 24: Main menu Figure25: Main menu extended view (1) Operating mode (2) Release (3) control interface (4) controller menu (5) client nodes (6) aflex modules (7) fieldbus config Operating mode (1) The current operating status is given back on the display status. The sliding button can be used to toggle between automatic/manual modes.
  • Page 39 • The aflex controller automatically switches to automatic mode when the con- nection to the "aflexConfigurator" is interrupted. • If the control unit is in manual mode, it can not be set to the "automatic mode" via the fieldbus interface. The aflexConfigurator takes precedence. If the aflex- Configurator is closed and the connection is interrupted, the control unit auto- matically changes to the "automatic mode".
  • Page 40 User Switching (1) User change for extended display of options. Further information on the user groups can be found in the section4.2 Return to home page (2) Deletes the connection to the current control unit and returns to the start page. Page 40 22.10.2019 R01.43...

  • Page 41: Control Interface

    Control interface The menu "control interface" provides all functions for the manual operation of the aflex. INSTRUCTION The operating mode "manual" is a prerequisite for controlling the aflex via aflexConfigurator. 4.5.1 Aflex control panel The aflex control panel is used to manually control and configure the aflex control panel.
  • Page 42 (6) vertical phase (7) horizontal max power (8) vertical max power (9) frequency aflex Control Pad(1) The aflex control pad is used to control the aflex manually. The left mouse button is pressed and the mouse pointer is moved over the control pad. The intensity increases as the mouse pointer moves away from the centre of the control pad.
  • Page 43 In addition to the intensity of the total system, the maximum strength and ratio of the horizontal and vertical actuators can be adjusted via these two sliders. If, for example, the aflex is controlled with an intensity of 100%, the horizontal actuators can be con- trolled by the max.

  • Page 44: Aflex Configurations

    All actuators are controlled according to the oscillation frequency. The process is re- peated periodically. The on and off times of the actuators are defined in percent [%]. �� For example, a start time of 50% corresponds to a half period .
  • Page 45 Figure 29: aflex configuration standard view Figure 30: aflex configuration advanced view Figure 31: aflex configuration advanced view (1) Available configurations (2) Load configuration (3) Help page (4) Import/Export of Configurations (5) Select configuration number (6) Configuration name Input (7) Save configuration (8) Delete configuration Available configurations (1) Display saved configurations.

  • Page 46: Backlight

    Import/Export of Configurations (4) A new window opens in which the parameter records saved in the computer are loaded. The current parameter set can also be stored locally. Only the current aflex parameters are exported or overwritten during import. This must be observed. INSTRUCTION Import Configuration: The current parameters are overwritten with the imported ones.

  • Page 47: Simulation Of The External Control

    4.5.4 Simulation of the external control In automatic mode, the aflex should only be operated in short pulses between 100 and 500 ms in order to keep the cycle times as low as possible. This function is pro- vided to take account of this pulsed control already dur- ing the creation of the aflex configurations.
  • Page 48 From user level "advanced" visible. Opens the "demo configurator" to edit the current simulation. Information on the "demo configurator" can be found in the following sec- tion. Delete the selected demo (6) From user level "advanced" visible. Deletes the currently selected simulation. 4.5.4.1 Demo Configurator The "demo configurator"...
  • Page 49 Select configuration (1) A different configuration can be loaded in each sequence. If the same configuration is used for the previous sequence, it is not reloaded. If no configuration is selected, there is also no loading process. Select direction (2) A different direction of movement is given in each sequence.

  • Page 50: Sub Menu Controller

    adapt, the configuration is saved with the same name and the name supplemented with an index (X). Cancel (11) Abort the process without saving and close the window. Sub menu controller The control unit is parametrized in the "controller menu". The TCP/IP connection is configured, the telnet server is activated and backups are saved or imported.
  • Page 51 Display ControlUnit information (1) Displays the device name, the serial number, the hardware version, and the firmware version. This information is required for support requests. Interrupt connection (2) Disconnects the connection between aflexConfigurator and control unit. The aflexCon- figurator opens the start page. Restart ControlUnit (3) This button restarts the control unit.
  • Page 52 Figure 38: ControlUnit Digital IO & Power Output 24V Status of the digital input/output Help page DigitalIO Help page PowerOuptut 24V PWM Power output Status of the digital input/output (1) The digital inputs and outputs are the simplest form of the control and communication of the aflex controller.
  • Page 53 Figure 39: TCP / IP Configuration (1) Help page (2) Enter new settings, including the "Device name" of the control unit (3) Transfer settings (4) Displays the current TCP/IP settings Help page (1) Opens an extract from the operating manual TCP/IP Configuration This section describes the TCP/IP configuration of the aflex controller.
  • Page 54 Figure 40: Save / Restore Controller Configuration (1) Create a backup file from all the control data (2) Overwrite all control settings from a backup file. Backup of the control data All settings are stored on the control unit. To back up these settings you can create a complete backup of the EEPROM.
  • Page 55 Figure 41: Telnet Configuration (1) Activate Telnet-Server (2) Telnet Port (3) Console for Telnet-Control (4) Telnet Heartbeat (5) Establish connection (6) Login (7) Sending the command line (8) Delete the receiving messages Telnet-Server Each control unit has a telnet server from which the aflex can communicate with a higher-level control.

  • Page 56: Sub Menu Clients

    The Telnet Heartbeat is visualized through this display. The blinking LED shows the active Telnet connection. If the LED is not blinking green, no active connection is pre- sent. Establish connection (5) Connect to Telnet Server Login(6) Login with username and password. Further information can be found in the section Telnet-Server.
  • Page 57 Operating modes of the client nodes (1-4) The different operating modes are shown in colour. Depending on the operating mode, various functions are activated or deactivated. Offline (1) If the client's power supply is interrupted or the client is not connected to the control unit via the BackSideBus, this is displayed as "offline".
  • Page 58 Unregistered(4) The client is located on the BackSideBus and a connection to the control unit is possi- ble. However, the client is not registered in the control unit. It is possible to register the client with a mouse click. The client switches to the "connected" or "bootloader" status and the corresponding functions become available.

  • Page 59: Client Nodes Functions

    4.7.1 Client Nodes Functions A client node is selected by a mouse click. The currently selected client node is visu- alized with a red frame. Depending on the user level, the user has several type-inde- pendent functions available. These are described below. Figure 46: Client Node Functions "Standard"...
  • Page 60 Save to EEPROM(3) This function is available from the user level "advanced". Saves the settings of the selected client node in the permanent memory. Add Client Node(3) This function is available from user level "admin". Adds a new client node. The client node type and the serial number must be entered.

  • Page 61: T4X Client Node

    4.7.2 T4X Client Node The T4X module is a driver unit with four power channels. This module is used for controlling the aflex actuators. For a standard aflex with eight actuators, two T4X mod- ules are required. Only "Pulse Mode Continuous" is used to control the aflex actuators. The actuator is controlled by a pulse-modulated signal.
  • Page 62 Figure 53: T4X Channel Node, general release (1) Power (2) Frequency (3) Channel Phase Power (1) Activate the T4X channel. The power can be adjusted from 0-100%, in this case the duty cycle of the PWM is adjusted. Frequency(2) The control frequency of the T4X channel. At this frequency, the PWM output is pulsed. Channel Phase (3) The PWM output is not controlled permanently, but pulsed.
  • Page 63 Figure 54: T4X Channel Node "Admin" view Min/Max Power Pulse Mode Slider Min/Max Power (1) The maximum intensity set by this slider, limits the controller intensity of the actuators. The intensity is converted as a percentage to the maximum setting. If this is for e.g. set to 80%, the actuator is only controlled at 80% with a control of 100%.

  • Page 64: Backlight Node

    4.7.3 Backlight Node The aflex qc is equipped with a back light node. This is the background lighting and is used in the electrical connection test (see Chapter 4.9.1). Figure 55: Back light Node (1) Client Node Information Line (2) Temperature display The general information about the client node is displayed in the client node information line (1).
  • Page 65 From the user level "advanced" the back lighting can be parametrized. The background lighting is divided into 48 clusters whose intensity can be set separately. In this way, as homogeneous a background illumination as possible is achieved. Figure 57: LED Cluster (1) LED Cluster (2) Set LED Intensity (3) Current selected channel...

  • Page 66: Profibus Module

    4.7.4 Profibus Module The control module "Profibus module" is used to integrate the aflex control into a Pro- fibus system. This module is optional and is only required in connection with the Profi- bus. Figure 58: Profibusmodule "standard" view Figure 59: Profibusmodul "advanced" view Client Node Information Line Profibus Address Data width of the fieldbus inputs...

  • Page 67: Ethercat Module

    4.7.5 EtherCAT Module INSTRUCTION The control unit must have at least firmware version v1.32 in or- der to use the EtherCAT Client Node. The control module "EtherCAT" is used to integrate the aflex control into an EtherCAT system. This module is optional. (1) Client Node Information Line (2) Client Node Driver State (3) Client Node Sync State...
  • Page 68 Fieldbus Device State(4) Status display of the fieldbus connection WAIT_PROCESS Client Node is connected to the network PROCESS_ACTIVE There is a connection to the PLC, the data exchange is active IDLE PLC is in STOP mode ERROR Network errors (e.g., cable break) Reinitialize Client Node(5) Reinitialize the client node.

  • Page 69: Profinet Modul

    4.7.6 Profinet Modul INSTRUCTION The control unit must have at least firmware version v1.32 in or- der to use the Profinet Client Node.. The control module "Profinet" is used to integrate the aflex control into an Profinet system. This module is optional. (1) Client Node Information Line (2) Client Node Driver State (3) Client Node Sync State...
  • Page 70 DRV_RUNNING Driver active, normal operating condition STOP Drivers stopped. Restart via "reboot" or "reinitialize" possible. Client Node Sync State(3) The fieldbus configuration between Profinet Node and control unit is synchronized. This check takes place at every restart, reinitialization process or changes to the fieldbus configuration.
  • Page 71 IPConfig(8) Starts the external tool “IPConfig”. This tool is used to adjust the IP Configuration of the Profinet Modul. The Tool is al- ways on top. The configuration made by the PLC will be overwritten. INSTRUCITON The Tool “IPConfig” communicates with the Profinet interface by the Ports X2/X3 of the Profinet Modul.

  • Page 72: Webserver Profinet

    4.7.7 Webserver Profinet The Profinet modul provides a webserver. To open it there must be an established TCP/IP connection to one of the Modul ports. (1) Serial number (2) Menu Parameters (3) Menu Status (4) Menu Configuration Serial number(1) The serial number is hexadecimal coded. Menu Parameters(2) Shows the actual aflex values.
  • Page 73 In the menu “parameters” the actual parameters are shown. (1) aflex Inputs (2) aflex Outputs (3) Refresh (4) Set Input aflex Inputs(1): From the superior PLC to the aflex. aflex Outputs(2): From the aflex to the superior PLC. Ausgänge des aflex aus Sicht des aflex. Vom aflex in die Übergeordnete Steuerung. Refresh (3): Values only actualized by clicking this button.

  • Page 74: Sub Menu Fieldbus Configuration

    Sub menu Fieldbus configuration This menu is visible from the user level "advanced". The aflex is addressed by the higher-level controller via the fieldbus interface. The control unit provides eight digital inputs/outputs as well as a Telnet server. In addition, fieldbus modules, e.g.
  • Page 75 Load a configuration (1) This function provides several standard configurations. These comprise all the param- eters which are required for a complete control of the aflex. It is highly recommended to use these configurations. Clicking on the button opens the window shown below. The corresponding configuration is selected in the upper combo box Figure 61: Loading a fieldbus configuration Save the fieldbus settings (2)
  • Page 76 Overview of the fieldbus input (7) Display the fieldbus input. Display the fieldbus configuration (8) Display the fieldbus configuration. Figure 62: Structure of the inputs/outputs Fieldbus interface Command identification addressed parameters Addressed control module whose parameter is controlled Symbol for fieldbus input Identification number of the fieldbus input Delete the fieldbus input Data range of the fieldbus input...
  • Page 77 bit is defined as 16 bit further input, it corresponds to 100% (32 bit = 4294967295 dec.) 65535 decimal is given. Byte Offset of the Fieldbus Inputs (8) The byte offset defines the position at which the parameter is located in the fieldbus. A standard application of aflex, which uses both flipping and feeding, requires the fol- lowing fieldbus inputs: Direction = Direction of movement...

  • Page 78: Sub Menu Aflex Module

    Sub menu aflex module The aflex is parametrized in this menu. The aflex is displayed in the control unit. The driver outputs of the T4X client nodes are linked to their actuators. If the aflex is con- trolled, the control unit recognizes which driver outputs are to be controlled and con- trols the client nodes accordingly.
  • Page 79 The user "standard" has no rights in the aflex menu. Only the current settings are dis- played, they can not be changed. The driver assignment can be changed only from the user level "admin". Figure 65: aflex Module "admin" view Add an aflex module Delete the aflex module Save the aflex module...
  • Page 80 This function is available from user level "admin". Adds a new aflex module Delete the aflex module (2) This function is available from user level "admin". Deletes the currently selected aflex module Save the aflex module (3) This function is available from user level "advanced". Saves the setting of the aflex module.
  • Page 81 This function is available from user level "Admin". The button "remove" triggers a cur- rent link of the button "assign" establishes a link with the selected channel. Help page (9) Opens an extract from the manual. Unassigned channels (10) The available channels not assigned yet. For the proper function of the aflex, all driver channels must be assigned and must match the electrical wiring.

  • Page 82: Test Electrical Connection

    4.9.1 Test electrical Connection This function allows you to check the wiring of driver modules to the aflex to the set mapping. The test automatically controls each actuator one at a time. The correspond- ing control signal is checked via the integrated back light board in aflex. If wires are interchanged or open, this is detected.

  • Page 83: Soft Release Mode

    4.9.2 Soft Release Mode The "Soft Release Mode" is used to reduce the aflex vibration. This mode is not re- quired for all components. In the case of very light components, however, the vibration of the aflex can lead to the components moving in one direction in an undefined man- ner.

  • Page 84: Software Update

    The software update of the control unit differs from that of the client nodes. It is per- formed using the application "control unit Bootloader" installed with the "aflexConfigu- rator". The application can be found in the Afag GmbH folder via the start menu. Pro- ceed as follows: •...
  • Page 85 • In order for the bootloader to become active, the control unit must be re- started. In the "aflexConfigurator", execute a restart of the control unit via the "Restart Controller" button. • The bootloader is active, the three status LEDs flash in the same clock. INSTRUCTION After each reboot, the bootloader mode is activated in the control unit for only 15 seconds.
  • Page 86 recorded in the delivery state can be found on the supplied USB stick in the directory "Firmware Files" Figure 70: Software update ControlUnit 3 Run software update • Start the software update via the "Erase-Program-Verify" button (1). The bootloader application loads the new software update in the ControlUnit. After successful completion, the confirmation "Verification successful"...

  • Page 87: Software Update Client Node

    4.10.3 Software update Client Node The software update of a client node is performed in the "aflexConfigurator". If the client node is in bootloader mode and the user level is "advanced", the corresponding menu is displayed in the client node. Figure 72: Activate Bootloader (1) Activate Bootloader A prerequisite for the firmware update is the active bootloader mode of the client node.
  • Page 88 Firmware update process current client node (1) If a firmware update process is already active, the client node serial number used there is displayed. INSTRUCTION It is not possible to provide a firmware update for several client nodes simultaneously. For this reason, the currently used Client Node Serial is displayed.

  • Page 89: First Commissioning

    5 First commissioning Assembly of the system The aflex is mounted. Information about it can be found in the chapter Installation in- structions and the accompanying Quick Guide. The control unit is installed and connected according to the circuit diagram. Refer also to the chapter Installation instructions and the accompanying circuit diagram.

  • Page 90: Configure Software Modules

    Configure software modules The aflex software module is already configured in the delivery state. The T4X client nodes are assigned to the individual channels. Two configurations are already prede- fined. One configuration is suitable for separating components ("flip") the second for conveying components ("move").
  • Page 91 Set General Release General release without which all power outputs are disa- bled. Must be set to use the aflex. Intensity Control intensity of the aflex. If this is greater than "0", the aflex is activated with the cur- rently selected direction and activated configuration. To turn the aflex off, set it to "0".

  • Page 92: Development Of Transfer Values

    5.6.1 Development of transfer values Due to the various fieldbus interfaces, the command range of the individual commands is variable. Depending on the interface, commands of 1-32 bits can be widely defined. Depending on the defined command range, the transmission values must be calcu- lated.

  • Page 93: Digital Input/Output

    5.6.2 Digital input/output The control unit has eight 24V DC digital inputs and outputs. The following figure shows an integration to a "customer device". Figure 75: Digital IO Connection Control Unit LED - actual states Input Output In contrast to other fieldbus interfaces, the "load config #" command must be used instead of the "load config number"...
  • Page 94 Strategy 1: Components are not supported at all, but up to three different configurations can be called up. The intensity can be controlled in seven steps from 0-100%. Strategy 2: Components can be separated and conveyed with two configurations. The in- tensity can only be set here from 0% to 100%.
  • Page 95 5.6.2.1 Strategy 1 No conveying of components is given up. Components are merely isolated. In this case, the "Direction" command is not required. For this, there is the possibility to call up more different configurations and to control the intensity steps. If it is mandatory to promote the development of components, Strategy 2 must be applied.
  • Page 96 Figure76: Fieldbus Configuration IO Type1 Because the Direction command is not controlled in this strategy, it is important to set the Horizontal Max Power to 0%. In this way, the configuration is independent of the direction since the horizontal actuators are deactivated. The following figure shows the corresponding slider from the sub-menu "control interface".
  • Page 97 5.6.2.2 Strategy 2 There is the possibility to convey the components in different directions, but only two configurations can be called and the intensity can not be controlled level-wise. Input Load Load General Direction Direction Direction Command Power Config Config Intensity Release Output...
  • Page 98 Status „101“ (24V,0V,24V): 225° Conveying direction Status „011“ (0V,24V,24V): 270° Conveying direction Status „111“ (24V,24V,24V): 315° Conveying direction In the aflexConfigurator, you must configure the fieldbus interface as shown in the fol- lowing figure. By configuring the outputs equal to the inputs, you get a response about the current values of the aflex system.
  • Page 99 5.6.2.3 Strategy 3 HINWEIS From ControlUnit Firmware v1.40 useable There is the possibility to convey the components in different directions and separate them. The configuration 1 is used to separate, the configuration 2 is used for convey the parts. The intensity can be controlled level-wise. Input Load Load...
  • Page 100 Figure 79: Fieldbus Konfiguration IO Typ 3 Page 100 22.10.2019 R01.43...

  • Page 101: Telnet-Server

    5.6.3 Telnet-Server In addition to the digital inputs / outputs, the control unit has a Telnet server. Like the digital inputs / outputs, the configured fieldbus interfaces are addressed. The bit ad- dress can be used to access each input / output. The port of the Telnet server is defined via the menu of the control unit in the "aflexConfigurator".
  • Page 102 Table 11: Definition Telnet-Commands Command Separator Separator Value CR LF dress Space Space XXXXXXXXXX \r\n Space \r\n Set Input "SI" An input of the aflex system is set via the Set Input command. This is defined by the bit address. The transferred value is set as new. The value and bit address is passed ASCII-coded.
  • Page 103 ER Error notification If a faulty structure is transferred to the Telnet server, it sends an error message. The Telnet server distinguishes between the following errors. Table 12: Telnet error codes Error code Designation Faulty command Faulty value Faulty Bit Address The error message for a non-existent or incorrect bit address is defined as follows: "ER 4\r\n"...

  • Page 104: Profibus Module

    End the connection using a command The Telnet server is dis- connected Heartbeat of the Telnet server for que- If connection terminations rying the connection are detected, the Telnet server closes the current connection. A new con- nection can be estab- lished.
  • Page 105 Figure 82: Profibus module FieldbusConfig In order to establish a connection via the Profibus, an ID and a maximum available data range are assigned to the Profibus module. In this example, ID 7 and a maximum of 32 byte input/output data. These settings must match the settings of the Profibus master.
  • Page 106 With these configurations, the individual commands are addressed with the following addresses and command lengths. Address Command Command lengths 1 Byte Load Config Number 2 Byte Aux Power Output 1 Byte Controller Restart 1 Byte AutoMode: 1 Byte General Release 2 Byte Direction 2 Byte...

  • Page 107: Ethercat Module

    5.6.5 EtherCAT Module As an alternative to the two standard interfaces, digital I/O and TCP/IP, there is the option of an optional EtherCAT interface. Like the two T4X driver modules, this module is connected to the control unit via the back-side bus. The EtherCAT module has an input port X2 and an output port X3.
  • Page 108 No additional settings need to be made in the EtherCAT Client Node. However, the current device status is displayed. A description of these functions can be found in the section.4.7.5 Figure 87: EtherCAT Client Node Display Integration of the interface in TwinCAT 3 1.

  • Page 109: Profinet Modul

    5.6.6 Profinet Modul As an alternative to the two standard interfaces, digital I/O and TCP/IP, there is the option of an optional Profinet interface. Like the two T4X driver modules, this module is connected to the control unit via the back-side bus. The Profinet module has two ports X2 and X3 to communicate with the Profinet system.
  • Page 110 In the Profinet Client Node menu you can see the actual device states. There is de- tailed description in chapter 4.7.6. Figure 90: Profinet Client Node Anzeige INSTRUCTION The device description file can only used with the standard Profinet fieldbus configuration. Page 110 22.10.2019 R01.43...

  • Page 111: Input Commands

    5.6.7 Input commands All fieldbus inputs can be defined via "alexConfigurator". In the data range and also data position. The suggested range of data listed in the table below gives the original data range of the command, but all commands can be stretched or compressed to any data range.
  • Page 112 aflex-Mod- Frequency Set the oscillation frequency of aflex 32 Bit Caution: minimum 16 bit necessary aflex-Mod- Direction Set the direction of movement of aflex 32 Bit T4X Driver Channel1 Separate control of individual driver outputs 32 Bit Power T4X Driver Channel2 Separate control of individual driver outputs 32 Bit...

  • Page 113: Output Commands

    5.6.8 Output commands All fieldbus outputs can be freely defined via the "aflexConfigurator", both in the data range as well as in the data position. The suggested range of data listed in the table below indicates the original data range of the command. These are recommended for e.g.
  • Page 114 T4X Driver Channel2 Power Status of the control intensity of driver 32 Bit output T4X Driver Channel3 Power Status of the control intensity of driver 32 Bit output T4X Driver Channel4 Power Status of the control intensity of driver 32 Bit output T4X Driver Channel1 Phase...

  • Page 115: Operating Manual

    6 Operating manual The aflex is integrated in automated industrial systems and operated in the automatic mode via the communication interface. In addition, manual operation is possible via the configuration software. Safety instructions for operation WARNING Danger of injury through electro-magnetic fields Persons who carry pacemakers or other active medial implants may be particularly vulnerable to EMF.
  • Page 116 T4X: Client Node Table 17: LED-Displays Client Node con err pwr Reporting Power supply IO, connected to control modules Power supply IO, no connection to further control modules Fault occurred during operation "Bootloader" mode is active "Bootloader" mode active, no executable program available PB Node: Table 18: PB Node con err pwr pbcon...
  • Page 117 Table 20: EtherCAT LED "nwstate" Reporting INIT – State (or no voltage) from green stays on OPERATIONAL State blinking green PRE-OPERATIONAL State flashing green SAVE-OPERATIONAL State flickering green BOOT state red off No existing error blinking red Incorrect configuration red on Internal errors Table 21: EtherCAT LED "x2 con"...

  • Page 118: Maintenance Instructions

    Tabelle 23: Profinet LED „nwstate“ nwstate LED description comment Offline No network connection green on Online (Run) Connection to IO Controller established. IO controller in RUN state green flash Online (Stop) Connection to IO Controller established. IO controller in Stop. green blink Blink Identification blink code.

  • Page 119: Order Address

    8 Order address Germany: Switzerland: Afag GmbH Afag Automation AG Wernher-von-Braun-Straße 1 Zuführtechnik D – 92224 Amberg Fiechtenstrasse 32 CH – 4950 Huttwil Tel.: ++49 (0) 96 21 / 65 0 27-0 Fax: ++49 (0) 96 21 / 65 0 27-490 Tel.: ++41 (0) 62 / 959 86 86...

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