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Lapple FIBRO FIBROTOR EM Series Assembly And Operation Manual

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TRANSLATION OF THE ORIGINAL
ASSEMBLY AND OPERATION MANUAL
FIBROTOR EM and ER

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  • Page 1 TRANSLATION OF THE ORIGINAL ASSEMBLY AND OPERATION MANUAL FIBROTOR EM and ER...
  • Page 3 1 INTRODUCTION 1.1 DEFINITION Rotary table FIBROTOR EM and ER Type: Item number: Serial number: Dimensions drawing: Year of manufacture: Order number:  This document has been created by FIBRO GmbH Rotary Table Division Postfach 11 20 D-74183 Weinsberg Weidachstrasse 41 - 43 D-74189 Weinsberg Service rtservice@fibro.de...
  • Page 4 1 INTRODUCTION 1.1 DEFINITION 4 | 72 FIBROTOR...

  • Page 5: Table Of Contents

    1 INTRODUCTION 1.1 DEFINITION Contents Introduction .........................9 1.1 Definition ......................9 1.2 Intendeduse ......................9 1.3 Improper use .......................9 1.4 Applicable documents..................10 1.5 Structure......................10 1.5.1 Bearing....................10 1.5.2 Path of motion..................10 1.5.3 Drive, cam .................... 10 1.5.4 Positioning .................... 11 1.5.5 End switch ....................
  • Page 6 1 INTRODUCTION 1.1 DEFINITION 3.5.7 Intermittent operation with special braking motor KOD (Optional) 3.5.7.1 Braking voltage..............29 3.5.7.2 Switching and connection........... 29 3.5.7.3 Special sealing against dust, dirt and moisture....30 3.5.7.4 General .................. 30 3.5.7.5 15.6 Connection ..............30 3.5.7.6 Brake maintenance..............
  • Page 7 1 INTRODUCTION 1.1 DEFINITION 9.2.2 Maintenance / cleaning ..............50 9.2.2.1 Long-term lubrication ............51 9.2.2.1 Mounting position of horizontal table top ......51 9.2.2.2 Mounting position of vertical and upside-down table top 9.2.2.3 Lubrication plan..............52 9.2.2.4 Lubricants ................52 9.2.2.5 Filling quantities ..............
  • Page 8 1 INTRODUCTION 1.1 DEFINITION Index of figures Fig. 1 Cam drive Fig. 2 Table top and operating cam Fig. 3 Wiring diagram end switch Fig. 4 End switch Fig. 5 Sequence diagram Fig. 6 Holding phases operating cam Fig. 7 Personal protective clothing Fig.

  • Page 9: Introduction

    1 INTRODUCTION 1.1 DEFINITION Introduction Definition Rotary table Rotary table: The rotary table is a partly completed machine in the sense of European Guideline 2006 / 42 / EG, Art. 1g and 2g. Intendeduse The purpose of the rotary table is to be mounted in other machines or in other partly completed machinery or equipment, or to be assembled with them.

  • Page 10: Applicable Documents

    1 INTRODUCTION 1.4 APPLICABLE DOCUMENTS The operator of the machine described in this document bears the responsibility for any injuries and damages caused by its improper use. Applicable documents Along with this manual, other applicable documents are necessary for the safe operation of the machine.

  • Page 11: Positioning

    1 INTRODUCTION 1.5 STRUCTURE _______________________________________________________________ _______________________________________________________________ Fig. 1 Cam drive 1.5.4 Positioning The table top is held in an exact play-free position in the holding phase by the operating cam and the cam rollers. In the event of high tangential forces, a hydraulic table top clamping can be used (relief of the gearbox parts).

  • Page 12: Basic Wiring Diagram

    1 INTRODUCTION 1.5 STRUCTURE 1.5.5.1 Basic wiring diagram ________________________________________________________ ________________________________________________________ Fig. 3 Wiring diagram end switch   Brown Output   Black Load   Blue BESM12MI-PSC20B-S04G 1.5.6 Adjusting the end switches The end switches S10 and S12 are factory set during the test run (Standard = table top direction of rotation clockwise).

  • Page 13: Fig. 4 End Switch

    1 INTRODUCTION 1.5 STRUCTURE The drive must come to a standstill within the holding phase (pointer in the "Stop" range).  Pointer  Disk cam  S10 "Table top at standstill"  S12 "Motor off" _________________________________________________________________ _________________________________________________________________ Fig. 4 End switch FIBROTOR 13 | 72...

  • Page 14: Sequence Diagram

    1 INTRODUCTION 1.5 STRUCTURE 1.5.7 Sequence diagram _________________________________________________________________ 1 Umdrehung der Steuerkurve 1 turn of control cam Une rotation compléte de la came Zykluszeit tz Cycle time Temps du cycle Haltephase th Beschleunigung Holding phase Haltephase th Acceleration th Phase d'arrét Holding phase Accélération th Phase d'arrét...

  • Page 15: Holding Phase Of The Operating Cam

    1 INTRODUCTION 1.5 STRUCTURE 1.5.9 Table top direction of rotation Standard design: Direction of rotation clockwise After connection of the motor: Check the table top direction of rotation. If the table top rotates in the opposite direction, the connections of 2 phases (e.g. L1 and L2) must be changed on the network terminals.

  • Page 16: Emergency Stop Mode

    1 INTRODUCTION 1.6 WARRANTY 1.5.11 Emergency Stop mode When the rotary indexing table is operating in normal mode (start from the base position) the moment of inertia created is gently accelerated via the cam drive and decelerates. During an emergency stop the rotary table is stopped in the indexing phase via the motor brake or accelerated after this via the three-phase motor.

  • Page 17: Legend

    1 INTRODUCTION 1.7 TRANSLATION OF THE ORIGINAL MAINTENANCE AND OPERATION MANUAL 1.7.1 Legend Certain marks, symbols and abbreviations with the following meaning are used in this manual for clear organisation of its contents: 1. indicates an enumeration. a) indicates the second level of an enumeration. ...

  • Page 18: Definitions Of Terms

    1 INTRODUCTION 1.8 DEFINITIONS OF TERMS ATTENTION designates additional instructions, provides information about possible property damage and is not related to possible injuries. Definitions of terms Manual General designation of this document. Immediate interruption of all motion processes by EMERGENCY STOP activation of an emergency stop button.

  • Page 19: Safety

    2 SAFETY 2.1 BASIC SAFETY INSTRUCTIONS Safety BASIC SAFETY INSTRUCTIONS Most accidents during work with machines are due to disregarding the basic safety instructions. Perceiving a possible hazard can prevent an accident before it occurs. If there are hazards, the safety information on the rotary table and in this document provides warnings about these hazards.

  • Page 20: Due Diligence Of The Operator

    2 SAFETY 2.1 BASIC SAFETY INSTRUCTIONS 2.1.1 Due diligence of the operator The rotary table is designed and manufactured according to the state of the art. The requirements for ensuring the safety and protection of health have been fulfilled. However, this safety can be achieved in operational practice only when all necessary measures in this respect have been taken.

  • Page 21: Personnel Requirements

    2 SAFETY 2.2 QUALIFICATION OF THE PERSONNEL 2.1.2 PERSONNEL REQUIREMENTS The following safety instructions must be observed in all operations on the rotary table. Their violation can cause serious injuries or death. All persons working on and with the rotary table must: •...

  • Page 22: Safety Devices On The Machine

    2 SAFETY 2.3 SAFETY DEVICES ON THE MACHINE Safety devices on the machine The rotary table is designed for mounting in other machines or for assembly with other machines. FIBRO GmbH has no control over the intended use of the machine. The operator is responsible for the safety devices for operation of the machine.

  • Page 23: Technical Description

    3 TECHNICAL DESCRIPTION 3.1 GENERAL TECHNICAL DATA Technical description General technical data The technical data of the rotary table depend on the contract.  A name plate with number, year of manufacture and type is fixed on the rotary table. __________________________________________________________________________ __________________________________________________________________________ Fig.

  • Page 24: Sealing Air (Optional)

    3 TECHNICAL DESCRIPTION 3.3 SEALING AIR (OPTIONAL) Sealing air (optional) The rotary table has a connection for the sealing air between the housing and the table top (for position and connection thread see the dimensional drawing). The necessary compressed air must be provided by the supply facilities of the operator.

  • Page 25: Intermittent Operation With Braking Motor (Optional)

    3 TECHNICAL DESCRIPTION 3.5 ASSEMBLY UNITS The table top is held in an exact play-free position by the operating cam and the cam rollers. The direction of rotation can optionally be to the left or right. The rotary table can swing between the positions by a change in the direction of rotation on the drive motor.

  • Page 26: Fig. 10 Connection Braking System 240Vac

    3 TECHNICAL DESCRIPTION 3.5 ASSEMBLY UNITS The brake must only be switched on on the direct current side. In the event of an alternating current braking process, switching precision must be taken into account. In the direct current circuit an additional jumper is provided which will have to be replaced by a contact point in order to switch off on the direct current side.

  • Page 27: Fig. 11 Connection Braking System 400Vac

    3 TECHNICAL DESCRIPTION 3.5 ASSEMBLY UNITS _________________________________________________________________    _________________________________________________________________ Fig. 11 Connection braking system 400VAC _________________________________________________________________    _________________________________________________________________ Fig. 12 Connection braking system 24VAC In the case of special voltage or motors the wiring diagram in the terminal box must be observed.

  • Page 28: Special Sealing Against Dust, Dirt And Moisture

    3 TECHNICAL DESCRIPTION 3.5 ASSEMBLY UNITS 3.5.5 Special sealing against dust, dirt and moisture. For extreme operating conditions with dust, fibre fly, dirt and the effect of water, as well as intermittent operation in conjunction with frost, the brakes can be delivered in the following designs (surcharge upon request).

  • Page 29: Braking Voltage

    3 TECHNICAL DESCRIPTION 3.5 ASSEMBLY UNITS  For a further increase in the switching frequency and the service life an external fan can be used. 3.5.7.1 Braking voltage The brake is ventilated by supplying the stipulated control voltage. The brake is either directly connected to direct voltage, or alternating voltage is rectified by a rectifier built into the terminal box.

  • Page 30: Special Sealing Against Dust, Dirt And Moisture

    3 TECHNICAL DESCRIPTION 3.5 ASSEMBLY UNITS 3.5.7.3 Special sealing against dust, dirt and moisture. For extreme operating conditions with dust, fibre fly, dirt and the effect of water, as well as intermittent operation in conjunction with frost, the brakes can be delivered in the following designs (surcharge upon request): ...

  • Page 31: Fig. 15 Brake Dimension "A

    3 TECHNICAL DESCRIPTION 3.5 ASSEMBLY UNITS The procedure below is recommended if, for any reason, the trailing ring referred to under "General" sits so markedly on the shaft that the brake torque significantly reduces: Remove ventilation cover 7 and end plate 5, pull off the circumferential brake part 4 using the pull-off device or ventilate the brake by applying voltage and remove the circumferential brake part.

  • Page 32: Additional Component Assemblies And Accessories

    3 TECHNICAL DESCRIPTION 3.6 ADDITIONAL COMPONENT ASSEMBLIES AND ACCESSORIES ________________________________________________________________ _________________________________________________________________ Fig. 16 Cross section brake Additional component assemblies and accessories 3.6.1 Hydraulic table top clamping In its positioned state, the table top is connected with the housing in a friction-locked and backlash-free manner by means of hydraulically impinged clamping.

  • Page 33: Connection Diagram Table Top Clamping

    3 TECHNICAL DESCRIPTION 3.6 ADDITIONAL COMPONENT ASSEMBLIES AND ACCESSORIES The clamping should never be activated during the rotation motion of the table top (also not at emergency stop!). The rotary table should never start against closed clamping. This leads to damages.

  • Page 34: Functional Diagram Table Top Positioning

    3 TECHNICAL DESCRIPTION 3.6 ADDITIONAL COMPONENT ASSEMBLIES AND ACCESSORIES 3.6.2.1 Functional diagram table top positioning Initial position: The table top is in any position _________________________________________________________________             _________________________________________________________________ Fig. 19 Functional diagram table top positioning ...

  • Page 35: Position Detection

    3 TECHNICAL DESCRIPTION 3.6 ADDITIONAL COMPONENT ASSEMBLIES AND ACCESSORIES 3.6.3 Position detection In order to request the individual positions a positioning detector (BCD Code) can be attached. Example for division 06: Switch 0° 60° 120° 180° 240° 300° 0 = not pressed (hole diameter 8mm) X = pressed ________________________________________________________ ________________________________________________________...

  • Page 36: Safety Microswitch

    3 TECHNICAL DESCRIPTION 3.6 ADDITIONAL COMPONENT ASSEMBLIES AND ACCESSORIES 3.6.5 Safety microswitch During pendulum mode between various positions, through a change in the direction of rotation of the motor, an overrun of the end stations can be prevented by  using mechanical end switches (emergency stop function).

  • Page 37: Transport

    4 TRANSPORT 4.1 IMPORTANT SAFETY GUIDELINES Transport Important safety guidelines Suspended loads Dimensioned load suspension device that are too weak can break. The suspended loads can swing. The lifting equipment and the load suspension devices must correspond to the regulations and should be designed for the weight of the components, including the packaging.

  • Page 38: Packaging And Weight

    4 TRANSPORT 4.2 PACKAGING AND WEIGHT Packaging and weight For shipping by truck, the rotary table is secured with transport locks and packaged in foil. For shipping by sea the rotary table is secured at FIBRO GmbH with transport locks and packaged in a wooden box.

  • Page 39: Permitted Equipment And Auxiliary Devices For The Transport

    4 TRANSPORT 4.5 PERMITTED EQUIPMENT AND AUXILIARY DEVICES FOR THE TRANSPORT Permitted equipment and auxiliary devices for the transport The unloading of the boxes and their transport to the installation site can be performed with an overhead crane. Use crossbars. Fig.

  • Page 40: Return Shipping

    4 TRANSPORT 4.7 RETURN SHIPPING Damage to components. Never lift the rotary table suddenly with a jerk. 5. Hook the belts onto the attachment eyes and lift the rotary table from the box while observing the safety instructions and transport regulations. 6.

  • Page 41: Assembly

    5 ASSEMBLY 5.1 IMPORTANT SAFETY GUIDELINES Assembly Important safety guidelines Incorrect installation The assembly work should be performed by qualified personnel only. Work on the power supply line connections should be performed by qualified electricians only. A check must be carried out to ensure that the power supply frequency and voltage correspond with the data in the technical specification.

  • Page 42: Modifications And Alterations

    5 ASSEMBLY 5.4 MODIFICATIONS AND ALTERATIONS Transport the rotary table to the assembly site in compliance with the safety instructions and transport regulations. Sagging load. Do not hold between the rotary table and the installation surface. Crushing of hands or fingers. ...

  • Page 43: Commissioning

    6 COMMISSIONING 6.1 IMPORTANT SAFETY GUIDELINES Commissioning Important safety guidelines The rotary table is designed for mounting in other machines or for assembly with other machines. FIBRO GmbH has no control over the intended use of the rotary table. The commissioning is a responsibility of the operating company. Prior to the commissioning Prior to the commissioning, visual inspection of the rotary table has to be performed.
  • Page 44 7 OPERATION 6.2 PRIOR TO THE COMMISSIONING 44 | 72 FIBROTOR...

  • Page 45: Operation

    7 OPERATION 7.1 IMPORTANT SAFETY GUIDELINES Operation Important safety guidelines Inadmissible operating parameters / software. The change of the operating parameters leads to a change in the system behaviour of the rotating or moving parts of the rotary table. The use of a controller with unlicensed software creates a risk for the safety of the rotary table.
  • Page 46 7 OPERATION 7.4 ROTARY TABLE - TURNING ON AND OPERATION 46 | 72 FIBROTOR...

  • Page 47: Faults

    8 FAULTS 8.1 IMPORTANT SAFETY GUIDELINES Faults Important safety guidelines Unauthorised personnel Any personnel that has not been adequately trained does not have the necessary authorisation to localise faults or correct errors. Any defects may only be corrected by FIBRO Customer Service or by members of staff from the operating company who are trained and authorised for performing the respective activity.
  • Page 48 9 REPAIR 8.2 CUSTOMER SERVICE 48 | 72 FIBROTOR...

  • Page 49: Repair

    9 REPAIR 9.1 IMPORTANT SAFETY GUIDELINES Repair Important safety guidelines Unauthorised personnel The personnel of the operator may perform only the maintenance work described in this manual. This personnel must be trained and authorised for performing these activities. The action area of the moving machine parts must be secured. All other work and repairs must be performed by FIBRO personnel only.

  • Page 50: Maintenance Work

    9 REPAIR 9.2 MAINTENANCE WORK Maintenance work The following activities are considered maintenance work: • Inspection • Maintenance / cleaning • Repair 9.2.1 Inspections Daily before the start of the work shift: • Inspection of the essential functional units. • Inspection of the air pressure on the manometer.

  • Page 51: Long-Term Lubrication

    9 REPAIR 9.2 MAINTENANCE WORK When maintaining the rotary table, the following must be ensured: • all work steps are performed in the specified order. After the maintenance work has been completed, it must be checked whether • the work has been performed completely. •...

  • Page 52: Lubrication Plan

    9 REPAIR 9.2 MAINTENANCE WORK 9.2.2.3 Lubrication plan _________________________________________________________________ ________________________________________________________________ Fig. 24 Lubrication plan  Lubricant rotary indexing table  +  Lubricant rolling bearing  Lubricant gearbox  Lubricant rolling bearing  Motor brake control 9.2.2.4 Lubricants  Lubricant rotary table: The following synthetic oils are permitted for the rotary table: Manufacturer / supplier Designation...

  • Page 53: Filling Quantities

    9 REPAIR 9.2 MAINTENANCE WORK + Lubricant rolling bearing The following synthetic greasesare permitted for the rolling bearing: Manufacturer / supplier Designation Arcanol MULTITOP ARAL Aralub HLP2 Discor 8 – EP 2 ESSO Beacon 325 KLÜBER Isoflex NCA 15 MOBIL Mobiltemp SHC 32 SHELL AERO Shell Grease 16 or 7...

  • Page 54: Repair

    9 REPAIR 9.2 MAINTENANCE WORK Type (1) Rotary table (4) Gearbox ER.10 0,03 l ER.11 T02 0,10 l ER.11 >T02 0,06 l ER.12 0,17 l ER.13 T02 0,25 l ER.13 >T02 0,4 l ER.15 0,6 l ER.16 1,1 l ER.17 2,5 l 9.2.3 Repair...

  • Page 55: Shutdown

    10 SHUTDOWN 10.1 IMPORTANT SAFETY GUIDELINES Shutdown 10.1 Important safety guidelines Restoring the power supply The restoration of the energy supply to a shut-down machine can lead to unexpected start. In order to shut down the machine, it must be turned off from the main switch and secured against unintended starting.

  • Page 56: Permanent Shutdown

    10 SHUTDOWN 10.3 PERMANENT SHUTDOWN 10.3 Permanent shutdown For permanent shutdown and decommissioning: • Turn off the machine in a proper manner. • Secure the machine against unintentional restarting. • Put a warning sign on the machine that shows clearly that it is permanently out of operation.

  • Page 57: Disassembly And Disposal

    11 DISASSEMBLY AND DISPOSAL 11.1 IMPORTANT SAFETY GUIDELINES Disassembly and disposal 11.1 Important safety guidelines The rotary table should be disassembled by specialised personnel of FIBRO GmbH only. Disassembly by personnel of the operator is prohibited. Unauthorised personnel In the process of disassembly and during transportation, parts can tilt or fall. Loads can swing or fall down.

  • Page 58: Disposal

    11 DISASSEMBLY AND DISPOSAL 11.2 DISPOSAL 11.2 Disposal 11.3 Disposal of components Dispose of the components in a proper manner! The improper disposal of components can cause damage to the environment and is subject to criminal prosecution. The components have to be disposed of in accordance with the applicable local and regional laws and guidelines.

  • Page 59: Service And Spare Parts

    12 SERVICE AND SPARE PARTS 12.1 SERVICE Service and spare parts 12.1 Service You can reach our customer service Monday to Friday from 07:00 am to 5:00 pm under the Service number +49 (0) 7134 - 73-243 or under rtservice@fibro.de Outside the times stated, a recorded message with additional information is available.

  • Page 60: Spare Parts Ordering

    12 SERVICE AND SPARE PARTS 12.3 SPARE PARTS ORDERING 12.3 Spare parts ordering When ordering spare parts, please provide the following data: • Name, address, shipping address • Exact designation of the equipment (take serial number from the name plate) •...

  • Page 61: Declaration Of Incorporation

    13 DECLARATION OF INCORPORATION 13.1 DECLARATION OF INCORPORATION Declaration of incorporation 13.1 Declaration of incorporation in accordance with EU machinery directive 2006/42/EC (Annex II B) The manufacturer FIBRO GmbH Weidachstr. 41-43 D-74189 Weinsberg We herewith declare, that the incomplete machine described below Product description Rotary table type: FIBROTOR EM and ER...

  • Page 63: Index

    14 INDEX 14.1 LIST Index 14.1 List Holding phase .... 10, 11, 12, 13, 15, 24 Hydraulic diagram ........10 Hydraulic oil..........58 Accident prevention regulations ..20, 37 Additional component assemblies ..10, 32 Assembly......... 19, 37, 41 Außerbetriebnahme........55 Inspection ............. 50 Installation requirements ......
  • Page 64 14 INDEX 14.1 LIST Pendulum mode ......12, 15, 36 Servo motor ........... 24, 45 Personal protective clothing ....20, 57 Shipping by sea ...........38 Position detection......... 12, 35 Shutdown ..........55, 56 Pressure switch ........... 33 Spare parts ........49, 59, 60 Process consumables ........

  • Page 65: Personal Notes

    15 PERSONAL NOTES 15.1 NOTES Personal notes 15.1 Notes ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------ FIBROTOR 65 | 72...
  • Page 66 15 PERSONAL NOTES 15.1 NOTES 66 | 72 FIBROTOR...

  • Page 67: Annex

    16 ANNEX 16.1 WIRING GUIDELINES Annex 16.1 Wiring guidelines FIBROTOR 67 | 72...
  • Page 68 16 ANNEX 68 | 72 FIBROTOR...

  • Page 69: 16.2 Mounting Instructions For Gears And Geared Motos

    16 ANNEX 16.2 MOUNTING INSTRUCTIONS FOR GEARS AND GEARED MOTOS 16.2 FIBROTOR 69 | 72...
  • Page 70 16 ANNEX 16.2 MOUNTING INSTRUCTIONS FOR GEARS AND GEARED MOTOS Mounting instructions for gears and geared motos (gears and geared motors only optional available for EM.10, ER.10, ER.11, ER.12 and ER.13) 70 | 72 FIBROTOR...
  • Page 71 16 ANNEX 16.2 MOUNTING INSTRUCTIONS FOR GEARS AND GEARED MOTOS FIBROTOR 71 | 72...

  • Page 72: Other Documents

    16 ANNEX 16.3 OTHER DOCUMENTS 16.3 Other documents Technical data / specification Dimensional drawing(s) Connection diagram 72 | 72 FIBROTOR...

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