Lapple FIBRO FIBROTOR EM Series Installation and operating instructions

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

1INTRODUCTION
1.1 DEFINITION
FIBROTOR
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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
[e-mail]
Tel: [phone] / 73 - 243
Fax: [phone] / 73 - 344
© FIBRO GmbH
All rights to this document are subject to the copyright of FIBRO GmbH. This
document may not be copied or reproduced, either in full or inpart, without the prior
written permissionby FIBRO GmbH. This document is intended only for the user of
the described components and therefore may not be made available to uninvolved
third parties - in particular to competitors.
Document: Translation of the original assembly and operation manual
Version 1.4

1INTRODUCTION
1.1 DEFINITION
FIBROTOR
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1INTRODUCTION
1.1 DEFINITION
FIBROTOR
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Contents
1Introduction.................................................................................................................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 Pathof motion......................................................................................10
1.5.3 Drive, cam ............................................................................................10
1.5.4 Positioning............................................................................................11
1.5.5 End switch............................................................................................11
1.5.5.1 Basic wiring diagram...........................................................12
1.5.6 Adjusting the end switches................................................................12
1.5.7 Sequence diagram..............................................................................14
1.5.8 Position overrun ..................................................................................14
1.5.9 Table top directionof rotation............................................................15
1.5.10 Holding phase of the operating cam.............................................15
1.5.11 EmergencyStop mode ....................................................................16
1.6Warranty............................................................................................................16
1.7 Translation of the Original maintenance and operation manual ..............16
1.7.1 Legend..................................................................................................17
1.7.2 Figures..................................................................................................17
1.7.3 List of the valid pages.........................................................................17
1.7.4 Meaning of the safety instructions in this manual..........................17
1.8 Definitions of terms.......................................................................................... 18
2Safety ......................................................................................................................... 19
2.1 BASIC SAFETY INSTRUCTIONS................................................................19
2.1.1 Due diligence of the operator............................................................20
2.1.2 PERSONNEL REQUIREMENTS .....................................................21
2.2 Qualification of the personnel........................................................................21
2.3 Safety devices on the machine .....................................................................22
2.4 Remaining risks ...............................................................................................22
3Technical description ............................................................................................23
3.1 General technical data....................................................................................23
3.1.1 Noise leve.............................................................................................23
3.1.2 Electrical connections.........................................................................23
3.2 Temperature ranges........................................................................................23
3.3 Sealing air (optional).......................................................................................24
3.4Operating parameters.....................................................................................24
3.5 Assembly units.................................................................................................24
3.5.1 Rotary table..........................................................................................24
3.5.2 Cam roller gearbox .............................................................................24
3.5.3 Intermittent operation with braking motor (Optional) .....................25
3.5.3.1 Braking voltage ....................................................................25
3.5.4 Switching and connection..................................................................25
3.5.5 Special sealing against dust, dirt and moisture..............................28
3.5.6 Brake.....................................................................................................28

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1.1 DEFINITION
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3.5.7 Intermittent operation with specialbraking motor KOD (Optional)
28
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..............................................................30
3.6 Additional component assemblies and accessories ..................................32
3.6.1 Hydraulic table top clamping .............................................................32
3.6.2 Connection diagram table top clamping ..........................................33
3.6.2.1 Functional diagram table top positioning .........................34
3.6.3 Positiondetection................................................................................35
3.6.4 Wiring diagram position detection ....................................................35
3.6.5 Safety microswitch..............................................................................36
4Transport...................................................................................................................37
4.1 Important safetyguidelines ............................................................................37
4.2 Packaging and weight.....................................................................................38
4.3 Transport damages .........................................................................................38
4.4 Interim storage .................................................................................................38
4.5 Permitted equipment and auxiliarydevices for the transport....................39
4.6 Transport locks.................................................................................................39
4.6.1 Unpacking and transporting of the rotary table ..............................39
4.7 Return shipping................................................................................................40
4.8 Instructions for disposal of packaging material...........................................40
5Assembly...................................................................................................................41
5.1 Important safetyguidelines ............................................................................41
5.2 Installationrequirements.................................................................................41
5.3 Assembly of the rotary table...........................................................................41
5.3.1 Mechanical assembly .........................................................................41
5.4Modifications and alterations .........................................................................42
5.4.1 Admissible modifications and alterations ........................................42
5.4.2 Forbiddenmodifications and alterations..........................................42
6Commissioning........................................................................................................43
6.1 Important safetyguidelines ............................................................................43
6.2 Prior to the commissioning.............................................................................43
6.2.1 Test run.................................................................................................43
7Operation...................................................................................................................45
7.1 Important safetyguidelines ............................................................................45
7.2 Workplaces of the operating personnel........................................................45
7.3 Operating modes .............................................................................................45
7.4 Rotary table - turning on and operation........................................................45
8Faults..........................................................................................................................47
8.1 Important safetyguidelines ............................................................................47
8.2 Customer service.............................................................................................47
9Repair.........................................................................................................................49
9.1 Important safetyguidelines ............................................................................49
9.2 Maintenance work............................................................................................50
9.2.1 Inspections ...........................................................................................50

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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
51
9.2.2.3 Lubrication plan....................................................................52
9.2.2.4 Lubricants .............................................................................52
9.2.2.5 Filling quantities ...................................................................53
9.2.3 Repair....................................................................................................54
10 Shutdown.................................................................................................................. 55
10.1 Important safety guidelines ............................................................................55
10.2 Temporary shutdown ......................................................................................55
10.3 Permanent shutdown......................................................................................56
11 Disassembly and disposal................................................................................... 57
11.1 Important safety guidelines ............................................................................57
11.2 Disposal.............................................................................................................58
11.3 Disposal of components .................................................................................58
12 Service and spare parts ........................................................................................ 59
12.1 Service...............................................................................................................59
12.2 Spare parts.......................................................................................................59
12.3 Spare parts ordering .......................................................................................60
13 Declaration of incorporation................................................................................ 61
13.1 Declarationof incorporation...........................................................................61
14 Index........................................................................................................................... 63
14.1 List......................................................................................................................63
15 Personal notes.........................................................................................................65
15.1 Notes ................................................................................................................. 65
16 Annex......................................................................................................................... 67
16.1 Wiring guidelines .............................................................................................67
16.2 Mounting instructions for gears and geared motos....................................69
16.3 Other documents.............................................................................................72

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1.1 DEFINITION
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Index of figures
Fig. 1 Cam drive 11
Fig. 2 Table top and operating cam 11
Fig. 3 Wiring diagram end switch 12
Fig. 4 End switch 13
Fig. 5 Sequence diagram 14
Fig. 6 Holding phases operating cam 15
Fig. 7 Personal protective clothing 20
Fig. 8 Name plate 23
Fig. 9 Worm gearbox 25
Fig. 10 Connectionbraking system 240VAC 26
Fig. 11 Connectionbraking system 400VAC 27
Fig. 12 Connectionbraking system 24VAC 27
Fig. 13 Brake 28
Fig. 14 Connection Georgii Kobold motor 29
Fig. 15 Brake dimension "A" 31
Fig. 16 Cross sectionbrake 32
Fig. 17 Hydraulic table top clamping 32
Fig. 18 Connectiondiagram table top clamping 33
Fig. 19 Functional diagram table top positioning 34
Fig. 20 Positiondetection 35
Fig. 21 Wiring diagram position detection 35
Fig. 22 Safety microswitch 36
Fig. 23 Transporting boxes 39
Fig. 24 Lubrication plan 52

1INTRODUCTION
1.1 DEFINITION
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1Introduction
1.1 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.
1.2 Intendeduse
The purpose of the rotary table is to be mounted inother machines or inother partly
completed machinery or equipment, or to be assembled with them.
Thecommissioning is not permitted untilthe necessarysafety has beenguaranteed
for the entire installation, into which the rotary table has been mounted, and its
conformitywith the laws and guidelines of the countrywhere the rotarytable isto be
operated, has been established and confirmed.
Its use is permitted only within the limits defined inthe order characteristics.
The intended use includes also
the reading of this manual and observing the safety information.
Observing the relevant documentation.
Observing the maintenance instructions.
The rotary table may only be used as intended. Only methods and procedures
described in this manual may be used.
1.3 Improperuse
Anyuse that does not comply with the intended use of the rotarytable is considered
a misuse and is prohibited.
The rotary table may not be subjected to loads above its maximum load limits.
As a matter of principle, the rotary table is not suitable for
• Operation in mobile or portable systems, on ships or inaircraft
• Operation in life support systems
• Operation in residential housing
• Operation beyond the limits of the specifiedperformance data and operating
parameters
• Use in explosive atmospheres
• Use in vacuum spaces
• Use under operating conditions where highly inflammable or explosive
substances are processed
• Use under operating conditions with aggressive or solvent-containing
substances (e.g. acids, lyes, hydrocarbons, etc.)

1INTRODUCTION
1.4 APPLICABLEDOCUMENTS
FIBROTOR
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The operator of the machine described in this document bears the responsibility for
any injuries and damages caused by its improper use.
1.4 Applicabledocuments
Along with this manual, other applicable documents are necessary for the safe
operation of the machine. The data in these documents must be observed.
Instruction for the assembly of a partly completed machine according to
Guideline 2006/42/EG
Electric diagram
Hydraulic diagram
Pneumatic diagram
Drawings
1.5 Structure
The structural design is characterised by a rigid mechanical structure. The basic
device is comprised of the housing, table top, bearings, cam drive, drive motor with
gearbox and holding brake. Horizontal and vertical use with several motor layouts is
possible.
Additional component assemblies are available if the structure is to be extended.
The rotary table may also be used as a built-in table.
1.5.1 Bearing
The arrangement is subject to a service life of MTTF = 20,000 h.
1.5.2 Path of motion
The figure with the operating curve ensures that the operation is smooth and
impact-free, even in the event of considerable loads (see the evolution of the
operating cam). The indexing time can be taken from the load diagram in
accordance with the moment of inertia.
The time for the cam rotationis divided into a stipulated ratio between indexing and
holding time.
1.5.3 Drive, cam
The operationis generated from the drive motor via a gearboxand the cam drive to
the table top. The cam rollers are pretensioned onbothsides onthe operating cam
in the holding phase. This enables the play-free transition from standstill to
movement and vice versa.