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
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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

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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.

1INTRODUCTION
1.5 STRUCTURE
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_______________________________________________________________
_______________________________________________________________
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).
_________________________________________________________________
_________________________________________________________________
Fig. 2 Table top and operating cam
1.5.5 End switch
Standard switch:
2 inductive proximity
switches
Basic technology:
PNP
Type:
BESM12MI-PSC20B-
S04G
Voltagerange:
10V-30V
Standard size according
to:
EN 50 008 A 12
Breaking capacity:
200mA
Fixing thread:
M12x1
Basic function:
BES: Normally
open contact

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1.5 STRUCTURE
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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).
This factory setting does not mean that an adjustment of the end switch setting to
the rotary table control system used on site may not be required.
S10 "Table top at standstill"
S12 "Motor off"
In the case of pendulum mode we recommend attaching a position detector.
A dividing process occurs from S12 to S12.
The length of the holding phase is displayed with a position diagram.
In divisions as from T 16 there are several standstills on the circumference of the
operating cam.

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

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1.5 STRUCTURE
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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
Schaltphase = Schaltzeit ts
Index phase = Index time ts
Phase d'indexage = Temps d'indexage
ts
Haltephase th
Holding phase
th
Phase d'arrét
Haltephase th
Holding phase
th
Phase d'arrét
Ablaufdiagramm
Running sequence diagram
Diagramme des mouvements
1
0
1
0
1
0
1
0
1
0
Beschleunigung
Acceleration
Accélération
Geschwindigkeit
Speed
Vitesse
Winkel
Movement
Déplacement
1
2
3
t1
t2
t3
t5
t6
t4
t7
t8
t9
t10
t11
t12
Startimpuls
Start pulse
Impulsion de démarrage
Antriebsmotor "Ein"
Drive motor "On"
Moteur d'entrainament en marche
Schaltteller "dreht"
Index table "turning"
Le plateau tourne
S10 "Schaltteller im Stillstand"
S10 "Index table stationary"
S10 "le plateau est areté”
S12 "Motor Aus"
S12 "Motor off"
S12 "Moteur hors circuit"
1 Winkelschritt
1 angular step
1 pas angulaire
1
2
3
_________________________________________________________________
Fig. 5 Sequence diagram
S12 Signal "Motor off" end switch not pressed
alternative:
S12 Signal "Motor off" end switch pressed
1.5.8 Position overrun
If the signal S10 "Table top at standstill" is overrun, the trip cam for "Motor off" must
be readjusted. After an extended period of operation the braking system must be
readjusted or replaced.

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1.5 STRUCTURE
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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 oppositedirection, the connections of 2 phases (e.g. L1
and L2) must be changed on the network terminals.
Should the rotary indexing table rotate counter-clockwise this must be indicated in
the order or the end trip cam must be readjusted.
During pendulum mode the end trip cams are parallel, i.e. the signals S10 and S12
are emitted at the same time.
A change in direction of rotation during the rotational
movement leads to the destruction of the driving elements.
1.5.10 Holding phase of the operating cam
The middle of the holding phase is identified by a pointer at the drive shaft and a
STOP sign on the fixing flange.
Division 2 to division 12:
In the case of a rotation of the operating cam the table top continues to perform a
cyclebyone partialstep. The middle of the holding phase isidentifiedbyapointer at
the drive shaft and a STOP signon the fixing flange.
As from division 16:
In the case of a rotation of the operating cam the table top continues to perform a
cycle by two partial steps. In this case the trip cams for the end switches are
designed in such a way that two pulses are emitted during one rotation.
_________________________________________________________________
Division 2 - 12
As from division 16
_________________________________________________________________
Fig. 6 Holding phases operating cam
1Holding phase
2Indexing phase
1
2
1

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1.6 WARRANTY
FIBROTOR
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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. This
causes excessive acceleration.
This leads to an increased load of the driving elements and thus to a reduced
service life.
In order to reduce this torque peak we would suggest adopting the following
measures:
Extension of the indexing time or reduction in the moment of inertia.
Use of a frequency converter for a soft start at creeping speed after
emergency stop up to the next base position.
Use of a pole-changeable motor.
Jog mode in the nominal speed of the drive motor is not
permitted. If jog mode is required, a pole-changeable motor or a
frequencyconverter must be used. In the jog mode creeping speed must always be
applied.
1.6 Warranty
The warranty is regulated by contract (see General Terms and Conditions or
Contract).
1.7 Translationof the Originalmaintenanceandoperation manual
This manual is the translation of the original maintenance and operation manualand
is part of the scope of delivery.
This manual describes the operation of the machine and contains important
information about its intended use.
This manual is addressed especially to the personnel that has been trained and
authorised for operating and servicing the machine.
A copy of this manual must be stored and made continuously available at the
operatingsite of the machineand everyone assigned to workonor withthe machine
must read, understand and apply it.
The safety instructions in the individual chapters must be observed.
This manual and the other relevant documents (see Chapter 1.4 Applicable
documents on page 10) are not subject to any modification service.
We reserve the right to update data and drawings in this manual based on further
technical development.
The respectively current version can be requested from the manufacturer.

1INTRODUCTION
1.7 TRANSLATION OF THE ORIGINAL MAINTENANCE AND OPERATION MANUAL
FIBROTOR
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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.
indicates a listing.
indicates the second level of a listing.
The book symbol before the text is a reference to another applicable document.
The content of this document must be observed.
The information symbol before the text indicates an additional instruction or an
important application tip.
1.7.2 Figures
The figures show the machine as an example. Deviations in the graphical
presentation compared to the delivered machine are possible.
1.7.3 List of the valid pages
The number of pages in this manual, including the title page: 72
1.7.4 Meaning of the safety instructions in this manual
This manual contains instructions which must be observed for the protection of
personnel and the prevention of property damage.
The safety instructions related to warnings about injuries are emphasised with the
help of a code chart containing a warning triangle and a signal word. The respective
text describes the type of hazard, its source, the means of prevention and the
consequences of disregarding the safety instruction.
The general instructions or those related to possible property damage are
designated with a code chart without a warning triangle.
The code charts used in this manual have the following meaning:
DANGER designates a hazardous situation
which, if not prevented, can lead to death or serious injury.
WARNING designates a hazardous
situation which, if not prevented, can lead to death or serious injury.
CAUTION designates a hazardous
situation which, if not prevented, can lead to light to medium-level injuries.

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1.8 DEFINITIONS OF TERMS
FIBROTOR
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ATTENTION designatesadditional
instructions, provides information about possible property damage and is
not related to possible injuries.
1.8 Definitionsof terms
Manual
General designation of this document.
EMERGENCY STOP
Immediate interruption of all motion processes by
activation of an emergency stop button.
Protective equipment
Technical equipment on the machine whose purpose is
to guarantee its safety.
Safety instruction
Instruction in manuals and handbooks related to
possible physical injuries.
Safety information
Information about the safe operation of the machine.

2SAFETY
2.1 BASIC SAFETYINSTRUCTIONS
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2Safety
2.1 BASIC SAFETYINSTRUCTIONS
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. If the warnings are disregarded, this
can lead to physical injuries or death.
FIBRO GmbH cannot foresee all possible circumstances that can lead to
potential hazards. Therefore, the warnings in this document and on the rotary
table do not include all hazards.
Personnel must have the necessary training and experience and possess the
necessary tools in order to be able to perform the work on the machine correctly.
Improper operation, maintenance or repair can be dangerous and cause serious or
fatal injuries.
No work related to transport, assembly, maintenance or repair may be performed if
the informationabout transport, assembly, maintenance or repair has not been read
and understood.
The rotary table is designed for mounting in other machines or for assembly with
other machines. FIBRO GmbH has no controlover theintended use of the machine.
The operator is responsible for the safety devices for operation of the machine.
Operation without safety devices is prohibited.
The operator is responsible for the safe operation and the information that is
necessary for the operation.
The rotary table may not be used in any way that deviates from the instructions in
this manual. All safety rules and safety measures, including the site-related
regulations and safety measures at the workplace, which are applicable to its use,
must be observed.
If work equipment, operation, work methods or work techniques that have not been
explicitly proposed byFIBRO GmbHare used, the operator must himself ensure the
safety for himself and for other persons.
It must also be ensured that the rotary table does not get damaged or become
unstable over the course of the intended operation, maintenance and repair work.
The information, descriptions and figures in this document are based on the
information that was available at the time of creation of this document.
The descriptions, operating pressures, measurement methods, figures and other
items can be changed at any time. These changes can affect the characteristics of
the rotary table. The currently applicable information must be provided prior to
starting the performance of any work.

2SAFETY
2.1 BASIC SAFETYINSTRUCTIONS
FIBROTOR
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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. The operator of the machine
must plan these measures and control their implementation.
The operator must make sure that
• the rotary table is used only as intended.
• The rotary table must be operated only in a fully functional state with all
mechanical and/or electrical safety devices in place.
• A copy of this manual and of all other applicable documents must be always
available in a complete and good legible condition at the operation site of the
rotary table. It must be ensured that all persons who have to perform activities
on the rotary table can consult the manual at any time.
• The rotarytable is operated and maintained byspecially trained and authorised
personnel.
• Personnel are familiar with the manual and especially the safety instructions
contained within it.
• The responsibilities of personnel in the operation and maintenance are clearly
defined and observed.
• Personnel is regularly instructed in all applicable issues related to the work
safety and environmental protection.
• The operating instructions related to the work safety and accident prevention
are enforced.
• The national accident prevention regulations and in-house rules are observed.
• When necessary, personal protective clothing is provided.
Fig. 7 Personal protective clothing