Lapple FIBRO FIBROTOR EM.NC Series Installation and operating instructions

FIBROTOR EM.NC
TRANSLATION OF THE ORIGINAL
ASSEMBLY AND OPERATION MANUAL

1INTRODUCTION
1.1 DEFINITION
FIBROTOR
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Rotary table FIBROTOR EM.NC
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 V1.2

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 Middle throughlet.................................................................................10
1.5.3 Directionof rotation.............................................................................10
1.5.4 Service life............................................................................................10
1.5.5 Cam drive .............................................................................................10
1.5.6 Positioning............................................................................................11
1.5.7 Drive motors.........................................................................................11
1.5.8 Reference point...................................................................................11
1.5.9 Holding brake.......................................................................................11
1.5.10 Indirect measuring system (Standard design) .............................12
1.5.11 Measuring system on the motor.....................................................12
1.5.12 Direct measurement (as from EM.NC.13 possible).....................12
1.5.13 Manufacturers and types of incremental encoders .....................12
1.5.14 Cable colours and connections ......................................................13
1.6 Warranty............................................................................................................13
1.7 Translation of the Original maintenance and operation manual ..............14
1.7.1 Legend..................................................................................................14
1.7.2 Figures..................................................................................................14
1.7.3 List of the valid pages.........................................................................14
1.7.4 Meaning of the safety instructions in this manual..........................14
1.8 Definitions of terms..........................................................................................15
2Safety ......................................................................................................................... 17
2.1 BASIC SAFETY INSTRUCTIONS................................................................17
2.1.1 Due diligence of the operator............................................................18
2.1.2 PERSONNEL REQUIREMENTS .....................................................19
2.2 Qualification of the personnel........................................................................19
2.3 Safety devices on the machine .....................................................................20
2.4 Remaining risks ............................................................................................... 20
3Technical description ............................................................................................21
3.1 General technical data....................................................................................21
3.2 Electrical connections .....................................................................................21
3.3 Temperature ranges........................................................................................21
3.4 Sealing air (optional).......................................................................................22
3.5 Operating parameters..................................................................................... 22
3.6 Assembly units.................................................................................................22
3.6.1 Rotary table..........................................................................................22
3.6.2 Cam roller gearbox.............................................................................23
3.7 Additional component assemblies and accessories ..................................23
3.7.1 Hydraulic table top clamping .............................................................23
3.7.2 Connectiondiagram table top clamping..........................................24
3.7.2.1 Functional diagram table top positioning .....................................26

1INTRODUCTION
1.1 DEFINITION
FIBROTOR
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4Transport...................................................................................................................27
4.1 Important safetyguidelines ............................................................................27
4.2Packaging and weight.....................................................................................28
4.3 Transport damages .........................................................................................28
4.4 Interim storage .................................................................................................28
4.5 Permitted equipment and auxiliarydevices for the transport....................29
4.6 Transport locks.................................................................................................29
4.6.1 Unpacking and transporting of the rotary table ..............................29
4.7 Return shipping................................................................................................30
4.8 Instructions for disposal of packaging material...........................................30
5Assembly...................................................................................................................31
5.1 Important safety guidelines ............................................................................31
5.2 Installationrequirements.................................................................................31
5.3 Assembly of the rotary table...........................................................................31
5.3.1 Mechanical assembly .........................................................................31
5.4 Modifications and alterations .........................................................................32
5.4.1 Admissible modifications and alterations ........................................32
5.4.2 Forbiddenmodifications and alterations..........................................32
6Commissioning........................................................................................................33
6.1 Important safety guidelines ............................................................................33
6.2 Prior to the commissioning.............................................................................33
6.2.1 Test run.................................................................................................33
7Operation...................................................................................................................35
7.1 Important safetyguidelines ............................................................................35
7.2 Workplaces of the operating personnel........................................................35
7.3 Operating modes .............................................................................................35
7.4 Functional sequences.....................................................................................35
7.4.1 Functional sequence of a dividing movement ................................35
7.4.2 Pathof motion......................................................................................36
7.5 Rotary table - turning onand operation........................................................36
8Faults..........................................................................................................................37
8.1 Important safetyguidelines ............................................................................37
8.2 Customer service.............................................................................................37
9Repair.........................................................................................................................39
9.1 Important safetyguidelines ............................................................................39
9.2 Maintenance work............................................................................................40
9.2.1 Inspections ...........................................................................................40
9.2.2 Maintenance / cleaning ......................................................................40
9.2.2.1 Long-term lubrication.......................................................................41
9.2.2.1 Mounting position of horizontal table top .....................................41
9.2.2.2 Mounting position of vertical and upside-down table top ..........41
9.2.2.3 Lubrication plan................................................................................42
9.2.2.4 Lubricants..........................................................................................42
9.2.2.5 Filling quantities ...............................................................................43
9.2.3 Repair....................................................................................................44

1INTRODUCTION
1.1 DEFINITION
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10 Shutdown.................................................................................................................. 45
10.1 Important safetyguidelines............................................................................45
10.2 Temporary shutdown ......................................................................................45
10.3 Permanent shutdown......................................................................................46
11 Disassembly and disposal................................................................................... 47
11.1 Important safety guidelines ............................................................................47
11.2 Disposal of components .................................................................................48
12 Service and spare parts ........................................................................................ 49
12.1 Service...............................................................................................................49
12.2 Spare parts.......................................................................................................49
12.3 Spare parts ordering .......................................................................................50
13 Declaration of incorporation................................................................................ 51
13.1 Declarationof incorporation...........................................................................51
14 Index........................................................................................................................... 53
14.1 List......................................................................................................................53
15 Personal notes.........................................................................................................55
15.1 Notes ................................................................................................................. 55
16 Annex......................................................................................................................... 57
16.1 Wiring guidelines .............................................................................................57
16.2 Other documents.............................................................................................59
Index of figures
Fig. 1 Holding brake 12
Fig. 2 Encoder 13
Fig. 3 Personal protective clothing 18
Fig. 4 Name plate 21
Fig. 5 Worm gearbox 23
Fig. 6 Hydraulic table top clamping 24
Fig. 7 Connectiondiagram table top clamping 25
Fig. 8 Functional diagram table top positioning 26
Fig. 9 Transporting boxes 29
Fig. 10 Pathof motion 36
Fig. 11 Lubrication plan 42

1INTRODUCTION
1.1 DEFINITION
FIBROTOR
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1INTRODUCTION
1.1 DEFINITION
FIBROTOR
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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 complywiththe 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 specified performance 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.)
The operator of the machine described in this document bears the responsibility for
any injuries and damages caused by its improper use.

1INTRODUCTION
1.4 APPLICABLEDOCUMENTS
FIBROTOR
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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.
Instructionfor the assemblyof a partlycompleted 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
gears 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 bearing for the table topis large and isbothaxiallyand radiallypretensioned. In
order toabsorb large tilting moments, e.g. whenthe table top isina verticalposition,
the additional component assembly "reinforced table top bearing" is available.
1.5.2 Middle throughlet
The rotary table is delivered with a large clear middle throughlet.
1.5.3 Direction of rotation
The direction of rotation can optionally be to the left or right. Pendulum mode is
possible.
1.5.4 Service life
The arrangement is subject to a service life of MTTF = 20,000 h.
1.5.5 Cam drive
The operationis generated by the drive motor via the gearboxand the cam drive on
the table top. The cam rollers are pretensioned on bothsides on the operating cam.

1INTRODUCTION
1.5 STRUCTURE
FIBROTOR
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1.5.6 Positioning
Positioning is achieved throughthe NC control system withposition rule capture via
encoder. In the positioned condition the cam is stopped play-free by an electric
brake. In the event of high tangential forces, a hydraulic table top clamping can be
used (greater rigidity, relief of the gearbox parts).
1.5.7 Drive motors
As standard, three-phase servo motors are used as drive motors. Directcurrent or
hydraulic servo motors can also be used. For individual cases with low precision
requirement the use of three-phasestandard motors inconjunctionwitha frequency
converter is possible.
1.5.8 Reference point
The rotary table can, as an option, be equipped with a fixed reference point switch.
The measuring system isset to this. Theswitchis used toreduce the speedand has
a signal length of approx. 3-4°. The switch is operated in the zero position. The
start-up of the reference point switch canbeperformed witha clockwise (CW) and a
counter-clockwise (CCW) direction of rotation.
1.5.9 Holding brake
The holding brake is energised to stop the worm shaft. Voltage 24 VDC
The operation is performed from the motor via spur wheel transmission to a worm,
whichdrives the table top via rollers. Positioning is achieved throughan NC control
system with position rule capture via a corresponding measuring system. In the
positioned condition the worm shaft is stopped play-free by the holding brake.
If the solenoid [1] is switched on the dotted magnetic field is depicted. The anchor
plate [3] is pressed onto the braking coil carrier with friction lining [4]. The shaft is
braked. The brake torque runs from the coil carrier [3] via the friction lining [4],
anchor plate [3] and membrane transmission spring [5] to the flange [6] and the
shaft.
If the solenoid [1] is de-energised, the membrane transmission spring [5] pulls the
anchor plate [3] away from the coil carrier [1]. The shaft can run through freely.
Type
Brake
Voltage
Torque
Power
EM.NC.11
Gr. 3
24 VDC
13 Nm
10 W
EM.NC.13
Gr. 4
24 VDC
24 Nm
15 W
EM.NC.15
Gr. 4
24 VDC
24 Nm
15 W
EM.NC.16
Gr. 6
24 VDC
80 Nm
27 W
EM.NC.17
Gr. 7
24 VDC
160 Nm
34 W
EM.NC.18
Gr. 7
24 VDC
160 Nm
34 W

1INTRODUCTION
1.5 STRUCTURE
FIBROTOR
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_________________________________________________________________





_________________________________________________________________
Fig. 1 Holding brake
Magnet Membrane transmission spring
Anchor plate Flange
Friction lining
1.5.10 Indirect measuring system (Standard design)
The encoder is arranged in the wormshaftaxis. The tolerances of the worm rolling
gearbox are included in the measurement.
1.5.11 Measuring system on the motor
In particular in the case of digital servo drives the measuring system is placed
directly on the motor shaft.
The precision and play of the reduction gearbox are included in the measurement
result.
This is only recommendable in relation with mathematically exact gear reduction.
1.5.12 Direct measurement (as from EM.NC.13 possible)
The measuring system isattached to the table top axis. The measuringaccuracyis,
to a great extent, dependent on the accuracy of the measuring system.
1.5.13 Manufacturers and types of incremental encoders
Standard manufacturer: Heidenhain
Number of lines
Type
Ident. No.
1.500
ROD 426 E/1500
05 51 895
5.000
ROD 426 B/5000
5 m cable
Radial output without plug
(4x2x0,14+4x0.25)mm²
Voltage supply 5V + 5%

1INTRODUCTION
1.6 WARRANTY
FIBROTOR
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1.5.14 Cable colours and connections
Function
Core colour
Signal 1
Brown
\Signal 1
Green
\Signal 2
Pink
Signal 2
Grey
+5V
Brown-Green
0V
White-Green
Sensor +5V
Blue
Sensor 0V
White
Signal 0
Red
\Signal 0
Black
_________________________________________________________________

_________________________________________________________________
Fig. 2 Encoder
Encoder
Structurally similar increm.
encoder
BDG 63 10
Balluff
DG 118
RSF Elektronik
DG 60 D
Stegmann
63-2
Leine & Linde
To avoid mechanical overloads on the rotary table, even in
the event of an emergency stop, the acceleration time ta (see “Technical Data” in
the appendix) must not be undershot.
1.6 Warranty
The warranty is regulated by contract (see General Terms and Conditions or
Contract).

1INTRODUCTION
1.7 TRANSLATION OF THE ORIGINAL MAINTENANCE AND OPERATION MANUAL
FIBROTOR
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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 machineandeveryone assigned to workonor with the 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.
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: 60
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.

1INTRODUCTION
1.8 DEFINITIONS OF TERMS
FIBROTOR
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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.
ATTENTION designatesadditional
instructions, provides information about possible property damage and is
not related to possible injuries.
1.8 Definitionsofterms
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.

1INTRODUCTION
1.8 DEFINITIONS OF TERMS
FIBROTOR
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2SAFETY
2.1 BASIC SAFETY INSTRUCTIONS
FIBROTOR
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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 possiblehazard can prevent an accidentbefore 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 SAFETY INSTRUCTIONS
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. 3 Personal protective clothing

2SAFETY
2.2 QUALIFICATION OF THE PERSONNEL
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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:
• read the manual and confirm with their signature that they have understood it.
• observe the safety information and guidelines in the manual and the
instructions contained in it.
• make sure that there are no unauthorised persons inthe rotary table area.
• make sure that the personnel in training works first on the rotary table only
under the supervision of an experienced and trained person.
• inadditionto the manual,observe also theoperating instructions for work safety
and accident prevention issued by the operator.
• inform the operator or the supervisory personnel about any malfunctions.
• inform immediately the respective managers about any changes in the rotary
table which can affect its safety.
2.2 Qualificationof the personnel
For certain task areas, a special qualification is necessary for personnel.
Task area
Qualification
Electrical system
Work on the electrical equipment
Skilled electricians
Mechanics
Commissioning and operation
Authorised and trained personnel
Inspections
Trained personnel
Maintenance
Authorised and trained personnel
Cleaning
Trained personnel
Repair
Service personnel of FIBRO GmbH

2SAFETY
2.3 SAFETY DEVICES ON THE MACHINE
FIBROTOR
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2.3 Safetydevices onthe machine
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 operator must take all the necessary measures to protect his personnel against
injuries from the machine
2.4 Remainingrisks
Movement of the table top
The table top turns with high torque. Safety precautions such as, for example,
protective grids, jog mode, two-hand operation, emergency stop button, etc. must
be taken. Do not reach in the path of motion. Danger of crushing.
Explosive atmospheres
The rotary table is not designed for operation in an explosive atmosphere.
Operation in explosive atmosphere or the processing of inflammable substances
canlead to explosion. The operator must take all necessary measures for operating
the rotary table only as intended. An explosion can cause serious to fatal injuries.
Unauthorised changes
Any unauthorised changes or any mounting of additional equipment not approved
by the manufacturer compromise the function of the rotary table and can lead to
dangerous situations. Therefore, any structural changes of the rotary table are
prohibited. The mounting of additional equipment must be discussed with the
manufacturer. Serious injuries or death are possible.