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FIBROTOR EM and ER

TRANSLATION OF THE ORIGINAL

ASSEMBLY AND OPERATION MANUAL

Summary of Contents for FIBRO FIBROTOR EM Series

Page 1: ...FIBROTOR EM and ER TRANSLATION OF THE ORIGINAL ASSEMBLY AND OPERATION MANUAL ...

Page 2: ......

Page 3: ...ervice fibro de Tel 49 0 7134 73 243 Fax 49 0 7134 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 in part without the prior written permission by FIBRO GmbH This document is intended only for the user of the described components and therefore may not be made available to uninvolved third parti...

Page 4: ...1 INTRODUCTION 1 1 DEFINITION FIBROTOR 4 72 ...

Page 5: ... 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 2 Safety 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 3 Technical description 23 3 1 General technical...

Page 6: ...Permitted equipment and auxiliary devices 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 5 Assembly 41 5 1 Important safety guidelines 41 5 2 Installation requirements 41 5 3 Assembly of the rotary table 41 5 3 1 Mechanical assembly 41 5 4 Modifications and alterations...

Page 7: ...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 Declaration of incorporation 61 14 Index 63 14 1 List 63 15 Perso...

Page 8: ...ection braking system 240VAC 26 Fig 11 Connection braking system 400VAC 27 Fig 12 Connection braking system 24VAC 27 Fig 13 Brake 28 Fig 14 Connection Georgii Kobold motor 29 Fig 15 Brake dimension A 31 Fig 16 Cross section brake 32 Fig 17 Hydraulic table top clamping 32 Fig 18 Connection diagram table top clamping 33 Fig 19 Functional diagram table top positioning 34 Fig 20 Position detection 35 ...

Page 9: ...ding 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 Any use that does not comply with the intended use of the rotary table is considered a misuse and is prohibited The rotary table may not be ...

Page 10: ... 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 c...

Page 11: ... 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 30...

Page 12: ...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 hol...

Page 13: ... 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 ...

Page 14: ...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 an...

Page 15: ...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 cycle by one partial step The middle of the holding phase is identified by a pointer at the drive shaft and a STOP sign on the fixing fla...

Page 16: ... 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 Translation of the Originalmaintenance and operation manual This manual is the translation of the original maintenance and operation manual and is part of the scope of delivery This manual describes the operation of the machine and ...

Page 17: ...nual 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 th...

Page 18: ...erms 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 ...

Page 19: ...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 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 ...

Page 20: ...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 rotary table is operated and maintained by specially trained and authorised personnel Personnel are familiar with the manual and especially the s...

Page 21: ...ry table only under the supervision of an experienced and trained person inaddition to the manual observe also the operating 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 Qualification ...

Page 22: ...autions 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 can lead to explosion The operator must take all necessary ...

Page 23: ...ust be provided Number Type Year of manufacture The maximum values of the airborne noise emission of the machine permitted by law should not be exceeded 3 1 1 Noise leve The maximum values of the airborne noise emission of the machine permitted by law should not be exceeded 3 1 2 Electrical connections Operating voltage Motor dependent see the technical specification Control voltage Motor dependen...

Page 24: ...le for the connection to the mains network is designed with 3x 400V 50Hz During operation with the frequency converter the characteristic values featured in the specification must be observed The acceleration and deceleration times are determined by the operating cam A ramp is not required on the three phase braking motor 3 5 Assembly units 3 5 1 Rotary table The table top is operated with various...

Page 25: ...l The max switching frequency according to the technical data should not be exceeded 3 5 3 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 Various coil designs are possible inorder to adapt to the usual connection voltages 3 5...

Page 26: ...replaced by a contact point in order to switch off on the direct current side This achieves an externally lower overrun The contact point is generally switched in parallel with the motor control switch Mains connection 400V 10 3AC 50 60Hz Braking motor Braking coil Connection according to the internal wiring diagram remove jumpers 3 4 _______________________________________________________________...

Page 27: ..._________________________________________ 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: ...e of the KEB Combistopp is not a problem A prerequisite is that the size selection has been made with care and that it is ensured that grease or oil does not penetrate the friction surface Moderate dust build up does not cause damage _________________________________________________________________ _________________________________________________________________ Fig 13 Brake 1 Manual ventilation ...

Page 29: ... applied is featured in the wiring diagram The motor may only be switched on in conjunction with the direct current brake The rectifier is not connected to the mains 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 w...

Page 30: ...product By the application of permanent magnets the brake has its full brake torque in a voltage free condition The application of direct current voltage produces a directional electromagnetic field in the brake releasing coil in the opposite direction to the permanent magnet field and compensates it A disc spring built into part 11 rests on a trailing ring and ensures a complete removal of the fr...

Page 31: ...e part 4 using the pull off device or ventilate the brake by applying voltage and remove the circumferential brake part Coat the toothing and shaft with Optimoly PL and assemble parts 4 5 and 7 again Type Dimension A new worn COD 3 MB COD 4 MB COD 5 MB COD 6 MB COD 7 MB COD 8 MB COD 5 MB 54 COD 6 MB 65 9 1 9 1 9 10 7 12 9 12 9 9 1 9 6 6 6 7 8 8 6 6 _________________________________________________...

Page 32: ...ned state the table top is connected with the housing in a friction locked and backlash free manner by means of hydraulically impinged clamping The monitoring of the pressure is performed with the pressure switch The level of the admissible pressures is taken from the hydraulic diagram or the technical specification in the annex Clamping time approx 0 4 s Release time approx 0 2s _________________...

Page 33: ...amaged The activation of the tangential forces may take place only within the limits defined by the technical specification If the tangential moments at the clamped table top are exceeded the clamping elements and possibly the driving elements are destroyed 3 6 2 Connection diagram table top clamping Pressure switch setting range 2 20 bar Ident No 070 572 3 Pressure switch setting range 10 100 bar...

Page 34: ...___________ _________________________________________________________________ Fig 19 Functional diagram table top positioning Clamping table top Initial position 4 2 directional valve new initial position of the table top Turn the motor for the table top 4 2 directional valve on B1 Turn the table top Table top clamped Pressure switch S1 1 Clamping released Pressure switch S2 1 new position of the ...

Page 35: ...le diameter 8mm X pressed ________________________________________________________ ________________________________________________________ Fig 20 Position detection 3 6 4 Wiring diagram position detection For the position detection as standard the same end switches are used as for the evaluation of the disk cams ________________________________________________________ ____________________________...

Page 36: ...ween various positions through a change in the directionof rotation of the motor anoverrunof the end stations can be prevented by using mechanical end switches emergency stop function _________________________________________________________________ _________________________________________________________________ Fig 22 Safety microswitch ...

Page 37: ...ng boxes Tilted loads If the centre of gravity is disregarded a load can tilt The rotary table must be positioned so that the load can be in equilibrium Always take into consideration the centre of gravity when fastening the transport means Secure the load against tilting Injuries from tilted loads Unsecured rotary table The rotary table can turn or become displaced from the linear axis depending ...

Page 38: ...ccording to the International Plant Protection Convention IPPC The packaging materials must be either reused or properly disposed of in accordance with the country specific regulations 4 3 Transportdamages The shipment must be inspected for completeness and transport damages immediately after the delivery If damage is found on the packaging that indicates possible damage to the content the content...

Page 39: ...sportlocks The rotary table can be transported as an individual device without separate transport locks In the case of combination layouts transport locks according to the supplementary sheet must be used 4 6 1 Unpacking and transporting of the rotary table 1 Unpack the rotary table and make it freely accessible on all sides 2 Inspect the rotary table for damage during the transport 3 Verify the e...

Page 40: ...he box while observing the safety instructions and transport regulations 4 7 Return shipping All parts which are forwarded to the manufacturer for repair must be securely packaged for the return shipping The air vent screws of the gear boxes must be closed in order to prevent oil leakage The electronic components must be always transported in antistatic packaging The transport locks must be re att...

Page 41: ...y site is suitable for the operational weight including the superstructural parts of the client and the tools the expected loads torques and moments of inertia have been taken into consideration the assembly site has been isolated with a signal strip the assembly site has been marked with danger signs only authorised persons have access to the work area and no other persons could be endangered by ...

Page 42: ...unctional sequence see chapter 7 3 Operating modes Measuring system 5 4 Modifications and alterations 5 4 1 Admissible modifications and alterations The admissible alterations can affect the performance of the rotary table The admissible alterations are Installing tools workpieces and devices on the table top Attaching hoses pneumatic lines or cables to the rotary table The hoses pneumatic lines o...

Page 43: ...issioning Prior to the commissioning visual inspection of the rotary table has to be performed Hereby it is necessary to check and make sure that the safety devices are operational there are no damages on the rotary table there are no foreign bodies tools or other objects on the machine all supply facilities are connected and operational Prior to the return to operation a test run must be performe...

Page 44: ...7 OPERATION 6 2 PRIOR TO THE COMMISSIONING FIBROTOR 44 72 ...

Page 45: ...starting the rotary table about the correct behaviour in the event of accidents the operation is performed only by persons who have been trained instructed and authorised for that These persons must know this manual and proceed according to it the rotary table is used deployed only in accordance with its intended use see Chapter 1 2 Intendeduse on page 9 during power up and operation there is no o...

Page 46: ...7 OPERATION 7 4 ROTARY TABLE TURNING ON AND OPERATION FIBROTOR 46 72 ...

Page 47: ...e action area of the moving machine parts must be secured The repairs must be performed by FIBRO personnel only The use of unauthorised personnel can lead to injuries resulting from incorrect action 8 2 Customerservice If you need assistance from our customer service please provide the following data Serial number according to the name plate Description of the occurring fault The point in time and...

Page 48: ...9 REPAIR 8 2 CUSTOMER SERVICE FIBROTOR 48 72 ...

Page 49: ...ts must be always replaced with new ones All prescribed tightening torques must be adhered to exactly as specified Failure of unapproved spare parts can cause injuries Missing safety devices Under certain circumstances safety devices may have to be removed when maintenance work is performed The removed parts must be reassembled immediately after completing the maintenance work The protection funct...

Page 50: ...machine in a secure manner Performing maintenance and cleaning work when the power supply is turned on is dangerous Perform the 5 steps to securely turn off the electric power supply All other power supply sources must be also turned off Injuries when the power supply is turned on 5 steps for securely turning off the electric power supply Turn off the main switch disconnect all sides Secure the ma...

Page 51: ...Contact our customer service in this regard It is recommendable to thoroughly clean the gearbox when changing the lubricant The rolling bearings filled with grease must be cleaned every 20 000 operating hours and filled with new grease Whilst doing so ensure that the bearing space is filled with approx 1 3 grease Synthetic and mineral lubricants must not be mixed with each other In the case of amb...

Page 52: ...ig 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 Q8 Q8 EL Greco 220 MOBIL Mobilgear SHC XMP 220 ARAL Aral Degol GS 220 BP BP Enersynl SG XP 220 KLÜBER Syntheso D 22...

Page 53: ...itted for the offset gearbox Manufacturer supplier Designation Q8 Q8 EL Greco 220 MOBIL Mobilgear SHC XMP 220 ARAL Aral Degol GS 220 BP BP Enersyn SG XP 220 In the case of external reservoirs observe their lubrication instructions 9 2 2 5 Filling quantities Type 1 Rotary table 4 Offset Gearbox EM 10 EM NC 10 0 03 l EM 11 T02 0 10 l 0 07 l EM 11 T02 EM NC 11 0 06 l 0 07 l EM 12 EM NC 12 0 17 l 0 07...

Page 54: ...1 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 The operator of the rotary table should not perform any overhaul repair work If there is a need of overhaul repair work the FIBRO GmbH customer service must be informed ...

Page 55: ...Unauthorised personnel Personnel that has not been properly trained does not have the authorisation to take the machine out of operation The shutdown must only be performed by trained personnel that has been authorised for performing the respective activities The use of unauthorised personnel can lead to injuries resulting from incorrect action 10 2 Temporary shutdown For the temporary shutdown Tu...

Page 56: ... 10 3 Permanentshutdown 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: ...not stand under suspended loads The auxiliary personnel may act only on instructions by the specialised personnel During the transport the safety measures for the transport should also be observed Disregarding the safety measures can lead to serious injuries The auxiliary personnel of the operator must strictly adhere to the instructions of the FIBRO personnel and observe the safety instructions T...

Page 58: ...l and regional laws and guidelines Attention must be paid to the environmentally compatible disposal of the process consumables The local regulations regarding the proper waste recycling or removal must be observed The local authorities provide information about the disposal and collection depots The machine consists of Iron steel Aluminium Grey cast iron Brass Copper motors and electric lines Pla...

Page 59: ...tion is available Address all written enquiries to FIBRO GmbH Rotary Table Division Weidachstrasse 41 43 D 74189 Weinsberg rtservice fibro de All FIBRO representation offices worldwide can be found under www fibro de 12 2 Spare parts Spare parts must meet the technical requirements specified by FIBRO GmbH By ordering original spare parts from FIBRO GmbH you are assured that these requirements will...

Page 60: ...photos or sketches Quantity of the spare parts needed Please address your spare parts order to FIBRO GmbH Rotary Table Division Weidachstrasse 41 43 D 74189 Weinsberg rtservice fibro de All FIBRO representation offices worldwide can be found under www fibro de Upon receipt of the spare parts delivery Check that the right number of parts has been delivered and that they are all correct and in good ...

Page 61: ...ex VII Part B of this guideline The incomplete machine also meets the requirements of Directives 2014 35 EU regarding electrical equipment and 2014 30 EU regarding electromagnetic compatibility We undertake to submit via our documentation department the special documents for the incomplete machine to the market supervisory authorities upon justified request The incomplete machine must not be put i...

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Page 63: ...8 22 End switch 11 12 13 14 15 35 36 Entsorgung 57 Ersatzteile 59 G Georgii Kobold motor 29 H Hazard 19 Holding phase 10 11 12 13 15 24 Hydraulic diagram 10 Hydraulic oil 58 I Inspection 50 Installation requirements 41 Instandhaltung 49 Intended use 9 Interim storage 38 Intermittent mode 25 28 30 L Linear axis 37 Load suspension devices 37 39 Long term lubrication 51 Lubricants 51 52 Lubrication p...

Page 64: ... 37 40 41 42 43 45 47 49 55 57 Safety microswitch 36 Sealing air 24 Sealing air pressure 24 Sequence diagram 14 Service life 10 16 29 30 51 Service number 47 59 Servo motor 24 45 Shipping by sea 38 Shutdown 55 56 Spare parts 49 59 60 Spare parts ordering 60 Special braking motor KOD 28 synthetic greases 53 synthetic oils 53 synthetic viscous oils 52 T Table top clamping 11 32 33 Technical Data 23 ...

Page 65: ...15 PERSONAL NOTES 15 1 NOTES FIBROTOR 65 72 15 Personal notes 15 1 Notes ...

Page 66: ...15 PERSONAL NOTES 15 1 NOTES FIBROTOR 66 72 ...

Page 67: ...16 ANNEX 16 1 WIRING GUIDELINES FIBROTOR 67 72 16 Annex 16 1 Wiring guidelines ...

Page 68: ...16 ANNEX 0 FIBROTOR 68 72 ...

Page 69: ...16 ANNEX 16 2 MOUNTING INSTRUCTIONS FOR GEARS AND GEARED MOTOS FIBROTOR 69 72 16 2 ...

Page 70: ...NNEX 16 2 MOUNTING INSTRUCTIONS FOR GEARS AND GEARED MOTOS FIBROTOR 70 72 Mountinginstructionsfor gears and gearedmotos gears and geared motors only optional available for EM 10 ER 10 ER 11 ER 12 and ER 13 ...

Page 71: ...16 ANNEX 16 2 MOUNTING INSTRUCTIONS FOR GEARS AND GEARED MOTOS FIBROTOR 71 72 ...

Page 72: ...16 ANNEX 16 3 OTHER DOCUMENTS FIBROTOR 72 72 16 3 Other documents Technical data specification Dimensional drawing s Connection diagram ...

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