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Shibuya Hoppmann FR-20, Installation & Maintenance Manual

The Shibuya Hoppmann FR-20 is a high-performance machine, designed to streamline your assembly line operations. To ensure effortless installation and smooth operations, it comes with an comprehensive "Installation & Maintenance Manual". Download this manual for free from our website, and unlock the full potential of your FR-20 machine.

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38

FR-20 & FR-30 Feeder Installation/Maintenance

Before ordering, please read the notice at the beginning of this chapter.

FR-20 & 30 Critical Replacement Parts - Metric (AC Motors)

FR-20 & 30 Recommended Replacement Parts - Metric (AC Motors)

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Summary of Contents for FR-20

Page 1: ...l numbers lower than 19448 except where noted Serial Number Date Model Number Inventory Number Check One FR20XXXDSA FR30XXXDSA FR20XXXASA FR30XXXASA FR20XXXASM FR30XXXASM Second Edition Revision 3 All Rights Reserved Copyright 2005 1996 1994 1992 by Shibuya Hoppmann 13129 Airpark Drive Suite 120 Elkwood Virginia 22718 Phone 540 829 2564 Toll Free 800 368 3582 Fax 540 829 1724 www hoppmann com emai...

Page 2: ... parts and other hazardous condi tions The exclamation point caution symbol denotes possible personal injury and or damage to the equipment Thelightningboltcautionsymboldenotespossiblepersonalinjury and or damage to the equipment from electrical hazards Quick Start Acknowledgments Grateful acknowledgment is made to HCCI for permission to reproduce the chain tensioning graphic in Chapter 5 Plug In ...

Page 3: ...c versions For maximum compatibility ANSI units are classifiedas softANSI construction meaningthatmetricthreads and hardware are used throughout Both metric and ANSI units require metric tools for repair and or adjustment If your direct supplier tooled your metric feeder with ANSI hardware you will need ANSI tools as well Any part of the feeder that touches your parts has been precision tooled to ...

Page 4: ...ons 11 Operating Maintenance Do s Don ts Installation Startup 13 Unpacking Inspection 13 Physical Setup 14 Starting The Feeder For The First Time 15 How to Set Proper Bowl Speed 16 Running Product For The First Time 16 General Tips Figures 15 Figure 3 1 Measuring Changing Bowl Speed 17 Figure 3 2 DC ANSI Wiring Diagram 18 Figure 3 3 DC Metric Wiring Diagram Preventive Maintenance 19 General Cleani...

Page 5: ...lder Style Backup Ring 27 Figure 5 5 Current Style Backup Ring 28 Figure 5 6 Machinable Bowl Surfaces 31 Figure 5 7 FR 20 FR 30 Feeder Troubleshooting 32 Figure 5 8 FR 20 FR 30 Feeder Troubleshooting Cont Spare Parts 33 Notice to Hoppmann Customers 33 Notice to Dealer OEM Customers 33 In North America 33 In Europe 34 ANSI FR 20 Replaceable Spares 35 Metric FR 20 Replaceable Spares 36 ANSI FR 30 Re...

Page 6: ...e Rotation shown Figure 1 1 FR 20 FR 30 Feeder Exploded View FR 30 Side View ANSI Gearmotor Clutch Assy FR 30 Top View Frame Side Cover Replaceable Spare See Pages 34 37 Spindle Sprocket Drive Chain Ball Bearing Disk Shaft Spindle Lower Replaceable Spare See Pages 37 40 Motor Clutch Assembly may be different Drawing is for location only ...

Page 7: ...ct After dropping into the bowl product in the desired orientation is pushed up the stationary ramp This process may be assisted in some applications by compressed air After the product has been pushed up the ramp it is loaded onto the moving rim of the bowl The rim moves the product past mechanical pneumatic and or optical qualifiers which reject product that are not in the desired orientation Im...

Page 8: ...mm 25mm C Discharge Height 17 5 445mm D Bowl Outside Diameter 24 81 631mm E Rim Width 2 32 59mm Total Indication Runout ID 0 03 0 76mm Standard Models FR20XXXASM Part Number FR20XXXDSA FR20XXXASA Motor Style DC AC Motor Voltage 90V 180V Horsepower 1 8 hp 93 W Total Equipment Weight 210 lbs 95 kg Required Accessories Direction Rotation Clockwise Counter Clockwise Air Ramp ARCWFR20SU ARCCFR20SU Squa...

Page 9: ...Discharge Height 18 5 470mm D Bowl Outside Diameter 36 13 918mm E Rim Width 3 63 92mm Total Indication Runout ID 0 03 0 76mm Standard Models FR30XXXASM Part Number FR30XXXDSA FR30XXXASA Motor Style DC AC Motor Voltage 90V 240V Horsepower 1 8 hp 93 W Total Equipment Weight 350 lbs 159 kg Required Accessories Direction Rotation Clockwise Counter Clockwise Air Ramp ARCWFR30SU ARCCFR30SU Square Frame ...

Page 10: ...tools in the feeder when it is operating InstallSafetyCovers Makesurethefeederremainssafetooperate Besureallsafetycovershaveallbeeninstalledbeforereturningthe feeder to normal operation Safety covers on the FR 20 and FR 30 feeders include any covers installed by your direct supplier as well as the exit area cover which protects the operator from moving sprockets and belts Operating Maintenance Do ...

Page 11: ...nce procedures in Chapter 4 Do Carefully Replace Any Tooling You Remove To gain access for repairs you may need to remove tooling Because Shibuya Hoppmann and your dealer or OEM have no control over such activities they can not be responsible for any tooling you remove Carefully document the position of any tooling before you begin If you fail to replace all tooling exactly as it was you may creat...

Page 12: ... layout drawing provided by your direct supplier Step 2ÑLevel the Feeder Using a carpenter s level adjust the leveling feet Tighten the locknuts on the leveling feet In some applications leveling feet are not used because the feeder is connected directly to other framework Step 3ÑConnect Your Output Device Check that product can move smoothly from the exit of the feeder to your output device deadp...

Page 13: ...nted product Reposition the prefeeder as often as necessary until product lands correctly Step 5ÑConnect Power and Air Connect your feeder to main powerandcompressedair ifapplicable Don tchangethefeeder s main air regulator it should already be correct when you receive the feeder Starting the Feeder for the First Time Step 1ÑSecure Safety Covers and Clothes Before turning on powerandair makesuresa...

Page 14: ...wl speed place the hand held tachometer with surface speed indicator attachment on the inner wall of the moving bowl at its most upper inside diameter Adjust the bowl speed until the bowl is moving at correct number of linear feet per minute FPM Step 3ÑRecordNewSettings Turnoffthefeeder Markdialplate with new setting and remove any old marks Chapter 3 Installation Startup Measure Do not internally...

Page 15: ...however if you are providing your own prefeeder you ll have to set the prefeeder s speed To do this turn the prefeeder s speed control all the way down then turn on the feeder Slowly raise the prefeeder s speed control you may need to takeseveralminutes untilenoughproductexitsthefeedertokeep the line running at the required rate Stopraisingtheprefeederspeedwhenenoughproductisexitingthe feeder If y...

Page 16: ... Lichfield Staffs in Germany from Moll Motor Motors Donaustrasse Austria or Suter Form O Tronic AG Zurich Switzerland Motor 1 5 hp Motor 90VDC SBY_Hoppmann Part Number MOTRP 20HP 90VDC ANSI Motor Controller SBY_Hoppmann Part Number CNTRKBIC01 DC Motor Speed Controller 115 VAC Line Input 0 10 Ohm SBY_Hoppmann Part Number RESIKB 100 Plug In Horsepower Resistor R21 Replaceable Spare See Pages 37 40 F...

Page 17: ...ting Inverter Option AC Variable Speed Inverter option not provided with unit Contact Shibuya Hoppmann for inverter specifications and ordering instructions if desired Specifications Drive Motor 18 hp Motor 220 380 SBY_HC P N MOTRM 18HP Motors Model Inventory Number FR20XXXASM FR30XXXASM Drive Motor 1 3 hp Motor 220 380 3Ph SBY_HC P N MOTRMAC033 Protection Level IEC 63A Face Mounting IEC 71A Face ...

Page 18: ...ctions if desired FR 20 30 AC ANSI Suggested Wiring Diagram Note Reverse rotation by interchanging any two line leads Specifications Drive Motor 1 4 hp Motor 42CZ SBY_HC Part Number MOTRAC25HP Motors Model Inventory Number FR20XXXASA FR30XXXASA r o F e n i L s d a e L e i T s d a e L e i T s d a e L e i T o t A o t B o t C e g a t l o V w o L 9 3 8 2 7 1 4 5 6 e g a t l o V h g i H 1 2 3 9 6 8 5 7...

Page 19: ...pples for lubrication are located on the outside of the upper and lower spindle bearings Use any lithium grease conforming to NLGI Grade 2 consistency the grease should be free of dust particles and abrasives Instead use the maximum grease capacity of the bearings as a guide the upper spindle bearing can hold up to about 3 8 ounces ofgrease thelowerspindlebearingcanholduptoabout1 8 ounces of greas...

Page 20: ...ttighten the jam nuts until Step 4 Donotadjustspiderrimsupportarmswithoutmonitoringrunout because if you misalign any one spider rim support arm you may damage the feeder bowl Step 4ÑAdjust Horizontal Runout Move the indicator contact point horizontal resting on the inner wall of the bowl up to 1 4 6 mm from the bowl s upper ID Gently tap the bowl s ID with the palm of your hand or a rubber mallet...

Page 21: ...im is free wheeling FR 20 Parts Dependingonitsserialnumber yourFR 20containseitheramotor sprocket or one of two types of torque limiters For best results use identical replacement parts Replacement parts by serial number arelistedforthemetricFR 20inChapter6 SpareParts Retrofitting a torque limiter onto a unit that has none is not required Replacement Step 1ÑDisconnect Power Disconnect power and ai...

Page 22: ... misaligned When inspecting the torque limiter look for wear on the bushing and the friction facings To lock the adjusting nut in place one lockwasher tab up is bent up not shown against the adjusting nut Sprocket Disk Drive Reducer Output Shaft Adjusting Nut Torque Limiter Assembly The output shaft is part of the speed reducer in the ANSI models however it constitutes a separate part in the metri...

Page 23: ...l Drive Torque Limiter Sprocket 28 Teeth FR 20 Bowl Drive Chain 51 Links 40 x 25 5 Long FR 30 Bowl Drive Chain 57 Links 40 x 28 5 Long Sprocket Name Location of Teeth Chain Lengths Figure 5 2 FR 20 FR 30 Feeder Ð Drive Sprocket Location Diagram Reference only Refer to Replacement Parts List for component part numbers Bowl Drive Torque Limiter Sprocket 28 Teeth Bowl Drive Spindle Sprocket 20 Teeth ...

Page 24: ...e feeder until the proper tension is achieved Step 4ÑTightenDrive Tightenthemotormountingbolts Replace all safety covers and check your work Adjusting Backup Ring Clearance A number of design improvements were made to all models cold rolled and stainless steel ANSI and metric of the FR 20 and FR 30 that affect the backup ring clearance adjustment of the units listed below If FR serial no is lower ...

Page 25: ... spindle shaft This is located directly above the lower spindle bearing Step 5ÑCheck Backup Ring Clearance There must be enough clearance between the backup ring and the top surface of the bowl rim for the feeder to operate properly If you have as built tooling documentation from the dealer or OEM that tooled the feeder adjust the clearance to that shown on the as built tooling documentation Other...

Page 26: ...Tochangetheclearancebetweenthebackupringandtoprimofthebowlon olderstyleFR 20andFR 30feeders loosenthethreadedclampcollaronthe lower spindle bearing Next turn the threaded spindle shaft while holding thelowerspindlebearing sthreadedclampcollarstationary Tolowerbowl turn clockwise CW To raise bowl turn counterclockwise CCW Tooling Bracket Upper Frame Cover Backup Ring Bowl Spider Rim Support Upper S...

Page 27: ... to determine if this procedure applies to you If the square tooling frame adjustment points have been fixed to prevent incorrect adjustments or If you have an earlier version of the feeder which does not have an adjustable tooling frame refer to the OLDER STYLE Backup Ring Clearance Adjustment procedure above There must be enough clearance between the backup ring and the topsurfaceofthebowlrimfor...

Page 28: ... 3ÑMachine Bowl if necessary Machine the bowl as necessary Step 4ÑSet Bowl Runout Replace the bowl After putting the bowl in place first set the bowl elevation to the correct height 0 03 0 8 mm Next set bowl runout and check backup ring clearance Check that all safety covers are in place before returning the feeder into service If Parts Jam General Tips Step 1ÑInspect The Feeder If parts jam repea...

Page 29: ...d since the last batch Aretheylarger Smaller Adifferentshape Adifferentmaterial Different color Different quality If you are orienting freshly molded product have you made a change in how they are released from the mold Are they hotter drier or stickier for example Finally if your product has changed or if you cannot isolate why your product is jamming contact your direct supplier for assistance T...

Page 30: ...i a k c e h C r i a n i a m t a e r u s s e r p r o t a l u g e r t r a p t c e r r o c n I y l t c e r r o c s i r e d e e f t a h t y f i r e V t r a p s i h t n u r o t p u t e s t s a l n a h t t n e r e f f i d e r a s t r a P h c t a b d e l o o t s a w r e d e e f t a h t y f i r e V t r a p s i h t n u r o t d e e n s t e j r i a r o g n i l o o T t n e m t s u j d a m e t s y S r u o y o ...

Page 31: ... r o t o m s e h s u r b r o t o m C D e c a l p e R r o t o m e c a l p e r n r u t t o n s e o d l w o B r e d e e f n i d e m m a j t r a P d n a e t a c o l r e w o p t c e n n o c s i D e u n i t n o c n e h t t r a p e v o m e r n o i t a r e p o e s o o l r e t i m i l e u q r o T r e t i m i l e u q r o t t s u j d A k r e j g o c c s i d d n a l w o B g n i v o m n e h w r e l l o r t n o...

Page 32: ...arts or service The system operations manual lists as tooled components Notice to Dealer OEM Customers Some components listed might have been changed by your dealer or OEM to work better with your application To avoid ordering the wrong spare part verify the part number listed in this manual when you place your order with your dealer or OEM In North America Shibuya Hoppmann Corporation 13129 Airpa...

Page 33: ...C g n i l o o T 4 4 2 1 0 0 0 0 2 R F M t e k c o r p S t u o h t i w r e t i m i L e u q r o T 5 2 1 1 4 0 5 2 Q T T K P S T 8 2 t e k c o r p S r e t i m i L e u q r o T 5 2 1 1 0 2 S B 4 M T K P S h t e e T 0 2 t e k c o r p S 0 4 1 1 1 5 0 4 S C N A H C g n o L 5 5 2 s k n i L 1 5 n i a h C 0 4 8 2 6 2 1 1 1 0 M G L F G N R B g n i r a e B 5 1 1 1 1 0 M L I P G N R B k c o l B w o l l i P g n ...

Page 34: ...s i s e R 4 1 1 r e b m u N t r a P n o i t p i r c s e D e g a P y t i t n a u Q 2 0 0 0 R M 0 3 T F 2 1 M k c a l B p m a l C g n i l o o T 4 4 2 1 0 0 0 0 2 R F M t e k c o r p S t u o h t i w r e t i m i L e u q r o T 5 2 1 1 4 0 5 2 Q T T K P S T 8 2 t e k c o r p S r e t i m i L e u q r o T 5 2 1 1 0 2 S B 4 M T K P S h t e e T 0 2 t e k c o r p S 0 4 1 1 7 5 0 4 S C N A H C g n o L 5 8 2 s ...

Page 35: ...p i r c s e D e g a P y t i t n a u Q 2 0 0 0 R M 0 3 T F 2 1 M k c a l B p m a l C g n i l o o T 4 4 2 1 0 0 0 0 2 R F M t e k c o r p S t u o h t i w r e t i m i L e u q r o T 5 2 1 1 4 0 5 2 Q T T K P S T 8 2 t e k c o r p S r e t i m i L e u q r o T 5 2 1 1 0 2 S B 4 M T K P S h t e e T 0 2 t e k c o r p S 0 4 1 1 7 5 0 4 S C N A H C g n o L 5 8 2 s k n i L 7 5 n i a h C 0 4 8 2 6 2 1 1 1 0 M ...

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