Taktomat RT Series User manual

Rotary indexing table
Type RT - TT
Translation of original
operating instructions
Version 2.1.1 |
18.04.2019

Operating instructions
Table of contents
Page 2 of 44
Rotary indexing table RT - TT
Version 2.1.1
Table of contents
1About these Operating Instructions..........................................................................3
1.2 Continuative documents ............................................................................................................5
1.3 Excerpt of Declaration of Incorporation ....................................................................................6
2Safety information....................................................................................................7
2.1 Explanation of the symbols used...............................................................................................7
2.2 Intended use...............................................................................................................................8
2.3 Foreseeable misuse ...................................................................................................................9
2.4 Directives, statutory provisions and standards.........................................................................9
2.5 Technical condition of the partly completed machinery...........................................................9
2.6General hazards..........................................................................................................................9
2.7 Responsibility of the operator .................................................................................................10
2.8 Staff qualification ....................................................................................................................11
2.9 Personal protective equipment................................................................................................12
2.10 Nameplate................................................................................................................................13
3Construction and function ......................................................................................14
3.1 Construction Rotary indexing table type RT - TT ....................................................................14
3.2 Function ....................................................................................................................................15
3.3 Operating modes......................................................................................................................16
3.4 Technical Data Rotary indexing table .....................................................................................17
3.5 Ambient conditions ..................................................................................................................17
4Transport................................................................................................................29
4.1 Transport inspection ................................................................................................................29
4.2 Packaging, handling, unpacking ..............................................................................................29
5Mechanical installation..........................................................................................33
5.1 Installation orientation.............................................................................................................33
5.2 Securing the drive ....................................................................................................................34
5.3 Installation and commissioning...............................................................................................35
5.4 Adjustment of the position cam series with open position indicator....................................37
5.5 Maintenance task ....................................................................................................................38
5.6 Lubrication................................................................................................................................39
6Troubleshooting .....................................................................................................40
7Disposal .................................................................................................................42
8Spare part and wear part RT - TT ...........................................................................43
9Annex.....................................................................................................................44
9.1 Safety data sheets ...................................................................................................................44

About these Operating Instructions
Operating instructions
Version 2.1.1
Rotary indexing table RT - TT
Page 3 of 44
1About these Operating Instructions
These Operating Instructions describe the partly completed machinery Rotary indexing table. The Rotary indexing
table is referred to below as the partly completed machinery.
Purpose of these Operating Instructions
The Operating Instructions are intended to help you to:
work efficiently
ensure quality
find information quickly
avoid danger
Table of contents
The Operating Instructions have a table of contents at the front. This gives you an overview of all the sections in the
document.
Headings and page numbers
The chapters are numbered sequentially. The sections within each chapter are numbered sequentially.
Safety information
Any safety information is placed before the descriptions of actions that may pose a risk. You will find a detailed
description of the safety information in the chapter entitled Safety.
Text, symbols, figures
Instructions for performing various activities and other information are presented in small, discrete sections.
The information is presented using a combination of text, symbols and figures.
Instructions for performing action are described in the appropriate sequence and numbered accordingly.
Instructions for action
For the sake of clarity the instructions for action have been broken down into individual steps:
Introductory text…
Instruction result
Lists
Any lists which do not include individual operating steps are indicated as follows:
Lists…
oSub-items in lists
Figures
Figures, dimensions and technical data presented in these Operating Instructions may be
Subject to change.
Cross-references
Cross-references point you to additional descriptions within the Operating Instructions. (Chapter number/page
number).
Third-party components
Refer to the Operating Instructions of the relevant manufacturers for information on operation and maintenance of
third-party components fitted in the system.
Additional documentation
To complement the information in these Operating Instructions, please read the following regulations and directives:
safety regulations and accident prevention regulations
instruction sheets, instruction booklets
work instructions provided by the statutory accident insurance provider
generally accepted occupational health regulations

Operating instructions
About these Operating Instructions
Page 4 of 44
Rotary indexing table RT - TT
Version 2.1.1
Manufacturer
TAKTOMAT GmbH
Rudolf-Diesel-Straße 14
D-86554 Pöttmes
Tel: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: http://www.taktomat.de/
Technical information
The technical information, figures and data contained in these Operating Instructions are correct at the time of
printing.
Our products undergo continuous further develop.
We therefore reserve the right to make any changes and improvements that we deem appropriate.
However, this does not, imply any obligation to apply such changes retrospectively to equipment already supplied.
1.1.1 Published by
TAKTOMAT GmbH
Rudolf-Diesel-Straße 14
D-86554 Pöttmes
Reproduction of these Operating Instructions or extracts thereof in the form of a reprint or photocopy, on electronic
storage media or by any other means is not permitted except with our written consent.
All rights reserved.
Printed in the Federal Republic of Germany
Pöttmes, 04/2019
Document revision
Version
Date
Comment
Version 2.1.1
13.02.2019
Formattting
Version 2.1.0
13.02.2019
Maintenance
Version 2.0.6
18.05.2016
Chapter Lubricating Rotary indexing table removed
Version 2.0.1
18.05.2016
Technical data updated
Version 2.0.1
19.03.2015
Layout adaption, added excerpt of Atex and declaration of incorporation
Version 1.0.4
20.10.2014
Initial release

About these Operating Instructions
Operating instructions
Version 2.1.1
Rotary indexing table RT - TT
Page 5 of 44
1.2 Continuative documents
Read the following documents according to the provided components before you use these partly completed
machinery with Operating instructions.
Designation
Manufacturer
Version / Revision / Date
Number
Assembly and Operating Instructions
Gear unit
Every type
-
-
Operating Instructions AC Motors
Every type
-
-
Operating instructions inductive
Sensors
Every type
-
-
Operating instructions encoder
Every type
-
-

Operating instructions
About these Operating Instructions
Page 6 of 44
Rotary indexing table RT - TT
Version 2.1.1
1.3 Excerpt of Declaration of Incorporation

Safety information
Operating instructions
Version 2.1.1
Rotary indexing table RT - TT
Page 7 of 44
2Safety information
General information
This document contains important information on the safe use of the partly completed machinery. This information is
intended to ensure personal safety and prevent damage to the partly completed machinery. The information is
intended for the operator and for properly trained, qualified and instructed staff responsible for operating and
servicing the partly completed machinery.
Additional task-specific safety information is included in the relevant sections on the different phases during the
service life of the system.
2.1 Explanation of the symbols used
2.1.1 Warnings
DANGER
DANGER!
This combination of symbol and alert word indicates an inherently dangerous situation which can
be fatal or cause serious injury if it is not avoided.
WARNING
WARNING!
This combination of symbol and alert word indicates a potentially dangerous situation which can
be fatal or cause serious injury if it is not avoided.
CAUTION
CAUTION!
This combination of symbol and alert word indicates a potentially dangerous situation which can
cause minor injury if it is not avoided.
NOTICE
NOTICE!
This combination of symbol and alert word indicates a potentially dangerous situation which can
cause damage to property or harm the environment if it is not avoided.

Operating instructions
Safety information
Page 8 of 44
Rotary indexing table RT - TT
Version 2.1.1
2.1.2 MANDATORY SIGNS
REFER TO INSTRUCTION MANUAL/BOOKLET!
This symbol signifies that the instruction manual/booklet of the component supplier must be read.
WEAR HEAD PROTECTION!
This symbol signifies that head protection must be worn.
WEAR EYE PROTECTION!
This symbol signifies that eye protection must be worn.
WEAR SAFETY FOOTWEAR!
This symbol signifies that safety footwear must be worn.
WEAR PROTECTIVE GLOVES!
This symbol signifies that protective gloves must be worn.
2.2 Intended use
The partly completed machinery is intended for installation in a surrounding construction, thus integrating it to form
part of an overall system. The partly completed machinery is controlled by the overall system. The functions of the
protective equipment are also connected to the partly completed machinery via the controller. The partly completed
machinery may only be operated as part of a CE-compliant system.
Customer specific constructions are mounted on the Rotary indexing table. They’re used as support for different
products. The Rotary indexing table has a fixed or flexible division (for an exact design see data sheet). ). The Rotary
indexing table is inside a safety enclosure or is installed in another work equipment. The safety enclosure or
assembly are realized by the integrator. This also applies to the electrical connection and control.
Any use that deviates from the intended use is regarded as inappropriate use.
This includes:
any use outside the permitted operating limits
any use in conjunction with foodstuffs
any use in conjunction with aggressive materials (such as acids)
transporting the system using the designated lifting points or eye bolts
The manufacturer shall not be liable for any damage resulting from such use. Intended use also includes observance
of all the information in these instructions.

Safety information
Operating instructions
Version 2.1.1
Rotary indexing table RT - TT
Page 9 of 44
2.3 Foreseeable misuse
Any use beyond or other than the intended use is regarded as misuse.
2.3.1 Guarantee conditions
Changes to the structure of the materials used in the machine, e.g. the drilling of additional holes, can result in
damage to the components. This is not regarded as intended use and may lead to loss of warranty or liability claims
as a consequence.
2.4 Directives, statutory provisions and standards
The following statutory provisions and standards were applied:
Machine Directive 2006/42/EG, Annex I
Low Voltage Directive 2014/35/EU
EMC Directive 2014/30/EU
Safety of machinery - basic concepts - risk assessment and risk mitigation DIN EN ISO 12100
2.5 Technical condition of the partly completed machinery
Do not use the partly completed machinery if it is not in sound condition technically. If the partly completed
machinery is used when it is not in a sound condition technically, there is a risk of death or injury to staff and a risk of
damage to property.
2.5.1 Make no changes in the safety provisions
The manufacturer has made safety provisions. No liability will be accepted if the operator of the partly completed
machinery makes any changes in the safety provisions without express permission.
2.6 General hazards
This section lists risks associated with the partly completed machinery that remain even when it is operated
according to its intended use.
In order to reduce the risk of personal injury or damage to property, and to avoid potentially dangerous situations, the
safety information provided here and in the other sections of these Operating Instructions must be observed.
Risk of death by electrocution
DANGER
Risk of death by electrocution!
There is an immediate risk of fatal injury due to electric shock if live components are touched.
Damage to the insulation or to individual components can cause fatal injury.
Only allow work on the electrical system to be carried out by qualified electrical
engineers.
In the event of damage to the insulation, immediately shut off the power supply and
initiate a repair.
Before starting work on active parts of the electrical system or equipment, ensure that it
is completely powered down and cannot be switched on again.
Risk of injury from moving parts
WARNING
Risk of injury from moving parts!
Moving parts can cause serious injury.
Do not reach into moving parts or carry out work on moving parts while the system is in
operation.
Never open any covers while the system is in operation.

Operating instructions
Safety information
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Rotary indexing table RT - TT
Version 2.1.1
2.7 Responsibility of the operator
The partly completed machinery is to be used commercially according to its intended use. The operator of the partly
completed machinery is therefore subject to statutory occupational health and safety provisions.
In addition to the general safety information contained in this document, any further safety, accident prevention and
environmental regulations applicable to the field of application of the partly completed machinery must also be
observed.
In particular, operators have the following obligations:
They must always be fully informed of the most recent occupational safety regulations and perform a risk
assessment to identify any additional hazardous locations and places resulting from the specific working
conditions at the place of use. They must document any such findings in the form of operating instructions (work
instructions, work descriptions, etc.) for use during operation.
During the entire service life of the partly completed machinery, they must check whether the operating
instructions they have written are compliant with current regulations and make any necessary adjustments.
They must unambiguously regulate and define who is responsible for carrying out installation, operation,
maintenance and cleaning.
They must ensure that the staff deployed have the necessary qualifications for the work they are instructed to
perform.
They must ensure that all staff who work on the partly completed machinery have read and understood all the
documents relevant for its operation (Operating Instructions, maintenance regulations, safety guidelines).
The must provide training for the staff at regular intervals and inform them of potential dangers.
They must bear the responsibility for personal injury and damage to property arising from manipulation of the
partly completed machinery. For this reason, the partly completed machinery and its safety equipment must be
inspected at regular intervals to ensure that they are in sound condition and functioning properly, and the results
of this inspection must be suitably documented.
They must ensure that the partly completed machinery is always in a sound condition technically.
2.7.1 Preventive measures
It is recommended that the operator take the following preventive measures:
Only allow qualified, trained and properly instructed staff to work on the partly completed machinery.
Unambiguously define the responsibilities of operating and service personnel.
Supplement these Operating Instructions with
ostipulations deriving from national and regional labor and environmental regulations
oadjust information covering specific operational aspects (workflows, supervisory obligations, reporting
obligations, fire alarm equipment, etc.)
Occasionally check to confirm that the Operating Instructions are being used and that such use is correct, and
when necessary repeat the instruction process.
Ensure that all documentation is permanently available in a readable form and easily accessible at the point of
use.
Observe any periodic checks and inspections that are required (by law) or specified in this document.
Replace in good time any components indicated in these documents as being crucial for safety.
Regularly inspect the partly completed machinery to ensure that the safety equipment operates correctly.
Make sure that safety information and hazard warnings on the partly completed machinery and in the working
area are always legible.
Take steps to ensure that the partly completed machinery is regularly inspected for visible damage and defects.

Safety information
Operating instructions
Version 2.1.1
Rotary indexing table RT - TT
Page 11 of 44
2.8 Staff qualification
The various activities described in these Operating Instructions require different qualifications of the staff entrusted
with these duties.
WARNING
Danger if staff are insufficiently qualified!
Persons who are inadequately qualified are unable to assess the risks associated with working
on the partly completed machinery and expose themselves and others to the risk of serious or
fatal injury.
Ensure that all work is performed only by suitably qualified persons.
Keep insufficiently qualified persons at a safe distance from the working area.
2.8.1 Qualified staff
For the purposes of these Operating Instructions, qualified staff are understood to be
Operators who have been specially trained and instructed in working with the partly completed machinery.
Installation and service staff who have appropriate expertise in setting up and maintaining the partly completed
machinery and who are familiar with the safety information.
The qualified staff must have read and understood the contents of the Operating Instructions before the partly
completed machinery is taken into service and must have been informed of the risks associated with working
with the partly completed machinery by the partly completed machinery operator.
A knowledge of first aid is required.
2.8.2 Competent specialists
Competent specialists are persons whose specialist training and experience have given them sufficient knowledge
with respect to using this partly completed machinery and who are sufficiently familiar with the relevant statutory
occupational health regulations, accident prevention regulations, directives, and generally approved technical
practice that they are able to assess whether the condition of the partly completed machinery allows it to be used
safely.
2.8.3 Auxiliary staff
Work on or in the vicinity of this partly completed machinery which is not associated with the actual operation of the
partly completed machinery (e.g. cleaning, transport, material provisioning, etc.) can be performed by other persons.
Before the partly completed machinery is taken into service, the qualified staff of the partly completed machinery
operator must instruct such persons with regard to the nature of the work to be performed and the risks associated
with working on the partly completed machinery. Take special care when instructing persons who cannot read or
write, and instruct them separately!
2.8.4 Servicing, repairing and maintaining the partly completed machinery
Service, repair and maintenance work on the partly completed machinery may only be carried out by service
engineers of the manufacturer or by qualified staff authorized by Taktomat GmbH. When carrying out such work,
always cordon off the working area carefully!

Operating instructions
Safety information
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Rotary indexing table RT - TT
Version 2.1.1
2.9 Personal protective equipment
Personal protective equipment is intended to protect individuals from safety and health risks at work.
When performing certain tasks on and with the partly completed machinery, staff must wear personal protective
equipment. This is explicitly indicated in the relevant sections of these Operating Instructions.
WARNING
Risk of injury from moving parts!
Exposed jewellery and long hair can be trapped by moving parts and lead to serious injury.
Always remove exposed jewellery such as chains, rings and watches before starting
work.
Protect long hair with a hair net.

Safety information
Operating instructions
Version 2.1.1
Rotary indexing table RT - TT
Page 13 of 44
2.10 Nameplate
Fig. 1 Example of a nameplate
There is a nameplate attached to the partly completed machinery:
Fig. 2 Position Nameplate (1)
1

Operating instructions
Construction and function
Page 14 of 44
Rotary indexing table RT - TT
Version 2.1.1
3Construction and function
3.1 Construction Rotary indexing table type RT - TT
3.1.1 Rotary indexing table RT100 - RT250 and TT075 - TT315
Fig. 3 Rotary indexing table type RT
open position indicator
Fig. 4 Rotary indexing table type RT
closed position indicator
Fig. 5 Rotary indexing table type TT
open position indicator
Fig. 6 Rotary indexing table type TT
closed position indicator
Item
Designation
1
Output flange / Star wheel
2
Drive
3
Input shaft (drive)
4
Position indicator
5
Housing
6
Nameplate
3
4
1
6
5
2
5
2
3
1
6
4
5
2
1
6
4
3
4
1
6
5
2

Construction and function
Operating instructions
Version 2.1.1
Rotary indexing table RT - TT
Page 15 of 44
Fig. 7 Rotary indexing table RT400 RT630
closed position indicator
Item
Designation
A
Output flange / Star wheel
B
Drive
C
Input shaft (drive)
D
Position indicator
E
Housing
F
Nameplate
G
Center colum
3.2 Function
The drive drives (2 und B) the output flange / star wheel (1 and A) via the input shaft (3and C) and
the cylinder cam. The output plane is perpendicular to the drive plane. It converts a uniform radial movement on
the drive side to an intermittent or uniformly reduced output movement. The accessories are mounted on the output
flange / star wheel (1 and A). The position indicator (4and D) shows the current position of the cylinder cam. The
nameplate (6and F) is attached to the housing (5and E). If required additional accessories are mounted on
the center column (G).
No additional mechanical locking for the output flange / star wheel is necessary. This can lead to mechanical over
tightening and ultimately to the destruction of the rotary indexing table. Power is provided either by means of a
three-phase motor (with / without brake) via reduction gear unit or by means of a chain-wheel or belt wheel on
the drive shaft of the rotary indexing table.
This is firmly connected to the cylinder cam, without any further internal gear sets, and it turns the output flange /
star wheel through cam followers.
The type RT the output flange / star wheel is mounted within a wire-race bearing assembly, stiff and free of play
(inside steel rings not in the casting. The shaft seals appropriate for each size seal off the rotary indexing table inside
and out.
A
B
F
G
E
C
D

Operating instructions
Construction and function
Page 16 of 44
Rotary indexing table RT - TT
Version 2.1.1
3.3 Operating modes
The partly completed machinery has the following operating modes:
Normal operational
oIntermittent operation
oContinuous operation
oReversing operation (Oscillating operation)
Inching mode
Emergency-Stop
NOTICE
Damage arising from operation without an appropriate machine controller!
Improper control of the machine can cause serious material damage.
Do not operate in inching mode without an appropriate universal machine controller.
Use an appropriate universal machine controller.
3.3.1 Normal operation
Normal operation is regarded as the movement of the output flange in a direction from one position to the next. The
rotational direction of the output flange is determined by the rotational direction of the drive. With a three-phase
motor this can easily be reversed by swapping two phases of the supply voltage.
3.3.2 Intermittent operation
The drive shaft stops in the dwell phase. The step time is fixed. The dwell period is variable. This mode of operation
is used in plants with much longer processing times than times and is the most common mode of operation.
3.3.3 Continuous operation
The partly completed machinery runs continuously without the motor stopping. Step and dwell times are fixed and
are run through continuously. The drive motor has only one rotational direction. This mode of operation is frequently
used in fast-running plants with short processing times. The partly completed machinery is mechanically
synchronized to the rest of the plant by the free drive shaft. The ratio of dwell to step time can be adjusted within
certain limits by TAKTOMAT when producing the cam.
3.3.4 Reversing operation (reciprocating operation)
The drive of the partly completed machinery is always decelerated to the reverse position and accelerated after the
reverse phase. In this mode of operation, the output flange shuttles back and forth between two positions.
3.3.5 Inching mode
In inching operation, the output flange moves in small increments between two positions. The cylinder cam cannot
gently accelerate and decelerate the accumulated load. This puts the hardware under stress, since any acceleration
that occurs during the inching operation exceeds that of normal operation many times over. No inching operation is
permitted if there are no suitable machine controller (TIC) that allow gentle acceleration and braking of the load.
3.3.6 Emergency-Stop
Emergency stop is comparable with the stopping in inching operation. Frequent emergency-stop situations should be
avoided.

Construction and function
Operating instructions
Version 2.1.1
Rotary indexing table RT - TT
Page 17 of 44
3.4 Technical Data Rotary indexing table
3.5 Ambient conditions
Following ambient conditions apply to all Rotary indexing table described in this operating manual.
NOTICE
Deviating ambient conditions can cause material damage.
Do not operate in deviating ambient conditions.
Adhere to the given operating –and storage conditions.
Other ambient condition only in consultation with Taktomat.
3.5.1 Operating conditions
Area of application
Inside
Temperature range [°C]
+10 to + 40
Relative humidity [%]
max 40 to 70
Media
do not expose the system to any aggressive agents
3.5.2 Storage conditions
Area of application
Inside
Lighting [Lux]
min. 300
Temperature range [°C]
-22 to + 50
Relative air humidity [%]
max. 40 to 70
Media
do not expose the system to any aggressive agents
Storage period > 6 month
coat the partly completed machinery with corrosive protection
3.5.3 Noise emission
The direct noise emission from the partly completed machinery depends upon the ambient conditions. Deduced from
these conditions there must be further acoustic pressure measurements performed on the installation location of the
partly completed machinery.

Operating instructions
Construction and function
Page 18 of 44
Rotary indexing table RT - TT
Version 2.1.1
3.5.4 Rotary indexing table TT075 / TT080
Fig. 8 Dimensional drawing Rotary indexing table TT075 / TT080
Primary dimensions
Star wheel / Output flange Ø [mm]
95
Height (mounting surface of output flange) [mm]
105
Internal diameter Ø [mm]
9,8
Maximum recommended accessory plate diameter [mm]
500
Approx. weight of Rotary indexing table without drive [kg]
12
Standard internal transmission ratio
2,3,4,6,8,10,12,16,20,24,30,36
Direction
cw, ccw, reversing
Installation orientation
horizontal, vertical, upside down
Precision
Indexing accuracy in angular seconds ± [“]
85
Indexing accuracy in radians ± [mm]
0,016 / 0,017
Max. strain on output flange
Axial force Fa [kN]
1,5
Radial force Fr [kN]
0,6
Tilting moment Mk [kNm]
0,5
Max. strain on center colum
Axial force Fa [kN]
0,5
Tilting moment Mk [kNm]
0,04

Construction and function
Operating instructions
Version 2.1.1
Rotary indexing table RT - TT
Page 19 of 44
3.5.5 Rotary indexing table RT100
Fig. 9 Dimensional drawing Rotary indexing table RT100
Primary dimensions
Star wheel / Output flange Ø [mm]
125
Height (mounting surface of output flange) [mm]
112
Internal diameter Ø [mm]
20 / 22
Maximum recommended accessory plate diameter [mm]
800
Approx. weight of Rotary indexing table without drive [kg]
18
Standard internal transmission ratio
2,3,4,6,8,10,12,16,20,24,30,36
Direction
cw, ccw, reversing
Installation orientation
horizontal, vertical, upside down
Precision
Indexing accuracy in angular seconds ± [“]
70
Indexing accuracy in radians ± [mm]
0,018
Max. strain on output flange
Axial force Fa [kN]
6
Radial force Fr [kN]
3,8
Tilting moment Mk [kNm]
0,7
Max. strain on center colum
Axial force Fa [kN]
5
Tilting moment Mk [kNm]
0,19

Operating instructions
Construction and function
Page 20 of 44
Rotary indexing table RT - TT
Version 2.1.1
3.5.6 Rotary indexing table TT125
Fig. 10 Dimensional drawing Rotary indexing table TT125
Primary dimensions
Star wheel / Output flange Ø [mm]
160
Height (mounting surface of output flange) [mm]
120
Internal diameter Ø [mm]
35
Maximum recommended accessory plate diameter [mm]
1000
Approx. weight of Rotary indexing table without drive [kg]
24
Standard internal transmission ratio
2,3,4,6,8,10,12,16,20,24,30,36
Direction
cw, ccw, reversing
Installation orientation
horizontal, vertical, upside down
Precision
Indexing accuracy in angular seconds ± [“]
55
Indexing accuracy in radians ± [mm]
0,019
Max. strain on output flange
Axial force Fa [kN]
6
Radial force Fr [kN]
2,8
Tilting moment Mk [kNm]
0,2
Max. strain on center colum
Axial force Fa [kN]
3
Tilting moment Mk [kNm]
0,2