Taktomat RT User manual

Cylinder Cam Rotary Indexing Table RT and TT
Original Operating Instructions
ATEX 95

Original Operating Instructions
Page 2 Cylinder Cam Rotary Indexing Table RT and TT Version 1.0.3

Original Operating Instructions
Overview / brief description
Version 1.0.3 Cylinder Cam Rotary Indexing Table RT and TT Page 3
Contents
Contents ......................................................................................................3
1Overview / brief description ..........................................................7
1.1 General description...................................................................................7
2About these Operating Instructions .............................................9
2.1 Purpose of these Operating Instructions...................................................9
2.1.1 Published by..........................................................................................................10
3Safety information........................................................................12
3.1 General information................................................................................ 12
3.2 Explanation of the symbols used ............................................................ 12
3.3 Intended use...........................................................................................12
3.4 Foreseeable misuse ............................................................................... 13
3.4.1 Guarantee conditions ............................................................................................13
3.4.2 Directives, statutory provisions and standards......................................................13
3.5 Technical condition of the machine......................................................... 13
3.5.1 Make no changes in the safety provisions ............................................................13
3.6 General hazards....................................................................................14
3.6.1 Risk of electric shock..........................................................................................14
3.6.2 Danger arising from mechanical components .................................................14
3.7 Responsibility of the operator.............................................................15
3.7.1 Preventive measures...........................................................................................15
3.8 Staff qualification ....................................................................................16
3.8.1 Qualified staff.......................................................................................................16
3.8.2 Competent specialists ........................................................................................16
3.8.3 Auxiliary staff.......................................................................................................16
3.8.4 Servicing, repairing and maintaining the machine..........................................16
3.9 Labeling.................................................................................................. 17
3.9.1 Rating plate ...........................................................................................................17
4Construction and function...........................................................19
4.1 Construction Type RT and TT series S01...............................................19
4.2 Construction Type RT and TT series S03...............................................19
4.3 Construction Type RT400, RT 500, RT630, series S03....................... 20
4.4 Function ................................................................................................20
4.5 Operating modes.................................................................................. 21
4.5.1 Normal operation.................................................................................................21
4.5.2 Intermittent operation .........................................................................................21
4.5.3 Continuous operation .........................................................................................21
4.5.4 Reversing operation (reciprocating operation)................................................21
4.5.5 Inching mode .......................................................................................................21
4.5.6 Emergency-Stop..................................................................................................21
4.6 Cycle time..............................................................................................22
4.7 Technical Data........................................................................................ 23
4.7.1 Indexing accuracy for all Cylinder Cam Rotary Indexing Tables...........................23
4.7.2 Construction of the Cylinder Cam Rotary Indexing Table Type TT075 S03.........23
4.7.3 Construction of the Cylinder Cam Rotary Indexing Table Type RT100 S03.........24
4.7.4 Construction of the Cylinder Cam Rotary Indexing Table Type TT125 S03.........25
4.7.5 Construction of the Cylinder Cam Rotary Indexing Table Type RT160 S03.........26
4.7.6 Construction of the Cylinder Cam Rotary Indexing Table Type RT 200 S03........27
4.7.7 Construction of the Cylinder Cam Rotary Indexing Table Type RT250 S03.........28
4.7.8 Construction of the Cylinder Cam Rotary Indexing Table Type TT250 ................29
4.7.9 Construction of the Cylinder Cam Rotary Indexing Table Type TT315 S03.........30
4.7.10 Construction of the Cylinder Cam Rotary Indexing Table Type RT400 S03.........31
4.7.11 Construction of the Cylinder Cam Rotary Indexing Table Type RT500 S03.........32

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4.7.12 Construction of the Cylinder Cam Rotary Indexing Table Type RT630 S03.........33
5Transport.......................................................................................35
5.1 Safety information...................................................................................35
5.2 Transport inspection...............................................................................35
5.2.1 Transport using sling equipment ...........................................................................36
5.3 Packaging, handling, unpacking .............................................................38
5.4 Installation location, place of use............................................................38
6Mechanical installation................................................................ 40
6.1 Installation orientation............................................................................. 40
6.2 Installation and commissioning............................................................... 41
6.2.1 Safety information..................................................................................................41
6.2.2 Installation..............................................................................................................41
6.3 Adjustment of the position cam series S01 ............................................. 43
6.3.1 Minimizing time losses...........................................................................................43
7Service and maintenance ............................................................45
7.1 Safety information in respect of maintenance ......................................... 45
7.1.1 Qualified staff required ..........................................................................................45
7.1.2 Maintenance tasks.................................................................................................45
7.1.3 Cleaning.................................................................................................................45
7.2 Maintenance tasks.................................................................................. 46
7.2.1 Maintenance plan ..................................................................................................46
7.3 Checking the oil level..............................................................................47
7.4 Lubrication..............................................................................................48
7.4.1 Requirements for lubricants...................................................................................48
7.4.2 Lubricating the rotary indexing table Type RT400, RT500, RT630.......................48
7.5 Replacing cam follower...........................................................................49
7.5.1 Replacing cam follower assembly sequence ........................................................49
8Troubleshooting...........................................................................52
8.1 Safety information...................................................................................52
9Disposal ........................................................................................54
9.1 Disassembly........................................................................................... 54
9.2 Disposal.................................................................................................. 54
10 Replacement parts and consumables........................................56
10.1 Replacement parts and consumables Type RT ......................................56
10.2 Replacement parts and consumables Type TT.......................................57

Original Operating Instructions
Page 6 Cylinder Cam Rotary Indexing Table RT and TT Version 1.0.3

Original Operating Instructions
Overview / brief description
Version 1.0.3 Cylinder Cam Rotary Indexing Table RT and TT Page 7
1Overview / brief description
1.1 General description
The Cylinder Cam Rotary Indexing Table Type RT or TT converts uniform input movement to an
intermittent or uniformly, reduced and intermittent output movement. The intermittent, reduced
and uniform output movement is generated by an induction-hardened, precision-finished cylin-
der cam.
The use of mathematical laws of motion guarantees a soft, shockproof and jerk-free movement
that has been optimally designed for its intended purpose. The construction makes it possible to
position the star wheel positively without any play.
No additional mechanical locking for the star wheel is necessary.
This can lead to mechanical over tightening and ultimately to the destruction of the rotary index-
ing table.
Power is provided either by means of a three-phase brake motor via worm drive 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 star wheel through cam followers.
The type RT star wheel is mounted within a wire-race bearing assembly, stiff and free of play
(inside steel rings –not in the casting). The type TT star wheel is mounted in tapered roller
bearings, stiff and free of play. The shaft seals appropriate for each size seal off the rotary in-
dexing table inside and out.
Figure: Construction of the Cylinder Cam Rotary Indexing Table, series S01 and S03
(1) Input shaft (drive)
(2) Star wheel (output)
(3) Rating plate
(4) Position indicator
(5) Housing
(6) Non-rotating center column only on series S03

Original Operating Instructions
Page 8 Cylinder Cam Rotary Indexing Table RT and TT Version 1.0.3

Original Operating Instructions
About these Operating Instructions
Version 1.0.3 Cylinder Cam Rotary Indexing Table RT and TT Page 9
2About these Operating Instructions
Designation
These Operating Instructions describe the Cylinder Cam Rotary Indexing Table RT and TT. The
Cylinder Cam Rotary Indexing Table RT and TT is referred to below as 'the machine'.
2.1 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 se-
quentially.
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, dis-
crete 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 ...
Sub-items in lists
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.

Original Operating Instructions
Page 10 Cylinder Cam Rotary Indexing Table RT and TT Version 1.0.3
Cross-references
Cross-references point you to additional descriptions within the Operating Instructions. (chap-ter
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 regu-
lations 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
Manufacturer
TAKTOMAT GmbH
Rudolf-Diesel-Straße 14
D-86554 Pöttmes
Fon [phone]
Fax [phone]
eMail: [e-mail]
Internet: 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 equip-
ment already supplied.
2.1.1 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 pho-
tocopy, 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, Februar 2014

Original Operating Instructions
About these Operating Instructions
Version 1.0.3 Cylinder Cam Rotary Indexing Table RT and TT Page 11

Original Operating Instructions
Page 12 Cylinder Cam Rotary Indexing Table RT and TT Version 1.0.3
3Safety information
3.1 General information
This document contains important information on the safe use of the machine. This information
is intended to ensure personal safety and prevent damage to the machine. The information is
intended for the operator and for properly trained, qualified and instructed staff responsible for
operating and servicing the machine.
Additional task-specific safety information is included in the relevant sections on the different
phases during the service life of the system.
3.2 Explanation of the symbols used
DANGER
DANGER!
This combination of symbol and alert word indicates an inherently dangerous situa-
tion 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 situa-
tion 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 situa-
tion which can cause minor injury.
NOTE
NOTE
This combination of symbol and alert word indicates a potentially dangerous situa-
tion which can cause damage to property or harm the environment if it is not
avoided.
3.3 Intended use
The cylinder cam rotary indexing table is intended for installation in a surrounding construction,
thus integrating it to form part of an overall system. The cylinder cam rotary indexing table is
controlled by the overall system. The functions of the protective equipment are also connected
to the cylinder cam rotary indexing table via the controller. The cylinder cam rotary indexing
table may only be operated as part of a CE-compliant system.
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 cylinder cam rotary indexing table of the given series is intended for use in potentially
explosive environments according to EX II 2 G T4 (135°C), if they are equipped with the ap-
propriate rating plate (see Section 3.9.1) and the appropriate declaration of conformity..
Any add - on components must comply to the same appropriate declaration of conformity.

Original Operating Instructions
Safety information
Version 1.0.3 Cylinder Cam Rotary Indexing Table RT and TT Page 13
Any add - on components must comply to the same appropriate declaration of conformity.
To ensure conformity to ATEX the cylinder cam rotary indexing table may not be used for
purposes other than those for which it has been selected and ordered.
For use under different potentially explosive environments other than EX II 2 G T4 (135°C)
please contact with TAKTOMAT GmbH.
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.
3.4 Foreseeable misuse
Any use beyond or other than the intended use is regarded as misuse.
3.4.1 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.
3.4.2 Directives, statutory provisions and standards
The following statutory provisions and standards were applied:
Machine Directive 2006/42/EC, Annex I
Low Voltage Directive 2006/96/EC
EMC Directive 2004/108/EC
ATEX 95 Directive 94/9/EC
3.5 Technical condition of the machine
Do not use the machine if it is not in sound condition technically. If the machine 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.
3.5.1 Make no changes in the safety provisions
The manufacturer has made safety provisions. No liability will be accepted if the operator of the
machine makes any changes in the safety provisions without express permission.

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3.6 General hazards
This section lists risks associated with the machine that remain even when it is operated accord-
ing 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.
3.6.1 Risk of electric shock
DANGER
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, en-
sure that it is completely powered down and cannot be switched on again.
3.6.2 Danger arising from mechanical components
WARNING
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 sys-
tem is in operation.
Never open any covers while the system is in operation.

Original Operating Instructions
Safety information
Version 1.0.3 Cylinder Cam Rotary Indexing Table RT and TT Page 15
3.7 Responsibility of the operator
The machine is to be used commercially according to its intended use. The operator of the ma-
chine is therefore subject to statutory occupational health and safety provisions.
In addition to the general safety information contained in this document, any further safety, ac-
cident prevention and environmental regulations applicable to the field of application of the ma-
chine 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 find-
ings in the form of operating instructions (work instructions, work descriptions, etc.) for use
during operation.
During the entire service life of the machine, they must check whether the operating instruc-
tions they have written are compliant with current regulations and make any necessary ad-
justments.
They must unambiguously regulate and define who is responsible for carrying out installa-
tion, 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 machine 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 dan-
gers.
They must bear the responsibility for personal injury and damage to property arising from
manipulation of the machine. For this reason, the machine 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 machine is always in a sound condition technically.
3.7.1 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 machine.
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 obliga-
tions, 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 acces-
sible 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 machine to ensure that the safety equipment operates correctly.
Make sure that safety information and hazard warnings on the machine and in the working
area are always legible.
Take steps to ensure that the machine is regularly inspected for visible damage and defects.

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3.8 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 machine and expose themselves and others to the risk of seri-
ous 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.
3.8.1 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 machine,
installation and service staff who have appropriate expertise in setting up and maintaining
the machine and who are familiar with the safety information,
The qualified staff must have read and understood the contents of the Operating Instructions
before the machine is taken into service and must have been informed of the risks associat-
ed with working with the machine by the machine operator.
A knowledge of first aid is required.
3.8.2 Competent specialists
Competent specialists are persons whose specialist training and experience have given them
sufficient knowledge with respect to using this machine 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 machine allows it to be used safely.
3.8.3 Auxiliary staff
Work on or in the vicinity of this machine which is not associated with the actual operation of the
machine (e.g. cleaning, transport, material provisioning, etc.) can be performed by other per-
sons. Before the machine is taken into service, the qualified staff of the machine operator must
instruct such persons with regard to the nature of the work to be performed and the risks asso-
ciated with working on the machine. Take special care when instructing persons who cannot
read or write, and instruct them separately!
3.8.4 Servicing, repairing and maintaining the machine
Service, repair and maintenance work on the machine may only be carried out by service engi-
neers of the manufacturer or by qualified staff authorized by Taktomat GmbH. When carrying
out such work, always cordon off the working area carefully!

Original Operating Instructions
Safety information
Version 1.0.3 Cylinder Cam Rotary Indexing Table RT and TT Page 17
3.9 Labeling
3.9.1 Rating plate
There is a rating plate attached to the machine:
Figure: Position of a rating plate
Figure: Example of a rating plate
Figure: Example of a rating plate ATEX 95

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Original Operating Instructions
Construction and function
Version 1.0.3 Cylinder Cam Rotary Indexing Table RT and TT Page 19
4Construction and function
4.1 Construction Type RT and TT series S01
Figure: Construction of the Cylinder Cam Rotary Indexing Table RT and TT series S01
4.2 Construction Type RT and TT series S03
Figure: Construction of the Cylinder Cam Rotary Indexing Table RT and TT series S03
(1) Input shaft (drive)
(2) Star wheel (output)
(3) Rating plate
(4) Position indicator
(5) Housing
(6) Non rotating center column

Original Operating Instructions
Page 20 Cylinder Cam Rotary Indexing Table RT and TT Version 1.0.3
4.3 Construction Type RT400, RT 500, RT630,
series S03
(1) Input shaft (drive)
(2) Star wheel (output)
(3) Rating plate
(4) Position indicator
(5) Housing
(6) Non rotating center column
(7) Cable aperture
4.4 Function
The drive unit drives the star wheel (2) via the input shaft (1) and the cylinder cam. The output
plane is perpendicular to the drive plane. The machine converts a uniform radial movement on
the drive side to an intermittent or uniformly reduced output movement. The accessories are
mounted on the star wheel (2). The position indicator (4) shows the current position of the cylin-
der cam. The rating plate (3) is attached to the housing. If required additional accessories are
mounted on the non rotating center column (6) (only possible on series S03). The housing (5) of
the cylinder cam rotary indexing table from type RT400 on has a cable aperture (7).