Taktomat RTX Series User manual

Rotary indexer
Type RTX
Original operating instructions
Version 1.0.0 |
14.06.2021

Operating instructions
Table of contents
Page 2 of 35
Rotary indexer RTX
Version 1.0.0
Table of contents
1About these Operating Instructions..........................................................................3
1.2 Further documentation...............................................................................................................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
2.6 General 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 indexer type RTX.....................................................................................14
3.2 Function ....................................................................................................................................15
3.3 Operating modes......................................................................................................................16
3.4 Technical data rotary indexer ..................................................................................................17
3.5 Ambient conditions ..................................................................................................................17
4Transport................................................................................................................18
4.1 Transport inspection ................................................................................................................18
4.2 Packaging, handling, unpacking ..............................................................................................18
5Mechanical installation..........................................................................................22
5.1 Installation orientation.............................................................................................................22
5.2 Assembly of drive.....................................................................................................................23
5.3 Installation and commissioning...............................................................................................24
5.4 Guidelines for drive control of rotary indexers .......................................................................26
5.5 Maintenance task ....................................................................................................................29
5.6 Lubrication................................................................................................................................30
6Faults .....................................................................................................................31
6.1 Safety instructions ...................................................................................................................31
7Disposal .................................................................................................................33
8Spare parts and wear parts for rotary indexers ......................................................34
9Annex.....................................................................................................................35
9.1 Safety data sheets ...................................................................................................................35

About these Operating Instructions
Operating instructions
Version 1.0.0
Rotary indexer RTX
Page 3 of 35
1About these Operating Instructions
These Operating Instructions describe the partly completed machinery Rotary indexer.
The Rotary indexer is referred to below as the partly completed machinery.
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 35
Rotary indexer RTX
Version 1.0.0
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, 06/2021
Document revision
Version
Date
Comment
Version 1.0.0
14.06.2021
Translation of the operating instructions

About these Operating Instructions
Operating instructions
Version 1.0.0
Rotary indexer RTX
Page 5 of 35
1.2 Further documentation
Please read the following documents according to the provided products before you operate the incomplete machine
with these operating instructions.
Description
Manufacturer
Version / Revision /
Date
Number
Assembly and operating
instructions gearbox
All
-
-
Operating instructions engines
All
-
-
Operating instructions sensors
All
-
-
Operating instructions encoders
All
-
-

Operating instructions
About these Operating Instructions
Page 6 of 35
Rotary indexer RTX
Version 1.0.0
1.3 Excerpt of Declaration of Incorporation

Safety information
Operating instructions
Version 1.0.0
Rotary indexer RTX
Page 7 of 35
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 35
Rotary indexer RTX
Version 1.0.0
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 indexer. They’re used as support for different products.
The Rotary indexer has a fixed or flexible division (for an exact design see data sheet). The Rotary indexer 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
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Rotary indexer RTX
Page 9 of 35
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 indexer RTX
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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
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Rotary indexer RTX
Page 11 of 35
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 indexer RTX
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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
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Rotary indexer RTX
Page 13 of 35
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 35
Rotary indexer RTX
Version 1.0.0
3Construction and function
3.1 Construction Rotary indexer type RTX
3.1.1 Rotary indexer RTX350 –RTX900
Fig. 3 Rotary indexer
Rotary indexer type RTX
closed circuit
Fig. 4 Distance design
Rotary indexer type RTX
closed circuit
Pos.
Description
1
Indexing ring / output flange (output)
2
Drive
3
Input shaft (drive)
4
Position indicator
5
Housing
6
Centre section (stationary)
5
2
1
4
3
4
1
5
6

Construction and function
Operating instructions
Version 1.0.0
Rotary indexer RTX
Page 15 of 35
3.2 Function
The drive (2) drives the indexing ring / output flange (1) via the input shaft (3) through the drum cam. The output plane
is offset by 90° to the drive plane. A uniform radial motion is converted on the input side into a clocked or uniformly
reduced output motion. The superstructures are mounted on the indexing ring / output flange (1). The position
indicator (4) shows the respective position of the drum cam. The type plate is attached to the housing (5). If required,
additional superstructures can be fastened to the non-rotating centre section (6).
An additional locking of the indexing ring / output flange is not necessary. It can lead to mechanical
overdetermination and thus in the long term to destruction of the rotary indexer. The power flow is either from a
three-phase motor (with / without brake) via a reduction gear or from a chain wheel or belt wheel to the input shaft
of the rotary indexer. This is permanently connected to the drum cam without any further internal gear stages and
rotates the indexing ring / output flange via drum cams. The indexing ring is mounted rigidly and clearance-free in a
wire bearing assembly (in steel rings not directly in cast iron). Shaft sealing rings corresponding to the respective size
seal the rotary indexer internally and externally.

Operating instructions
Construction and function
Page 16 of 35
Rotary indexer RTX
Version 1.0.0
3.3 Operating modes
The incomplete machine can be operated in the following modes:
•Normal mode
oIntermittent mode
oContinuous mode
oReverse operation (oscillating operation)
•Jog mode
•Emergency stop
NOTICE
Damage to the incomplete machine without electronic control!
Improper control of the incomplete machine can result in substantial damage to property.
No jog mode may be operated without a suitable universal control unit (TIC).
Use a suitable universal control unit (TIC).
3.3.1 Normal mode
By normal operation we mean the cycling of the indexing ring / output flange in one direction from one position to
the next. The direction of rotation of the indexing ring / output flange is determined by the direction of rotation of
the drive. This can easily be reversed in the case of the three-phase motor by swapping two phases of the supply
voltage.
3.3.2 Intermittent mode
The drive shaft stops in the cogging phase of the drum cam. The step time is fixed. The cogging time is variable.
This operating mode is used in systems with much longer machining times than turning times and is the most
common operating mode.
3.3.3 Continuous mode
The incomplete machine runs continuously without motor stop. Step and cogging times are fixed
and are run through evenly. The drive motor has only one direction of rotation.
This operating mode is often used in fast-running systems with short machining times. The
incomplete machine is mechanically synchronized to the rest of the system via the free drive shaft.
The ratio between cogging and stepping time can be adjusted within certain limits by TAKTOMAT
during cam production.
3.3.4 Reverse operation (oscillating operation)
Reversing operation (pendulum operation) The drive of the incomplete machine is reversed in each
case during the cogging phase.
3.3.5 Jog mode
The indexing ring / output flange constantly oscillates back and forth between two positions in this operating
mode. The drum cam cannot smoothly accelerate and brake the built-up load.
This represents a stress situation for the mechanical system, since the accelerations occurring during jog
mode exceed those of normal operation many times over. Jog mode may only be operated with a suitable
universal controller (TIC).
3.3.6 Emergency stop
The emergency stop is comparable to stopping in jog mode. Here too, the stopping and restarting of the established
load takes place outside the cogging phase. Frequent emergency stop situations must be avoided.

Construction and function
Operating instructions
Version 1.0.0
Rotary indexer RTX
Page 17 of 35
3.4 Technical data rotary indexer
3.5 Ambient conditions
Following ambient conditions apply to all Rotary indexer 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 air 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 months
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
Transport
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Rotary indexer RTX
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4Transport
Safety information
NOTICE
Damage arising from improper transport!
Improper transport can cause significant damage to property.
Take care and take note of the symbols on the packaging when unloading the partly
completed machinery on delivery and when transporting it on the premises.
4.1 Transport inspection
Immediately on receipt, check to make certain that the delivery is complete and has not been damaged during
transport. Proceed as follows if there are visible signs of damage during transport:
Do not accept the delivery or only do so conditionally.
Record the extent of the damage on the transport documentation or on the associated delivery note.
Immediately report any damage to the manufacturer of the partly completed machinery.
DANGER
Risk of fatal injury from suspended loads and falling parts!
Parts can fall during transport and cause serious or fatal injury.
Do not walk under suspended loads.
Keep people clear of the danger zone.
Always use lifting gear with a sufficient load capacity.
Always use forklift trucks or pallet trucks with a sufficient load capacity and fork length.
Do not leave the load suspended if you leave the working area.
4.2 Packaging, handling, unpacking
The partly completed machinery is packed in plastic sheeting or cardboard packaging and secured to a pallet for
transportation.
NOTICE
Damage arising from improper transport!
Improper transport can cause significant damage to property.
The partly completed machinery must not be allowed to become wet while it is being
transported.
Take the partly completed machinery out of the packaging just before installation
Remove the packaging carefully and dispose of it with due regard to environmental considerations.

Transport
Operating instructions
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Rotary indexer RTX
Page 19 of 35
4.2.1 Transport using sling equipment
Staff
Protective equipment
Qualified staff
The sling equipment (see figure) must be attached to the attachment points (see table and dimensions sheet) in
the positions shown in the figure and checked to ensure that it is working correctly (see the instructions for the
sling equipment).
Transport the partly completed machinery as follows if you are using sling equipment:
Fig. 5 Transport using sling equipment

Operating instructions
Transport
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Lifting instructions:
The angle between the perpendicular and the sling chain must lie between 0° and 45°.
WARNING
Risk of injury from falling or sinking load!
Too weak dimensioned sling equipment can break.
Transport vehicles can fail or topple if they are not designed for the weight of the partly
completed machinery.
Falling or toppling machines may lead to serious personal injury.
Lifting equipment, industrial trucks and sling equipment have to comply and designed
to the rules for the weight of the machine including.
It is prohibited to stand under suspended loads or raised machine parts.
NOTICE
Damage arising from improper transport!
Improper transport can cause significant damage to property.
Take care and take note of the symbols on the packaging when unloading the
partly completed machinery on delivery and when transporting it on the premises.
Use slinging equipment with sufficient load capacity.
Align slinging equipment in load direction.
If the recommended angle between perpendicular and the sling chain or sling strap
exceeds 45° the load capacity of the sling equipment is reduced.
Fig. 6 Lifting instructions