Taktomat RTX350 User manual

Rotary indexer
RTX
Version 1.0
2022-05-30
Assembly instructions

Assembly instructions
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Rotary indexer RTX
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Table of contents
1About these instructions .................................................................................................................................................................3
1.1 Purpose..................................................................................................................................................................................................3
1.2 Contact information ..............................................................................................................................................................................3
1.3 Product designation..............................................................................................................................................................................3
1.4 Symbols.................................................................................................................................................................................................4
2Safety ...................................................................................................................................................................................................5
2.1 Safety instructions................................................................................................................................................................................5
2.2 Warnings...............................................................................................................................................................................................5
2.3 Requirements for personnel.................................................................................................................................................................7
2.4 Personal protective equipment ............................................................................................................................................................7
2.5 Requirements for incorporation into a complete machine .................................................................................................................7
3Product description..........................................................................................................................................................................8
3.1 Intended use..........................................................................................................................................................................................8
3.2 Technical data.......................................................................................................................................................................................8
3.3 Product overview ..................................................................................................................................................................................9
4Transport...........................................................................................................................................................................................10
4.1 Transport with slings..........................................................................................................................................................................11
5Assembly...........................................................................................................................................................................................14
5.1 Attachment positions .........................................................................................................................................................................14
5.2 Drive attachment ................................................................................................................................................................................15
5.3 Guidelines for drive control of indexing tables.................................................................................................................................17
6Operation...........................................................................................................................................................................................19
6.1 Operating modes.................................................................................................................................................................................19
7Maintenance ....................................................................................................................................................................................21
7.1 Maintenance tasks .............................................................................................................................................................................22
7.2 Lubricating...........................................................................................................................................................................................23
8Troubleshooting...............................................................................................................................................................................24
9Disposal.............................................................................................................................................................................................25
10 Spare and wear parts.....................................................................................................................................................................26
11 Annexes.............................................................................................................................................................................................27
11.1 Content of the declaration of incorporation......................................................................................................................................27

Assembly instructions
About these instructions
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1About these instructions
1.1 Purpose
The purpose of these Assembly Instructions is to provide users with all the information necessary for proper and safe
installation of the rotary indexer in a complete machine.
1.2 Contact information
TAKTOMAT GmbH
Rudolf-Diesel-Straße 14
86554 Pöttmes
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: http://www.taktomat.de/
1.3 Product designation
Product
designation:
Rotary indexer
Product type:
RTX

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About these instructions
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1.4 Symbols
The following symbols are used in these instructions:
Instructions and directions
Requirements for performing an instruction are indicated by a check mark.
The action steps to be executed are numbered.
The results of individual action steps are indicated by a black arrow. The overall result of an instruction is marked by a white
arrow in a black circle.
Example
Requirement
1. Instruction (step 1)
2. Instruction (step 2)
Result or response of system to step 2
3. Instruction (step 3)
Overall result of the instruction
Enumerations
Enumerations in no strict order are indicated as follows:
•Property A
oDetail 1
oDetail 2
•Property B
oDetail 1
oDetail 2

Assembly instructions
Safety
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2Safety
2.1 Safety instructions
General safety instructions
•Read through these instructions completely
•Observe the information and instructions in these instructions
•Keep unauthorized persons away from the working area
•Work on electrical systems may only be carried out by qualified electricians
•Keep the instructions in a safe place and make them available to all employees
•Observe the documentation of the supplier components
2.2 Warnings
2.2.1 Structure of the warnings
All the warnings in these instructions have the following structure:
Fig. 1: Structure of the warnings
1 Hazard-specific symbol 2 Hazard symbol
3 Signal word 4 Type and source of danger
5 Possible consequences of non-observance 6 Procedure for hazard prevention
4
5
6
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Safety
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2.2.2 Meaning of the signal words and symbols
The following signal words are used in this document:
Signal word Meaning
DANGER Indicates a hazardous situation which will result in death or serious injury.
WARNING Indicates a potentially hazardous situation which may result in death or serious injury.
CAUTION Indicates a potentially hazardous situation which may result in minor or moderate injury.
NOTICE Indicates a potentially hazardous situation which may result in property and environmental
damage.
The following symbols for dangers, warnings, mandatory requirements and prohibitions are used in this document:
General warning sign
Warning: Electrical voltage
Warning: Suspended load
Warning: Slipping hazard
Warning: Crushing hazard
Wear head protection
Wear eye protection

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Wear foot protection
Wear hand protection
2.3 Requirements for personnel
The activities described in these instructions may only be performed by qualified personnel.
Qualified personnel are persons who are able to carry out the work assigned to them due to their technical training, knowledge
and experience. They are familiar with the relevant standards and regulations and are able to recognize potential hazards on
their own.
2.4 Personal protective equipment
Personal protective equipment is used to protect personnel from impairments to safety and health during work. Personnel
must wear the personal protective equipment when performing all of the activities described in these instructions. The
required personal protective equipment is indicated in the different chapters of these instructions.
2.5 Requirements for incorporation into a complete machine
The rotary indexer is partly completed machinery. Operation of the rotary indexer is only permitted in a complete, CE-compliant
machine or system.
The manufacturer of the complete machinery or system is responsible for integrating the rotary indexer into the system in
such a way that completely safe operation is guaranteed.
•During operation, it is prohibited to remain in the immediate vicinity of the rotary indexer. Staying in the vicinity of the
rotary indexer is only permitted within the scope of inspection tasks, maintenance or servicing work by specially trained
personnel.
•Maintenance work must be carried out in accordance with the maintenance plan and the operating instructions.
•All tasks on or at the rotary indexer may only be carried out by trained, qualified personnel.

Assembly instructions
Product description
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3Product description
3.1 Intended use
The rotary indexer is designed for incorporation in CE-compliant complete machinery or an overall system.
The rotary indexer turns and tilts loads about the vertical rotary axis. To this end, customer attachments can be mounted on
the rotary indexer.
All applications deviating from this intended use are not permitted.
•Modifications must be approved by TAKTOMAT
•The rotary indexer may only be operated within the defined operating parameters
•Use of the rotary indexer in the food sector is not permitted
3.2 Technical data
Application range Indoors/in enclosed spaces:
the installation room must be dry, clean and low-vibration.
Not suitable for use in high-vacuum area.
Temperature range [°C] +10 to +40
Relative humidity [%] 40 to 70
Media do not expose to aggressive media
3.2.1 Storage conditions
Application range indoors
Temperature range [°C] -22 to +50
Relative humidity [%] 40 to 70
Media do not expose to aggressive media
Storage period > 6 months provide additional corrosion protection
3.2.2 Dimensions
The dimensions of the different versions are given on the TAKTOMAT website: https://www.taktomat.de/.

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Product description
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3.3 Product overview
Fig. 2: Rotary indexer structure – basic type with closed circuit
1 Roll star / output flange 2 Middle part (fixed) in basic type
3 Drive unit 4 Housing
5 Position indicator
Fig. 3: Rotary indexer structure – distance type with closed circuit
1 Roll star / output flange 2 Middle section (fixed) in distance type
3 Drive unit 4 Housing
5 Position indicator
The input shaft is driven by a three-phase a.c. motor, an gear reducer or a sprocket or belt pulley. A drum cam converts the
radial movement of the input side into a clocked or uniformly reduced movement of the roll star / output flange.
The attachments are fixed onto the roll star / output flange. If necessary, further fixed attachments can be fixed onto the
middle section.
1 2
45
3
1 2
45
3

Assembly instructions
Transport
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4Transport
Required personal protective equipment
WARNING
Tipping or falling loads
Suspended loads can tip or fall down. This can cause serious or fatal injuries to persons.
•Do not step under suspended loads
•Keep unauthorized persons out of the danger zone
•Observe the weight and centre of gravity
•Only use suitable, approved and undamaged load handling attachments
NOTICE
Damage to components
Improper transport can cause material damage
•Carry out transport carefully and note the symbols on the packaging
•Align the lifting eyes in the direction of the load
•Follow the operating instructions for the lifting gear
Check the delivery immediately on receipt for completeness and transport damage.
In the event of externally visible transport damage, observe the following:
•Do not accept the delivery or accept it only with reservations
•Note the extent of the damage on the transport documents or on the transport delivery note
•Report material damage to the manufacturer immediately

Assembly instructions
Transport
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4.1 Transport with slings
4.1.1 Slings on the middle section (RTX350/RTX450)
Transport the rotary indexer with the slings as follows:
Fig. 4: Transport with slings
Attach the slings in the threaded holes as shown below and check their function.
Recommended slings
RTX Quantity Manufacturer Designation Type
350 1 CODIPRO Swivel eyebolt M10 DSR M10 UP - 0.70t
350 1 CODIPRO Eyebolt flange RTX350 ART20003500
450 1 CODIPRO Swivel eyebolt M10 DSR M10 UP - 0.70t
450 1 CODIPRO Eyebolt flange RTX450 ART20003528

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4.1.2 Slings on the housing (RTX 550-RTX900)
Transport the rotary indexer with the slings as follows:
Fig. 5: Transport with slings
Attach the slings in the threaded holes as shown below and check their function.
The angle between the vertical and the chain sling or sling strap must be between 0 and 45°.
Fig. 6: Lifting instruction

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Transport
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Recommended slings
RTX Quantity Manufacturer Designation Type
550 4 CODIPRO Swivel eyebolt M6 DSR M6 UP - 0.15t
650 4 CODIPRO Swivel eyebolt M8 DSR M8 UP - 0.40t
750 4 CODIPRO Swivel eyebolt M8 DSR M8 UP - 0.40t
900 4 CODIPRO Swivel eyebolt M10 DSR M10 UP - 0.70t

Assembly instructions
Assembly
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5Assembly
Required personal protective equipment
DANGER
Electric shock
Touching live parts poses an immediate danger to life
•Work on electrical systems may only be carried out by qualified electricians
•Before starting work, disconnect the system, secure it against being switched on again and
make sure that no voltage is present
WARNING
Crushing during assembly and dismantling
Persons within the work area of the rotary indexer can be crushed during assembly and dismantling.
•Wear suitable personal protective equipment.
•The assembly and dismantling may only be carried out by instructed skilled personnel.
5.1 Attachment positions
Fix. 7: RTX drive attachment positions
1SR1801SR2701SL180
1SL90
2SR180
2SR270 2SL90 2SL180

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Assembly
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5.2 Drive attachment
NOTICE
Damage to components
Improper attachment of the drive can cause material damage
•The type of drive, e.g. a servomotor or three-phase a.c. motor must be agreed with TAKTOMAT
•On attaching the drive, note and follow the manufacturer’s operating instructions
•Note the spatial positions of the drive
•Fix the drive in the specified mounting points
•Tighten the screws to the specified torque
Attach the drive to the rotary indexer as follows:
Fig. 8: Drive attachment order
1 Drive unit 2 Drive flange
3 Cylindrical head screw + Schnorr washer 4 Stud bolt
5 Nut + Schnorr washer
4 3 5
21

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Assembly
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5.2.1 Installation
DANGER
Electric shock
Touching live parts poses an immediate danger to life
•Work on electrical systems may only be carried out by qualified electricians
•Before starting work, disconnect the system, secure it against being switched on again and
make sure that no voltage is present
Fig. 9: Installation of the rotary indexer - standard installation position
The mounting surface must be level.
1. Clean the mounting surface and apply an oil film.
2. Place the rotary indexer on the mounting surface.
3. Fix the rotary indexer with screws and alignment pins according to the requirements.
4. Compare the supply voltage with the data on the nameplate.
5. Connect the drive unit.
6. Earth the housing of the rotary indexer with an adequate cross-section.
Roll star / output flange attachments
Note the following regarding attachments on the roll star / output flange:
•Maximum weight moved (according to TAKTOMAT project planning).
•Minimum time until positioning (according to TAKTOMAT project planning).
•Maximum overhang (tipping moment) (according to TAKTOMAT project planning).
•Do not exceed the max. tightening torque of the mounting screws.

Assembly instructions
Assembly
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5.3 Guidelines for drive control of indexing tables
The specified switching time must be reached for correct operation of the indexing table. The switching time is the time
required for the output flange to move from station to station (circuit) at a constant rated motor speed (50 Hz). The switching
time does not include any times for the motor movement in the dwell area, as well as the time for motor acceleration and
delay.
Fig. 10: Switching time diagram
Fig. 11: Indexing table example, 4 stations (90°), switching time 0.8 s, switching angle 300°, dwell area 60°
1 Output flange 2 Switching range
3 Dwell area
The motor must stop within the dwell area on braking. The stopping time must therefore be kept as short as possible.
2
3
1

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Assembly
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Immediate reaction to sensor signal:
Motor remains stopped in the dwell area
Delayed reaction to sensor signal:
Motor remains stopped outside the dwell area
Fig. 12: Run-up and stopping time of the motor
Not the following regarding the drive control to enable optimum operation of indexing tables:
•The reaction to the sensor signal must take place immediately
oUse the sensor signal directly to activate the mains contactor for motor and brake. This avoids the time delay due to
evaluation of the sensor signal by electronic equipment or the PLC.
oIf the sensor signal has to be processed in the PLC immediately, program and configure the PLC so that the reaction
time to the sensor signal for motor stop can be kept as short as possible.
oSensor signal time delays can occur if the sensor is attached to sensor boxes, intelligent terminals, distribution
boxes, bus systems or similar.
•Activation and wiring of the brake
oDo not connect the brake directly to the terminal board with alternating voltage, as this leads to the delaying of the
engaging of the brake.
oBrake with alternating voltage: The brake is switched off on the alternating and direct current side simultaneously.
The type of switching off offers faster engaging of the brake compared to alternating current switching off. Contact
the motor manufacturer for further information on optimum activation of the brake.
oUse brake activation components (e.g. relays) with faster reaction time.
•The stopping time increases due to brake wear. Check and adjust the brake wear.
•When operating the motor in TIC, the sensor must be connected to the TIC universal control. The sensor signal is sent to
the PLC directly via a fieldbus.
Speed, output flange
Sensor
Motor speed
Speed, output flange
Sensor
Dwell
area
Motor speed

Assembly instructions
Operation
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6Operation
DANGER
Electric shock
Touching live parts poses an immediate danger to life
•Work on electrical systems may only be carried out by qualified electricians
•Before starting work, disconnect the system, secure it against being switched on again and
make sure that no voltage is present
NOTICE
Improper activation can cause material damage
•Inching mode is not permitted without a suitable universal controller (TIC)
•Use a suitable universal controller (TIC)
General requirements for operation
Operation of the rotary indexer is only permitted in a complete, CE-compliant machine or system.
The rotary indexer may not be operated with defective or disabled safety devices.
6.1 Operating modes
Normal operation
In normal operation, the roll star / output flange moves in one direction from one position to the next. The rotational direction
of the roll star / output flange corresponds to the rotational direction of the drive. The rotational direction of a three-phase
a.c. motor can be reversed easily by swapping two phases of the supply voltage.
Intermittent operation
The drive shaft stops in the dwell phase of the drum curve. The step time is fixed. The dwell time is variable. This mode is
used in machines with significantly longer machining times than rotating times and is the most frequent mode.
Continuous operation
The rotary indexer runs continuously without the motor stopping. Step and dwell times are fixed and are run through uniformly.
The drive motor has only one direction of rotation.
This mode is frequently used in fast-running machines with short machining times. The partly completed machinery is
synchronised mechanically with the rest of the machine via the free drive shaft. The ration between the dwell and step time
can be adjusted within certain limits by TAKTOMAT when producing the curve.
Reversing operation (reciprocating operation)
In this mode the roll star / output flange oscillates (shuttles) continuously, back and forth between two positions. The drive
of the partly completed machinery is reversed in the respective dwell phase.
Inching mode
In inching mode, the roll star / output flange move in small steps between two dwell positions.

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Operation
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The cylinder is unable to accelerate and decelerate the accumulated load gently. As a result, high accelerations occur, which
impact the mechanics. Inching may only be carried out with a suitable universal controller. A suitable controller is, for
example, the TIC controller (TAKTOMAT Indexing Controller).
Emergency stop
The emergency stop stops the movement of the roll star / output flange immediately. The resultant load that is built up
impacts the mechanics. The emergency stop should therefore only be used in emergency situations.