Related Manuals for TOX PRESSOTECHNIK Powerpackage Q Series
Summary of Contents for TOX PRESSOTECHNIK Powerpackage Q Series
- Page 1 Original operating instructions Powerpackage line-Q ® Type Q-S, Q-K ® PRESSOTECHNIK GmbH & Co. KG Riedstrasse 4 D-88250 Weingarten www.tox-pressotechnik.com...
- Page 2 TOX_Manual_Powerpackage_line-Q_en...
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Page 3: Table Of Contents
Table of contents Table of contents Important information Legal note .................... 7 Exclusion of liability .................. 7 Conformity.................... 7 Validity of the document................ 8 1.4.1 Content and target group ................ 8 1.4.2 Other applicable documents ............... 8 Gender note .................... 8 Displays in the document ................ - Page 4 Table of contents About this product Intended use .................... 17 3.1.1 Safe and correct operation................ 17 3.1.2 Foreseeable misuse.................. 18 Product Identification................. 18 3.2.1 Position and content of the type plate ............ 18 Function description of Powerpackage ............. 18 Product overview of Powerpackage line-Q .......... 19 3.4.1 Product attributes of Powerpackage line-Q..........
- Page 5 Table of contents 6.3.2 Installing position sensors of stroke monitoring for forward and return stroke (ZHU) ...................... 31 6.3.3 Installing the external linear position sensor (ZHW)........ 33 6.3.4 Installing pressure control in the power stroke line (ZDK)...... 35 6.3.5 Installing external power stroke connection (ZKHZ) ......... 36 6.3.6 Installing external power stroke release (ZKHF) and power stroke deactiva- tion (ZKHD) ....................
- Page 6 Table of contents Maintenance table of Powerpackage Maintenance 10.1 Safety during maintenance ............... 57 10.2 Requirements for maintenance .............. 59 10.2.1 Set system to maintenance position ............ 59 10.3 Checking oil level .................. 60 10.4 Refilling oil and venting drive .............. 61 10.5 Lowering of oil level...................
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Page 7: Important Information
Important information 1 Important information 1.1 Legal note All rights reserved. Operating instructions, manuals, technical descriptions and software pub- ® ® lished by TOX PRESSOTECHNIK GmbH & Co. KG ("TOX PRES- SOTECHNIK") are copyright and must not be reproduced, distributed and/ or otherwise processed or edited (e.g. -
Page 8: Validity Of The Document
Important information 1.4 Validity of the document 1.4.1 Content and target group This manual contains information and instructions for the safe operation and safe maintenance or servicing of the product. Ÿ All information in this manual is up to date at the time of print. ®... -
Page 9: Displays In The Document
Important information 1.6 Displays in the document 1.6.1 Display of warnings Warning signs indicate potential dangers and describe protective mea- sures. Warning signs precede the instructions for which they are applicable. Warning signs concerning personal injuries DANGER Identifies an immediate danger! Death or severe injuries will occur if appropriate safety measures are not taken. -
Page 10: Display Of General Notes
Important information 1.6.2 Display of general notes General notes show information on the product or the described action steps. Identifies important information and tips for users. 1.6.3 Highlighting of texts and images The highlighting of texts facilitates orientation in the document. ü... -
Page 11: Safety
Safety 2 Safety 2.1 Basic safety requirements The product is state of the art. However, operation of the product may in- volve danger to life and limb for the user or third parties or damage to the plant and other property. For this reason the following basic safety requirements will apply: Ÿ... -
Page 12: Selection And Qualifications Of Personnel
Safety Ÿ Take action to ensure safe operation and make sure that the product is maintained in a functional condition. Ÿ Only allow authorized persons access to the product. Ÿ Ensure that all personnel work with awareness of safety and potential dangers with reference to the information in the operating manual. -
Page 13: Fundamental Hazard Potential
Safety 2.3 Fundamental hazard potential Fundamental hazard potentials exist. The specified examples draw atten- tion to known hazardous situations, but are not complete and do not in any way provide safety and risk awareness action in all situations. 2.3.1 Electrical hazards Attention should be paid to electrical hazards particularly inside the compo- nents in the area of all assemblies of the control system and motors of the installation. -
Page 14: Contusions
Safety Ÿ Do not exceed the permissible pressure. Ÿ First switch on compressed air when all hose connections have been established and secured. Ÿ Do not uncouple any hoses under pressure. Ÿ If hoses slip off, switch off the compressed air supply immediately. 2.3.4 Contusions Contusions and hand injuries can occur in the radius of action of the prod-... -
Page 15: Electromagnetic Hazards
Safety 2.3.6 Electromagnetic hazards Electromagnetic hazards must be observed in the area of electromagneti- cally vibrating or oscillating components. Regular work on and with electromagnetically vibrating or oscillating com- ponents can lead to disturbances in the blood circulation of the fingers as well as neurological and motoric dysfunctions. -
Page 16: Safety Device On The Product
Safety 2.4 Safety device on the product Safety devices are important components of the safety concept and help to prevent accidents. 2.4.1 Safety device of system A superordinate safety concept must be developed. TOX_Manual_Powerpackage_line-Q_en... -
Page 17: About This Product
About this product 3 About this product Intended use The hydropneumatic drive performs the strokes that are generally defined as fast approach stroke, power stroke and return stroke. The drive is in- tended for installation in machines or robot tongs with the following techni- cal applications: Ÿ... -
Page 18: Foreseeable Misuse
About this product 3.1.2 Foreseeable misuse Use contrary to intended use includes the following foreseeable misuse: Ÿ Operation under conditions that deviate from the technical data. Ÿ Operation without fully assembled and functional connections. Ÿ Operation without fully assembled and functional safety devices. ®... -
Page 19: Product Overview Of Powerpackage Line-Q
About this product 3.4 Product overview of Powerpackage line-Q Working piston Compressed air supply return stroke [2] Control throttle 'X' Compressed air supply fast approach stroke [4] Oil filling nipple Power stroke valve Fig. 1 Product overview type Q-S, Q-K For product versions and product attributes see the design and installation guideline. -
Page 20: Optional Equipment
About this product 3.5 Optional equipment 3.5.1 Additional optional equipment Type Product attributes Linear position sensor Ÿ The travel sensor indicates the absolute actual position of the piston. Ÿ For external installation (for series line-Q and line-X to Q-S/Q-K 30, X-SX-K 30). Stroke monitoring Ÿ... -
Page 21: Technical Data
Technical data 4 Technical data 4.1 Type sheet and data sheet For technical data and installation dimensions see type sheet and data. (https://www.tox-pressotechnik.com) 4.2 Compressed air quality and pneumatic connection The following is required: Ÿ Filtered and dried compressed air Lightly oiled compressed air is permitted. -
Page 22: Press Force Table
Technical data Tool coupling Tightening torque ZWK 015 210 Nm ZWK 030 230 Nm ZWK 050 290 Nm ZWK 075 500 Nm ZWK 200 500 Nm 4.4 Press force table The effective press force is the ratio of the available press force at the specified air pressure to the press force required for the pressing process. Press force table see separate document. - Page 23 Technical data NOTE Loss of warranty in case of the use of non-approved hydraulic oils! Due to the negative effects on maintenance intervals, swelling behavior and lifetime of the seals in case of the use of hydraulic oils that have not been approved as standard, the granted warranty becomes extinct.
- Page 24 Technical data TOX_Manual_Powerpackage_line-Q_en...
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Page 25: Transport And Storage
Transport and storage 5 Transport and storage 5.1 Safety during transport WARNING Hazard from suspended loads! Severe crushing, impacts and serious accidents as a result of improper transportation and falling load! è Only use lifting gear that is appropriate and in perfect technical condi- tion, as well as load attachment devices with an adequate safe working load. -
Page 26: Lifting Device
Transport and storage 5.2 Lifting device Depending on the size of the drive, the flange cover at the rear is provided with threaded bore holes for ring bolts for hoisting. WARNING Risk of impact and crushing due to products swivelling out! Severe impacts, crushing, and serious accidents as a result of the product rotating and swiveling out. -
Page 27: Installation
Installation 6 Installation Safety during installation The installation may only be carried out by trained and authorized person- nel. DANGER Electrical hazards in case of contact with live parts! Electric shock, burns or death in case of contact with live parts! è... -
Page 28: Installing Drive
Installation 6.2 Installing drive Material required: Ÿ Screws of the strength class : 12.9 (in accordance with ISO 4762) Ÿ Torque wrench 1. WARNING! Risk of crushing! Attach lifting device (ring bolts) and use appropriate lifting gear. Place and align drive on the fastening element provided. 2. -
Page 29: Installing Accessories
Installation 6.3 Installing accessories 6.3.1 Installing electronic pressure switch (ZDO) Screw Assembly holder (ZMP) Cheese head screw Electronic pressure switch (ZDO) High-pressure measuring hose High pressure measuring con- (ZHM) nection Material required: Ÿ Electronic pressure switch (ZDO) Ÿ Assembly holder (ZMP) Ÿ... - Page 30 Installation ü Make sure that the system is depressurized and disconnected from the power supply. ü Observe the tightening torques. Chap. 4.3 Tightening torques, Page 1. Install assembly holder of pressure switch on the drive. Make sure that display and operating elements are easily accessible. 2.
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Page 31: Installing Position Sensors Of Stroke Monitoring For Forward And Return Stroke (Zhu)
Installation 6.3.2 Installing position sensors of stroke monitoring for forward and return stroke (ZHU) Fig. 2 Installing position sensors for stroke monitoring for forward and return stroke Material required: Ÿ Magnet-sensitive proximity switch with LED (ZHS 001.001) Ÿ Holding angle for proximity switch Ÿ... - Page 32 Installation Setting the position sensors ü Proximity switches are connected. ü Working piston in home position. 1. Push the proximity switch from the edge of the cylinder to the first switch-on point. The LED lights up. 2. Mark the edge of the proximity switch on the cylinder. 3.
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Page 33: Installing The External Linear Position Sensor (Zhw)
Installation 6.3.3 Installing the external linear position sensor (ZHW) Material required: Prerequisite for the installation of the external linear position sensor: - Powerpackage type line-Q, line-X or RZS - 20 mm stroke reduction either positioned inside in the Powerpackage or - positioned outside the tool Ÿ... - Page 34 Installation ü The operating manual of the linear position sensor is available. NOTE Risk of damage to the device due to incorrect installation and connec- tion! è The specifications of the operating manual of the manufacturer are to be adhered to. 1.
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Page 35: Installing Pressure Control In The Power Stroke Line (Zdk)
Installation 6.3.4 Installing pressure control in the power stroke line (ZDK) Fig. 3 Installing pressure control in the power stroke line (assembly ZDK) Material required: Ÿ Manual pressure regulator (ZDK) Ÿ Screw plug with collar, size M 5 (laterally on power stroke valve next to connection [12]) TOX_Manual_Powerpackage_line-Q_en... -
Page 36: Installing External Power Stroke Connection (Zkhz)
Installation ü For connections see Pressure control in the power stroke line (assem- bly ZDK) (optional). 1. Remove the screw plug on the control connection [12]. The lower positioned M 5 threaded hole is set free. 2. Remove the M5 screw plug from the par position. 3. -
Page 37: Installing External Power Stroke Release (Zkhf) And Power Stroke Deactivation (Zkhd)
Installation 6.3.6 Installing external power stroke release (ZKHF) and power stroke deactivation (ZKHD) Material required: Ÿ Electrical switching valve power stroke release (ZKHF) and power stroke deactivation (ZKHD) with pneumatic OR valve Installing the external power stroke release (ZKHF) ü For connections see External power stroke deactivation (assembly ZKHD) (optional). -
Page 38: Preparing External Power Stroke Supply
Installation 6.3.7 Preparing external power stroke supply Fig. 4 Preparing external power stroke supply Material required: Ÿ Screw plug M 5 with collar (laterally on power stroke valve next to con- nection [12]) ü For connections see External power stroke supply (optional). 1. -
Page 39: Installing The Stroke Frequency Optimization (Zho)
Installation 6.3.8 Installing the stroke frequency optimization (ZHO) Installing the stroke frequency optimization (ZHO) for drive with integrated power stroke valve Optimization of stroke fre- Slide valve quency (ZHO) Plug Circlip Fig. 5 Installing the stroke frequency optimization ZHO Material required: Ÿ... - Page 40 Installation Installing the stroke frequency optimization (ZHO) for drive with external power stroke valve Fig. 6 Installing the stroke frequency optimization ZHO Material required: Ÿ Installing the stroke frequency optimization (ZHO) for drive with exter- nal power stroke valve Ÿ Pneumatic supply line including all series-connected valves in the size fitting to the connections.
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Page 41: Installing The Speed Reduction For Power Stroke Venting
Installation 6.3.9 Installing the speed reduction for power stroke venting Fig. 7 Installing the speed reduction for power stroke venting Material required: Ÿ Adjustable exhaust air damper (ZD) 1. Install the exhaust throttle between the power stroke valve output [3] and the muffler. 2. -
Page 42: Installing Tool Coupling (Zwk)
Installation 6.3.10 Installing tool coupling (ZWK) Fig. 8 Installing tool coupling (ZWK) Material required: Ÿ Tool coupling (ZWK) Ÿ Screw locking compound - low-strength (e.g. Loctite 222) Ÿ Food grade grease (e.g. UH1 14-151) ü Technical data, dimensions are observed. See data sheet, or type sheet at https://www.tox-pressotechnik.com. 1. -
Page 43: Commissioning
Commissioning 7 Commissioning 7.1 Safety during the commissioning 1. The commissioning may only be carried out by trained and authorized personnel. 2. Make sure that that no persons are located within the danger area of the machine. 3. Observe technical data and limit values. See Technical data. -
Page 44: Requirements For The Commissioning
Commissioning 7.2 Requirements for the commissioning This incomplete machine may not be commissioned until it has been ascer- tained that the incomplete machine in which the component is to be in- stalled complies with the requirements of the Machinery Directive (2006/42/ EC). -
Page 45: Avoidance Of Dynamic Oil Leakage
Commissioning 7.3 Avoidance of dynamic oil leakage The dynamic oil leakage is based on the physical effect of drag flow: the higher the speed, the thicker the oil film dragged along. In the case of an unfavorable speed ratio between the fast approach stroke and return stroke, an oil film could get into the pneumatic chambers of the Powerpack- age. -
Page 46: Setting Speed Ratio Of Return Stroke To Fast Approach Stroke
Commissioning 7.3.1 Setting speed ratio of return stroke to fast approach stroke The speed of the working piston in the fast approach stroke and return stroke can be set with external exhaust air dampers on the forward stroke and return stroke. The exhaust air dampers may have to be retrofitted. Type line-Q Necessary speed ratio... -
Page 47: Setting Control Throttle 'X
Commissioning 7.4 Setting control throttle 'X' The control throttle 'X' is used to set the timing of the switchover from fast approach stroke to power stroke, and must be readjusted for each applica- tion (e.g. tool weight drawing/pressing). The effect of the control throttle 'X' is influenced by the system pressure and by setting an optional fast ap- proach stroke throttle. -
Page 48: Setting Total Length Of Stroke (Optional)
Commissioning 7.5 Setting total length of stroke (optional) In the series with total stroke adjustment, the length of the total stroke can be adjusted independently of the length of the power stroke and the length of the cylinder. Fig. 10 Setting total length of stroke 1. -
Page 49: Operation
Operation 8 Operation 8.1 Safety in operation WARNING Dangerous machine movements! Serious contusions and injuries! è Make sure that that no persons are located in the danger area during operation. CAUTION Noise during operation! Hearing impairment! è Wear individual protective equipment. CAUTION Hazard from flying parts! Injuries to eyes and body cavities! -
Page 50: Requirements For Operation
Operation 8.2 Requirements for operation Ÿ The safety devices of the entire machine are properly assembled and functional. Ÿ All components are properly maintained, clean and without damage. Ÿ Supply connections, communication and control connections, material or media hoses are installed properly. The permissible values are com- plied with. -
Page 51: Troubleshooting
Troubleshooting 9 Troubleshooting 9.1 Safety during troubleshooting Ÿ Troubleshooting may only be carried out by trained and authorized per- sonnel. Ÿ Make sure that that no persons are located within the danger area of the machine. TOX_Manual_Powerpackage_line-Q_en... -
Page 52: Searching For Causes Of Fault
Troubleshooting 9.2 Searching for causes of fault Fault Possible cause Measure Piston rod does not extend. Tool jams. Mechanically decouple the Powerpack- age and check ease of movement by Guiding columns are jammed. extending and retracting. Air pressure too low (only for assembly Check air pressure and increase if nec- direction from the bottom to the top). - Page 53 Troubleshooting Fault Possible cause Measure Piston rod does not retract. Tool jams. Mechanically decouple the Powerpack- age and check ease of movement by Guiding columns are jammed. extending and retracting. Air pressure too low (only for assembly Check air pressure and increase if nec- direction from the bottom to the top).
- Page 54 Troubleshooting TOX_Manual_Powerpackage_line-Q_en...
- Page 55 Maintenance table of Powerpackage Maintenance table of Powerpackage The specified intervals are only approximate values. Depending on the area of application, the actual values may differ from the guide values. The ac- tual intervals can be found in the system control. Maintenance cycle Additional information according to counter (flexible)
- Page 56 Maintenance table of Powerpackage TOX_Manual_Powerpackage_line-Q_en...
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Page 57: Maintenance
Maintenance 10 Maintenance 10.1 Safety during maintenance DANGER Electrical hazards in case of contact with live parts! Electric shock, burns or death in case of contact with live parts! è Have all work on the electrical equipment performed by an electrician. è... - Page 58 Maintenance NOTE Incorrect cleaning agents or cleaning processes, lack of corrosion protection! Damage to machine components! è Only touch bare areas with gloves. è Use cleaning set, such as industrial cleaner (e.g. Loctite 7063, or Würth Montagekraftreiniger 0890 107), vacuum cleaner, dry cloth and brush. è...
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Page 59: Requirements For Maintenance
Maintenance 10.2 Requirements for maintenance 10.2.1 Set system to maintenance position Unless specified otherwise, before all maintenance work: 1. Retract the working piston. The machine is in initial position (working piston retracted). 2. Install a restraint device if necessary. 3. Make sure that fast approach stroke and power stroke cannot be acti- vated in maintenance position. -
Page 60: Checking Oil Level
Maintenance 10.3 Checking oil level Fig. 11 Checking oil level ü System is in maintenance position. Set system to maintenance position, Page è Check needle of the oil level indicator. The needle of the oil level indicator is flush with the surface of the cylin- der: Oil level is ok. -
Page 61: Refilling Oil And Venting Drive
Maintenance 10.4 Refilling oil and venting drive Vent screw Vent screw Vent screw Vent screw Vent screw Vent screw Vent screw High pressure measuring connection Oil filling nipple Oil level indicator Venting plate Oil anti-overfill safety device Vent screw Fig. 12 Refilling oil and venting drive Material required: Ÿ... - Page 62 Maintenance The top vent screws or the top HP measuring connection must be selected for the venting. Venting points according to installation position Installation position Type Q-S Type Q-K Vertical, working piston Vent screw 2 Vent screws 2, 4, 6, 5, 7 downward Vertical, working piston Vent screw 1...
- Page 63 Maintenance ü System is in maintenance position. Set system to maintenance position, Page 1. Remove venting plate with locking wire. 2. Unscrew knurled cap of the oil filling nipple. 3. Vent filling hose of the oil pump. 4. Install filling hose of the oil pump on oil filling nipple. 5.
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Page 64: Lowering Of Oil Level
Maintenance 10.5 Lowering of oil level CAUTION Environmental pollution caused by environmentally harmful liquids! è Absorb spilled liquids and remove without residue. è Dispose of liquid according to the statutory regulations. NOTE Damage to seal due to high oil level! After refilling and venting, lower the oil level by a defined value (lowering volume "ΔV"). -
Page 65: Checking Hydraulic Hoses
Maintenance 10.6 Checking hydraulic hoses è Check hydraulic hoses regularly. è Change hydraulic hoses after 6 years at the latest. è Observe country-specific guidelines. TOX_Manual_Powerpackage_line-Q_en... - Page 66 Maintenance TOX_Manual_Powerpackage_line-Q_en...
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Page 67: Repairs
Repairs 11 Repairs 11.1 Safety during repairs Repair work may only be carried out by trained and authorized service per- sonnel. For information and contact seeSources and contact to customer service. 11.2 Changing seals Seals may only replaced by trained and authorized service personnel. TOX_Manual_Powerpackage_line-Q_en... - Page 68 Repairs TOX_Manual_Powerpackage_line-Q_en...
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Page 69: Disassembly And Disposal
Disassembly and Disposal 12 Disassembly and Disposal 12.1 Safety during disassembly and disposal DANGER Electrical hazards in case of contact with live parts! Electric shock, burns or death in case of contact with live parts! è Have all work on the electrical equipment performed by an electrician. è... -
Page 70: Decommissioning
Disassembly and Disposal 12.2 Decommissioning Decommissioning means that the plant is not in operation for a longer pe- riod of time but remains at the installation site for recommissioning later. 1. Move plant into home position. 2. Install a restraint device if necessary. 3. -
Page 71: Disassembling
Disassembly and Disposal 12.4 Disassembling The system consists of recyclable materials. NOTE Environmental damage! Improper recycling endangers the environment! è Dispose of materials separately and properly. è Regional disposal regulations must be observed. 1. Strip the system down into its constituent parts. 2. - Page 72 Disassembly and Disposal TOX_Manual_Powerpackage_line-Q_en...
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Page 73: Appendices
Appendices 13 Appendices 13.1 DECLARATION OF INCORPORATION TOX_Manual_Powerpackage_line-Q_en... - Page 74 Appendices TOX_Manual_Powerpackage_line-Q_en...
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Page 77: Index
Index Index Avoidance of dynamic oil leakage .... 45 Equipment Optional ............ 20 Exclusion of liability ......... 7 External power stroke connection (ZKHZ) Basic safety requirements ...... 11 Installing............ 36 External power stroke release (ZKHF) Installing............ 37 Change Seal............ 67 Changing seals.......... - Page 78 Index Identification Laser Product ............. 18 Hazard ............ 15 Images Legal note............ 7 Highlighting .......... 10 Lifting device .......... 26 Important information ........ 7 line-Q information Product overview ........ 19 Important............. 7 Lowering Installation ............. 27 Oil level ............. 64 Accessories ..........
- Page 79 Index Piston rod Safety ............ 11 Tightening torques ........ 21 Disassembly .......... 69 Pneumatic connection ........ 21 Disposal ............ 69 Position sensors of stroke monitoring for for- Installation.......... 27 ward and return stroke (ZHU) Maintenance .......... 57 Installing............ 31 Operation .......... 49 Power stroke Repairs .............
- Page 80 Index Target group ............ 8 Technical data .......... 21 Texts Highlighting .......... 10 Tightening torques Installation.......... 21 Piston rod.......... 21 Total length of stroke Setting............ 48 Transport ............ 25 Safety............ 25 Troubleshooting.......... 51 Safety............ 51 Type plate............ 18 Intended............ 17 Validity Document ...........
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