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TOX Powerpackage line-X-S Series Operating Instructions Manual

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Original operating instructions
®
TOX
Powerpackage line-X
Type X-S, X-K
TOX
®
PRESSOTECHNIK GmbH & Co. KG, Riedstrasse 4, 88250 Weingarten / Germany
www.tox.com

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Summary of Contents for TOX Powerpackage line-X-S Series

  • Page 1 Original operating instructions ® Powerpackage line-X Type X-S, X-K ® PRESSOTECHNIK GmbH & Co. KG, Riedstrasse 4, 88250 Weingarten / Germany www.tox.com...

  • Page 2: Table Of Contents

    Table of contents Table of contents Important information Legal note .................... 8 Exclusion of liability.................. 8 Conformity .................... 8 Validity of the document ................ 9 1.4.1 Content and target group................ 9 1.4.2 Other applicable documents ................ 9 Gender note.................... 9 Displays in the document................ 10 1.6.1 Display of warnings.................. 10 1.6.2 Display of general notes ................ 10 1.6.3...
  • Page 3 Powerpackage with integrated damping function ZED...................... 26 ® 3.5.2 Product overview of TOX Powerpackage with cutting impact damping ZSD ........................ 27 3.5.3 Product overview and product attributes of TOX ® Powerpackage with inte- grated holding brake ZSL ................ 28 3.5.4 Additional optional equipment.............. 29 Product planning.................. 30 3.6.1 Design data.................... 30...
  • Page 4 Table of contents 3.7.5 External power stroke switch (assembly ZKHZ) (optional) ...... 46 3.7.6 External power stroke deactivation (assembly ZKHD) (optional) .... 48 3.7.7 External power stroke release (assembly ZKHF) (optional) ...... 50 3.7.8 External power stroke supply (optional)............. 52 3.7.9 Adjustable damping (assembly ZED) (optional) ........ 54 3.7.10 Integrated cutting impact damping (module ZSD) (option) ...... 56 Technical data...
  • Page 5 Table of contents 6.3.4 Installing pressure control in the power stroke line (ZDK) ...... 72 6.3.5 Installing proportional pressure control valve in the power stroke line .. 74 6.3.6 Installing external power stroke connection (ZKHZ) ........ 75 6.3.7 Installing external power stroke release (ZKHF) and power stroke deactiva- tion (ZKHD).................... 76 6.3.8 Preparing external power stroke supply ............ 77...
  • Page 6 Table of contents Maintenance table of Powerpackage Maintenance 10.1 General information ................. 101 10.2 Safety during maintenance .............. 102 10.3 Requirements for maintenance.............. 104 10.3.1 Set system to maintenance position ............ 104 10.4 Checking oil level.................. 105 10.5 Refilling oil and venting drive .............. 106 10.6 Refilling oil and venting the drive of Powerpackage with optional equipment ......................... 110 10.6.1...
  • Page 7 Table of contents Appendices 13.1 DECLARATION OF INCORPORATION.......... 120 Index TOX_Manual_Powerpackage_line-X_en...

  • Page 8: Important Information

    ®  PRESSOTECHNIK and may be subject to criminal and civil legal sanc- tions. If this manual refers to goods and/or services of third parties, this is for example only or is a recommendation by TOX ®  PRESSOTECHNIK. ®  PRESSOTECHNIK does not accept any liability or warranty/guarantee with reference to the selection, specifications and/or usability of these goods and services.

  • Page 9: 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 10: 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 measures. 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 11: Highlighting Of Texts And Images

    1.7 Contact and source of supply Only use original spare parts or spare parts approved by ®  PRESSOTECHNIK. ®  PRESSOTECHNIK GmbH & Co. KG Riedstraße 4 88250 Weingarten / Germany Tel. +49 (0) 751/5007-767 E-Mail: info@tox-de.com For additional information and forms see www.tox.com TOX_Manual_Powerpackage_line-X_en...

  • Page 12: Safety

    Safety 2 Safety 2.1 Basic safety requirements The product is state of the art. However, operation of the product may involve 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 13: Selection And Qualifications Of Personnel

    Ÿ Do not make any changes, carry out attachments or conversions to the product without the written approval of TOX ®  PRESSOTECHNIK. Action contrary to the above will not be covered by the warranty or the operating approval.

  • Page 14: Fundamental Hazard Potential

    Safety 2.3 Fundamental hazard potential Fundamental hazard potentials exist. The specified examples draw attention to known hazardous situations, but are not complete and do not in any way pro- vide safety and risk awareness action in all situations. 2.3.1 Electrical hazards Attention should be paid to electrical hazards particularly inside the components in the area of all assemblies of the control system and motors of the installation.

  • Page 15: Contusions

    Safety Ÿ Do not exceed the permissible pressure. Ÿ First switch on compressed air when all hose connections have been estab- lished 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 product.

  • Page 16: Laser

    Safety The following applies generally: Ÿ Wear protective anti-vibration gloves when performing necessary work! Ÿ Electromagnetic fields can have an indirect effect on heart pacemakers and other implants. Adhere to safety distances. 2.3.7 Laser Depending on the model and features, lasers can be installed for the purpose of recognition.

  • Page 17: Lithium Ion Battery

    Safety 2.3.10 Lithium ion battery Lithium ion (Li-Ion) batteries are a hazardous material. The following safety requirements apply for handling: Ÿ Check the battery before use for damage. Damaged Li-Ion batteries must no longer be used or charged. Ÿ Do not drop batteries, throw them, subject them to shocks or other mechan- ical stress, which could lead to damaging the batteries.

  • Page 18: About This Product

    About this product 3 About this product 3.1 Intended use The hydropneumatic drive performs the strokes that are generally defined as fast approach stroke, power stroke and return stroke. The drive is intended for installation in machines or robot tongs with the following technical applications: Ÿ...

  • Page 19: Safe And Correct Design And Construction

    Ÿ The dynamic forces must at no time exceed the maximum admissible (static) press forces in the direction of pressure and tension. These are specified for every drive of TOX ®  PRESSOTECHNIK. Ÿ Dynamic forces must be limited with suitable precautionary measures to en- sure that the admissible (static) press forces are not exceeded.

  • Page 20: Product Identification

    About this product Ÿ Incorrect parameterization. Ÿ Execution of activities by persons who are not qualified or authorized to do The operating company is exclusively responsible for all personal injury and property damage resulting from non-intended use. Non-intended use will not be covered by the warranty or the operating approval.

  • Page 21: Function Description Of Tox

    About this product ® 3.3 Function description of TOX Powerpackage with pressure regulator pneumatic spring The drive works with a pneumatically operated cylinder with pneumohydraulic power stroke. At the same time, a closed oil cylinder and valve system is driven with compressed air, which is controlled in the same way as a double-acting pneumatic cylinder.
  • Page 22 About this product Pneumatically operated fast approach stroke Return stroke chamber Working piston Power stroke valve Power stroke chamber Intensifier piston Pressure valve (pneumatic spring) Storage piston Plunger High-pressure chamber Fast approach stroke chamber Main control valve Fig. 2 Fast approach stroke Ÿ...
  • Page 23 About this product Pneumohydraulic power stroke Return stroke chamber Working piston Power stroke valve Power stroke chamber Intensifier piston Pressure valve (pneumatic spring) Storage piston Plunger High-pressure chamber Fast approach stroke chamber Main control valve Fig. 3 Power stroke Ÿ Compressed air from the forward stroke connection penetrates into the power stroke chamber of the intensifier piston via a connection line.
  • Page 24 About this product Return stroke Return stroke chamber Working piston Power stroke valve Power stroke chamber Intensifier piston Pressure valve (pneumatic spring) Storage piston Plunger High-pressure chamber Fast approach stroke chamber Main control valve Fig. 4 Return stroke Ÿ The main control valve is switched over to return stroke by a signal. The re- turn stroke chamber is being filled with compressed air.

  • Page 25: Product Overview Of Tox Powerpackage Line-X

    About this product ® 3.4 Product overview of TOX Powerpackage line-X Working piston Compressed air supply return stroke [2] Control throttle 'X' Compressed air supply fast approach stroke [4] Oil filling nipple Pressure valve (pneumatic spring) with compressed air supply for permanent air...

  • Page 26: Product Overview Of Tox ® Powerpackage With Integrated Damping Function

    About this product 3.5 Optional equipment 3.5.1 Product overview of TOX ® Powerpackage with integrated damping function ZED High pressure measuring con- Oil filling nipple nection Electric switch-over valve for fast Compensation line for reservoir approach stroke/damping stroke (yellow) Hydraulic return stroke line...

  • Page 27: Powerpackage With Cutting Impact Damping Zsd

    About this product ® 3.5.2 Product overview of TOX Powerpackage with cutting impact damping ZSD Fig. 7 Product overview of TOX ® Powerpackage with cutting impact damping ZSD Product attributes of Powerpackage with cutting impact damping Type X-KSD Additional characteristics of type X-K Ÿ...

  • Page 28: Product Overview And Product Attributes Of Tox

    The oil pressure cannot be used as signal for the return stroke. To switch over from power stroke to return stroke, a distance-dependent signal must be selected. Ÿ Equipped with pressure control valve (pneumatic spring). 3.5.3 Product overview and product attributes of TOX ® Powerpackage with integrated holding brake ZSL Fig. 8...

  • Page 29: Additional Optional Equipment

    Replaces the existing power stroke valve with one of the next size. Pressing force sensor Ÿ Measures the press forces in the direction of the pres- sure. For optional equipment, see data sheet and brochure TOX ® Powerpackage. http://tox-pressotechnik.com/ TOX_Manual_Powerpackage_line-X_en...

  • Page 30: Product Planning

    About this product 3.6 Product planning 3.6.1 Design data Data sheet For technical data and installation dimensions see data sheet. (http://www.tox-pressotechnik.de) 3.6.2 Design principles Ÿ When fastening, note the following: – Installation dimensions – Weight, including weight of the accessories –...

  • Page 31: Air Consumption

    About this product 3.6.3 Air consumption Ÿ For the air consumption, the fast and return stroke are calculated with the available air pressure. Ÿ The air requirement in the power stroke is calculated depending on the re- quired press force. For example, this depends on when the required oil pressure is reached.

  • Page 32: Cycle Times

    About this product 3.6.4 Cycle times The cycle time is calculated depending on the required press force. The follow- ing applies: Ÿ The smaller the effective press force, the shorter the cycle time. Ÿ An effective press force over 90 % should be avoided. Ÿ...

  • Page 33: Performance Optimization

    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 TOX Powerpackage. The following applies: Ÿ...
  • Page 34 About this product 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.

  • Page 35: Stroke Limitation Of The Power Stroke

    About this product 3.6.7 Stroke limitation of the power stroke For applications that require a fixed end stop, the total stroke of the drive can be limited. For punch applications a limiting the travel of the power stroke must take place. The travel of the power stroke must be limited to a maximum of 80%.

  • Page 36: Power Limit Of The Power Stroke

    About this product 3.6.8 Power limit of the power stroke It is possible to monitor the press force of the power stroke by connecting an oil pressure switch or an oil pressure monitor. Upon reaching the desired press force, the return stroke must be induced. The press force can be reduced permanently by installing a pressure control in the power stroke line.

  • Page 37: Horizontal Installation Type K And Z

    About this product 3.6.11 Horizontal installation Type K and Z Working part Intensifier Bracket Bow (machine) Horizontal assembly with stand- Horizontal assembly with hang- ing intensifier ing intensifier Fig. 10 Horizontal installation For horizontal installation type K, Z the following applies: Ÿ...

  • Page 38: Holding Brake (Assembly Zsl)

    About this product 3.6.12 Holding brake (Assembly ZSL) The following applies for the installation and use of the holding brake (ZSL): Ÿ The holding brake serves exclusively for the mechanical safety of a tool up to the maximum admissible load (see type plate). Ÿ...

  • Page 39: Activation And Pressure Control

    About this product 3.7 Activation and pressure control 3.7.1 Design principles of activation A distance-dependent external power stroke switch is recommendable: Ÿ For a piston rod working upwards. Ÿ In the case of a heavy tool weight. Ÿ In the case of fast approach stroke travel that is interrupted on account of the application (e.g.

  • Page 40: Activation According To Dynamic Pressure Method

    About this product 3.7.2 Activation according to dynamic pressure method If the working piston meets a counterforce during the fast approach stroke, it stops and the dynamic pressure acting on the piston surface falls. The power stroke valve switches and the intensifier piston is impinged with compressed air. The changeover time is controlled and adjusted with the control throttle X.
  • Page 41 About this product Assembly Power stroke valve Power stroke output Power stroke signal Control connection Muffler output Power stroke input Control connection Pressure valve (pneumatic spring) Fast stroke support Pneumatic spring switch-off (type X-K 75/X-K 100 only) Control throttle 'X' Drive (example type X-S) Plunger return stroke input Reservoir input...
  • Page 42 About this product Powerpackage with pneumatic spring cut-out in power stroke line For the pneumatic spring switch-off, a valve is mounted between connection [8] of drive connection [3] of the fast stroke support and connection [2] of the fast stroke support. The valve is connected to connection [6.1] of the power stroke valve.

  • Page 43: Pressure Control In The Power Stroke Line (Assembly Zdk) (Optional)

    About this product Assembly Plunger return stroke input Reservoir input Fast approach stroke output Control throttle 'X' output Return stroke input Fast approach stroke input High pressure measuring connection Power stroke input To be carried out by the customer: Compressed air supply and maintenance unit (not included in delivery) Pneumatic spring switch-off (with standard only for type X-K 75/ X-K 100)
  • Page 44 About this product Powerpackage with pressure valve (pneumatic spring) ‘X‘ 5 1 3 Fig. 13 Pressure control in the power stroke line (assembly ZDK) Assembly Power stroke valve Power stroke output Power stroke signal Control connection Muffler output Power stroke input Control connection Pressure valve (pneumatic spring) Fast stroke support...

  • Page 45: Pressure Control In The Power Stroke Line With Proportional Pressure Control Valve (Optional)

    About this product Assembly Plunger return stroke input Reservoir input Fast approach stroke output Return stroke output Return stroke input Fast approach stroke input High pressure measuring connection Power stroke input To be carried out by the customer: Compressed air supply and maintenance unit (not included in delivery) 3.7.4...

  • Page 46: External Power Stroke Switch (Assembly Zkhz) (Optional)

    About this product Assembly Power stroke valve Power stroke output Power stroke signal Control connection Muffler output Power stroke input Control connection Pressure valve (pneumatic spring) Fast stroke support Electrical proportional valve Fast approach stroke input Power stroke output Control throttle 'X' Drive (example type X-S) Plunger return stroke input Reservoir input...
  • Page 47 About this product Powerpackage with pressure valve (pneumatic spring) 5 1 3 Fig. 15 External power stroke switch (subassembly ZKHZ) Assembly Power stroke valve Power stroke output Power stroke signal Control connection Muffler output Power stroke input Control connection Pressure valve (pneumatic spring) Fast stroke support Power stroke switch valve Muffler output...

  • Page 48: External Power Stroke Deactivation (Assembly Zkhd) (Optional)

    About this product Assembly Plunger return stroke input Reservoir input Fast approach stroke output Return stroke output Return stroke input Fast approach stroke input High pressure measuring connection Power stroke input To be carried out by the customer: Compressed air supply and maintenance unit (not included in delivery) 3.7.6...
  • Page 49 About this product Powerpackage with pressure valve (pneumatic spring) ‘X‘ 5 1 3 Fig. 16 External power stroke deactivation (assembly ZKHD) Assembly Power stroke valve Power stroke output Power stroke signal Control connection Muffler output Power stroke input Control connection Pressure valve (pneumatic spring) Fast stroke support Electrical switching valve Input (release)

  • Page 50: External Power Stroke Release (Assembly Zkhf) (Optional)

    About this product Assembly Control throttle 'X' Drive (example type X-S) Plunger return stroke input Reservoir input Fast approach stroke output Return stroke output Return stroke input Fast approach stroke input High pressure measuring connection Power stroke input To be carried out by the customer: Compressed air supply and maintenance unit (not included in delivery) 3.7.7...
  • Page 51 About this product Powerpackage with pressure valve (pneumatic spring) ‘X‘ 5 1 3 Fig. 17 External power stroke release (assembly ZKHF) Assembly Power stroke valve Power stroke output Power stroke signal Control connection Muffler output Power stroke input Control connection Pressure valve (pneumatic spring) Fast stroke support Electrical switching valve Input (release)

  • Page 52: External Power Stroke Supply (Optional)

    About this product Assembly Control throttle 'X' Drive (example type X-S) Plunger return stroke input Reservoir input Fast approach stroke output Return stroke output Return stroke input Fast approach stroke input High pressure measuring connection Power stroke input To be carried out by the customer: Compressed air supply and maintenance unit (not included in delivery) 3.7.8...
  • Page 53 About this product Powerpackage with pressure valve (pneumatic spring) ‘X‘ 5 1 3 Fig. 18 External power stroke supply (optional) Assembly Power stroke valve Power stroke output Power stroke signal Control connection Muffler output Power stroke input Control connection Pressure valve (pneumatic spring) Control throttle 'X' Drive (example type X-S) TOX_Manual_Powerpackage_line-X_en...

  • Page 54: Adjustable Damping (Assembly Zed) (Optional)

    About this product Assembly Plunger return stroke input Reservoir input Fast approach stroke output Return stroke output Return stroke input Fast approach stroke input High pressure measuring connection Power stroke input To be carried out by the customer: Compressed air supply and maintenance unit (not included in delivery) 3.7.9...
  • Page 55 About this product 1V62 1V61 ZED-1 ZED-2 X-SD / ELD with ZED 5 1 3 Fig. 19 Adjustable damping ZED (optional) Assembly Power stroke valve Pressure valve (pneumatic spring) Fast stroke support External power stroke connection 1V61 Manual flow control valve 1V62 Electric proportional flow control valve (optional) Damping On / Off...

  • Page 56: Integrated Cutting Impact Damping (Module Zsd) (Option)

    About this product 3.7.10 Integrated cutting impact damping (module ZSD) (option) The cutting impact damping dampens the working piston when the counterforce is removed, e.g. for punching applications. As pure mechanical damping, it can also be used with limitations as stroke damping. 12<->1 1V61 ÖL...
  • Page 57 About this product Assembly Drive To be carried out by the customer: Compressed air supply and maintenance unit (not included in delivery) TOX_Manual_Powerpackage_line-X_en...

  • Page 58: Technical Data

    No guarantee for use in environments with strongly corrosive environmental conditions such as increased salt content (maritime climate), cleaning with corrosive cleaning agents, or the use of high-pressure cleaners. If the drives are used in a corrosive environment, TOX ®  PRESSOTECHNIK can supply drives in corrosion-protected design.

  • Page 59: Compressed Air Quality And Pneumatic Connection

    Class [°C] Class [mg/m3] 4.4.1 Pneumatic connection, air pressure, oil pressure See data sheet. www.tox.com Separate compressed air supply for the permanent air supply of pressure valve (pneumatic spring): Ÿ Default setting: P 0.8 bar Ÿ Minimum supply pressure of pressure valve: P = 2.5 bar.

  • Page 60: Tightening Torques On The Piston Rod

    Technical data 4.5.2 Tightening torques on the piston rod Tool coupling Piston rod thread Tightening torque ZWK 001 M12 x 1.5 10 Nm ZWK 002 M16 x 1.5 15 Nm ZWK 004 M22 x 2.0 40 Nm ZWK 008 M30 x 2.0 180 Nm ZWK 015 M30 x 2.0 210 Nm...
  • Page 61 Due to the negative effects on maintenance intervals, swelling behavior and life- time of the seals in case of the use of hydraulic oils that have not been ap- proved as standard, the granted warranty becomes extinct. è Use hydraulic oils that have bee approved by TOX ®  PRESSOTECHNIK as standard.

  • Page 62: 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 trans- portation and falling load! è Only use lifting gear that is appropriate and in perfect technical condition, as well as load attachment devices with an adequate safe working load.

  • Page 63: Lifting Device

    Ÿ Store the product only in closed, dry, dust-free and dirt-free rooms at room temperature. 5.4 Dispatch for repair To dispatch the product for repair to TOX ®  PRESSOTECHNIK, please proceed as follows: Ÿ Fill in the "Accompanying repair form". This we supply in the service sector on our website or upon request via e-mail.

  • Page 64: Installation

    Installation 6 Installation Safety during installation The installation may only be carried out by trained and authorized personnel. DANGER Electrical hazards in case of contact with live parts! Electric shock, burns or death in case of contact with live parts! è...

  • Page 65: 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 ap- propriate lifting gear.   Place and align drive on the fastening element provided. 2.

  • Page 66: Installing Optional Accessories

    Installation 6.3 Installing optional 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 67 Installation ü Make sure that the system is depressurized and disconnected from the power supply. ü Observe the tightening torques. Tightening torques, Page 1. Install assembly holder of pressure switch on the drive. Make sure that dis- play and operating elements are easily accessible. 2.

  • Page 68: Installing And Setting Position Sensors Of Stroke Monitoring For Forward And Return Stroke (Zhu)

    Installation 6.3.2 Installing and setting position sensors of stroke monitoring for forward and return stroke (ZHU) Fig. 21 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 69 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.

  • Page 70: Installing The External Linear Position Sensor (Zhw)

    Installing the external linear position sensor (ZHW) Material required: Prerequisite for the installation of the external linear position sensor: - TOX ® 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 71 Installation ü The operating manual of the linear position sensor is available. NOTE Risk of damage to the device due to incorrect installation and connection! è The specifications of the operating manual of the manufacturer are to be adhered to. 1.

  • Page 72: Installing Pressure Control In The Power Stroke Line (Zdk)

    Installation 6.3.4 Installing pressure control in the power stroke line (ZDK) Fig. 22 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 con- nection [12]) TOX_Manual_Powerpackage_line-X_en...
  • Page 73 Installation ü For connections see Pressure control in the power stroke line (assembly ZDK) (optional), Page 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 74: Installing Proportional Pressure Control Valve In The Power Stroke Line

    Installation 6.3.5 Installing proportional pressure control valve in the power stroke line Fig. 23 Installing proportional pressure control valve in the power stroke line Material required: Ÿ Proportional pressure control valve Ÿ Screw plug with collar, size M 5 (laterally on power stroke valve next to con- nection [12]) ü...

  • Page 75: Installing External Power Stroke Connection (Zkhz)

    Installation 6.3.6 Installing external power stroke connection (ZKHZ) Fig. 24 Installing external power stroke connection (ZKHZ) Material required: Ÿ Electrical switching valve power stroke switch (ZKHZ) Ÿ Screw plug ü For connections see External power stroke switch (assembly ZKHZ) (op- tional), Page 1.

  • Page 76: Installing External Power Stroke Release (Zkhf) And Power Stroke Deactivation (Zkhd)

    Installation 6.3.7 Installing external power stroke release (ZKHF) and power stroke deactivation (ZKHD) Fig. 25 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...

  • Page 77: Preparing External Power Stroke Supply

    Installation 6.3.8 Preparing external power stroke supply Fig. 26 Preparing external power stroke supply Material required: Ÿ Screw plug M 5 with collar (laterally on power stroke valve next to connec- tion [12]) ü For connections see External power stroke supply (optional), Page 1.

  • Page 78: Installing The Stroke Frequency Optimization (Zho)

    Installation 6.3.9 Installing the stroke frequency optimization (ZHO) Installing the stroke frequency optimization (ZHO) for drive with integrated power stroke valve Optimization of stroke frequency Slide valve (ZHO) Plug Circlip Fig. 27 Installing the stroke frequency optimization ZHO Material required: Ÿ Stroke frequency optimization (ZHO) for drive with integrated power stroke valve Ÿ...
  • Page 79 Installation Installing the stroke frequency optimization (ZHO) for drive with external power stroke valve Fig. 28 Installing the stroke frequency optimization ZHO Material required: Ÿ Installing the stroke frequency optimization (ZHO) for drive with external power stroke valve Ÿ Pneumatic supply line including all series-connected valves in the size fit- ting to the connections.

  • Page 80: Installing The Speed Reduction For Power Stroke Venting

    Installation 6.3.10 Installing the speed reduction for power stroke venting Fig. 29 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.

  • Page 81: Installing Tool Coupling (Zwk)

    Lubricating grease (Klübersynth UH1 14-151 or a technically comparable one) ü Technical data, dimensions are observed. See data sheet, or type sheet at www.tox.com. 1. Install the tool holding fixture on the thread of the working piston. Observe tightening torques. Tightening torques on the piston rod, Page 2.

  • Page 82: Commissioning

    Commissioning 7 Commissioning 7.1 Safety during the commissioning The commissioning may only be carried out by trained and authorized person- nel. The following applies: Ÿ Make sure that that no persons are located within the danger area of the machine. Ÿ...

  • Page 83: 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 installed complies with the requirements of the Machinery Directive (2006/42/EC). The requirements are: Ÿ...

  • Page 84: Setting Control Throttle 'X

    è Check the firm seating of the pneumatic screw fittings. è For pneumatic screw fittings on the TOX ® Powerpackage, see: Tightening torques of pneumatic screw fittings on the Powerpackage, Page 7.3 Setting control throttle 'X'...
  • Page 85 Commissioning ü Working piston is retracted. ü Compressed air supply is switched on. 1. Close control throttle 'X' when piston is retracted and impinged by turning clockwise. 2. Extend working piston rod. 3. Open control throttle 'X' slowly by turning counterclockwise until the power stroke is noticeably activated on meeting a counterforce.

  • Page 86: Setting Speed Ratio Of Return Stroke To Fast Approach Stroke

    Commissioning 7.4 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.

  • Page 87: Setting The (Zed) Damping (Optional)

    Commissioning 7.6 Setting the (ZED) damping (optional) Fig. 32 Setting (ZED) damping (optional) TOX_Manual_Powerpackage_line-X_en...
  • Page 88 Commissioning The integrated damping function allows a selectable, adjustable constant speed of the working piston during the fast approach stroke and power stroke, independent of the respective working forces. This makes it is possible to almost fully compensate the acceleration of the working piston when the counterforce is removed (during punching) or also a stick-slip- effect (during pressing in.
  • Page 89 Commissioning Ÿ Activation of damping during the fast approach stroke for a soft placement on the piece part (Soft Touch) Activation of damping during the fast approach stroke. – Damping can be activated already via an external distance signal. – For a smooth contact with the piece part, the response time of the sole- noid valve (1V8) listed in the data sheet and the response distance trav- eled by the working piston during this time must be taken into consider-...

  • Page 90: Setting Cutting Impact Damping (X-Ksd) (Optional)

    Commissioning 7.7 Setting cutting impact damping (X-KSD) (optional) Setting the damping effect WARNING Bursting, flying parts and ejecting oil due to excessive oil pressure! Severest injuries to eyes, body cavities and all over the body! è The oil pressure at the cutting impact damping (X-KSD) must not exceed 450 bar at closed damping.

  • Page 91: Setting The Proximity Sensors Of The Holding Brake (Zsl) (Optional)

    Commissioning 7.8 Setting the proximity sensors of the holding brake (ZSL) (optional) Fig. 33 Setting the proximity sensors of the holding brake Holding fixture for sensor "Lock loos- Holding fixture for sensor "Load se- ened" [B] cured" [A] "Loosen" pressure connection [L] "Pressure compensation"...
  • Page 92 Commissioning Material required: Ÿ 2 Proximity switch, inductive: External thread: M 12 x 1 / Ø 12 mm Closing function Nominal distance: 2 mm, can be installed flush The connections are marked permanently. The position of the connections can vary depending on the model. TOX_Manual_Powerpackage_line-X_en...
  • Page 93 Commissioning NOTE Destruction of sensors! Sensors that are screwed too deep into the holding fixture for sensor "Lock loosened" [B], are destroyed when the locking head is activated! è Ensure that the sensors are seated correctly. è Observe the operating instructions of the holding brake. 1.

  • Page 94: Check The Holding Force Of The Holding Brake

    Commissioning 7.9 Check the holding force of the holding brake In the installed state the holding force of the holding brake must have a safety reserve of at least the 1.5-fold of the existing load. WARNING Risk of injury due to a non-functioning holding brake! è...

  • Page 95: 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 oper- ation. CAUTION Noise during operation! Hearing impairment! è Wear individual protective equipment. CAUTION Hazard from flying parts! Injuries to eyes and body cavities!

  • Page 96: Requirements For Operation

    Operation 8.2 Requirements for operation Ÿ The safety devices of the entire machine are properly assembled and func- tional. 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 complied with.

  • Page 97: Troubleshooting

    Troubleshooting 9 Troubleshooting 9.1 Safety during troubleshooting Troubleshooting may only be carried out by trained and authorized personnel. Ÿ Make sure that that no persons are located within the danger area of the machine. TOX_Manual_Powerpackage_line-X_en...

  • Page 98: Searching For Causes Of Fault On The Powerpackage

    Troubleshooting 9.2 Searching for causes of fault on the Powerpackage Fault Possible cause Measure Piston rod does not extend. Tool jams. Mechanically decouple the Powerpackage and check ease of Guiding columns are jammed. movement by 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 99 Troubleshooting Fault Possible cause Measure Frequent refilling of hydraulic Speed ratio of fast approach stroke to Setting speed ratio of return stroke to oil is necessary. return stroke is set incorrectly. fast approach stroke, Page Contact authorized service personnel. Speed ratio of power stroke and power Set the speed ratio between power stroke venting is set incorrectly.
  • Page 100 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. Maintenance cycle Additional information according to counter (flexible) 10.5 Refilling oil and venting drive 10.6.1 Refilling oil and venting drive with integrated damping function ZED Weekly...

  • Page 101: Maintenance

    Maintenance 10 Maintenance 10.1 General information Maintenance may only be carried out by trained and authorized personnel. The following applies: Ÿ Observe maintenance intervals if present and stipulated. Ÿ Maintenance intervals may vary from the stipulated maintenance intervals. The maintenance intervals may have to be verified with the manufacturer if necessary.

  • Page 102: Safety During Maintenance

    Maintenance 10.2 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 Disconnect power supply.
  • Page 103 Maintenance NOTE Incorrect cleaning agents or cleaning procedures, lack of corrosion pro- tection! Damage to machine components! è Clean plastic parts such as panes (safety guard door, housing, etc.) and control elements with cotton cloths (smooth woven structure) and suitable cleaning agents (e.g.

  • Page 104: Requirements For Maintenance

    Maintenance 10.3 Requirements for maintenance 10.3.1 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 activated in maintenance position.

  • Page 105: Checking Oil Level

    Maintenance 10.4 Checking oil level Fig. 35 Checking oil level ü System is in maintenance position. Set system to maintenance position, Page 104. è Check needle of the oil level indicator. The needle of the oil level indicator is flush with the surface of the cylinder: Oil level is ok.

  • Page 106: Refilling Oil And Venting Drive

    Maintenance 10.5 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 Fig. 36 Refilling oil and venting drive Material required: Ÿ...
  • Page 107 Maintenance The top vent screws or the top HD measuring connections must be selected for the venting. Venting points according to installation position Installation position Type X-S Type X-K Vertical, working piston Vent screw 2 Vent screws 2, 4, 6, 5, 7 downward Vertical, working piston up- Vent screw 1...
  • Page 108 Maintenance ü System is in maintenance position. Set system to maintenance position, Page 104. 1. Remove venting plate with locking wire on the intensifier (X-ES). 2. Unscrew knurled cap of the oil filling nipple. 3. Vent filling hose of the oil pump. 4.
  • Page 109 Maintenance 19. Fasten locking wire. 20. NOTE! Device damage due to overfilling!  Lower oil level. Lowering of oil level, Page 115. TOX_Manual_Powerpackage_line-X_en...

  • Page 110: Refilling Oil And Venting The Drive Of Powerpackage With Optional Equipment

    Maintenance 10.6 Refilling oil and venting the drive of Powerpackage with optional equipment 10.6.1 Refilling oil and venting drive with integrated damping function ZED 9 11 Vent screw Vent screw Vent screw Vent screw Vent screw Vent screw High pressure measuring connection Oil filling nipple Oil level indicator Venting plate...
  • Page 111 Maintenance Installation position Type X-SD, ELD Type X-KD, EKD Ÿ Ÿ Vertical, working piston Vent screw 2 Vent screw 2, 3, 4, 5, 6, downward Ÿ Venting plate 11 Ÿ Venting plate 11 Ÿ Vent screws ZED 14, 15 Ÿ Vent screws ZED 14, 15 Ÿ...
  • Page 112 Maintenance NOTE Damage caused by trapped air! è Vent drive after filling with oil. è Use highest vent screw or high pressure measuring connection for venting. TOX_Manual_Powerpackage_line-X_en...
  • Page 113 Maintenance ü System is in maintenance position. Set system to maintenance position, Page 104. 1. Remove venting plate with locking wire on the intensifier (X-ES). 2. Unscrew knurled cap of the oil filling nipple. 3. Vent filling hose of the oil pump. 4.
  • Page 114 Maintenance 19. Fasten locking wire. 20. NOTE! Device damage due to overfilling!  Lower oil level. Lowering of oil level, Page 115. TOX_Manual_Powerpackage_line-X_en...

  • Page 115: Lowering Of Oil Level

    Maintenance 10.7 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 vol- ume "ΔV").

  • Page 116: Repairs

    Repairs 11 Repairs 11.1 Safety during repairs Repairs may only be carried out by trained and authorized personnel. 11.2 Changing seals Seals may only replaced by trained and authorized service personnel. TOX_Manual_Powerpackage_line-X_en...

  • Page 117: Disassembly And Disposal

    Disassembly and Disposal 12 Disassembly and Disposal 12.1 Safety during disassembly and disposal The dismantling and disposal may only be carried out by trained and authorized personnel. DANGER Electrical hazards in case of contact with live parts! Electric shock, burns or death in case of contact with live parts! è...

  • Page 118: Decommissioning

    Disassembly and Disposal 12.2 Decommissioning Decommissioning means that the plant is not in operation for a longer period 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 119: Disassembling

    TOX ®  PRESSOTECHNIK. For further information about the take-back and forms see www.tox.com in the service sector. Regarding questions about disposal please contact TOX ®  PRESSOTECHNIK GmbH &...
  • Page 120 Appendices 13 Appendices 13.1 DECLARATION OF INCORPORATION TOX_Manual_Powerpackage_line-X_en...
  • Page 123 Index Index Symbols (Safety lock of proximity sensors) Causes of fault .......... 98 Setting............ 91 Change (ZSD) Seal ............ 116 Cutting impact damping ...... 56 Changeover from power stroke to return stroke For Powerpackages with hydraulic damping .............. 36 Changeover of power stroke to return stroke Activation ZED ............ 36 Design principles ........
  • Page 124 Index Damping (ZED) Fast approach stroke ........ 22 Setting............ 87 Function description........ 21 Data sheet .............  30 Decommissioning ........ 118 Design data ...........  30 Gender note ............. 9 Design principles ...........  30 General information Design principles of activation .......  39 Maintenance.......... 101 Disassembly ........ 117, 119 Guidelines ............ 8 Safety............
  • Page 125 Index Product overview........ 28 Integrated holding brake ZSL Identification Product attributes ........ 28 Product .............  20 Intended use .......... 18 Images Highlighting .......... 11 Important information ........ 8 Laser Information Hazard............ 16 Important.............  8 Legal note ............ 8 Installation .............  64 Lifting device .......... 63 Accessories .......... 66 line-X Drive ............
  • Page 126 Index Performance optimization ...... 33 Refilling ...........  106, 110 Piston rod Oil leakage Tightening torques ........ 60 Avoiding ............  33 Pneumatic connection ........ 59 Oil level Pneumatic screw fittings on the Powerpackage Checking .......... 105 Tightening torques ........ 60 Lowering .......... 115 Position sensors of stroke monitoring for for- ward and return stroke (ZHU) Oil pressure Installing ............ 68...
  • Page 127 Index Qualifications .......... 13 Safe Construction .......... 19 Design ............ 19 Safety............. 12 Refilling Commissioning.......... 82 Oil ...........  106, 110 Disassembly .......... 117 Repair Disposal .......... 117 Dispatch ............  63 Installation .......... 64 Repairs ............ 116 Maintenance.......... 102 Safety............ 116 Operation .......... 95 Requirement Repairs ............ 116 Maintenance ...........  104 Transport ........... 62 Return stroke ..........
  • Page 128 Index Stroke frequency optimization (ZHO) for drive with integrated power stroke valve Installing............  78 Pressure regulation in power stroke line ... 43 Stroke limitation Power stroke .......... 35 Installing ............ 66 Adjustable damping........ 54 Target group ............  9 Product overview........ 26 Technical data .......... 58 Technical design data ........

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Powerpackage line-x-k series

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