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TOX X Series Original Operating Instructions

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

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  • Page 1 Original operating instructions ® Powerpackage line-X Type X-KT ® 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 ................ 11 1.6.3...
  • Page 3 Product overview and product attributes of Powerpackage KT System .. 26 3.4.1 Product overview of TOX ® Powerpackage X-KT system...... 26 3.4.2 Product overview and product attributes of TOX ® Powerpackage type X-AT, X-ATD ...................... 27 3.4.3 Product overview and product attributes of TOX ®...
  • Page 4 Table of contents 3.7.2 Design principles of activation .............. 46 Technical data Type sheet and data sheet ................ 47 General environmental conditions ............. 47 Ambient temperature ................. 47 Compressed air quality and pneumatic connection ........ 48 4.4.1 Pneumatic connection, air pressure, oil pressure........ 48 Tightening torques .................. 48 4.5.1 Tightening torques for flange mounting the drive ........ 48 4.5.2...
  • Page 5 Table of contents 6.5.4 Installing pressure control in the power stroke line (ZDK) ...... 66 6.5.5 Installing proportional pressure control valve in the power stroke line .. 68 6.5.6 Installing external power stroke connection (ZKHZ) ........ 69 6.5.7 Installing external power stroke release (ZKHF) and power stroke deactiva- tion (ZKHD).................... 70 6.5.8 Preparing external power stroke supply ............ 71...
  • Page 6 Table of contents Troubleshooting Safety during troubleshooting .............. 96 Searching for causes of fault on the Powerpackage ......... 97 Maintenance table of Powerpackage Maintenance 10.1 General information ................. 100 10.2 Safety during maintenance .............. 100 10.3 Requirements for maintenance.............. 102 10.3.1 Set system to maintenance position ............ 102 10.4 Checking oil level.................. 103 10.5...
  • Page 7 Table of contents Disassembly and Disposal 12.1 Safety during disassembly and disposal.......... 121 12.2 Decommissioning .................. 122 12.3 Shutdown.................... 122 12.4 Disassembling .................. 123 12.5 Disposal .................... 123 Appendices 13.1 DECLARATION OF INCORPORATION.......... 124 Index TOX_Manual_Powerpackage_line-X_X-KT_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: 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 12: Contact And Source Of Supply

    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_X-KT_en...

  • Page 13: 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 14: 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 15: 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 16: 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 17: Electromagnetic Hazards

    Safety 2.3.6 Electromagnetic hazards Electromagnetic hazards are to be taken into account in the area of electromag- netically vibrating or oscillating components. Regular work on and with electromagnetically vibrating or oscillating compo- nents can cause disorders in the blood flow of the fingers as well as neurologi- cal and motoric dysfunctions.

  • Page 18: Noise

    Safety 2.3.9 Noise Depending on the equipment, an increase in the noise level can arise in the sphere of the product. Ÿ Keep the duration of the exposure at a minimum. Ÿ Wear individual protective equipment. 2.3.10 Lithium ion battery Lithium ion (Li-Ion) batteries are a hazardous material.

  • Page 19: 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 20: 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 21: 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 22: 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 23 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 24 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 25 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 26: Product Overview And Product Attributes Of Powerpackage Kt System

    About this product 3.4 Product overview and product attributes of Powerpackage KT System ® 3.4.1 Product overview of TOX Powerpackage X-KT system X-ES X-AT HZL / HZO Return stroke line Compressed air supply return stroke [2] Pneumatic OR valve (fast stroke support)

  • Page 27: Powerpackage Type X-At, X-Atd

    Ÿ Prepared for external linear position sensor Optional: integrated linear position sensor ZKW. ZHW (up to and including X-AT 30). ® 3.4.2 Product overview and product attributes of TOX Powerpackage type X-AT, X-ATD X-ATD X-AT Fig. 6 Product overview of TOX Powerpackage type X-AT, X-ATD ®...
  • Page 28 About this product ® Product attributes of TOX Powerpackage type X-AT, X-ATD 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 Manually adjustable flow control...

  • Page 29: Powerpackage Type At, At 51, Atsd, Atw

    About this product ® 3.4.3 Product overview and product attributes of TOX Powerpackage type AT, AT 51, ATSD, ATW ATSD AT 51 Fig. 8 Product overview of TOX ® Powerpackage type AT, AT 51, ATSD, ATW ® Product attributes of TOX...

  • Page 30: Powerpackage With Integrated Holding Brake Zsl

    About this product ® 3.4.4 Product overview and product attributes of TOX Powerpackage with integrated holding brake ZSL X-ATSL Fig. 9 Product overview of TOX ® Powerpackage with integrated holding brake ZSL ® Product attributes of TOX Powerpackage with integrated holding...

  • Page 31: Product Overview And Product Attributes Of Tox

    About this product ® 3.4.5 Product overview and product attributes of TOX Powerpackage type HZL, HZL 51, HZL - pulling, HZLW HZL 51 HZLW Fig. 10 Product overview of TOX Powerpackage type HZL, HZL 51, HZL - pulling, HZLW ® Product attributes of TOX ®...

  • Page 32: Product Overview Of Tox Powerpackage Type Rzhl, Rzhlw

    About this product ® 3.4.6 Product overview of TOX Powerpackage type RZHL, RZHLW RZHLW RZHL Fig. 11 Product overview of TOX Powerpackage type RZHL, RZHLW ® TOX_Manual_Powerpackage_line-X_X-KT_en...

  • Page 33: Product Overview And Product Attributes Of Hydrosplit Coupling Zhk

    About this product ® Product attributes of TOX Powerpackage type RZHL, RZHLW Characteristics Ÿ For use in robot tongs and machine tongs. Ÿ For the return stroke the hydraulic cylinder is impinged with compressed air. Type RHZL (additional characteristics) Ÿ...
  • Page 34 Hydrosplit coupling ZHK, with electrically switchable valve Type: ZHK 018.001, ZHK 020.001 ® With the electrically switchable TOX - hydrosplit couplings type ZHK, the hy- draulic lines of the connected working cylinders AT/X-AT or HZL can be switched on and off with an integrated pneumatic cylinder.
  • Page 35 About this product Specification / Technical data Ÿ Operating voltage:24 V / DC Ÿ Power consumption: 4.4 W Ÿ Weight approx.: 7.5 kg Ÿ Closing force of spring pressureless: 160 N Ÿ Min. switching pressure: 3 bar Ÿ Max. switching pressure: 10 bar Ÿ...

  • Page 36: Product Overview And Product Attributes Of Hydraulic Hose Lines

    The hydraulic hoses are dimensioned in the factory so that adherence to the maximum admissible operating pressure requires no additional measures such as re-mantling with additional protective hoses are necessary. However, for TOX ®  PRESSOTECHNIK all hydraulic hoses are supplied with an...

  • Page 37: 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_X-KT_en...

  • Page 38: 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 39: 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 40: 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 41: Performance Optimization

    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 TOX ® Powerpackage.
  • Page 42 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 43: 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 44: 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 45: Holding Brake (Assembly Zsl)

    About this product 3.6.11 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 46: Activation And Pressure Control

    About this product 3.7 Activation and pressure control 3.7.1 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.

  • Page 47: 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. Ÿ...

  • Page 48: Compressed Air Quality And Pneumatic Connection

    Class [μm] Class [°C] Class [mg/m3] 4.4.1 Pneumatic connection, air pressure, oil pressure See data sheet. www.tox.com Ÿ Default setting: P 0.8 bar Ÿ Minimum supply pressure of pressure valve: P = 2.5 bar. 4.5 Tightening torques 4.5.1 Tightening torques for flange mounting the drive Prescribed tightening torques for fastening screws of property class ISO 4762-12.9:...

  • Page 49: 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 50: Tightening Torques Of Pneumatic Screw Fittings On The Powerpackage

    Technical data 4.5.4 Tightening torques of pneumatic screw fittings on the Powerpackage The specified tightening torques only apply to pneumatic screw fittings on the Powerpackage. Connecting thread Tightening torque 1/8" 10 Nm 1/4" 15 Nm 3/8" 25 Nm 1/2" 30 Nm 4.5.5 Tightening torques for hydraulic screwings Connecting thread Tightening torque 3/8"...

  • Page 51: Press Force Table

    Technical data Hydrosplit coupling ZHK, with electrically switchable valve Type: ZHK 018.001, ZHK 020.001 Type Screws Pos. 5 Screws Pos. 6 Screws Pos. 7 Hydraulic lineconnection ZHK 018.001 M 8 / 27 kN M 10 / 60 kN 10 Nm G 3/4"...
  • Page 52 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 53: 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 54: 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 55: 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 56: 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 57: Connecting And Separating Hydrosplit Coupling

    Installation 6.3 Connecting and separating hydrosplit coupling Coupling part hose Coupling part installer Fixing lid (do not open!) Vent screw Fastening screws housing Fastening screws ES Valve stern /Screws (opening / closing) Fig. 17 Hydrosplit coupling Type Screws Pos. 5 Screws Pos. 6 Screws Pos.
  • Page 58 Installation Hydrosplit coupling separating NOTE Seal damage due to overpressure During the separating of the hydrosplit coupling overpressure can be generated in the coupling which might damage the seals. è Before dividing the hydrosplit coupling you must first close the coupling part on the hose side.

  • Page 59: Installing Hydraulic Hose Lines

    Installation 6.4 Installing hydraulic hose lines If hydraulic components are installed in the system, the requirements and na- tional legal provisions must be adhered to. For example, in Germany the following requirements are stated according to BG-Regulation 237 For the direct mounting of hydraulic components, only hydraulic screw fittings with elastomer flat seals are permitted to be used.

  • Page 60: Installing Optional Accessories

    Installation 6.5 Installing optional accessories 6.5.1 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 61 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 62: Installing And Setting Position Sensors Of Stroke Monitoring For Forward And Return Stroke (Zhu)

    Installation 6.5.2 Installing and setting position sensors of stroke monitoring for forward and return stroke (ZHU) Fig. 19 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 63 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 64: 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 65 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 66: Installing Pressure Control In The Power Stroke Line (Zdk)

    Installation 6.5.4 Installing pressure control in the power stroke line (ZDK) Fig. 20 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_X-KT_en...
  • Page 67 Installation ü For connections see Pressure control in the power stroke line (assembly 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 68: Installing Proportional Pressure Control Valve In The Power Stroke Line

    Installation 6.5.5 Installing proportional pressure control valve in the power stroke line Fig. 21 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 69: Installing External Power Stroke Connection (Zkhz)

    Installation 6.5.6 Installing external power stroke connection (ZKHZ) Fig. 22 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). 1.

  • Page 70: Installing External Power Stroke Release (Zkhf) And Power Stroke Deactivation (Zkhd)

    Installation 6.5.7 Installing external power stroke release (ZKHF) and power stroke deactivation (ZKHD) Fig. 23 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) Ÿ...

  • Page 71: Preparing External Power Stroke Supply

    Installation 6.5.8 Preparing external power stroke supply Fig. 24 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). 1.

  • Page 72: Installing The Stroke Frequency Optimization (Zho)

    Installation 6.5.9 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. 25 Installing the stroke frequency optimization ZHO Material required: Ÿ Stroke frequency optimization (ZHO) for drive with integrated power stroke valve Ÿ...
  • Page 73 Installation Installing the stroke frequency optimization (ZHO) for drive with external power stroke valve Fig. 26 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 74: Installing The Speed Reduction For Power Stroke Venting

    Installation 6.5.10 Installing the speed reduction for power stroke venting Fig. 27 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 75: 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 76: 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 77: Setting Control Throttle 'X

    Commissioning 7.3 Setting control throttle 'X' The control throttle 'X' is used to set the timing of the switchover from fast ap- proach stroke to power stroke, and must be readjusted for each application (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 approach stroke throttle.

  • Page 78: 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 79: Commissioning Hydrosplit Coupling Zhk

    Commissioning 7.6 Commissioning hydrosplit coupling ZHK 7.6.1 Commissioning hydrosplit coupling (manually switchable) Type: ZHK 018.000, ZHK 020.000, ZHK 042.000 Before the separating of the hydrosplit coupling ZHK, first the hose-side coupling part must be closed, otherwise overpressure can be generated in the coupling which might damage the seals.

  • Page 80: Commissioning Hydrosplit Coupling (With Electrically Switchable Valve)

    Commissioning 7.6.2 Commissioning hydrosplit coupling (with electrically switchable valve) Before the separating of the hydrosplit coupling ZHK, first the hose-side coupling part must be closed, otherwise overpressure can be generated in the coupling which might damage the seals. Maximum admissible operating pressure: 400 bar. Tightening torques, for hydraulic line connection see Tightening torque of hy- drosplit coupling ZHK, Page...
  • Page 81 Commissioning Control plan X-AT, AT ZHK 2 ZHK 1 Fig. 30 Control plan X-AT, AT hydrosplit coupling ZHK Control plan HZL ZHK 2 HZL 2 ZHK 1 HZL 1 TOX_Manual_Powerpackage_line-X_X-KT_en...
  • Page 82 Commissioning Signal sequence program Cylinder ZHK 1 V 1.1 V 1.2 Cylinder ZHK 2 V 2.1 V 2.2 Designation Designation Cylinder 1 Working cycle of drive ZHK 1 Switch position for cylinder 1 Signal off V 1.1 Valve Signal on V 1.2 Valve Forward stroke...
  • Page 83 Commissioning A forward or return stroke of the working cylinder at a closed hydrosplit coupling ZHK is not admissible. è Observe the enclosed control plans of the KT-system. è The hydrosplit coupling cannot be opened or closed during the power stroke.

  • Page 84: Setting Total Length Of Stroke (Optional)

    Commissioning 7.7 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. 32 Setting total length of stroke 1.

  • Page 85: Setting The (Zed) Damping (Optional)

    Commissioning 7.8 Setting the (ZED) damping (optional) Fig. 33 Setting (ZED) damping (optional) 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 86 Commissioning Function sequence and switching states 1V62 1V61 ZED-1 ZED-2 X-SD / ELD with ZED 5 1 3 The damping is set on the flow control valve (1V61 or 1V62). The electrically switchable solenoid valve (1V8) makes individual activation and deactivation of damping possible.
  • Page 87 Commissioning Ÿ Activation of damping during the power stroke – The power stroke must, for example, be activated via an external dis- tance signal electrically on valve (1V6). – Solenoid valve (1V8) switched off (0-active), so the oil flows through the flow control valve (1V61 or 1V62) and the damping effect begins.

  • Page 88: Setting Cutting Impact Damping (Zsd) (Optional)

    Commissioning 7.9 Setting cutting impact damping (ZSD) (optional) Cutting impact damping is set in 2 steps: Ÿ Setting the total length of stroke, Page Ÿ Setting the damping effect, Page 7.9.1 Setting the damping effect TOX_Manual_Powerpackage_line-X_X-KT_en...
  • Page 89 Commissioning ü The total stroke is set. Setting total length of stroke (optional), Page 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 (ZSD) must not exceed 450 bar at closed damping.

  • Page 90: Setting The Proximity Sensors Of The Holding Brake (Zsl) (Optional)

    Commissioning 7.10 Setting the proximity sensors of the holding brake (ZSL) (optional) Fig. 34 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 91 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_X-KT_en...
  • Page 92 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 93: Check The Holding Force Of The Holding Brake

    Commissioning 7.11 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 94: 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 95: 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 96: 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_X-KT_en...

  • Page 97: 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 98 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 99: Maintenance Table Of Powerpackage

    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 10.6.2...

  • Page 100: 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 101 Maintenance WARNING Dangerous machine movements! Serious contusions and injuries! è Make sure that that no persons are located in the danger area during oper- ation. NOTE Incorrect cleaning agents or cleaning procedures, lack of corrosion pro- tection! Damage to machine components! è...

  • Page 102: 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 103: Checking Oil Level

    Maintenance 10.4 Checking oil level Fig. 36 Checking oil level ü System is in maintenance position. Set system to maintenance position, Page 102. 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 104: Refilling Oil And Venting Drive

    Maintenance 10.5 Refilling oil and venting drive Oil filling nipple Oil level indicator High pressure measuring con- Vent screw (AT / X-AT) nection Venting plate ventilation hole po- Oil anti-overfill safety device sitioned below Vent screw (X-ES) Vent screw (ZHK) Vent screw (HZL) Fig. 37 Refilling oil and venting drive...
  • Page 105 Maintenance Venting point according to installation position: Installation position Venting points Type X-ES Venting points X-ES Vertical Venting plate 5 Hydrosplit coupling ZHK or hydraulic hose Vent screws 7 at X-ES toward the top HP measuring connection 3 at X-ES Vent screws 8 of the hydrosplit coupling Vertical Vent screws 7 at X-ES...
  • Page 106 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. ü System is in maintenance position. Set system to maintenance position, Page 102. 1. Remove venting plate with locking wire on the intensifier (X-ES). 2.
  • Page 107 Maintenance 13. CAUTION! Splashing oil! Open vent screw slowly!  Unscrew the corresponding vent screw (see table "Venting point according to installation position") a maximum of 2 turns until the oil comes out under the vent screw without bubbles. Then immediately close the vent screw. - OR - Unscrew corresponding high pressure measuring connection cover (see ta- ble "Venting point according to installation position") and push in with a...

  • Page 108: 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 Oil filling nipple Oil level indicator High pressure measuring connection High pressure measuring connection X-ES Venting plate Oil anti-overfill safety device...
  • Page 109 Maintenance Installation position Venting points Type X-ES Venting points X-ES Ÿ Vertical Venting plate 5 Hydrosplit coupling ZHK or hydraulic hose Ÿ Vent screws 7 at X-ES toward the top Ÿ HP measuring connection 3 at X-ES Ÿ Vent screws 8 of the hydrosplit coupling Ÿ...
  • Page 110 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_X-KT_en...
  • Page 111 Maintenance ü System is in maintenance position. Set system to maintenance position, Page 102. 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 112 Maintenance 19. Fasten locking wire. 20. NOTE! Device damage due to overfilling!  Lower oil level. Lowering of oil level, Page 117. TOX_Manual_Powerpackage_line-X_X-KT_en...

  • Page 113: Refilling Oil And Venting Drive With Cutting Impact Damping Zsd

    Maintenance 10.6.2 Refilling oil and venting drive with cutting impact damping ZSD Oil filling nipple Oil level indicator High pressure measuring con- High pressure measuring con- nection X-ES nection ZSD Venting plate Oil anti-overfill safety device Vent screw X-ES Vent screw ZHK Vent screw ZSD Fig. 38 Refilling oil and venting drive with cutting impact damping ZSD...
  • Page 114 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 Venting points Type X-ES Venting points X-ES Vertical Venting plate 5 Hydrosplit coupling ZHK or hydraulic hose Vent screws 7 at X-ES toward the top HP measuring connection 3 at X-ES...
  • Page 115 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. ü System is in maintenance position. Set system to maintenance position, Page 102. 1. Remove venting plate with locking wire on the intensifier (X-ES). 2.
  • Page 116 Maintenance 13. CAUTION! Splashing oil! Open vent screw slowly!  Unscrew the corresponding vent screw (see table "Venting point according to installation position") a maximum of 2 turns until the oil comes out under the vent screw without bubbles. Then immediately close the vent screw. - OR - Unscrew corresponding high pressure measuring connection cover (see ta- ble "Venting point according to installation position") and push in with a...

  • Page 117: 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 118: Check Hydraulic Hose Lines

    Maintenance 10.8 Check hydraulic hose lines All hose lines are subject to a natural aging process that limits the duration of use of the hydraulic hose lines. Tests may only be carried out by authorized personnel. Load stress of hydraulic Recommended test inter- Recommended replace- hose lines...

  • Page 119: Replacing Hydraulic Hoses

    Maintenance 10.9 Replacing hydraulic hoses è Change hydraulic hoses after 6 years at the latest. è Observe country-specific guidelines. ü To be carried out by service personnel only. è Contact authorized service personnel. 10.10 Check the holding force of the holding brake Check the holding force of the holding brake, Page TOX_Manual_Powerpackage_line-X_X-KT_en...

  • Page 120: 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_X-KT_en...

  • Page 121: 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 122: 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 123: Disassembling

    ® return it to 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 124: Appendices

    Appendices 13 Appendices 13.1 DECLARATION OF INCORPORATION TOX_Manual_Powerpackage_line-X_X-KT_en...

  • Page 127: Index

    Index Index Symbols (Safety lock of proximity sensors) Causes of fault .......... 97 Setting............ 90 Change Seal ............ 120 Changeover from power stroke to return stroke For Powerpackages with hydraulic damping Accessories hydrosplit coupling ZHK .............. 44 Electrically switchable valve .....  35 Changeover of power stroke to return stroke Activation ZED ............ 44 Design principles ........
  • Page 128 Index Damping (ZED) Fast approach stroke ........ 23 Setting............ 85 Function description........ 22 Damping effect Setting............ 88 Data sheet .............  38 Gender note ............. 9 Decommissioning ........ 122 General information Design data ...........  38 Maintenance.......... 100 Design principles ...........  38 Guidelines ............ 8 Design principles of activation .......  46 Disassembly ........
  • Page 129 Index Hazard Identification Contusion.......... 16 Product ............ 21 Electrical ...........  15 Images electromagnetic ........ 17 Highlighting .......... 11 Hazardous substances ...... 17 Important information ........ 8 hydraulic ...........  16 Information Laser ............ 17 Important ............. 8 Lithium ion battery ........ 18 Installation............ 55 Noise............ 18 Accessories .......... 60 Pneumatic..........
  • Page 130 Index Integrated holding brake ZSL Product attributes........ 30 Intended use.......... 19 Refilling ........ 104, 108, 113 Oil leakage Avoiding ............ 41 Laser Oil level Hazard ............ 17 Checking .......... 103 Legal note............ 8 Lowering.......... 117 Lifting device .......... 54 Oil pressure Lowering Type X-S, Type X-K ........ 48 Oil level ...........
  • Page 131 Index X-KT system.......... 26 Proportional pressure control valve Performance optimization...... 41 Installing ............ 68 Piston rod Proximity sensors of the holding brake Tightening torques ........ 49 Setting ............ 90 Pneumatic connection ........ 48 Pneumatic screw fittings on the Powerpackage Tightening torques ........ 50 Qualifications .......... 14 Position sensors of stroke monitoring for for- ward and return stroke (ZHU)
  • Page 132 Index Installing ............ 74 Storage ............ 53 Safe Temporary storage ........ 54 Construction.......... 20 Stroke frequency optimization (ZHO) Design............ 20 Installing ............ 72 Safety ............ 13 Stroke frequency optimization (ZHO) for drive Commissioning .........  76 with integrated power stroke valve Disassembly ...........  121 Installing ............ 72 Disposal ..........
  • Page 133 Index Target group ............  9 Validity Technical data .......... 47 Document ............ 9 Technical design data ........ 38 Venting Texts Drive ............ 104 Highlighting .......... 11 Drive with integrated damping function ZED ............ 108 Tightening torque Tightening torque of hydrosplit coupling ...  50 Tightening torque of hydrosplit coupling Tightening torque........
  • Page 134 Index TOX_Manual_Powerpackage_line-X_X-KT_en...

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