Related Manuals for TOX Powerpackage K
Summary of Contents for TOX Powerpackage K
- Page 1 Original operating instructions ® Powerpackage line-Q Type Q-S, Q-K ® PRESSOTECHNIK GmbH & Co. KG, Riedstrasse 4, 88250 Weingarten / Germany www.tox.com...
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Page 2: Table Of Contents
Table of contents Table of contents Important information Legal note .................... 7 Exclusion of liability.................. 7 Conformity .................... 7 Validity of the document ................ 8 1.4.1 Content and target group................ 8 1.4.2 Other applicable documents ................ 8 Gender note.................... 8 Displays in the document................ 9 1.6.1 Display of warnings.................. 9 1.6.2 Display of general notes ................ 10 1.6.3... - Page 3 Safe and correct design and construction .......... 19 3.1.3 Foreseeable misuse .................. 19 Product Identification ................. 20 3.2.1 Position and content of the type plate............ 20 Function description of TOX ® Powerpackage with mechanical spring .. 21 ® Product overview of TOX Powerpackage line-Q........ 25 3.4.1 Product attributes of Powerpackage line-Q .......... 25...
- Page 4 Table of contents Ambient temperature ................. 50 Compressed air quality and pneumatic connection ........ 51 Tightening torques .................. 51 4.5.1 Tightening torques for flange mounting the drive ........ 51 4.5.2 Tightening torques on the piston rod ............ 51 4.5.3 Tightening torques of pneumatic screw fittings on the Powerpackage.. 52 Press force table.................. 52 Specification for hydraulic oil .............. 52 Transport and storage...
- Page 5 Table of contents Setting control throttle 'X' ................ 75 Setting speed ratio of return stroke to fast approach stroke ...... 77 Set the speed ratio between power stroke and power stroke venting (op- tional) ...................... 77 Operation Safety in operation.................. 78 Requirements for operation ............... 79 Operating drive .................. 79 Troubleshooting Safety during troubleshooting .............. 80...
- Page 6 Table of contents 12.2 Decommissioning .................. 96 12.3 Shutdown.................... 96 12.4 Disassembling ................... 97 12.5 Disposal ..................... 97 Appendices 13.1 DECLARATION OF INCORPORATION............ 98 Index TOX_Manual_Powerpackage_line-Q_en...
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Page 7: 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 8: Validity Of The Document
Important information 1.4 Validity of the document 1.4.1 Content and target group This manual contains information and instructions for the safe operation and safe maintenance or servicing of the product. Ÿ All information in this manual is up to date at the time of print. ®... -
Page 9: Displays In The Document
Important information 1.6 Displays in the document 1.6.1 Display of warnings Warning signs indicate potential dangers and describe protective 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 10: Display Of General Notes
Important information 1.6.2 Display of general notes General notes show information on the product or the described action steps. Identifies important information and tips for users. 1.6.3 Highlighting of texts and images The highlighting of texts facilitates orientation in the document. ü... -
Page 11: 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-Q_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: 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 17: 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 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 mechanical 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 Plunger return stroke 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 Plunger return stroke 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 Plunger return stroke 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.
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Page 25: Product Overview Of Tox Powerpackage Line-Q
About this product ® 3.4 Product overview of TOX Powerpackage line-Q Working piston Compressed air supply return stroke [2] Control throttle 'X' Compressed air supply fast approach stroke [4] Oil filling nipple Power stroke valve Fig. 5 Product overview of TOX ®... -
Page 26: 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-Q_en... -
Page 27: 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 28: 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 29: 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 30: 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 31 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.
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Page 32: 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 33: Speed Reduction Of The Power Stroke
About this product 3.6.8 Speed reduction of the power stroke The speed of the power stroke can be reduced if a control throttle is installed in the supply line for the power stroke. To prevent a dynamic oil leakage, an additional exhaust throttle must be in- stalled in this case so that the speed ratio can be adjusted. -
Page 34: Horizontal Installation Type K And Z
About this product 3.6.9 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. 7 Horizontal installation For horizontal installation type K, Z the following applies: Ÿ... - Page 35 About this product An external power stroke release with an electrical release signal is recom- mendable: Ÿ If the power stroke release can accidentally be activated with the control throttle 'X' due to interference contours in the working area. When depressurizing a pressure valve (pneumatic spring), the following applies: Ÿ...
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Page 36: 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 37: Pressure Control In The Power Stroke Line (Assembly Zdk) (Optional)
About this product Assembly Power stroke valve Power stroke output Power stroke signal Control connection Muffler output Power stroke input Control connection Control throttle 'X' Drive 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... - Page 38 About this product Powerpackage with mechanical spring ‘X‘ line-Q, S/K-F -?KYP2 Fig. 9 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 regulator ZDK .2 Fast approach stroke input Power stroke output...
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Page 39: 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 40 About this product Powerpackage with mechanical spring ‘X‘ -138YH1 line-Q, S/K-F -?KYP2 Fig. 10 Pressure control in the power stroke line with proportional pressure control valve Assembly Power stroke valve Power stroke output Power stroke signal Control connection Muffler output Power stroke input Control connection Pressure regulator ZDK .2 Fast approach stroke input...
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Page 41: External Power Stroke Switch (Assembly Zkhz) (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) 3.7.5... - Page 42 About this product Powerpackage with mechanical spring 12 <-> 1 line-Q, S/K-F -?KYP4 Fig. 11 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 Power stroke switch valve Muffler output Output Input...
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Page 43: 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 44 About this product Powerpackage with mechanical spring 12 <-> 1 ‘X‘ line-Q, S/K-F -?KYP5 Fig. 12 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 Electrical switching valve Input (release) Output...
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Page 45: External Power Stroke Release (Assembly Zkhf) (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) 3.7.7... - Page 46 About this product Powerpackage with mechanical spring 12 <-> 1 ‘X‘ line-Q, S/K-F -?KYP5 Fig. 13 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 Electrical switching valve Input (release) Output...
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Page 47: External Power Stroke Supply (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) 3.7.8... - Page 48 About this product Powerpackage with mechanical spring ‘X‘ line-Q, S/K-F -?KYP2 Fig. 14 External power stroke supply (optional) Assembly Power stroke valve Power stroke output Power stroke signal Control connection Muffler output Power stroke input Control connection Control throttle 'X' Drive TOX_Manual_Powerpackage_line-Q_en...
- Page 49 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) TOX_Manual_Powerpackage_line-Q_en...
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Page 50: 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 51: Compressed Air Quality And Pneumatic Connection
Technical data 4.4 Compressed air quality and pneumatic connection The following is required: Ÿ Filtered and dried compressed air Lightly oiled compressed air is permitted. Compressed air quality (according to DIN ISO 8573-1): Solids Water dew point Maximum Oil content Class [μm] Class [°C] Class... -
Page 52: Tightening Torques Of Pneumatic Screw Fittings On The Powerpackage
Technical data 4.5.3 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 4.6 Press force table Press force table see separate document. - Page 53 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.
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Page 54: 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 55: 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 56: 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 57: 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 58: 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 59 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.
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Page 60: 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. 15 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 61 Installation Setting the position sensors ü Proximity switches are connected. ü Working piston in home position. 1. Push the proximity switch from the edge of the cylinder to the first switch-on point. The LED lights up. 2. Mark the edge of the proximity switch on the cylinder. 3.
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Page 62: 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 63 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.
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Page 64: Installing Pressure Control In The Power Stroke Line (Zdk)
Installation 6.3.4 Installing pressure control in the power stroke line (ZDK) Fig. 16 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-Q_en... - Page 65 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.
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Page 66: Installing External Power Stroke Connection (Zkhz)
Installation 6.3.5 Installing external power stroke connection (ZKHZ) Fig. 17 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 67: Installing External Power Stroke Release (Zkhf) And Power Stroke Deactivation (Zkhd)
Installation 6.3.6 Installing external power stroke release (ZKHF) and power stroke deactivation (ZKHD) Fig. 18 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 68: Preparing External Power Stroke Supply
Installation 6.3.7 Preparing external power stroke supply Fig. 19 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 69: Installing The Stroke Frequency Optimization (Zho)
Installation 6.3.8 Installing the stroke frequency optimization (ZHO) Installing the stroke frequency optimization (ZHO) for drive with integrated power stroke valve Optimization of stroke frequency Slide valve (ZHO) Plug Circlip Fig. 20 Installing the stroke frequency optimization ZHO Material required: Ÿ Stroke frequency optimization (ZHO) for drive with integrated power stroke valve Ÿ... - Page 70 Installation Installing the stroke frequency optimization (ZHO) for drive with external power stroke valve Fig. 21 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.
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Page 71: Installing The Speed Reduction For Power Stroke Venting
Installation 6.3.9 Installing the speed reduction for power stroke venting Fig. 22 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 72: 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 73: 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 74: 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 75: 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 76 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.
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Page 77: 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 78: 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 79: 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 80: 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-Q_en... -
Page 81: 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 82 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.
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Page 83: Maintenance Table
Maintenance table Maintenance table 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 Weekly 10.4 Checking oil level... -
Page 84: 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 85: 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 86 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.
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Page 87: 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 88: Checking Oil Level
Maintenance 10.4 Checking oil level Fig. 25 Checking oil level ü System is in maintenance position. Set system to maintenance position, Page è Check needle of the oil level indicator. The needle of the oil level indicator is flush with the surface of the cylinder: Oil level is ok. -
Page 89: 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 Vent screw Fig. 26 Refilling oil and venting drive Material required: Ÿ... - Page 90 Maintenance The top vent screws or the top HP measuring connection must be selected for the venting. Venting points according to installation position Installation position Type Q-S Type Q-K Vertical, working piston Vent screw 2 Vent screws 2, 4, 6, 5, 7 downward Vertical, working piston up- Vent screw 1...
- Page 91 Maintenance ü System is in maintenance position. Set system to maintenance position, Page 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 92 Maintenance 19. Fasten locking wire. 20. NOTE! Device damage due to overfilling! Lower oil level. Lowering of oil level, Page TOX_Manual_Powerpackage_line-Q_en...
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Page 93: Lowering Of Oil Level
Maintenance 10.6 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 94: 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-Q_en... -
Page 95: 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 96: 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 97: 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 98: Appendices
Appendices 13 Appendices 13.1 DECLARATION OF INCORPORATION TOX_Manual_Powerpackage_line-Q_en... -
Page 101: Index
Index Index Activation Data sheet............ 27 Design principles ........ 34 Decommissioning........... 96 Dynamic pressure method...... 36 Design data............ 27 Air consumption.......... 28 Design principles.......... 27 Ambient temperature ........ 50 Design principles of activation ....... 34 Avoidance of dynamic oil leakage .... 30 Disassembly.......... 95, 97 Safety ............ 95 Dispatch Repair............ 55 Basic safety requirements ...... - Page 102 Index Gender note ............ 8 Identification General information Product ............ 20 Maintenance .......... 84 Images Guidelines ............ 7 Highlighting .......... 10 Important information ........ 7 Information Important ............. 7 Hazard Installation............ 56 Contusion.......... 15 Accessories .......... 58 Electrical ........... 14 Drive ............ 57 electromagnetic ........ 16 External power stroke switch (ZKHZ).. 66 Hazardous substances ......
- Page 103 Index Laser Hazard ............ 16 Refilling ............. 89 Legal note............ 7 Oil leakage Lifting device .......... 55 Avoiding ............ 30 line-Q Oil level Product overview ........ 25 Checking ........... 88 Lowering Lowering............ 93 Oil level ............. 93 Operation ............ 78 Drive ............ 79 Requirements .......... 79 Safe ............ 18 Maintenance ..........
- Page 104 Index Performance optimization...... 30 Refilling Piston rod Oil .............. 89 Tightening torques ........ 51 Repair Pneumatic connection ........ 51 Dispatch ............ 55 Pneumatic screw fittings on the Powerpackage Repairs............ 94 Tightening torques ........ 52 Safety ............ 94 Position sensors of stroke monitoring for for- Requirement ward and return stroke (ZHU) Maintenance.......... 87...
- Page 105 Index Power stroke .......... 32 Safe Construction.......... 19 Target group ............ 8 Design............ 19 Technical data .......... 50 Safety ............ 12 Technical design data ........ 27 Commissioning ......... 73 Texts Disassembly .......... 95 Highlighting .......... 10 Disposal ............ 95 Tightening torques Installation.......... 56 Installation .......... 51 Maintenance ..........
- Page 106 Index Pressure regulation in power stroke line... 37 Installing............ 58 Installing............ 69 ZKHD External power stroke deactivation... 43 Installing............ 67 ZKHF External power stroke release .... 45 Installing............ 67 ZKHZ External power stroke connection..... 41 Installing............ 66 TOX_Manual_Powerpackage_line-Q_en...
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