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TOX®-Powerpackage
Installation and assembly guidelines
Data sheet 10.18
2019 / 07

TOX® PRESSOTECHNIK GmbH & Co. KG, Riedstrasse 4, 88250 Weingarten / Germany
Find your local contact at: www.tox.com
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General information
TOX®-Powerpackages have been produced according to today’s state-of-the-art and applicable rules and regulations. In addition to the information provided in this document, please always refer to the operating manual of the TOX®-Powerpackage
and the associated press force oil pressure-table. Please ask for these documents as required.

Installation and installation position
The TOX®-Drives can be installed in any position, provided
the following points are taken into consideration:
 In general, no transverse forces may act on the pistonrod. If necessary, a linear guide can be used for the working piston: either a press plate and guiding columns or aguiding rail with guiding carriage.
The flexible ZWK tool coupling available as accessory
 connects the working piston of the TOX®-Powerpackagewith a tool plunger. This means that the TOX®-Powerpackage cannot be affected by lateral forces and twisting ofthe working piston is avoided.
In order to be able to carry out servicing works, in the case of horizontal installation the connection side must
face upward.
 The parts of the TOX®-Powerpackage requiring servicing(oil filling nipple, vent hole, high pressure measuring connection, control throttle ‚X‘ and oil level indicator) shouldbe easily accessible at all times. It must be ensured
that ventilation of the hydraulic system is always possible also when installed. Ventilation openings (ventilation
plate or bleeder valves) should be at the highest point.
If TOX®-Powerpackages in K or Z design are to be installed in horizontal installation position with the intensifier
positioned laterally next to the working part, the weight of
the intensifier must be supported particularly in case oflarge differences in diameter between working part andintensifier part. An installation position where the intensifier part is positioned above or below the working part ispreferable to the horizontal lateral installation. Additional
installation information for the TOX®-Powerpackage inhorizontal installation position can be found in the operating manual.
 In the case of TOX®-Powerpackages type Q-S, X-S, Swith the working piston installed in a vertically upward
position, the vent screw on the working piston must befreely accessible.
The space requirement for supply lines must be taken
into consideration.

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Fastening:
The TOX®-Powerpackage must only be mounted withscrews of the property class 12.9. The tightening torques
can be found in the associated TOX®-Powerpackage operating manual. DIN EN 14399-8 must be applied for theplanning of high-strength screw connections that can beclamped as scheduled.
Usage:The effective press force is the ratio of the available press
force at the specified air pressure to the press force required
for the pressing process.
If the use of a TOX®-Powerpackage type Q-S, X-S, EL or S
with hydraulic end position damping ZHD and very short fast
approach stroke is planned, please contact TOX® PRESSOTECHNIK.
Temperature ranges:
Tmin = 10° C
Tmin = 60° C
Compressed air supply:
The TOX®-Drive must only be operated with filtered anddried compressed air. The maximum admissible particle size
is 40 μm (in accordance with DIN ISO 8573-1).
Control:
Various pneumatic control units are available for theTOX -Powerpackage. More information about this can befound in data sheet 10.16. TOX -Powerpackages must be
supplied according to the respective cross sections specified in the technical data sheet. This applies to the maintenance unit, valves, lines etc.
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Measuring and control connection:
The TOX®-Powerpackage has a measuring and control connection. The oil pressure proportional to the press force ispresent on this screw connection. It can be displayed forexample by connecting a manometer, or used via transmission to a pressure switch for generating a switching pulse.

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Applications

Air consumption

Applications with fixed end stop:
For all applications where a fixed end stop is required in thepowerpackage, the total stroke of the powerpackage canbe limited on request. For this purpose, the TOX®-Powerpackage is installed so that the fast stroke together with therequired power stroke is identical to the total stroke.
Example: Required power stroke 4 mm + fast stroke 28 mm= total stroke 32 mm. Powerpackage to be ordered e. g.
S 08.00.32.06.
Alternatively, a TOX®-Powerpackage with total stroke adjustment type K.51 can be used. Type K.51 with total stroke
adjustment enables the precise mechanical setting of thetotal stroke independent of the length of the stroke, as it isrequired for clinching for example.

For the air consumption, the fast and return stroke are calculated with the available air pressure. The air requirementin the power stroke is calculated depending on the requiredpress force. For example, this depends on when the required oil pressure is reached. If the intensifier chamber isfilled with complete air pressure, the air consumption canindeed be higher than the actually needed and calculated
requirement.

Punching application:
During punching, the working piston of the powerpackage
can continue to move after the punching process. To avoid
damage, this must be prevented by a limitation in the tool ora limitation of the total stroke in the powerpackage.
Particularly recommended for punching applications is
the use of a powerpackage with total stroke adjustment
and integrated cutting impact damping ZSD for punching
operations that go easy on the machine and have a significantly reduced noise level. Furthermore, for punching operations only TOX®-Powerpackages with pneumatic spring andintegrated bypass ZLB, ZHD should be used.

On request, the air requirement for the desired powerpackage can be determined depending on the individual application.
In general, the specification for the air requirement includes
all filling processes required for a stroke. The information only
refers to the specific drive. For hoses and valves - in particular for long hoses with large cross sections - which are filledand ventilated together with the drive, their consumption
must also be considered when selecting a compressor. The
following applies here: You save energy for short lines fromthe valve to the TOX®-Powerpackage.
When using pressure regulators (e. g. for the pneumatic spring), low internal air consumption cannot be avoided. This is usually in the range of a few litres per hour.
Similarly, there might be air losses in the hose and valve connections. In order to avoid air losses, e. g. at night, the drive
can be depressurised during this time.

Generally it must be ensured that the power stroke of theTOX®-Powerpackage used for punching operations is onlyused to a maximum of 80 %.

minimumrubbersprings

Tool after punching LDC(LDC = lower dead centre)
The tension of the rubber springmust be adapted to the punchingprocess.

travellimitation

rubbersprings

travellimitation

Tool in starting position UDC(UDC = upper dead centre)

Pressing applications:
For all applications with severely variable counterforce, e. g.
in case of markedly different static friction and dynamic friction coefficient values of the components, as they are generated for example by the pressing in of connectors, bearings, etc., TOX®-Powerpackages with integrated damping
ZED for jerk-free and damped press fitting and punching
are available.

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Cycle times
The cycle time is always calculated depending on the requested press force. On request, the cycle time that canbe realized can be determined depending on the individualapplication. The smaller the effective press force, the shorter
the cycle time. An effective press force over 90 % should beavoided. In addition to the specified cycle times, one mustalso take into consideration the switching times of the valvesand controls before the drive. In order to achieve the times
calculated, the following requirements must be considered: Air pressure:
The required air pressure is the result of the desired effective press force. To achieve a short cycle time, an airpressure as high as possible is recommended for fast approach and return stroke. If the maximum press force ofthe cylinder is to be reduced, this can be easily realizedwith a pressure control ZDK (manual or electric) in thepower stroke line.
 Hose cross sections
To achieve the calculated cycle time, the line cross sections must correspond to at least the connection specifications in the technical data sheet. This applies also
to the regulation valves and maintenance units installed
before the drive. Reduced line cross sections can considerably reduce the cycle time.

 Hose lengths
The length of the hoses should be kept to a minimum, as
the air consumption as well as the cycle time are increased with the length.
 Compressor performance
The compressor performance should always be sizedwith sufficient safety.

Stroke frequency optimization ZHO:The specified cycle time specifications correspond in general to the specific TOX®-Powerpackage under realistic conditions. If necessary, the cycle time can be further reduced
using our optional accessory module ZHO.
Speed setting:
The speed can be regulated as required by installing throttle
check valves in the fast approach stroke and return strokelines. Furthermore, the speed of the power stroke can be
adjusted by mounting a throttle in the power stroke line ofthe unit. The drive can thus also be used for special applications like for example for pressing in bushes, projecting etc.
Caution:Observe the piston speeds. More information can be foundin the TOX®-Powerpackage operating manual.

Hydraulic components
All hydraulic lines as well as hydraulic screwing and connection elements supplied by TOX® PRESSOTECHNIK inconnection with a TOX®-Powerpackage and X-KT systemcorrespond to the applicable statutory provisions and aredimensioned in such a way that there is no danger if themaximum permissible operating pressure specified in theoperating manual is complied with.
If you perform your own conversions, e. g. particularly in thearea of the hydraulic lines on X-KT systems, you must makesure that the hydraulic components used are suitable for theapplication and the intended pressure range. The specifications in the X-KT operating manual must be observed here.
If you have questions about hydraulic components, pleasecontact TOX® PRESSOTECHNIK. Please also observe thestatutory replacement intervals for hydraulic hoses (rules ofthe employers’ liability insurance association, BGR 237).

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Subject to technical modifications.