Original operating instructions®

TOX FinePress

Edition: 11/20/2023, Version: 6

ZFS / ZFL / ZFWTOX® PRESSOTECHNIK GmbH & Co. KG, Riedstrasse 4, 88250 Weingarten / Germany
www.tox.com

Table of contents

Table of contents
1

Important information

1.1

Legal note .................................................................................................... 6

1.2

Exclusion of liability...................................................................................... 6

1.3

Conformity ................................................................................................... 6

1.4

Validity of the document .............................................................................. 7

1.4.1

Content and target group............................................................................. 7

1.4.2

Other applicable documents ........................................................................ 7

1.5

Gender note................................................................................................. 7

1.6

Displays in the document............................................................................. 8

1.6.1

Display of warnings...................................................................................... 8

1.6.2

Display of general notes .............................................................................. 8

1.6.3

Highlighting of texts and images.................................................................. 9

1.7

Contact and source of supply .................................................................... 10

2

Safety2.1

Basic safety requirements ......................................................................... 11

2.2

Organizational measures........................................................................... 12

2.2.1

Safety requirements for the operating company........................................ 12

2.2.2

Selection and qualifications of personnel .................................................. 13

2.3

Fundamental hazard potential ................................................................... 14

2.3.1

Electrical hazards ...................................................................................... 14

2.3.2

Thermal hazards........................................................................................ 14

2.3.3

Pneumatic hazards .................................................................................... 15

2.3.4

Contusions................................................................................................. 15

2.3.5

Hydraulic hazards ...................................................................................... 15

2.3.6

Electromagnetic hazards ........................................................................... 16

2.3.7

Laser.......................................................................................................... 16

2.3.8

Hazardous substances .............................................................................. 16

2.3.9

Noise.......................................................................................................... 17

2.4

Safety symbols .......................................................................................... 18

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Table of contents

3

About this product

3.1

Intended use .............................................................................................. 19

3.1.1

Safe and correct operation ........................................................................ 19

3.1.2

Foreseeable misuse .................................................................................. 20

3.1.3

Substances harmful to the wetting properties of lacquers (LABS) ............ 20

3.2

Product identification ................................................................................. 20

3.2.1

Type plate .................................................................................................. 20

3.3

Product overview and function description ................................................ 21

4
4.1

5

Technical data
Type sheet and data sheet ........................................................................ 22

Transport and storage

5.1

Safety during transport .............................................................................. 23

5.2

Storage when not in use ............................................................................ 24

5.3

Transport by lifting device.......................................................................... 25

5.4

Dispatch for repair ..................................................................................... 26

6

Installation

6.1

Safety during installation............................................................................ 27

6.2

Requirements for installation ..................................................................... 29

6.2.1

Set-up location........................................................................................... 29

6.3

Installing accessories................................................................................. 30

6.3.1

Installing process monitoring (option) ........................................................ 30

6.3.2

Installing the ergonomic handle (optional) ................................................. 31

6.3.3

Installing the stroke counter (optional)....................................................... 32

6.3.4

Installing the force sensor (optional).......................................................... 34

6.3.5

Install the return stroke lock (option).......................................................... 36

6.3.6

Installing the slide table (optional) ............................................................. 38

6.3.7

Installing travel sensor (option).................................................................. 39

6.3.8

Installing the tool holding fixture (optional) ................................................ 40

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en3

Table of contents

7

Commissioning

7.1

Safety during the commissioning............................................................... 41

7.1.1

Safety device ............................................................................................. 41

7.2

Requirements for the commissioning ........................................................ 42

8Operation

8.1

Safety in operation..................................................................................... 43

8.2

Requirements for operation ....................................................................... 43

8.3

Process monitoring .................................................................................... 43

8.4

Setting the open height of the press head ................................................. 44

8.5

Fine adjustment of working stroke (option)................................................ 46

8.6

Setting working depth ................................................................................ 47

8.7

Resetting the stroke counter (optional)...................................................... 47

8.8

Adjusting the return stroke lock (optional) ................................................. 48

8.9

Setting the return stroke ............................................................................ 51

8.10

Setting the travel sensor (option)............................................................... 52

9Troubleshooting

9.1

Safety during troubleshooting .................................................................... 53

9.2

Detecting faults .......................................................................................... 54

Maintenance table

10

Maintenance

10.1

General information ................................................................................... 56

10.2

Safety during maintenance ........................................................................ 57

10.3

Requirements for maintenance.................................................................. 57

10.3.1

Set system to maintenance position .......................................................... 57

10.4

TOX® FinePress maintaining ..................................................................... 58

10.4.1

TOX® FinePress inspecting ....................................................................... 58

10.4.2

Inspecting the fastening of the press head ................................................ 59

10.4.3

Inspecting and cleaning movable parts and guides................................... 60

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Table of contents

11
11.1

12

Repairs
Safety during repairs.................................................................................. 61

Disassembly and Disposal

12.1

Safety during disassembly and disposal.................................................... 62

12.2

Decommissioning ...................................................................................... 62

12.3

Shutdown................................................................................................... 63

12.4

Disassembling ........................................................................................... 64

12.5

Disposal ..................................................................................................... 64

13
13.1

Appendices
Declaration of conformity ........................................................................... 65

Index

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en5

Important information

1 Important information
1.1

Legal noteAll rights reserved.
Operating instructions, manuals, technical descriptions and software publishedby TOX® PRESSOTECHNIK GmbH & Co. KG ("TOX® PRESSOTECHNIK") are
copyright and must not be reproduced, distributed and/or otherwise processedor edited (e.g. by copying, microfilming, translation, transmission in any electronic medium or machine-readable form). Any use - including of extracts - contrary to this condition is prohibited without approval in writing by TOX® PRESSOTECHNIK and may be subject to criminal and civil legal sanctions.
If this manual refers to goods and/or services of third parties, this is for example
only or is a recommendation by TOX® PRESSOTECHNIK. TOX® PRESSOTECHNIK does not accept any liability or warranty/guarantee with reference
to the selection, specifications and/or usability of these goods and services. The
use and/or representation of trademarked brands that do not belong to
TOX® PRESSOTECHNIK are for information only; all rights remain the propertyof the owner of the trademarked brand.
Operating instructions, manuals, technical descriptions and software are originally compiled in German.

1.2

Exclusion of liability
TOX® PRESSOTECHNIK has checked the contents of this publication to ensurethat it conforms to the technical properties and specifications of the products orplant and the description of the software. However, discrepancies may still bepresent, so we cannot guarantee complete accuracy. The supplier documentation included with the system documentation is an exception.
However, the information in this publication is checked regularly and any required corrections are included in subsequent editions. We are grateful for any
corrections and suggestions for improvement. TOX® PRESSOTECHNIK reserves the right to revise the technical specifications of the products or plant
and/or the software or documentation without prior notice.

1.3

Conformity
The product is compliant with EU guidelines.
See separate Declaration of conformity or installation declaration.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

6

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 andsafe maintenance or servicing of the product.

1.4.2



All information in this manual is up to date at the time of print. TOX® PRESSOTECHNIK reserves the right to make technical changes that improve thesystem or increase the standard of safety.



The information is intended for the operating company as well as operating
and service personnel.

Other applicable documents
In addition to the available manual, further documents can be supplied. These
documents must also be complied with. Other applicable documents can be, forexample:1.5

additional operating manuals (e.g. of components or of a whole system)

Supplier documentation



Instructions, such as software manual, etc.

Technical data sheetsSafety data sheetsData sheets

Schematics

Gender note
In order to enhance readability, references to persons that also relate to allsexes are normally only stated in the usual form in German or in the corresponding translated language in this manual, thus e.g. "operator" (singular) for
male or female, or "operators" (plural) for male or female". This should in noway convey any gender discrimination or any violation of the principle of equality, however.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

7

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.
è Measures for remedial action and protection.

WARNING
Identifies a potentially dangerous situation!
Death or serious injury may occur if appropriate safety measures are not taken.
è Measures for remedial action and protection.

CAUTION
Identifies a potentially dangerous situation!
Injury may occur if appropriate safety measures are not taken.
è Measures for remedial action and protection.

Warning signs indicating potential damage
NOTE
Identifies a potentially dangerous situation!
Property damage may occur if appropriate safety measures are not taken.
è Measures for remedial action and protection.

1.6.2

Display of general notes
General notes show information on the product or the described action steps.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en8Important information

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

Identifies prerequisites that must be followed.

1. Action step 1
2. Action step 2: identifies an action step in an operating sequence that mustbe followed to ensure trouble-free operation.
w Identifies the result of an action.
u Identifies the result of a complete action.
è Identifies a single action step or several action steps that are not in an operating sequence.
The highlighting of operating elements and software objects in texts facilitatesdistinction and orientation.
<In square brackets> identifies operating elements, such as buttons, leversand (valves) stopcocks.

''with quotation marks'' identifies software display panels, such as windows,
messages, display panels and values.



In bold identifies software buttons, such as buttons, sliders, checkboxes
and menus.

In bold identifies input fields for entering text and/or numerical values.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

9Important information

1.7

Contact and source of supply
Only use original spare parts or spare parts approved by TOX® PRESSOTECHNIK.
TOX® PRESSOTECHNIK GmbH & Co. KG
Riedstraße 488250 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_FinePress_ZFS-ZFL-ZFW_en10

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 andother property.
For this reason the following basic safety requirements will apply:Read the operating manual and observe all safety requirements and warnings.

Operate the product only as specified and only if it is in perfect technicalcondition.

Remedy any faults in the product or the plant immediately.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

11

Safety

2.2

Organizational measures

2.2.1

Safety requirements for the operating company
The operating company is responsible for compliance with the following safety
requirements:

The operating manual must always be kept available at the operation site of
the product. Ensure that the information is always complete and in legible
form.



In addition to the operating manual, the generally valid legal and other binding rules and regulations must be provided for the following content and all
personnel must be trained accordingly:–

Work safety–

Accident prevention–

Working with hazardous substances–First aid–

Environmental protection–

Traffic safety–

Hygiene

The requirements and contents of the operating manual must be supplemented by existing national regulations (e.g. for prevention of accidents andfor environmental protection).



Instructions for special operating features (e.g. work organization, work processes, appointed personnel) and supervisory and reporting obligations
must be added to the operating manual.



Take action to ensure safe operation and make sure that the product ismaintained in a functional condition.



Only allow authorized persons access to the product.

Ensure that all personnel work with awareness of safety and potential dangers with reference to the information in the operating manual.

Provide personal protective equipment.



Maintain all safety and information on dangers regarding the product complete and in legible condition and replace as required.



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.



Make sure that the annual safety inspections are carried out and documented by an expert.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

12

Safety

2.2.2

Selection and qualifications of personnel
The following safety requirements are applicable for the selection and qualifications of personnel:Only appoint persons to work on the plant who have read and understoodthe operating manual, and in particular, the safety instructions before starting work. This is particularly important for persons who only work on theplant occasionally, e.g. for maintenance work.

Only allow persons appointed and authorized for this work access to theplant.



Only appoint reliable and trained or instructed personnel.

Only appoint persons to work in the danger zone of the plant who can perceive and understand visual and acoustic indications of danger (e.g. visualand acoustic signals).



Ensure that assembly and installation work and the initial commissioning
are performed exclusively by qualified personnel who have been trained
and authorized by TOX® PRESSOTECHNIK.

Maintenance and repairs must be performed by qualified and trained personnel only.

Ensure that personnel who are being trained, instructed or are in an apprenticeship can only work on the plant under the supervision of an experienced person.

Have work on electrical equipment performed only by electricians or trained
persons under the direction and supervision of an electrician in accordancewith the electrotechnical regulations.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

13

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 provide 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.
The following basically applies:

2.3.2



Have work on electrical equipment performed only by electricians or trained
persons under the direction and supervision of an electrician in accordancewith the electrotechnical regulations.



Always keep the control box and/or terminal box closed.



Before commencing work on electrical equipment, switch off the main
switch of the system and secure it against being switched back on inadvertently.



Pay attention to the dissipation of residual energy from the control systemof the servomotors.

Make sure that the components are disconnected from the power supply
when carrying out the work.

Thermal hazards
During operation piece parts may become hot and cause burns when touched.
Hazardous positions are generally marked with a symbol.
See Safety symbols, Page 18Wear individual protective equipment.



Before starting work, make sure that surfaces have cooled down sufficiently.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

14

Safety

2.3.3

Pneumatic hazards
Attention must be paid to pneumatic hazards particularly on the pneumatic supply lines and connection points.
The following basically applies:

2.3.4



Allow work to be carried out on pneumatic equipment by authorized service
personnel only.

Wear individual protective equipment.



Do not exceed the permissible pressure.

First switch on compressed air when all hose connections have been established and secured.



Do not uncouple any hoses under pressure.

If hoses slip off, switch off the compressed air supply immediately.

Contusions
Contusions and hand injuries can occur in the radius of action of the product.
The following applies generally:

2.3.5



Make sure that that no persons are located in the danger area during operation.



During necessary work in the danger area (e.g. maintenance, cleaning), secure the system against unexpected, accidental and unauthorized activation.



Make sure that parts or tools cannot fall down or descend as a result of
stored energy. Use appropriate fuses.

Hydraulic hazards
Attention must be paid to hydraulic hazards particularly on the supply lines, connection points and vent points.
The following applies generally:Allow work to be carried out on hydraulic equipment by authorized service
personnel only.

Wear individual protective equipment.



Do not exceed the permissible pressure.

Do not remove any hoses under pressure.



Never vent hydraulic components under pressure.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

15

Safety

2.3.6

Electromagnetic hazards
Electromagnetic hazards are to be taken into account in the area of electromagnetically vibrating or oscillating components.
Regular work on and with electromagnetically vibrating or oscillating components can cause disorders in the blood flow of the fingers as well as neurological and motoric dysfunctions.
The following applies generally:

2.3.7



Wear protective anti-vibration gloves when performing necessary work!

Electromagnetic fields can have an indirect effect on heart pacemakers andother implants. Adhere to safety distances.

Laser
Depending on the model and features, lasers can be installed for the purpose ofrecognition. There is a danger of looking into the laser in some situations. If thisis not avoided, eye injuries may result.
The following applies generally:

2.3.8



Do not look into the direct or the reflected beam.



If the laser beam hits the eye, deliberately close the eyes and move thehead immediately out of the beam.

When using the laser, no optical instruments are to be used for viewing thesource of the beam, since this can lead to exceeding the exposure limit values.



Manipulation (modification) of the laser equipment is inadmissible.

Hazardous substances
The following safety requirements apply when handling chemical substances:

Observe the applicable safety regulations on handling chemical substances
and the information on the manufacturer's safety data sheets of hazardous
substances.



Wear individual protective equipment.

In the event of eye or skin contact, rinse the affected area, change contaminated clothing and visit a doctor if necessary. Provide appropriate equipment (eye wash bottle, washbasin) near the workplace.



Groundwater hazardous substances must not get into the ground or
sewage system. Collect groundwater hazardous substances and dispose ofthem properly.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en16

Safety

2.3.9

Noise
Depending on the equipment, an increase in the noise level can arise in thesphere of the product.


Keep the duration of the exposure at a minimum.



Wear individual protective equipment.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en17

Safety

2.4

Safety symbols
Safety symbols are important components of the safety concept and help toprevent accidents. The safety symbols provide information about potential hazards that could cause serious injuries.
The following safety symbols can be attached on the product:
SymbolHazardNotes

Warning of suspended load

Do not stay in the danger zone of thesuspended load.

Identifies fork-lift truck brackets.

Identifies attachment point.

Tab. 1

Warning of hot surfaces

In the area of motors, drives and fans.

Warning of electrical voltage

In the area of the entire control box.

Warning of crushing

Risk of crushing in the working area.

Safety symbols

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

18

About this product

3 About this product
3.1

Intended use
The machine in conjunction with the designated tool is used for

Installing, press fitting

Punching, pressing (of function elements)

Riveting, crimping, flaring

Punching, piercingEmbossing, marking

Tensioning, clamping, crimping

Pressing, compressingClinching, joiningof sheet metal or mechanical modules.

3.1.1

Safe and correct operation
Intended use includes the following conduct:

Only operate with the components for which it is specified.



Follow all instructions in this operating manual.

Comply with the specified maintenance intervals and perform maintenancework correctly.

Operate in compliance with the conditions of the technical data.



Operation with fully assembled and functional safety devices.



Activities may only be carried out by persons who are qualified or authorized for this purpose.

Any other use or application beyond this does not come under the scope of intended use.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

19About this product3.1.2

Foreseeable misuse
Use contrary to intended use includes the following foreseeable misuse:

Operation under conditions that deviate from the technical data.



Operation without fully assembled and functional connections.



Operation without fully assembled and functional safety devices.



Modifications to the product without prior approval by TOX® PRESSOTECHNIK and the approving authority.



Incorrect parameterization.



Execution of activities by persons who are not qualified or authorized to doso.

The operating company is exclusively responsible for all personal injury andproperty damage resulting from non-intended use. Non-intended use will not becovered by the warranty or the operating approval.

3.1.3

Substances harmful to the wetting properties of lacquers (LABS)
No substances containing silicone, are knowingly processed and used.

3.2

Product identification

3.2.1

Type plate
The details on the type plate ensure clear identification of components and thespecific operating parameters.
The type plate is attached permanently on the component.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

20

About this product3.3

Product overview and function description
The force of rotation of the hand level is tranferred to the working ram. This results in a constant force development over the entire working stroke.

1

2

3

4
5

7
6

Fig. 1

1
2
3
4
5
6
7

Product overview

Designation

Function

Hand lever
Knurled screw
Toothed rack
Ram
Height adjustment scale
Press bed
Fastening holes

Drives the ram onto the workpiece.
Fine adjustment of working depth.
Transfers the force to the ram.
Transfers the force to the workpiece.
Facilitates the adjustment of the open height.
With T-groove for taking up tools.
For screw fitting to the floor.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

21Technical data

4 Technical data
4.1

Type sheet and data sheet
For technical data and installation dimensions see data sheet.
www.tox.com

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

22Transport and storage

5 Transport and storage
5.1

Safety during transport
WARNING
Hazard from suspended loads!
Severe crushing, impacts and serious accidents as a result of improper transportation and falling load!
è Only use lifting gear that is appropriate and in perfect technical condition, as
well as load attachment devices with an adequate safe working load.
è Never stand or work under suspended loads.
è Make sure that that no person is in the danger area.
è When transporting and setting down, make sure that no parts of the body
become jammed.
è Wear suitable personal protective equipment (e.g. safety boots).

CAUTION
Injury from toppling and falling products!
è Secure product from toppling, falling and accidentally moving.

The transportation may only be carried out by authorized personnel.

The product may only be transported with empty liquid containers.

The product may only be transported with the transport pallet or transport
device provided.

The product may only be lifted with suitable lifting devices at suitable lifting
points.
See Safety symbols, Page 18.

Note the weight of the product.
See technical data sheet.

Note the center of gravity of the product.
See general arrangement drawing.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en23

Transport and storage

5.2

Storage when not in use
CAUTION
Injury from toppling and falling products!
è Secure product from toppling, falling and accidentally moving.

The following applies:

Do not store the product outdoors.

Protect the product against the influence of the weather.



Avoid temperature fluctuations, so as to prevent corrosion from condensation.



Seal connection openings.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en24Transport and storage

5.3

Transport by lifting device
A threaded bore hole is provided for a ring bolt for lifting the TOX® FinePress.

2

1

1

Fig. 2Threaded hole

2

Cover

Transport by lifting device

1. Remove the cover from the press frame.
2. Remove the crank, ring bolt and other loose parts from the TOX® FinePress.
3. Screw the ring bolt into the threaded bore.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en25

Transport and storage

5.4

Dispatch for repair
To dispatch the product for repair to TOX® PRESSOTECHNIK, please proceed
as follows:Fill in the "Accompanying repair form". This we supply in the service sector
on our website or upon request via e-mail.



Send us the completed form via e-mail.



Then you will receive the shipping documents from us via e-mail.



Send us the product with the shipping documents and a copy of the "Accompanying repair form".

For contact data see Contact and source of supply, Page 10 or www.tox.com.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en26

Installation

6 Installation
6.1

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 Have all work on the electrical equipment performed by an electrician.
è Disconnect power supply.
è Wait for residual energy to disspate safely (at least 3 minutes).

WARNING
Ejecting parts and compressed air from compressed air conducting lines!
Serious injuries to eyes and body cavities!
è Always connect and disconnect lines without pressure.
è Pay attention to maximum permitted pressures.
è Wear individual protective equipment.

WARNING
Hazard from suspended loads!
Severe crushing, impacts and serious accidents as a result of improper transportation and falling load!
è Only use lifting gear that is appropriate and in perfect technical condition, as
well as load attachment devices with an adequate safe working load.
è Never stand or work under suspended loads.
è Make sure that that no person is in the danger area.
è When transporting and setting down, make sure that no parts of the body
become jammed.
è Wear suitable personal protective equipment (e.g. safety boots).

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en27Installation

CAUTION
Tripping points from laid supply lines!
Injuries from tripping and falling!
è Avoid tripping points when setting up.
è Mark unavoidable tripping points with warning sign.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en28

Installation

6.2

Requirements for installation

6.2.1

Set-up location
The set-up location:Must be free from dust and dirt

Must be a closed roomMust have a firm, level floorMust have sufficient space and easy access to the system partsPrevent the spray of sparksThe floor must have sufficient load bearing capacity for the weight of thesystem parts and stresses caused by movements

The stability must be ensured
Information on technical data, operating conditions, etc. for the intended
use can be found in type sheet or the product-specific data sheet andcircuit diagram.
The plant must be screwed to the substrate.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en29Installation

6.3

Installing accessories

6.3.1

Installing process monitoring (option)
è Please see the separate operating manual for the installation of the processmonitoring system.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en30

Installation

6.3.2

Installing the ergonomic handle (optional)

2

1

3

1
3

Additional handle
Clamp screw

2

Handle1. Unscrew the handle of the hand lever.
2. Slide the ergonomic handle onto the hand lever.
3. Screw the additional handle in the desired position with the clamping screw.
4. Reattach the handle of the hand lever.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

31Installation

6.3.3

Installing the stroke counter (optional)

2

1

1

Cable set

2

Counter housing

1. Disconnect the cable set from the counter housing.
2. Install the counter housing on the press head using cylinder screw M 5x12.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en32

Installation

Installing the button

1

2

1

Button with fixing device

2

Spring sheet

1. Disassemble the spring sheet.
2. Screw the push button with fixing device onto the press head (cheese headscrews M 3x8).
3. Install the spring sheet.
4. Check the switching point of the push button. The push button must switch
shortly before reaching the final position. The switching point is set using
the two nuts on the push button.
5. Connect the cable set to the counter housing.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en33

Installation

6.3.4

Installing the force sensor (optional)

8
7
6
5

1
2

3
4

1
3
5
7

Screw clamp
Angled plugScrew fixing device
Straight connector

2
4
6
8

Cable clamp
Force sensor
Clamp
Fixing device

1. Screw the fixing device onto the press head.
2. Screw the force sensor onto the ram.
3. Fasten the cable clamp with the screw.
4. Connect the angled plug to the force sensor.
5. Screw the clamp in the lowest position onto the fixing device.
6. Connect the straight connector to the evaluation unit and insert it into theclamp.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en34

Installation

F1

F2

è NOTE! Observe the maximum thread length!
The tool must bear against flange 1 or flange 2.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en35

Installation

6.3.5

Install the return stroke lock (option)
During retrofitting it may be necessary to replace the shaft. In this case,please contact TOX® PRESSOTECHNIK.

2

1

1
3

Lever shaft
Cheese head screws M5 x 16

2

3

Cover

1. Unscrew the lever shaft from the cover. The flat spiral spring must nor beremoved.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en36Installation

1

1
3
5
7

2

3

4

5

Cheese head screws M5 x 16
Housing cover
Lock washer
Housing

6

7

2
4
6
8

8

Flat head screws
Locking screw M 6x12
Cam disc
Unlocking button

2. Attach the housing of the return stroke lock on the lever shaft and screw it
on with the M 5x16 cylinder screws.
3. The unlocking button must point to the front and be positioned on <STOP>.
4. Insert the cam disc into the housing. The cam disk must latch in on the lever
shaft.
5. Fix the lock washer with the M 6x12 locking screw.
6. The return stroke lock must be adjusted. See Adjusting the return stroke
lock, Page 48.
7. Install the housing cover with the flat head screws.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en37Installation

6.3.6

Installing the slide table (optional)

1

2
3

10
1
3
5
7
9

9

8

7

Base plate
Stop
Grease nipple
Fastening groove (T-groove)
Pneumatic the cylinder (optional)

6

5
2
4
6
8
10

4
HandleTool plate
Fastening holes
Retract pneumatic connection
Extend pneumatic connection

1. Insert the T-groove nuts into the fastening groove of the press frame.
2. Pull out the tool plate until the fastening holes are accessible.
3. Screw the base plate over the mounting holes using the T-groove nuts.
4. The insertion width is set via the stop.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en38Installation

6.3.7

Installing travel sensor (option)

2

1

3

4
5

6

7

1
3
5
7

Cheese head screw
Straight connector
Product tag
Counter nuts

2
4
6

Mounting clip
Flat head screw
Fixing device

1. Unscrew the product tag.
2. Screw on the fixing device together with the tag. The travel sensor is pointing towards the press frame.
3. Screw the rear fixing device onto the press head.
4. Connect the cable to the evaluation unit.
5. Screw the straight connector to the fixing device using the fastening clip.
6. Set the zero point, see: Setting the travel sensor, Page 52.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en39Installation

6.3.8

Installing the tool holding fixture (optional)

1

2

1

Ram

2

Tool holding fixtureè The tool holding fixture is screwed into the ram.
For technical data and installation dimensions see data sheet.
www.tox.com

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en40

Commissioning

7 Commissioning
7.1

Safety during the commissioning
The commissioning may only be carried out by trained and authorized personnel.

7.1.1

Safety device
All safety equipment must be properly assembled and functional.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

41

Commissioning

7.2

Requirements for the commissioning
The requirements are:All components are properly installed.

The safety devices of the entire system are properly assembled and functional.



Any transport locks are removed.



Supply connections, communication and control connections, material or
media hoses are installed properly. The permissible values are complied
with.



TOX® PRESSOTECHNIK has released the system and associated components for commissioning.

No tools, installation equipment or other interfering objects may be left in
the tool area or working area.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en42

Operation

8 Operation
8.1

Safety in operation
CAUTION
Dangerous lever movements!
Contusions and impacts!
è Always hold the hand lever.
è Release it only when it is in the top initial position.

8.2

8.3

Requirements for operation
The safety devices of the entire system are properly assembled and functional.

All piece parts are intact and properly maintained.

Supply connections, communication and control connections, material or
media hoses are installed properly. The permissible values are complied
with.

Process monitoring
See the separate operating manual for the installation of the process monitoring
system.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

43Operation

8.4

Setting the open height of the press head

1

2

3

4

1
3

Fig. 3

Cap
Square2
4Crank
Fastening screws

Setting the open height of the press head

NOTE! Damage on the tool or the workpiece! Calculate the open height before
starting operation!

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

44Operation

ü

Set the fine adjustment on the largest opening. See Fine adjustment ofworking stroke, Page 46.

1. Remove the cover from the press frame.
2. Loosen the fastening screws of the clamping plate. Do not unscrew thescrews!
3. Place the supplied crank onto the square and adjust the open height byturning it.
Turning clockwise - increases the open height.
Turning anti-clockwise - reduces the open height.
4. Remove the crank and stow it away.
5. Tighten the fastening screws of the clamping plate. Observe the tightening
torques, see Inspecting the fastening of the press head, Page 59.
6. NOTE! Damage on the tool! The tool must be aligned!
7. Place the cover on the press frame.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

45

Operation

8.5

Fine adjustment of working stroke (option)

1
2

3

1
3

Clamping screw
Clamping nut

2

Adjusting ring

1. Loosen the clamping screw.
2. Turn the adjusting ring to adjust the open height.
A line on the scale of the adjusting ring corresponds to a height adjustmentof 0.02 mm.
Turning clockwise - increases the open height.
Turning anticlockwise - reduces the open height.
3. Fix the adjusting ring with the clamping screw.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

46

Operation

8.6

Setting working depth

1

2

1

Knurled screw

2

Counter nut

One rotation of the knurled screw corresponds to an adjustment of 1 mm.
Turn clockwise - decrease working depth.
Turn anticlockwise - increase working depth.
1. The working depth can be set using the knurled screw.
2. Secure the setting by tightening the counter nut.

8.7

Resetting the stroke counter (optional)
The stroke counter has a reset button.
è Press the stroke counter button.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

47

Operation

8.8

Adjusting the return stroke lock (optional)
NOTE! Do not push the hand lever back while the mechanism is locked.

1

2

3

6
1
3
5

Threaded hole (position 1)
Cross bore hole
Inner mechanism

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

5

4
2
4
6

Cheese head screw (position 2)
Unlocking device
Cheese head screws

48

Operation

üThe housing cover is removed.

1. Loosen the cheese head screws (positions 2 and 6).
2. Pull the unlocking device and turn to position <STOP> to release the handlever.
3. Press the hand lever completely down and hold.
4. Turn the inner mechanism clockwise until the return stroke lock unlocks.
The lock engages twice audibly with a click, and unlocks by turning it further.
A suitable tool (e.g. Allen key) can be inserted into the cross bore hole toturn the mechanism.
5. Tighten the cheese head screws (positions 2 and 6).
6. Install the housing cover.
Lever travel for position 1

1

2

40°

3

24°
17°

4

1

Maximum lever opening (OT)2

3

The return stroke lock engages
during forward stroke

4

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

Return stroke activates returnstroke lock
Forward stroke unlocks returnstroke lock (UT)49

Operationü

The return stroke lock has engaged.

üThe housing cover is removed.

1. Lock the return stroke lock in the second position.
2. Unscrew the cheese head screw (position 2) and screw it into position 1(position 1).
3. Install the housing cover.
Lever travel for position 2

1
2

49°

42°

3

17°

4

1
3

Return stroke activates returnstroke lock
The return stroke lock engages
during forward strokeüThe return stroke lock has engaged.

üThe housing cover is removed.

2
4

The return stroke lock engages
during forward stroke
Forward stroke unlocks returnstroke lock (UT)

1. Unscrew the cheese head screw (position 1) and screw it into position 2(position 2).
2. Install the housing cover.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

50

Operation

8.9

Setting the return stroke

2

1

1

Cheese head screw

2

Threaded bores

1. Press the hand lever down and hold.
2. Remove the cheese head screw.
3. Screw in the cheese head screw into the threaded bore at the new position.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en51

Operation

8.10

Setting the travel sensor (option)

1

1

Counter nuts of travel sensor

1. Loosen the counter nuts of travel sensor.
2. Press the hand lever of the press firmly up and hold.
3. Set the zero point on the travel sensor by turning the nut.
4. Tighten the counter nuts of the travel sensor.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

52Troubleshooting

9 Troubleshooting
9.1

Safety during troubleshooting
Troubleshooting may only be carried out by trained and authorized personnel.
The following applies:

Inform operating personnel before starting repair work.

Appoint a supervisor.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

53Troubleshooting

9.2

Detecting faults
If the press is equipped with a control system, the faults or warnings on the central control unit are displayed and described.

Fault

Cause

Measures

The ram does not extend.
The nominal force notreached.

There is a mechanical fault on theguide.
There is a mechanical fault on theguide.
The press head is not adequately
fastened.

Contact authorized service personnel.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

Contact authorized service personnel.
Tighten the fastening screws evenly. Observe
the tightening torques, see: Inspecting the fastening of the press head, Page 59).

54

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

WeeklyMonthly
Half-yearly

10.4.1
10.4.310.4.2

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

TOX® FinePress inspecting
Inspecting and cleaning movable parts and guides
Inspecting the fastening of the press head55

Maintenance

10 Maintenance
10.1

General information
Maintenance may only be carried out by trained and authorized personnel.
The following applies:

Observe maintenance intervals if present and stipulated.



Maintenance intervals may vary from the stipulated maintenance intervals.
The maintenance intervals may have to be verified with the manufacturer ifnecessary.

Perform only maintenance work that is described in this manual.



Inform operating personnel before starting repair work.

Appoint a supervisor.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

56

Maintenance

10.2

Safety during maintenance
The following applies:

Observe maintenance intervals if present and stipulated.



Maintenance intervals may vary from the stipulated maintenance intervals.
The maintenance intervals may have to be verified with the manufacturer ifnecessary.

Perform only maintenance work that is described in this manual.



Inform operating personnel before starting repair work.

Appoint a supervisor.

10.3

Requirements for maintenance10.3.1

Set system to maintenance position
Unless specified otherwise, before all maintenance work:
1. Retract the working piston.
w Plant is in home position.
2. Install a restraint device if necessary.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

57

Maintenance

10.4

TOX® FinePress maintaining

10.4.1

TOX® FinePress inspecting
üSystem is in maintenance position.
See Set system to maintenance position, Page 57.

1. Check the plant, particularly moving parts for wear, obvious defects anddamage.
2. Check the supply connections for tightness.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

58

Maintenance10.4.2

Inspecting the fastening of the press head

1

1

ü

Fastening screws

System is in maintenance position.
See Set system to maintenance position, Page 57.

1. Check the tightening torque of the fastening screws.
2. NOTE! Damage on the tool! Check the alignment of the tool!

Screw size

Tightening torque

M 10

60 Nm

Tab. 2

Fastening screws of the press head on the frame

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

59Maintenance10.4.3

Inspecting and cleaning movable parts and guides
üSystem is in maintenance position.
See Set system to maintenance position, Page 57.

NOTE
Incorrect cleaning agents or cleaning procedures, lack of corrosion protection!
Damage to machine components!
è Clean plastic parts such as panes (safety guard door, housing, etc.) andcontrol elements with cotton cloths (smooth woven structure) and suitablecleaning agents (e.g. clear water and neutral rinsing liquid).
Do not use scouring (abrasive) cleaning agents.
è Only touch bare spots with gloves.
è For metallic surfaces use cleaning set, such as industrial cleaner (e.g. Loctite 7063, or Würth Montagekraftreiniger 0890 107), vacuum cleaner, dry
cloth and brush.
è After cleaning, protect bare outer surfaces from corrosion. Coat surfaces
with a cloth slightly moistened with anticorrosive fluid.
è Keep inside surfaces, especially element-carrying parts, dry and free ofgrease.

è Inspect movable parts and guides, clean and lubricate if necessary.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

60Repairs

11 Repairs
11.1

Safety during repairs
Repairs may only be carried out by trained and authorized personnel.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

61

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 Have all work on the electrical equipment performed by an electrician.
è Disconnect power supply.
è Wait for residual energy to disspate safely (at least 3 minutes).

WARNING
Ejecting parts and compressed air from compressed air conducting lines!
Serious injuries to eyes and body cavities!
è Always connect and disconnect lines without pressure.
è Pay attention to maximum permitted pressures.
è Wear individual protective equipment.

CAUTION
Sharp edges caused by material splintering!
Injuries from worn parts!
è Wear individual protective equipment.
è Do not move fingers along the cutting edges.
è Be particularly careful and attentive.

12.2

Decommissioning
Decommissioning means that the plant is not in operation for a longer period oftime but remains at the installation site for recommissioning later.
1. Switch off plant at the main switch.
2. Clean the system and protect it against corrosion.
3. Protect plant against loss of data and deep discharge.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

62

Disassembly and Disposal

12.3

Shutdown
Shutdown means that the system is shut down permanently and/or is preparedfor removal.
1. Stop system and wait for it to come to a standstill.
2. Remove material if necessary.
3. Switch off the system at the main switch and secure it against being
switched on again.
4. First disassemble or dismantle after switching off the power (electricity,pneumatics) and after residual energy has safely dissipated (at least 3 minutes).
5. Remove electrical supply line (first at the terminal, then on the machine).
6. Remove compressed air supply line.
7. Remove network connection.
8. Clean the system and protect it against corrosion.
9. Protect open cable ends against penetration of dirt.
10. Do not remove cable identifications.

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

63

Disassembly and Disposal

12.4

Disassembling
The system consists of recyclable materials.

NOTE
Environmental damage!
Improper recycling endangers the environment!
è Dispose of materials separately and properly.
è Regional disposal regulations must be observed.

1. Strip the system down into its constituent parts.
2. Dispose of greases and oils separately.
3. Sort the constituent parts by material and dispose of according to the local
regulations.

12.5

Disposal
When disposing of packaging, consumables and spare parts, including themachine and its accessories, the relevant national environmental
protection regulations must be complied with.

For the environmentally compatible utilization and disposal of its electronic components, please contact the certified disposal company for electronic waste or
return it to TOX® PRESSOTECHNIK.
For further information about the take-back and forms see www.tox.com in theservice sector.
Regarding questions about disposal please contact TOX® PRESSOTECHNIKGmbH & Co. KG (see Contact and source of supply, Page 10).

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en64Appendices

13 Appendices13.1

Declaration of conformity

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

65Index

Index
A

F

Accessories
Installing.................................................... 30
Adjustment
Return stroke lock..................................... 48
Attachment point ........................................... 25

Faults
Detect ........................................................ 54
Fine adjustment
Working stroke .......................................... 46
FinePress
Inspecting .................................................. 58
Maintaining ................................................ 58
Force sensor
Installing .................................................... 34
Function description....................................... 21

B
Basic safety requirements ............................. 11Ccommissioning............................................... 41
Requirements ........................................... 42
Safety........................................................ 41
Safety device ............................................ 41
Conformity ....................................................... 6
Contact .......................................................... 10
Contusion
Hazard ...................................................... 15D
Declaration of conformity............................... 65
Decommissioning .......................................... 62
Disassembly ............................................ 62, 64
Safety........................................................ 62
Dispatch
Repair ....................................................... 26
Disposal................................................... 62, 64
Safety........................................................ 62
Document
additional .................................................... 7
Validity ........................................................ 7
Drive/Fastening
Inspecting ................................................. 59

G
Gender note ..................................................... 7
General information
Maintenance.............................................. 56
Guidelines ........................................................ 6
Guides
Inspecting .................................................. 60

H
HazardContusion .................................................. 15
Electrical.................................................... 14
electromagnetic ......................................... 16
Hazardous substances.............................. 16
hydraulic .................................................... 15
Laser ......................................................... 16
Noise ......................................................... 17
Pneumatic ................................................. 15
Thermal ..................................................... 14
Hazard potential............................................. 14
Hazardous substances .................................. 16
HydraulicHazard....................................................... 15

E
Electromagnetic
Hazard ...................................................... 16
Ergonomic handle
Installing.................................................... 31
Exclusion of liability ......................................... 6

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

68IndexI

N

ImagesHighlighting ................................................. 9
Important information ...................................... 6
Information
Important..................................................... 6
Inspection
Drive/Fastening......................................... 59
FinePress.................................................. 58
Guides ...................................................... 60
Installation ..................................................... 27
Accessories .............................................. 30
Ergonomic handle..................................... 31
Force sensor ............................................. 34
Process monitoring ................................... 30
Requirement ............................................. 29
Return stroke lock..................................... 36
Safety........................................................ 27
Set-up location.......................................... 29
Slide table ................................................. 38
Stroke counter .......................................... 32
Tool holding fixture ................................... 40
Intended use.................................................. 19

NoiseHazard....................................................... 17
Note
Gender ........................................................ 7
General ....................................................... 8
Legal ........................................................... 6
Warning signs ............................................. 8

L
LABS ............................................................. 20
Laser
Hazard ...................................................... 16
Legal note........................................................ 6O
Open height of the press head
Setting ....................................................... 44
operation ........................................................ 43
Process monitoring ................................... 43
Requirements ............................................ 43
Safe ........................................................... 19
Safety ........................................................ 43
Organizational measures ............................... 12P
Process monitoring
Installing .................................................... 30
Process monitoring system
Operate ..................................................... 43
Product overview ........................................... 21

Q
Qualifications ................................................. 13

M

R

Maintenance .................................................. 56
FinePress.................................................. 58
General information .................................. 56
Requirement ............................................. 57
Safety........................................................ 57
Maintenance position .................................... 57
Measures
Organizational........................................... 12
Misuse ........................................................... 20
Mounting
Travel sensor ............................................ 39

Repair
Dispatch .................................................... 26
Repairs........................................................... 61
Safety ........................................................ 61
Requirement
Installation ................................................. 29
Maintenance.............................................. 57
Reset
Stroke counter ........................................... 47
Return stroke
Setting ....................................................... 51
Return stroke lock
Adjusting ................................................... 48
Install ......................................................... 36

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

69IndexS

T

Safety ............................................................ 11
Commissioning ......................................... 41
Disassembly ............................................. 62
Disposal .................................................... 62
Installation................................................. 27
Maintenance ............................................. 57
Operation .................................................. 43
Repairs ..................................................... 61
Transport .................................................. 23
Troubleshooting ........................................ 53
Safety device
Commissioning ......................................... 41
safety requirements
Basic ......................................................... 11
Operating company .................................. 12
Safety symbols .............................................. 18
Selection
Personnel.................................................. 13
Selection of personnel ................................... 13
Setting
Open height of the press head ................. 44
Return stroke ............................................ 51
Travel sensor ............................................ 52
Working depth........................................... 47
Set-up location .............................................. 29
Shutdown ...................................................... 63
Slide table
Installing.................................................... 38
Source of supply............................................ 10
Storage .................................................... 23, 24
Stroke counter
Installing.................................................... 32
Resetting................................................... 47
Substances harmful to the wetting properties oflacquers (LABS)........................................ 20

Target group .................................................... 7
Technical data ............................................... 22
Texts
Highlighting ................................................. 9Tool holding fixture
Installing .................................................... 40
Transport........................................................ 23
Attachment point ....................................... 25
Safety ........................................................ 23
Travel sensor
Installing .................................................... 39
Setting ....................................................... 52
Troubleshooting ............................................. 53
Safety ........................................................ 53

TOX_Manual_FinePress_ZFS-ZFL-ZFW_en

U
Use
Intended .................................................... 19

V
Validity
Document .................................................... 7W
Warning signs .................................................. 8
Working depth
Setting ....................................................... 47
Working stroke
Fine adjustment......................................... 4670