Original operating instructions

TOX® Powerpackage line-Q

Edition: 04/08/2024, Version: 6

Draft

Type Q-S, Q-K

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

Table of contents

Table of contents
1

Important information
Legal note .................................................................................................... 7

1.2

Exclusion of liability...................................................................................... 7

1.3

Conformity ................................................................................................... 7

1.4

Validity of the document .............................................................................. 8

1.4.1

Content and target group............................................................................. 8

1.4.2

Other applicable documents ........................................................................ 8

1.5

Gender note................................................................................................. 8

1.6

Displays in the document............................................................................. 9

1.6.1

Display of warnings...................................................................................... 9

1.6.2

Display of general notes ............................................................................ 10

1.6.3

Highlighting of texts and images................................................................ 10

1.7

Contact and source of supply .................................................................... 112

Safety

Draft

1.1

2.1

Basic safety requirements ......................................................................... 12

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 .................................................................................... 14

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

2.3.10Lithium ion battery ..................................................................................... 17

TOX_Manual_Powerpackage_line-Q_en2

Table of contents

3

About this product
Intended use .............................................................................................. 18

3.1.1

Safe and correct operation ........................................................................ 18

3.1.2

Safe and correct design and construction ................................................. 19

3.1.3

Foreseeable misuse .................................................................................. 19

3.2

Product Identification ................................................................................. 20

3.2.1

Position and content of the type plate........................................................ 20

3.3

Function description of TOX® Powerpackage with mechanical spring ...... 21

3.4

Product overview of TOX® Powerpackage line-Q...................................... 25

3.4.1

Product attributes of Powerpackage line-Q ............................................... 25

3.5

Optional equipment.................................................................................... 26

3.5.1

Additional optional equipment.................................................................... 26

3.6

Product planning........................................................................................ 27

3.6.1

Design data................................................................................................ 27

3.6.2

Design principles ....................................................................................... 27

3.6.3

Air consumption ......................................................................................... 28

3.6.4

Cycle times ................................................................................................ 29

3.6.5

Performance optimization .......................................................................... 30

3.6.6

Avoidance of dynamic oil leakage ............................................................. 30

3.6.7

Stroke limitation of the power stroke.......................................................... 32

3.6.8

Speed reduction of the power stroke ......................................................... 33

3.6.9

Horizontal installation Type K and Z .......................................................... 34

3.7

Activation and pressure control ................................................................. 34

3.7.1

Design principles of activation ................................................................... 34

3.7.2

Activation according to dynamic pressure method .................................... 36

3.7.3

Pressure control in the power stroke line (assembly ZDK) (optional)........ 37

3.7.4

Pressure control in the power stroke line with proportional pressure control
valve (optional) .......................................................................................... 39

3.7.5

External power stroke switch (assembly ZKHZ) (optional) ........................ 41

3.7.6

External power stroke deactivation (assembly ZKHD) (optional) .............. 43

3.7.7

External power stroke release (assembly ZKHF) (optional) ...................... 45

3.7.8

External power stroke supply (optional)..................................................... 47

4

Draft

3.1

Technical data

4.1

Type sheet and data sheet ........................................................................ 50

4.2

General environmental conditions ............................................................. 50

TOX_Manual_Powerpackage_line-Q_en3

Table of contents

4.3

Ambient temperature ................................................................................. 50

4.4

Compressed air quality and pneumatic connection ................................... 51

4.5

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

4.6

Press force table........................................................................................ 52

4.7

Specification for hydraulic oil ..................................................................... 52

5

Transport and storage
Safety during transport .............................................................................. 54

5.2

Lifting device.............................................................................................. 55

5.3

Temporary storages................................................................................... 55

5.4

Dispatch for repair ..................................................................................... 55

6

Installation

Draft

5.1

6.1

Safety during installation........................................................................... 56

6.2

Installing drive............................................................................................ 57

6.3

Installing optional accessories ................................................................... 58

6.3.1

Installing electronic pressure switch (ZDO) ............................................... 58

6.3.2

Installing and setting position sensors of stroke monitoring for forward andreturn stroke (ZHU).................................................................................... 60

6.3.3

Installing the external linear position sensor (ZHW) .................................. 62

6.3.4

Installing pressure control in the power stroke line (ZDK) ......................... 64

6.3.5

Installing external power stroke connection (ZKHZ) .................................. 66

6.3.6

Installing external power stroke release (ZKHF) and power stroke deactivation (ZKHD)................................................................................................ 67

6.3.7

Preparing external power stroke supply .................................................... 68

6.3.8

Installing the stroke frequency optimization (ZHO).................................... 69

6.3.9

Installing the speed reduction for power stroke venting............................. 71

6.3.10Installing tool coupling (ZWK) .................................................................... 72

7

Commissioning

7.1

Safety during the commissioning............................................................... 73

7.2

Requirements for the commissioning ........................................................ 74

TOX_Manual_Powerpackage_line-Q_en4

Table of contents

7.3

Setting control throttle 'X' ........................................................................... 75

7.4

Setting speed ratio of return stroke to fast approach stroke ...................... 77

7.5

Set the speed ratio between power stroke and power stroke venting (optional) ......................................................................................................... 77

8Operation

8.1

Safety in operation..................................................................................... 78

8.2

Requirements for operation ....................................................................... 79

8.3

Operating drive .......................................................................................... 79

9

Troubleshooting
Safety during troubleshooting .................................................................... 80

9.2

Searching for causes of fault on the Powerpackage ................................. 81

Maintenance table

10

Maintenance

Draft

9.1

10.1

General information ................................................................................... 84

10.2

Safety during maintenance ........................................................................ 85

10.3

Requirements for maintenance.................................................................. 87

10.3.1

Set system to maintenance position .......................................................... 87

10.4

Checking oil level....................................................................................... 88

10.5

Refilling oil and venting drive ..................................................................... 89

10.6

Lowering of oil level ................................................................................... 93

11

Repairs

11.1

Safety during repairs.................................................................................. 94

11.2

Changing seals .......................................................................................... 94

12
12.1

Disassembly and Disposal
Safety during disassembly and disposal.................................................... 95

TOX_Manual_Powerpackage_line-Q_en5

Table of contents

12.2

Decommissioning ...................................................................................... 96

12.3

Shutdown................................................................................................... 96

12.4

Disassembling ........................................................................................... 97

12.5

Disposal ..................................................................................................... 97

13
13.1

Appendices
DECLARATION OF INCORPORATION.................................................... 98

Draft

Index

TOX_Manual_Powerpackage_line-Q_en

6

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.

Operating instructions, manuals, technical descriptions and software are originally compiled in German.

1.2

Draft

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/guaranteewith reference to the selection, specifications and/or usability of these goods
and services. The use and/or representation of trademarked brands that do notbelong to TOX® PRESSOTECHNIK are for information only; all rights remain
the property of the owner of the trademarked brand.

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_Powerpackage_line-Q_en

7

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 the system or increase the standard of safety.



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

Other applicable documents

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

Draft

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

8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.

WARNING
Identifies a potentially dangerous situation!

Draft

è Measures for remedial action and protection.

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.

TOX_Manual_Powerpackage_line-Q_en

9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

Identifies prerequisites that must be followed.

1. Action step 1

w Identifies the result of an action.
u Identifies the result of a complete action.

Draft

2. Action step 2: identifies an action step in an operating sequence that mustbe followed to ensure trouble-free operation.

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_Powerpackage_line-Q_en

10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

Draft

For additional information and forms see
www.tox.com

TOX_Manual_Powerpackage_line-Q_en

11

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.


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.

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:

Draft

For this reason the following basic safety requirements will apply: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.

TOX_Manual_Powerpackage_line-Q_en

122.2.2

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.

Selection and qualifications of personnel

Draft

SafetyThe 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_Powerpackage_line-Q_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.

Draft



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

2.3.3



Wear individual protective equipment.



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

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

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

Wear individual protective equipment.

TOX_Manual_Powerpackage_line-Q_en

14

Safety

2.3.4

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:
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.

Draft

2.3.5



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_Powerpackage_line-Q_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

The following applies generally:

2.3.8

Draft

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.


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_Powerpackage_line-Q_en

16

Safety

2.3.9

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

2.3.10

Keep the duration of the exposure at a minimum.



Wear individual protective equipment.

Lithium ion battery
Lithium ion (Li-Ion) batteries are a hazardous material.
The following safety requirements apply for handling:
Check the battery before use for damage. Damaged Li-Ion batteries mustno longer be used or charged.

Do not drop batteries, throw them, subject them to shocks or other mechanical stress, which could lead to damaging the batteries.



After a mechanical effect due to a crash, impact or contusion, the further
use and charging of the battery is prohibited.



Due to improper use, fluid (electrolyte) can escape from the battery. Avoid
contact with liquids, and, in case of contact, thoroughly clean the affected
point with water. If the liquid entered the eyes, contact a doctor immediately.



If the operating period of a battery is found to lessen considerably, the use
is to be stopped immediately and the battery is to be replaced. Otherwise
there is the hazard of overheating and explosion.

Ensure that the battery cannot be short-circuited.



Do not subject the battery to rain nor dip it into conductive liquids (e.g. water, beverages, etc.).



Do not burn batteries since the battery can explode at high temperatures in
the fire.

TOX_Manual_Powerpackage_line-Q_en

Draft



17

About this product

3 About this product
3.1

Intended use



Installing, pressing

Punching, pressing (of function elements)

Riveting, crimping, flaring

Punching, piercingEmbossing, marking

Tensioning, clamping, crimping

Pressing, compressingClinching, joining

Draft

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:This incomplete machine may not be commissioned until it has been ascertained that the incomplete machine in which the component is to be installed
complies with the requirements of the Machinery Directive (2006/42/EC).

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_Powerpackage_line-Q_en

18About this product3.1.2

Safe and correct design and construction
The generated forces can be immense in case of different applications! Thiscan lead to damage or breakage of material. This can cause dangerous situations during operation!
The following aspects are an intrinsic part of the intended design and construction:
The design and construction must at all time guarantee that the maximum
generated forces do not lead to the failure or to a breakage of system components.

Especially during punching and hole applications must the dynamic forces
be effectively limited.

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.

Dynamic forces must be limited with suitable precautionary measures to ensure that the admissible (static) press forces are not exceeded.

Suitable precautionary measures can be as follows:–

Dampings in the tool–

Limit of the maximum accelerations,–

Use of optional modules such as damping of cutting impact or press-in

–

etc.

Draft



It must be ensured that there is no unauthorized, inadvertent, mistaken riseof the dynamic and static press forces and return stroke forces designed forthe application during operation.

If the Powerpackage is to be installed in movable applications (movable carriages, robots, etc.), the maximum occurring acceleration and brake forces must
not exceed the 5-fold of the dead weight of the Powerpackage. Higher brakeforces can cause danger to the life and limb of the user and damage to thedrive.
Non-observance of and non-adherence to the maximum admissible press
forces and return stroke forces is not valid as intended use and is not permitted.

3.1.3

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.

TOX_Manual_Powerpackage_line-Q_en

19About this product

Incorrect parameterization.



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

3.2

Product Identification

3.2.1

Position and content of the type plate
Designation on the type plate

MeaningType
No.
ΔV [ml]Product designation
Serial number
Lowering volume
Indicates the amount of oil that must be discharged again after completely filling.
Maximum pressure

Pmax

Type code structure
Type key

Description

X-S 008. 3030. 100. 12
X-S 008. 3030. 100. 12
X-S 008. 3030. 100. 12
X-S 008. 3030. 100. 12
X-S 008. 3030. 100. 12
X-S 008. 3030. 100. 12

Identifies the series type such as X-S, S, K, etc.
Indicates the press force in [tons].
Indicates the version.
Indicates the length of the total stroke.
Indicates the length of the power stroke.

TOX_Manual_Powerpackage_line-Q_en

Draft

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.

20About this product

3.3

Function description of TOX® Powerpackage withmechanical spring
The drive works with a pneumatically operated cylinder with pneumohydraulicpower 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.
Compressed air is converted to oil pressure in the intensifier part to generate
the necessary press force for the power stroke. In the working part, the oil pressure acts on the working piston.
The compressed air is also used for the fast approach of the working piston to
the working position (fast approach stroke) and for the return to the home position (return stroke).

1
3
5
7
9
11

Fig. 12

11

10

Return stroke chamberPower stroke valve
Intensifier piston
Storage piston
High-pressure chamber
Main control valve

3

9

8
2
4
6
8
10

7

6

5 4

Draft

1

Working piston
Power stroke chamber
Plunger return stroke spring
Plunger
Fast approach stroke chamber

Starting position

In home position, the drive is controlled via the main control valve in the return stroke.

The working piston is retracted.

TOX_Manual_Powerpackage_line-Q_en

21About this productPneumatically operated fast approach stroke

11
1
3
5
7
9
11

Fig. 2

3

10Return stroke chamberPower stroke valve
Intensifier piston
Storage piston
High-pressure chamber
Main control valve

6

5 4

9

87

2
4
6
8
10

Working piston
Power stroke chamber
Plunger return stroke spring
Plunger
Fast approach stroke chamber

Fast approach stroke

Draft

12



After switching over the main control valve to forward stroke, compressed
air enters the fast approach stroke chamber. The return stroke chamber isbeing vented.

The power stroke valve is supplied with compressed air.



The working piston extends with a fast approach stroke.

The feed piston pushes hydraulic oil from the reservoir into the high pressure chamber activated by the mechanical spring.



As soon as the working piston meets any resistance, it stops.

The power stroke valve switches over independently to power stroke after adelay, depending on the air volume flowing out of the control throttle 'X'.

TOX_Manual_Powerpackage_line-Q_en

22About this productPneumohydraulic power stroke

2

3

1

1
3
5
7
9
11

Fig. 3

10

Return stroke chamberPower stroke valve
Intensifier piston
Storage piston
High-pressure chamber
Main control valve

9

8 7 6
2
4
6
8
10

5

4

Working piston
Power stroke chamber
Plunger return stroke spring
Plunger
Fast approach stroke chamberPower stroke

Draft

11



Compressed air from the forward stroke connection penetrates into thepower stroke chamber of the intensifier piston via a connection line.

The plunger passes through the high pressure seal and separates the oilchamber into a working area and an oil reservoir.



A hydraulic pressure is generated in working area, which creates the powerstroke via the working piston.

TOX_Manual_Powerpackage_line-Q_en

23About this product

Return stroke

11
1
3
5
7
9
11

Fig. 43

10

Return stroke chamberPower stroke valve
Intensifier piston
Storage piston
High-pressure chamber
Main control valve

9

8
2
4
6
8
10

7

6

5 4

Working piston
Power stroke chamber
Plunger return stroke spring
Plunger
Fast approach stroke chamber

Return stroke

Draft

1 2



The main control valve is switched over to return stroke by a signal. The return stroke chamber is being filled with compressed air.



As a result, the power stroke valve is vented and moved to the home position.



The power stroke chamber of the intensifier piston is vented via the muffler
and the return stroke is triggered.

After the intensifier piston has released the high pressure seal, the working
piston moves back to the home position.

TOX_Manual_Powerpackage_line-Q_en

24About this product3.4

Product overview of TOX® Powerpackage line-Q

6

5

5

4
1

2 3

4
2 3

6
1
3

Working piston
Control throttle 'X'

2
4

5

Oil filling nipple

6Fig. 5Compressed air supply return stroke [2]Compressed air supply fast approach
stroke [4]Power stroke valve

Draft

1

Product overview of TOX® Powerpackage type Q-S, Q-K

For product versions and product attributes see the design and installation
guideline.

3.4.1

Product attributes of Powerpackage line-Q

Type Q-S








Type Q-K

Intensifier and working part are interconnected with  Intensifier and working part are connected with ana tension rod in a sandwich construction.
intermediate flange (compact construction).
Including power stroke valve and control throttle 'X'.
Equipped with mechanical spring.
Including power bypass ZLB with hydraulic end position cushioning ZHD in the upper final position.
Including fixed stop with elastomer cushioning in the lower final position.
Prepared for stroke monitoring ZHU.
Prepared for external linear position sensor ZHW.

TOX_Manual_Powerpackage_line-Q_en

25

3.5

Optional equipment

3.5.1

Additional optional equipment
Type

Product attributes

ZHW

Travel measuring system The travel sensor indicates the absolute actual positionof the piston.
 For external installation (for series line-Q and line-X to
Q-S/Q-K 30, X-SX-K 30).
Stroke monitoring Determines the position of the working piston during
forward stroke and return stroke via the external sensor.
Pressure regulation in power stroke line
 Make possible the individual adjustment of the press
force with a manual pressure valve or electrical proportional valve.
External power stroke connection
 Enables the connection of the power stroke valve with
an electrically actuated 3/2-way valve.
Tool coupling Connects the drive and tool flexibly to prevent transverse forces from affecting the drive.
Electronic pressure switch
 Records the oil pressure in the high-pressure part assystem pressure and visualizes it via a four-digit LED
display.
 The set switching function allows 2 output signals to becreated.
Stroke frequency optimization
 Reduces the cycle time.
 Replaces the existing power stroke valve with one of
the next size.
Pressing force sensor
 Measures the press forces in the direction of the pressure.

ZHU

ZDK

ZKHZ

ZWK

ZDO

ZHO

ZPS

Draft

About this productFor optional equipment, see data sheet and brochure TOX® Powerpackage.
http://tox-pressotechnik.com/

TOX_Manual_Powerpackage_line-Q_en

26

About this product3.6

Product planning

3.6.1

Design data

Data sheet
For technical data and installation dimensions see data sheet.
(http://www.tox-pressotechnik.de)

Design principles
When fastening, note the following:–

Installation dimensions–

Weight, including weight of the accessories–

Press force–

Loads caused by the working process (dynamics and vibrations)

Draft

3.6.2



No transverse forces may act on the piston rod.
If necessary, use a linear guide for the working piston: either a ram plateand guiding columns or a guiding rail with guiding carriage.

In the case of horizontal installation the connection side must face upwards.



Elements requiring servicing maintenance, such as oil filling nipple, venthole, high pressure measuring connection, control throttle‚X‘ and oil level indicator should be accessible.



Make sure that the ventilation of the hydraulic system is always possible
even when installed.

The space requirement for supply lines must be taken into consideration.



The length of the hose lines, the connection of an oil pressure switch or oilpressure monitor can significantly reduce the power stroke.

TOX_Manual_Powerpackage_line-Q_en

27About this product3.6.3

Air consumptionFor the air consumption, the fast and return stroke are calculated with theavailable air pressure.

The air requirement in the power stroke is calculated depending on the required press force.
For example, this depends on when the required oil pressure is reached.



If the intensifier chamber is filled with complete air pressure, the air consumption can indeed be higher than the requirement that is actually needed
and calculated.

In general, the specification for the air requirement includes all filling processes
required for a stroke. The information only refers to the specific drive.

The following applies here: Energy-saving are short lines from the valve to thedrive.
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 liters perhour. 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 depressurized during
this time.

WARNING

Draft

For hoses and valves - in particular for long hoses with large cross sections which are filled and ventilated together with the drive, their consumption mustalso be considered when selecting a compressor.

Risk of personal injury due to the lowering of the working piston
There is a risk of crushing when the working piston lowers.
The working piston of a Powerpackage / KT systems can only be held up with
sufficient return stroke pressure and sufficient air supply during the installation
in a press!
In the event of a compressed air failure, no return stroke will be initiated!
Depending on the size of the drive and the weight of the tool used, a slow lowering of the working piston is possible.
è Use a controlled check valve or holding brake (ZSL) or mechanical holding
device, especially with large tool weights.
è If controllable valves are installed as pneumatic holding brake at the customer, the corresponding safety regulations are to be observed and adhered to.

TOX_Manual_Powerpackage_line-Q_en

28

About this product

3.6.4

Cycle times
The cycle time is calculated depending on the required press force. The following applies:

The smaller the effective press force, the shorter the cycle time.

An effective press force over 90 % should be avoided.

The switching times of the valves and controls upstream of the drive must
be taken into consideration for the specified cycle times.

Requirement for achieving the calculated times:Air pressure
The required air pressure is the result of the desired effective press force.
To achieve a short cycle time, an air pressure as high as possible is recommended for fast and return stroke. If the maximum press force of the cylinder is to be reduced, this can be realized with a pressure control ZDK (manual or electric) in the power stroke line.
Cross-section of hose

Draft



The line cross sections must at least match the connection sizes provided inorder to achieve the calculated cycle time. This applies also to the regulation valves and maintenance units installed upstream of the drive.
Reduced line cross sections can considerably reduce the cycle time.
Reduced line cross sections can lead to oil leakages on the powerpackage,
see Avoidance of dynamic oil leakage, Page 30.
Tube lengths
The length of the hoses should be kept to a minimum, since the air consumption as well as the cycle time are increased with the length.

Compressor performance
The compressor performance should always be sized with sufficient safety.



Speed setting
The speed can be regulated as required by installing throttle check valvesin the fast approach stroke and return stroke lines (except for type RP, T).
Furthermore, the speed of the power stroke can be adjusted by mounting athrottle in the power stroke line of the unit. The drive can thus also be used
for special applications, such as pressing in bushes, projecting etc.

Optimization of stroke frequency ZHO
The cycle time specifications correspond in general only to the entire drive
under realistic conditions. If necessary, the cycle time can be further reduced using our optional accessory module ZHO.

TOX_Manual_Powerpackage_line-Q_en

29

About this product

3.6.5

Performance optimization
The ratio of the speed between the return stroke and the fast approach stroke
must be set in order to ensure optimum performance.
An optimum speed ratio between fast approach stroke and return stroke.

A balanced power stroke speed.

Adequately sized connection sizes (cross-section of hose, switching valves,maintenance unit) that prevent a reduction of the power stroke speed.

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

3.6.6

Avoidance of dynamic oil leakage

The following applies:

The ratio of the speed between the return stroke and the fast approach
stroke must be set.
–For setting the speed ratios, also the exhaust air dampers must be installed on the fast approach stroke connections and the return stroke
connections.

Draft

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.

A balanced power stroke speed.
–

For the attuned power stroke speed an exhaust air damper must also
be installed in the power stroke venting.



For the throttled power stroke speed, the speed ratios between powerstroke speed and venting of the power stroke must be set.
See Installing the speed reduction for power stroke venting, Page 71.



The power cross sections to the TOX® Powerpackage (hose cross sections,switching valves, maintenance unit) must at least meet the specifications in
the type sheet.

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

TOX_Manual_Powerpackage_line-Q_en

30

About this productSetting 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 returnstroke. The exhaust air dampers may have to be retrofitted.
Typeline-Q
Necessary speed ratio Return stroke equally fast as fast approach strokeor Return stroke faster than the fast approach stroke
Tab. 1

Necessary speed ratio

1. Set speed ratio according to the specifications.
2. Perform test and check the speed visually.

Draft

A visual check of the speeds is generally sufficient.

Set the speed ratio between power stroke and power stroke venting(optional)
At throttled power stroke speed
Necessary speed ratio between power stroke and power stroke venting Power stroke speed equal to the return stroke speed of the intensifier pistonor Power stroke speed faster than the return stroke speed of the intensifier piston
Tab. 2

Necessary speed ratio

A visual check of the speeds is generally sufficient.

1. Set speed ratio according to the specifications.
2. Perform test and check the speed visually.

TOX_Manual_Powerpackage_line-Q_en

31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 belimited.
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%.
The travel of the power stroke can be limited by:

Stroke limitation in the tool.

Stroke limitation by a set total stroke (fast approach stroke and powerstroke).



Stroke limitation by setting the total stroke length and cutting impact damping (ZSD).

2

1

3

A
A
1
3

Fig. 6Tool in starting position(UDC: Upper Dead Center
Stroke limitation
Minimum stroke

Draft

Stroke limitation of the power stroke in the tool

B
B
2

Tool after punching(LDC: Lower Dead Center)
Rubber spring

Stroke limitation in the tool

After the punching process the tool limits the power stroke (LDC).
Stroke limitation due to use of the internal fixed stop

Aside from the stroke limitation in the tool, also the internal fixed stop in thedrive at the end of the total stroke (fast approach stroke+power stroke) can beused.
If required, the total stroke can be reduced to the necessary total stroke whenplacing the order.

TOX_Manual_Powerpackage_line-Q_en

32About this product3.6.8

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 installed in this case so that the speed ratio can be adjusted.

Draft

See Installing the speed reduction for power stroke venting, Page 71.

TOX_Manual_Powerpackage_line-Q_en

33

About this product3.6.9

Horizontal installation Type K and Z

2
1

3 4

5

1
3
5

Fig. 7

Working part
BracketHorizontal assembly with standing intensifier

2
4
6

Intensifier
Bow (machine)
Horizontal assembly with hanging intensifier

Horizontal installation

For horizontal installation type K, Z the following applies:

When the diameter difference between the working part and the intensifierpart is large, the weight of the intensifier needs to be supported.



The intensifier may only rest on the support device and must not bescrewed onto the working part.

Draft

6

A horizontal assembly with a standing intensifier facing up or with ahanging intensifier facing down is preferable to a lateral assembly.

3.7

Activation and pressure control

3.7.1

Design principles of activation
A distance-dependent external power stroke switch is recommendable:

For a piston rod working upwards.

In the case of a heavy tool weight.

In the case of fast approach stroke travel that is interrupted on account of
the application (e.g. for fixing in place a spring-loaded holding-down clamp).



If the control throttle 'X' cannot be adjusted for reasons of installation.

TOX_Manual_Powerpackage_line-Q_en

34

About this productAn external power stroke release with an electrical release signal is recommendable:

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:

When the forward stroke connection and back stroke connection areswitched, the compressed air supply of the pneumatic spring must also be
turned off.

Measuring connection and control connection
The oil pressure proportional to the press force is present on the measuring
connection and control connection.

Draft

This can be displayed, for example, by connecting a pressure gauge or used via
transmission to a pressure switch for generating a switching pulse.

TOX_Manual_Powerpackage_line-Q_en

35

About this product3.7.2

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 powerstroke valve switches and the intensifier piston is impinged with compressed air.
The changeover time is controlled and adjusted with the control throttle X.
The drive is actuated like a double-acting pneumatic cylinder, via an electrical,
pneumatic or mechanical 4/2 or 5/2 directional control valve or via a 4/3 or 5/3
directional control valve.
The drive must be switched to initial position before changing over to the fast
approach stroke.

Powerpackage with mechanical spring

6.1

Draft

2

1V1
12 12 <-> 1
12

1 3
1

14

‘X‘

2

1

Z1

6

HDM

4.1

X

line-Q, S/K-F
2

4

P

4

2

-?KYP1
1

2

1

5 1 3
1 1

3
1

Fig. 8

Activation according to dynamic pressure method for Powerpackage with mechanicalspring

TOX_Manual_Powerpackage_line-Q_en

36

About this product

Assembly

'X'
Z1

P

3.7.3

Power stroke valve
2Power stroke output
6.1
Power stroke signal
14
Control connection
3
Muffler output
1
Power stroke input
12
Control connection
Control throttle 'X'
Drive
8
Plunger return stroke input
4.2
Reservoir input
4.1
Fast approach stroke output
2.1
Return stroke output
2
Return stroke input
4
Fast approach stroke input
HPM
High pressure measuring connection
6
Power stroke input
To be carried out by the customer: Compressed air supply andmaintenance unit
(not included in delivery)

Draft

1V1

Pressure control in the power stroke line (assembly ZDK) (optional)
A pressure valve in the power stroke line enables individual adaptation of thepress force. No additional rapid vent valve is required. The required size depends on the size of the power stroke valve.
For installing the pressure regulation, see the operating manual, chapter Installation.

TOX_Manual_Powerpackage_line-Q_en

37

About this productPowerpackage with mechanical spring

1V1

2

6.1

12
12

13
1

14

‘X‘

2

1V5
2
1

Z1

6

1

HDM

4.1

X

line-Q, S/K-F
2

P

4

2

-?KYP21

1

2
3
1

Fig. 9

5 13
1
1

Draft

4

Pressure control in the power stroke line (assembly ZDK)Assembly
1V1

1V5

'X'
Z1

TOX_Manual_Powerpackage_line-Q_en

Power stroke valve
2Power stroke output
6.1
Power stroke signal
14
Control connection
3
Muffler output
1
Power stroke input
12
Control connection
Pressure regulator ZDK .2
1
Fast approach stroke input
2
Power stroke output
Control throttle 'X'
Drive

38

About this product

Assembly

P

3.7.4

8
Plunger return stroke input
4.2
Reservoir input
4.1
Fast approach stroke output
2.1
Return stroke output
2
Return stroke input
4
Fast approach stroke input
HPM
High pressure measuring connection
6
Power stroke input
To be carried out by the customer: Compressed air supply andmaintenance unit
(not included in delivery)

Pressure control in the power stroke line with proportional pressure
control valve (optional)

For installing the pressure regulation, see the operating manual, chapter Installation.

TOX_Manual_Powerpackage_line-Q_en

Draft

The electrical proportional valve in the power stroke line enables individual
adaptation of the press force. No additional rapid vent valve is required. The required size depends on the size of the power stroke valve.

39About this productPowerpackage with mechanical spring

1V1

2

6.1

12
12

13
1

14

1V5

T

G

1

P -138YH1

Z1

6

HDM

‘X‘

2

4.1

X

line-Q, S/K-F
2

P

4-?KYP2
1

1

2

2

5 13
1 1

3
1

Fig. 10Draft

4

Pressure control in the power stroke line with proportional pressure control valve

Assembly
1V1

1V5

'X'
Z1

TOX_Manual_Powerpackage_line-Q_en

Power stroke valve
2Power stroke output
6.1
Power stroke signal
14
Control connection
3
Muffler output
1
Power stroke input
12
Control connection
Pressure regulator ZDK .2
1
Fast approach stroke input
2
Power stroke output
Control throttle 'X'
Drive

40

About this product

Assembly

P

3.7.5

8
Plunger return stroke input
4.2
Reservoir input
4.1
Fast approach stroke output
2.1
Return stroke output
2
Return stroke input
4
Fast approach stroke input
HPM
High pressure measuring connection
6
Power stroke input
To be carried out by the customer: Compressed air supply andmaintenance unit
(not included in delivery)

External power stroke switch (assembly ZKHZ) (optional)

With the external power stroke switch option, the power stroke valve can beswitched using an electrically actuated 3/2-way valve.
An external power stroke switch can also be fitted retrospectively. The control
system can be combined with a pressure regulator in the power stroke line.
The following is required:

Draft

In the case of the external power stroke switch, the power stroke is initiated after reaching a particular distance or after a certain period of time.

Permanent compressed air supply of the electrical 3/2-way valve with 3 to 6
bar (connection G 1/8").

Electric switching signal (24 V) for switching the power stroke, e.g. a proximity switch ZHS 001 in combination with the stroke monitoring device ZHU,
or output signal of a travel transducer ZKW/ZHW.



Setting the position sensor of the stroke monitoring to the fast approach
stroke end position to prevent an overload.

TOX_Manual_Powerpackage_line-Q_en

41

About this productPowerpackage with mechanical spring

1V1

2

6.1

12 12 <-> 1

Z1

6

1 3
1

HDM

14

4.1

X

1V6

line-Q, S/K-F

1 3

4

2

P

4

2

-?KYP412

1
3
1

Fig. 11

2

5 1 3
1
1

Draft

12

External power stroke switch (subassembly ZKHZ)

Assembly
1V1

1V6

Z1

TOX_Manual_Powerpackage_line-Q_en

Power stroke valve
2Power stroke output
6.1
Power stroke signal
14
Control connection
3
Muffler output
1
Power stroke input
12
Control connection
Power stroke switch valve
1
Muffler output
2
Output
3
Input
Drive

42

About this product

Assembly

P

3.7.6

8
Plunger return stroke input
4.2
Reservoir input
4.1
Fast approach stroke output
2.1
Return stroke output
2
Return stroke input
4
Fast approach stroke input
HPM
High pressure measuring connection
6
Power stroke input
To be carried out by the customer: Compressed air supply andmaintenance unit
(not included in delivery)

External power stroke deactivation (assembly ZKHD) (optional)

An external power stroke deactivation can also be fitted retrospectively. The
control system can be combined with a pressure regulator in the power strokeline.
The following is required:


Draft

The power stroke can be deactivated with an electrical signal if necessary.

Permanent compressed air supply of the electrical 3/2-way valve with 3 to 6
bar (connection G 1/8").

TOX_Manual_Powerpackage_line-Q_en

43About this productPowerpackage with mechanical spring

1V1

2

6.1

12 12 <-> 1
12

1 3
1

14
3

‘X‘

2

2

1

1V7

1

Z1

6

HDM

4.1

2

1V6

X

1 3

line-Q, S/K-F

P

4

2

-?KYP512

1
3
1

Fig. 12

5 1 3
1
1

Draft

2

4

External power stroke deactivation (assembly ZKHD)

Assembly
1V1

1V6

1V7

'X'
Z1

TOX_Manual_Powerpackage_line-Q_en

Power stroke valve
2Power stroke output
6.1
Power stroke signal
14
Control connection
3
Muffler output
1
Power stroke input
12
Control connection
Electrical switching valve
3
Input (release)2
Output1
Input (deactivation)
OR valve3
Switching valve input
1
Control throttle 'X' input
2
OutputControl throttle 'X'
Drive

44

About this product

Assembly

P

3.7.7

8
Plunger return stroke input
4.2
Reservoir input
4.1
Fast approach stroke output
2.1
Return stroke output
2
Return stroke input
4
Fast approach stroke input
HPM
High pressure measuring connection
6
Power stroke input
To be carried out by the customer: Compressed air supply andmaintenance unit
(not included in delivery)

External power stroke release (assembly ZKHF) (optional)

An external power stroke deactivation can also be fitted retrospectively. The
control system can be combined with a pressure regulator in the power strokeline.
The following is required:


Draft

The power stroke can be released with an electrical signal if necessary.

Permanent compressed air supply of the electrical 3/2-way valve with 3 to 6
bar (connection G 1/8").

TOX_Manual_Powerpackage_line-Q_en

45About this productPowerpackage with mechanical spring

2

1V1

6.1

12 12 <-> 1
12

1 3
1

14
3

‘X‘

2

1

1V7

2

2

1

1 3

1V6
Z1

6

HDM

4.1

X

line-Q, S/K-F
4

P

4

2

-?KYP512

1
3
1

Fig. 13

5 1 3
1
1

Draft

2

External power stroke release (assembly ZKHF)

Assembly
1V1

1V6

1V7

'X'
Z1

TOX_Manual_Powerpackage_line-Q_en

Power stroke valve
2Power stroke output
6.1
Power stroke signal
14
Control connection
3
Muffler output
1
Power stroke input
12
Control connection
Electrical switching valve
3
Input (release)2
Output1
Input (deactivation)
OR valve3
Switching valve input
1
Control throttle 'X' input
2
OutputControl throttle 'X'
Drive

46

About this product

Assembly

P

3.7.8

8
Plunger return stroke input
4.2
Reservoir input
4.1
Fast approach stroke output
2.1
Return stroke output
2
Return stroke input
4
Fast approach stroke input
HPM
High pressure measuring connection
6
Power stroke input
To be carried out by the customer: Compressed air supply andmaintenance unit
(not included in delivery)

External power stroke supply (optional)

If a power stroke deactivation (assembly ZKHD) is installed, the power stroke
can be deactivated with an electrical signal if necessary.

Draft

In the case of the external power supply, the power stroke valve is supplied withcompressed air separately and independently from the fast approach stroke.
The power stroke can be released by a dynamic pressure switch, an external
power stroke switch (assembly ZKHZ), or by an external power stroke release(ZKHF).

The control system can be combined with a dynamic pressure switch, an external power stroke switch, an external power stroke release or a power stroke deactivation.
The following is required:External pressure supply at connection [1] of the power stroke valve.

TOX_Manual_Powerpackage_line-Q_en

47

About this productPowerpackage with mechanical spring

1V1

2

6.1

12
12

1 3
1

14

‘X‘

2
1

Z1

6

HDM

4.1

X

line-Q, S/K-F
2

P

4

2

-?KYP21

2

1
3
1

Fig. 14

5 1 3
1
1

Draft

4

External power stroke supply (optional)

Assembly
1V1

'X'
Z1

TOX_Manual_Powerpackage_line-Q_en

Power stroke valve
2Power stroke output
6.1
Power stroke signal
14
Control connection
3
Muffler output
1
Power stroke input
12
Control connection
Control throttle 'X'
Drive

48

About this product

Assembly

Draft

P

8
Plunger return stroke input
4.2
Reservoir input
4.1
Fast approach stroke output
2.1
Return stroke output
2
Return stroke input
4
Fast approach stroke input
HPM
High pressure measuring connection
6
Power stroke input
To be carried out by the customer: Compressed air supply andmaintenance unit
(not included in delivery)

TOX_Manual_Powerpackage_line-Q_en

49Technical data

4 Technical data
4.1

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

General environmental conditions


The TOX® Powerpackage is protected against the penetration of liquids andcontamination from the environment by means of seals, strippers and mufflers. However, the penetration of foreign substances during the use of
dusty or strongly contaminated environment cannot be completely excluded.
The damages resulting from contamination during operation are not covered by warranty regulations.



The penetration of water or other corrosive liquids must be prevented.



No guarantee for use in environments with strongly corrosive environmental
conditions such as increased salt content (maritime climate), cleaning withcorrosive cleaning agents, or the use of high-pressure cleaners.

Draft

4.2

If the drives are used in a corrosive environment, TOX® PRESSOTECHNIK
can supply drives in corrosion-protected design.

4.3

The specified maximum admissible environmental temperature must not be
exceeded to prevent damages to the sealing system and inadmissible expansion in the hydraulic system.
See Ambient temperature, Page 50.

The specified particle size and moisture for compressed air is to be adhered
to.
See Compressed air quality and pneumatic connection, Page 51.

Ambient temperature
Approved ambient temperature: 10 °C to 60 °C.

TOX_Manual_Powerpackage_line-Q_en

50Technical data

4.4

Compressed air quality and pneumatic connection
The following is required:

Filtered and dried compressed air

Lightly oiled compressed air is permitted.
Compressed air quality (according to DIN ISO 8573-1):

Class
5

Water dew point
[μm]
40

Class
4

Maximum Oil content

[°C]
3

Class
3

4.5

Tightening torques

4.5.1

Tightening torques for flange mounting the drive[mg/m3]
1

Prescribed tightening torques for fastening screws of property class ISO
4762-12.9:

4.5.2

Thread size

Torque

M6
M8
M 10
M 12
M 16
M 20
M 24
M 30

17 Nm
40 Nm
80 Nm
135 Nm340 Nm
660 Nm
1,130 Nm
2,250 Nm

Draft

SolidsTightening torques on the piston rod
Tool coupling

Piston rod thread

Tightening torqueM12 x 1.5
M16 x 1.5
M22 x 2.0
M30 x 2.0
M30 x 2.0
M39 x 2.0
M42 x 2.0
M64 x 2.0
M80 x 2.0

10 Nm
15 Nm
40 Nm
180 Nm
210 Nm230 Nm
290 Nm
500 Nm
500 NmZWK
ZWK 001
ZWK 002
ZWK 004
ZWK 008
ZWK 015ZWK 030ZWK 050ZWK 075
ZWK 200

TOX_Manual_Powerpackage_line-Q_en

51

Technical data

4.5.3

Tightening torques of pneumatic screw fittings on thePowerpackage
The specified tightening torques only apply to pneumatic screw fittings on thePowerpackage.

4.6

Connecting thread

Tightening torque

1/8"
1/4"
3/8"
1/2"

10 Nm
15 Nm
25 Nm
30 Nm

Press force table

4.7

Specification for hydraulic oil
The following oils are approved for standard application:
Hydraulic oil HLP32 (according to DIN 51524-2), filtered < 5µm, load rating> 30 N/mm2



Food grade oil Klüber Summit HySyn FG 32

Draft

Press force table see separate document.

The following hydraulic oils are approved with limitations for standard application:
Hydraulic oil UCON™ LB-165



Synthetic oil ISOTEX 46



Synthetic oil Envolubric PC 46 NWLThe use of hydraulic oils that have not been approved as standard can leadto an increase of maintenance intervals due to an increased intake of air.



The use of hydraulic oils that have not been approved as standard can reduce the lubrication capacity lower than for HLP32 hydraulic oils. This canlead to a shorter lifetime of seals.

Some sealing materials in case of hydraulic oils not approved as standard
tend towards increased swelling and therefore to a reduced lifetime of theseals.

TOX_Manual_Powerpackage_line-Q_en

52Technical data

NOTE
Loss of warranty in case of the use of non-approved hydraulic oils!
Due to the negative effects on maintenance intervals, swelling behavior and lifetime of the seals in case of the use of hydraulic oils that have not been approved as standard, the granted warranty becomes extinct.
è Use hydraulic oils that have bee approved by TOX® PRESSOTECHNIK as
standard.
è Use other hydraulic oils only after the express approval of
TOX® PRESSOTECHNIK.

Draft

è Do not mix different hydraulic oils. Negative effects such as flocculation
cannot be excluded.

TOX_Manual_Powerpackage_line-Q_en

53

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.

Draft

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.



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

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

TOX_Manual_Powerpackage_line-Q_en

54

Transport and storage

5.2

Lifting device
Depending on the size of the drive, the flange cover at the rear is provided withthreaded bore holes for ring bolts for hoisting.

WARNING
Risk of impact and crushing due to products swivelling out!
Severe impacts, crushing, and serious accidents as a result of the product rotating and swiveling out.
è Pay attention to the center of gravity and pivot point.
è Establish a V-shaped suspension connection in the center of gravity between the ring bolts.
è If there are no threaded holes, suspend the ring bolt between the working
part and intensifier.

5.3

5.4

Temporary storages

Use original packaging.



Make sure that all connections and threads are covered to prevent dust
ingress and shocks.

Store the product only in closed, dry, dust-free and dirt-free rooms at room
temperature.

Draft

è Lift up the product carefully.

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 11 or www.tox.com.

TOX_Manual_Powerpackage_line-Q_en

55

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.

WARNING

Draft

è Wait for residual energy to disspate safely (at least 3 minutes).

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
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_Powerpackage_line-Q_en

56

Installation

6.2

Installing drive
Material required:

Screws of the strength class : 12.9 (in accordance with ISO 4762)

Torque wrench

1. WARNING! Risk of crushing! Attach lifting device (ring bolts) and use appropriate lifting gear.
Place and align drive on the fastening element provided.

Draft

2. Tighten screws, observe torques while doing so.
See Tightening torques, Page 51.

TOX_Manual_Powerpackage_line-Q_en

57

Installation

6.3

Installing optional accessories

6.3.1

Installing electronic pressure switch (ZDO)

5

4

3

2

1

1
3
5

Screw
Cheese head screw
High-pressure measuring hose
(ZHM)

2
4
6

Assembly holder (ZMP)Electronic pressure switch (ZDO)
High pressure measuring connection

Draft

6

Material required:Electronic pressure switch (ZDO)

Assembly holder (ZMP)High-pressure measuring hose (ZHM)

NOTE
Air trapped in the connecting line!
Air could get into the high pressure chamber, impair the working process anddistort the measuring result.
è Fill connecting line with oil and vent.

TOX_Manual_Powerpackage_line-Q_en

58

Installationü

Make sure that the system is depressurized and disconnected from thepower supply.

ü

Observe the tightening torques.
See Tightening torques, Page 51.

1. Install assembly holder of pressure switch on the drive. Make sure that display and operating elements are easily accessible.
2. Fasten the pressure switch in the assembly holder.
3. Install high pressure hose on the pressure switch and on the high pressure
measuring connection.

Draft

4. Connect cable of the pressure switch on the control system according to circuit diagram.
See pressure switch ZDO operating manual.

TOX_Manual_Powerpackage_line-Q_en

59Installation

Installing and setting position sensors of stroke monitoring forforward and return stroke (ZHU)

Fig. 15

Installing position sensors for stroke monitoring for forward and return stroke

Material required:Magnet-sensitive proximity switch with LED (ZHS 001.001)

Holding angle for proximity switch



Cable box

Draft

6.3.2

1. Installing holding angle.
2. Installing proximity switch.
3. Connect the proximity switch to the control.
See circuit diagram.

TOX_Manual_Powerpackage_line-Q_en

60Installation

Setting the position sensors

üProximity switches are connected.

üWorking piston in home position.

1. Push the proximity switch from the edge of the cylinder to the first switch-on
point.
w The LED lights up.
2. Mark the edge of the proximity switch on the cylinder.
3. Push the proximity switch further to the switch-off point.
w The LED switches off.
4. Push the proximity switch back to the 2nd switch-on point.
w The LED lights up.
5. Mark the edge of the proximity switch on the cylinder.

Draft

6. Position and fix the proximity switch between the two markings.

TOX_Manual_Powerpackage_line-Q_en

61Installation

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Linear position sensor (ZHW)



Holding angle for linear position sensor

TOX_Manual_Powerpackage_line-Q_en

Draft

6.3.3

62

InstallationüThe 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 beadhered to.

1. Installing holding angle.
2. Insert the linear position sensor into the holding angle. Ensure that the position sensing system with contact bears against the front flange.

4. Ensure the parallel alignment of the position sensing system to the longitudinal axis.
5. Fix the position sensing system with set screws to the tension rods to prevent it from shifting. Tightening torque: 2 Nm.
6. Secure the set screws with the hexagon nuts and with safeguarding lacquer.
7. Connect the position sensing system to the control.
See circuit diagram and operating instructions of the position sensing system.

TOX_Manual_Powerpackage_line-Q_en

Draft

3. Adjust position sensing system. Ensure that for ZHW 002/004/008/015
there is a distance between the front flange and front edge of the travel sensor of 2 +/-0.05 mm, and for ZHW 030 a distance between the front flange
and front edge of the travel sensor 14 +/-0.05 mm.

63

Installation

Installing pressure control in the power stroke line (ZDK)

Fig. 16

Installing pressure control in the power stroke line (assembly ZDK)

Draft

12 1

6.3.4

Material required:

Manual pressure regulator (ZDK)

Screw plug with collar, size M 5 (laterally on power stroke valve next to connection [12])TOX_Manual_Powerpackage_line-Q_en

64InstallationüFor connections see Pressure control in the power stroke line (assembly
ZDK) (optional), Page 37.

1. Remove the screw plug on the control connection [12].
w The lower positioned M 5 threaded hole is set free.
2. Remove the M5 screw plug from the par position.
3. Screw the M 5 screw plug fully into the lower positioned M 5 threaded holeof the control connection [12].
w The M 5 threaded hole in power stroke valve is closed.
4. Connect control connection [12] on the power stroke valve to output of fast
approach stroke [4.1] or connection [4.4] on the pressure regulator. In addition, install hose line and seal.
5. Install pressure regulator on power stroke input [1].

Draft

6. When installing a proportional pressure regulator, connect it to the control.
See data sheet, or circuit diagram.

TOX_Manual_Powerpackage_line-Q_en

65Installation

6.3.5

Installing external power stroke connection (ZKHZ)

14

Installing external power stroke connection (ZKHZ)

Material required:Electrical switching valve power stroke switch (ZKHZ)Screw plugüFor connections see External power stroke switch (assembly ZKHZ) (optional), Page 41.

Draft

Fig. 17

1. Disassemble control throttle 'X'.
2. Connect the control throttle 'X' connection to screw plug.
3. Install power stroke switch to connection of the power stroke valve [14].
4. Connect the power stroke switch to permanent compressed air supply.
5. Connect the power stroke connection to the control.
See circuit diagram.

TOX_Manual_Powerpackage_line-Q_en

66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:Electrical switching valve power stroke release (ZKHF) and power stroke
deactivation (ZKHD) with pneumatic OR valve

Installing the external power stroke release (ZKHF)

ü

Draft

14

For connections see External power stroke deactivation (assembly ZKHD)(optional), Page 43.

1. Install switching valve power stroke release and power stroke deactivation
with OR valve on control connection [14].
2. Connect line of the control throttle 'X' to the OR valve.
3. Connect pneumatic input [3] of the switching valve to compressed air supply.
Installing the external power stroke deactivation (ZKHD)üFor connections see External power stroke deactivation (assembly ZKHD)(optional), Page 43.

1. Install switching valve power stroke release and power stroke deactivation
with OR valve on control connection [14].
2. Connect line of the control throttle 'X' to the OR valve.
3. Connect pneumatic input [1] of the switching valve to compressed air supply.

TOX_Manual_Powerpackage_line-Q_en

67

Installation

Preparing external power stroke supply

Fig. 19

Draft

12

1

6.3.7

Preparing external power stroke supply

Material required:

Screw plug M 5 with collar (laterally on power stroke valve next to connection [12])üFor connections see External power stroke supply (optional), Page 47.

1. Remove the screw plug from the control connection [12] and screw the M 5screw plug with collar fully in.
w Bore hole in power stroke valve is closed.
2. Connect control connection [12] on the power stroke valve to output of fast
approach stroke [4.1]. In addition, install hose line and seal.
3. Install external power stroke supply on power stroke input [1].

TOX_Manual_Powerpackage_line-Q_en

68Installation

6.3.8

Installing the stroke frequency optimization (ZHO)

Installing the stroke frequency optimization (ZHO) for drive withintegrated power stroke valve

2

1
3

Fig. 20

Optimization of stroke frequency
(ZHO)
Plug

2

Slide valve

4

Circlip

3

Draft

1

4

Installing the stroke frequency optimization ZHO

Material required:Stroke frequency optimization (ZHO) for drive with integrated power stroke
valve



Pneumatic supply line including all series-connected valves in the size fitting to the connections.

1. Remove circlip and plug.
2. Remove the valve slide.
3. Install the plug and circlip.
4. Installing the stroke frequency optimization (ZHO).

TOX_Manual_Powerpackage_line-Q_en

69

Installation

Draft

Installing the stroke frequency optimization (ZHO) for drive withexternal power stroke valve

Fig. 21

Installing the stroke frequency optimization ZHO

Material required:

Installing the stroke frequency optimization (ZHO) for drive with external
power stroke valvePneumatic supply line including all series-connected valves in the size fitting to the connections.

1. Dismantle the existing external power stroke valve.
2. Install the stroke frequency optimization (ZHO).

TOX_Manual_Powerpackage_line-Q_en

70Installation

Installing the speed reduction for power stroke venting

Draft

6.3.9

Fig. 22

Installing the speed reduction for power stroke venting

Material required:Adjustable exhaust air damper (ZD)

1. Install the exhaust throttle between the power stroke valve output [3] andthe muffler.
2. Connect the compressed air supply connections.
3. Set the exhaust air damper.
See Set the speed ratio between power stroke and power stroke venting(optional), Page 31.

TOX_Manual_Powerpackage_line-Q_en

71Installation

6.3.10Installing tool coupling (ZWK)

Fig. 23

Installing tool coupling (ZWK)

Draft

The thread at the end of the piston rod is intended for the installation of a tool
holding fixture or a tool.
Material required:

Tool holding fixture (ZWK) or toolLow-strength screw locking compound (e.g. Loctite 222)



Lubricating grease (Klübersynth UH1 14-151 or a technically comparableone)üTechnical 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. Observetightening torques.
See Tightening torques on the piston rod, Page 51.
2. Secure the tool holding fixture screw locking compound.
3. Wet the contact surface between the holding tray and tool holding fixture
with lubricating grease.
4. Install the holding tray on the ram or on the tool plate.

TOX_Manual_Powerpackage_line-Q_en

72

Commissioning

7 Commissioning
7.1

Safety during the commissioning
The commissioning may only be carried out by trained and authorized personnel.
The following applies:
Make sure that that no persons are located within the danger area of themachine.

Observe technical data and limit values.
See Technical data.

Draft



TOX_Manual_Powerpackage_line-Q_en

73Commissioning

7.2

Requirements for the commissioning
This incomplete machine may not be commissioned until it has been ascertained 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: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.



The necessary software for controlling the component is installed.



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

Draft



TOX_Manual_Powerpackage_line-Q_en

74

Commissioning

For the use of pneumatic systems, very small air leakages are possible on
the pneumatic screw fittings / seals and basically do not represent a defect.
For this there are no measurable limit values and specifications, theawareness takes place acoustically by the operator.
Pneumatic screw fittings can come loose under certain circumstances due
to vibrations during transport, differences in temperature or manipulation
during installation.
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 52.

Setting control throttle 'X'

Draft

7.3

The control throttle 'X' is used to set the timing of the switchover from fast approach stroke to power stroke, and must be readjusted for each application (e.g.
tool weight drawing/pressing). The effect of the control throttle 'X' is influenced
by the system pressure and by setting an optional fast approach stroke throttle.

Fig. 24

Setting control throttle 'X'

TOX_Manual_Powerpackage_line-Q_en

75CommissioningüWorking piston is retracted.

üCompressed air supply is switched on.

1. Close control throttle 'X' when piston is retracted and impinged by turning
clockwise.
2. Extend working piston rod.

Draft

3. Open control throttle 'X' slowly by turning counterclockwise until the powerstroke is noticeably activated on meeting a counterforce. Opening the control throttle 'X' further causes the power stroke to be activated earlier.

TOX_Manual_Powerpackage_line-Q_en76

Commissioning

7.4

Setting speed ratio of return stroke to fast approach
strokeThe 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 returnstroke. The exhaust air dampers may have to be retrofitted.
Typeline-Q
Necessary speed ratio Return stroke equally fast as fast approach strokeor Return stroke faster than the fast approach stroke
Tab. 3

Necessary speed ratio

1. Set speed ratio according to the specifications.
2. Perform test and check the speed visually.

7.5

Set the speed ratio between power stroke and powerstroke venting (optional)

Draft

A visual check of the speeds is generally sufficient.

At throttled power stroke speed
Necessary speed ratio between power stroke and power stroke venting Power stroke speed equal to the return stroke speed of the intensifier pistonor Power stroke speed faster than the return stroke speed of the intensifier piston
Tab. 4

Necessary speed ratio

A visual check of the speeds is generally sufficient.

1. Set speed ratio according to the specifications.
2. Perform test and check the speed visually.

TOX_Manual_Powerpackage_line-Q_en

77

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 operation.

CAUTION
Noise during operation!
è Wear individual protective equipment.

CAUTION
Hazard from flying parts!
Injuries to eyes and body cavities!
è Wear individual protective equipment.

TOX_Manual_Powerpackage_line-Q_en

Draft

Hearing impairment!

78

Operation

8.3

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

All components are properly maintained, clean and without damage.

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



The main switch of the machine is switched on.

Compressed air supply is open.

The fault message on the machine are acknowledged.

There are no persons are located in the danger area.

A visual inspection is carried out, especially:–

Position of the oil level indicator when the working piston is retracted(oil level indicator flush with the surface of the cylinder).

–No objects in the working area.

Operating drive
The operation depends on:Intended purpose

Control systemOperating elements



Safety equipment

Tooling and accessories

TOX_Manual_Powerpackage_line-Q_en

Draft

8.2

79

Troubleshooting

9 Troubleshooting
9.1

Safety during troubleshooting
Troubleshooting may only be carried out by trained and authorized personnel.
Make sure that that no persons are located within the danger area of themachine.

Draft



TOX_Manual_Powerpackage_line-Q_en

80Troubleshooting

Searching for causes of fault on the Powerpackage

Fault

Possible cause

MeasurePiston rod does not extend.

Tool jams.
Guiding columns are jammed.

Mechanically decouple thePowerpackage and check ease of
movement by extending and retracting.
Check air pressure and increase if necessary.
Check main control valve.
Contact authorized service personnel.
Check non-return valves.
Contact authorized service personnel.
Check the compressed air supply.
Contact authorized service personnel.
Increase air pressure.
Increase air pressure in power strokeline.

Air pressure too low (only for assembly
direction from the bottom to the top).
Main control valve does not switch.
Unlockable check valves (optional
equipment) do not open.
Faulty pneumatic hose.
No execution of power stroke.
Press force not reached.

Insufficient air pressure.
Compressed air setting on pressure
regulator in the power stroke line (optional) is too low.
Pneumatic spring pressure setting is
too high or the pneumatic spring is
faulty.
Oil level is too low.
Air is trapped in the hydraulic oil system.
Power stroke valve is faulty.
Control throttle 'X' incorrectly set, overloaded.
No air pressure in home position.

Power stroke not triggered withvery short fast approach stroke(only for type Q-S, X-S, S, EL
with hydraulic end position
cushioning ZHD)
Piston rod does not retract.

The fast approach distance traveled is
too short. Required: min. 8 mm.

Check compressed air supply of thepneumatic spring.
Contact authorized service personnel.
Checking oil level, Page 88.
Refilling oil and venting drive, Page
89.
Contact authorized service personnel.
Setting control throttle 'X', Page 75.
Impinge the return stroke with air pressure before initiating the fast approach
stroke.
Set sufficient travel for fast approach
stroke before the power stroke isswitched on.

Draft

9.2

Tool jams.
Guiding columns are jammed.

Mechanically decouple thePowerpackage and check ease of
movement by extending and retracting.
Insufficient air pressure.
Check air pressure and increase if necessary.
Main control valve does not switch.
Check main control valve.
Contact authorized service personnel.
Unlockable check valves (optional
Check non-return valves.
equipment) do not open.
Contact authorized service personnel.
Pneumatic hose is faulty.
Check the compressed air supply.
Contact authorized service personnel.
Tool is too heavy for return stroke force. Increase return stroke pressure.
Use additional return stroke cylinders.
Changeover signal for return stroke is
Check electrical switching signal (e.g.
not present.
for ZHU, ZHW, ZDO).
Contact authorized service personnel.
Power stroke valve is faulty.
Contact authorized service personnel.
Pneumatic spring pressure regulator or Check the compressed air pressure onpressure gauge pneumatic spring is
the pressure gauge.
faulty.
Contact authorized service personnel.

TOX_Manual_Powerpackage_line-Q_en

81Troubleshooting

Fault

Possible cause

MeasureFrequent refilling of hydraulicoil is necessary.

Speed ratio of fast approach stroke toreturn stroke is set incorrectly.

Setting speed ratio of return stroke tofast approach stroke, Page 77.
Contact authorized service personnel.
Set the speed ratio between powerstroke and power stroke venting (optional), Page 77.
Contact authorized service personnel.
Observe predefined connections sizes
and cross-sections.
See Datasheet.

Speed ratio of power stroke and powerstroke venting is set incorrectly.

Pneumatic supply insufficient. Crosssection of hose, size of connectors,
switching valves, maintenance unit are
too small.
Powerpackage is not fully vented.

Contact authorized service personnel.

Draft

Oil level after oil filling is not lowered.
The HP measuring connection, ventscrew or oil filling nipple is leaky or
faulty.
Seals are damaged.

Refilling oil and venting drive, Page
89.
Lowering of oil level, Page 93.
Contact authorized service personnel.

TOX_Manual_Powerpackage_line-Q_en

82

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 informationaccording to counter (flexible)
Weekly

10.5
10.4

Draft

Refilling oil and venting drive
Checking oil level

TOX_Manual_Powerpackage_line-Q_en

83

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.

Draft



TOX_Manual_Powerpackage_line-Q_en

84

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.
è Wait for residual energy to disspate safely (at least 3 minutes).

WARNINGHot surfaces on the drive and on the control box!
Injuries from burns!

Draft

è Allow hot surfaces and motors to cool down before touching them.

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
Dangerous machine movements!
Serious contusions and injuries!
è Make sure that that no persons are located in the danger area during operation.

TOX_Manual_Powerpackage_line-Q_en

85

Maintenance

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.

Draftè Keep inside surfaces, especially element-carrying parts, dry and free ofgrease.

TOX_Manual_Powerpackage_line-Q_en

86Maintenance

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 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 activatedin maintenance position.
4. Make sure that return stroke is impinged with compressed air.
6. Make sure that unauthorized, accidental or unexpected starting up of themachine and initiation or dangerous movements due to latent energies areprevented.

TOX_Manual_Powerpackage_line-Q_en

Draft

5. Make sure that the pressure valve (pneumatic spring) is impinged.

87

MaintenanceChecking oil level

Fig. 25

ü

Draft

10.4

Checking oil level

System is in maintenance position.
See Set system to maintenance position, Page 87.

è Check needle of the oil level indicator.
u The needle of the oil level indicator is flush with the surface of the cylinder:
Oil level is ok.
- OR u The needle of the oil level indicator comes out: Oil must be refilled.
See Refilling oil and venting drive, Page 89.

TOX_Manual_Powerpackage_line-Q_en

88Maintenance

10.5

Refilling oil and venting drive

2
8

11

9

4

12

1
8

2 3

9
10

12

5

6
11

1
3
5
7
9
11
13

Vent screw
Vent screw
Vent screw
Vent screw
Oil filling nipple
Venting plate
Vent screw

2
4
6
8
10
12

Draft

10

Vent screw
Vent screw
Vent screw
High pressure measuring connection
Oil level indicator
Oil anti-overfill safety device

Fig. 26 Refilling oil and venting drive

Material required:

Oil, filtered < 5 µm, load rating > 30 N/mm2 (in accordance with
DIN 51524-2 HLP32)
If different special oils are used, see sticker.

Oil pump ZP 20

TOX_Manual_Powerpackage_line-Q_en

89

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
downward
Vertical, working piston upward

Vent screw 2

Vent screws 2, 4, 6, 5, 7

Vent screw 1
HP measuring connection 8
Vent screw 2
HP measuring connection 8

Vent screws 3, 5
HP measuring connection 8
Vent screws 2, 3, 5, 6, 7
HP measuring connection 8

Horizontal, operating side
facing upward
Tab. 5Venting point according to installation position

WARNING
Contusions caused by uncontrolled extending working piston!
è Make sure that the return stroke is impinged with compressed air.
è Make sure that fast approach stroke and power stroke cannot be activated.
è Install a restraint device if necessary.
è Turn off compressed air supply of the pressure valve.

CAUTION

Draft

Serious contusions and injuries on hand and fingers.

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 caused by trapped air!
è Vent drive after filling with oil.
è Use highest vent screw or high pressure measuring connection for venting.

TOX_Manual_Powerpackage_line-Q_en

90MaintenanceüSystem is in maintenance position.
See Set system to maintenance position, Page 87.

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. Install filling hose of the oil pump on oil filling nipple.
5. Continue to fill until oil escapes from the vent hole free of bubbles.
6. CAUTION! Risk of slipping from leaking oil! Absorb oil immediately andwithout residue!
7. Wait 10 min. Afterwards, repeat filling procedure until oil escapes from thevent hole free of bubbles.
8. Deactivate power stroke. For this, turn the control throttle X fully closed.

10. Continue to refill until oil escapes from the open vent hole free of bubbles.

Draft

9. Move the working piston several times forward and backwards without
power stroke.
11. CAUTION! Splashing oil! Open vent screw slowly!
Unscrew the corresponding vent screw (see table "Venting point according
to installation position") a maximum of 2 turns until the oil comes out underthe vent screw without bubbles.
Then immediately close the vent screw.
- OR Unscrew the corresponding high pressure measuring connection cover (seetable "Venting point according to installation position") and push in with ablunt object (e.g. a pin) until the oil comes out without bubbles.
12. Move the working piston several times forward and backwards with powerstroke. For this, open control throttle X until the power stroke is audibly activated.
13. CAUTION! Splashing oil! Open vent screw slowly!
Unscrew the corresponding vent screw (see table "Venting point according
to installation position") a maximum of 2 turns until the oil comes out underthe vent screw without bubbles.
Then immediately close the vent screw.
- OR Unscrew corresponding high pressure measuring connection cover (see table "Venting point according to installation position") and push in with ablunt object (e.g. a pin) until the oil comes out without bubbles.
14. Tighten the vent screws. For tightening torque see Tightening torques.
15. If necessary, unscrew the sealing cap on high pressure measuring connection.
16. Unscrew filling hose of the oil pump.
17. Screw in knurled cap of the oil filling nipple.
18. Install venting plate.

TOX_Manual_Powerpackage_line-Q_en

91Maintenance

19. Fasten locking wire.

Draft

20. NOTE! Device damage due to overfilling!
Lower oil level.
See Lowering of oil level, Page 93.

TOX_Manual_Powerpackage_line-Q_en

92

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!

Material required:

Oil pump ZP 20ü

System is in maintenance position.
See Set system to maintenance position, Page 87.

üDrive is filled and vented.
See Refilling oil and venting drive, Page 89.

Draft

After refilling and venting, lower the oil level by a defined value (lowering volume "ΔV").
For lowering volume "ΔV" see type plate.

1. Remove venting plate with locking wire.
2. Unscrew knurled cap of the oil filling nipple.
3. Screw filling hose of the oil pump onto oil filling nipple.
4. CAUTION! Risk of slipping from leaking oil! Absorb oil immediately andwithout residue!
Remove oil quantity exactly according to lowering volume "ΔV".
5. Unscrew filling hose of the oil pump.
6. Install venting plate.
7. Screw on knurled cap of the oil filling nipple.
8. Fasten locking wire.
9. Push in oil level indicator needle.

TOX_Manual_Powerpackage_line-Q_en

93Repairs

11 Repairs
11.1

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

11.2

Changing seals

Draft

Seals may only replaced by trained and authorized service personnel.

TOX_Manual_Powerpackage_line-Q_en

94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.

WARNING

Draft

è Wait for residual energy to disspate safely (at least 3 minutes).

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.

TOX_Manual_Powerpackage_line-Q_en

95

Disassembly and Disposal

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. Move plant into home position.
2. Install a restraint device if necessary.
3. Switch off plant at the main switch.
4. Clean the system and protect it against corrosion.
5. Protect plant against loss of data and deep discharge.

12.3

Shutdown

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.

Draft

Shutdown means that the system is shut down permanently and/or is preparedfor removal.

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_Powerpackage_line-Q_en

96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.

12.5

Draft

3. Sort the constituent parts by material and dispose of according to the local
regulations.

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 11).

TOX_Manual_Powerpackage_line-Q_en

97Appendices

13 Appendices
DECLARATION OF INCORPORATION

Draft

13.1

TOX_Manual_Powerpackage_line-Q_en

98

Index

Index
D

Activation
Design principles ...................................... 34
Dynamic pressure method........................ 36
Air consumption............................................. 28
Ambient temperature ..................................... 50
Avoidance of dynamic oil leakage ................. 30

Data sheet...................................................... 27
Decommissioning........................................... 96
Design data.................................................... 27
Design principles............................................ 27
Design principles of activation ....................... 34
Disassembly............................................. 95, 97
Safety ........................................................ 95
Dispatch
Repair........................................................ 55
Disposal ................................................... 95, 97
Safety ........................................................ 95
Document
additional ..................................................... 8
Validity......................................................... 8
Drive
Install ......................................................... 57
Operating .................................................. 79
Venting ...................................................... 89
Dynamic oil leakage
Avoiding .................................................... 30
Dynamic pressure method
Activation................................................... 36

B
Basic safety requirements ............................. 12

C
Causes of fault .............................................. 81
ChangeSeal........................................................... 94
Changing seals.............................................. 94
Check
Oil level ..................................................... 88
Commissioning .............................................. 73
Requirements ........................................... 74
Safety........................................................ 73
Compressed air quality.................................. 51
Conformity ....................................................... 7
Contact .......................................................... 11
Control connection ........................................ 35
Control throttle 'X'
Setting....................................................... 75
Contusion
Hazard ...................................................... 15
Correct
Construction.............................................. 19
Design....................................................... 19
Cycle times .................................................... 29

Draft

A

E
Electromagnetic
Hazard....................................................... 16
Environmental conditions............................... 50
Equipment
Optional ..................................................... 26
Exclusion of liability.......................................... 7
External power stroke connection.................. 41
External power stroke connection (ZKHZ)
Installing .................................................... 66
External power stroke deactivation ................ 43
External power stroke release ....................... 45
External power stroke release (ZKHF)
Installing .................................................... 67
External power stroke supply......................... 47

F
Fast approach stroke ..................................... 22
Function description....................................... 21

TOX_Manual_Powerpackage_line-Q_en

101IndexI

Gender note .................................................... 8
General information
Maintenance ............................................. 84
Guidelines ....................................................... 7

Identification
Product ...................................................... 20
ImagesHighlighting ............................................... 10
Important information ....................................... 7
Information
Important ..................................................... 7
Installation...................................................... 56
Accessories ............................................... 58
Drive .......................................................... 57
External power stroke switch (ZKHZ)........ 66
Power stroke deactivation (ZKHD) ............ 67
Power stroke release (ZKHF).................... 67
Pressure control in the power stroke line
(ZDK) .................................................... 64
Safety ........................................................ 56
Speed reduction for power stroke ............. 71
Stroke frequency optimization (ZHO) for
drive with integrated power stroke valve.............................................................. 69
Tightening torques .................................... 51
Tool coupling (ZWK) ................................. 72
ZDK ........................................................... 64
ZHO........................................................... 69
ZKHD ........................................................ 67
ZKHF ......................................................... 67
ZKHZ ......................................................... 66
ZWK .......................................................... 72
Installing
Position sensors of stroke monitoring for forward and return stroke (ZHU)............... 60
Pressure switch ......................................... 58
Stroke frequency optimization (ZHO) ........ 69
ZDO........................................................... 58
ZHO........................................................... 69
Installing accessories..................................... 58
Installing pressure control in the power strokeline (ZDK) .................................................. 64
Installing tool coupling (ZWK) ........................ 72
Installing ZDK................................................. 64
Installing ZWK................................................ 72
Instructions
Tool installation ......................................... 72
Intended use .................................................. 18

H
HazardContusion.................................................. 15
Electrical ................................................... 14
electromagnetic ........................................ 16
Hazardous substances ............................. 16
hydraulic ................................................... 15
Laser ......................................................... 16
Lithium ion battery .................................... 17
Noise......................................................... 17
Pneumatic................................................. 14
Thermal..................................................... 14
Hazard potential ............................................ 14
Hazardous substances .................................. 16
Horizontal installation
Type K, Z .................................................. 34
HydraulicHazard ...................................................... 15
Hydraulic oil
Specification ............................................. 52

TOX_Manual_Powerpackage_line-Q_en

Draft

G

102

IndexLO

Laser
Hazard ...................................................... 16
Legal note........................................................ 7
Lifting device ................................................. 55
line-Q
Product overview ...................................... 25
Lowering
Oil level ..................................................... 93

Oil

Maintenance .................................................. 84
General information .................................. 84
Requirement ............................................. 87
Safety........................................................ 85
Maintenance position .................................... 87
Measures
Organizational........................................... 12
Measuring connection ................................... 35
Misuse ........................................................... 19N
NoiseHazard ...................................................... 17
Note
Gender........................................................ 8
General ..................................................... 10
Legal ........................................................... 7
Warning signs ............................................. 9

TOX_Manual_Powerpackage_line-Q_en

Draft

M

Refilling ..................................................... 89
Oil leakage
Avoiding .................................................... 30
Oil level
Checking ................................................... 88
Lowering.................................................... 93
Operation ....................................................... 78
Drive .......................................................... 79
Requirements ............................................ 79
Safe ........................................................... 18
Safety ........................................................ 78
Optional
Equipment ................................................. 26
Organizational measures ............................... 12103

IndexR

Performance optimization.............................. 30
Piston rod
Tightening torques .................................... 51
Pneumatic connection ................................... 51
Pneumatic screw fittings on the Powerpackage
Tightening torques .................................... 52
Position sensors of stroke monitoring for forward and return stroke (ZHU)
Installing.................................................... 60
Power stroke ................................................. 23
Installing speed reduction ......................... 71
Speed reduction........................................ 33
Stroke limitation ........................................ 32
Power stroke connection (ZKHZ)
Installing.................................................... 66
Power stroke deactivation (ZKHD)
Installing.................................................... 67
Power stroke release (ZKHF)
Installing.................................................... 67
Power stroke supply, external ....................... 47
Preparation
Power stroke supply, external................... 68
Preparing external power stroke supply ... 68
Preparing external power stroke supply ........ 68
Press force table ........................................... 52
Pressure control in the power stroke line with
Proportional pressure control valve .......... 39
Pressure regulation in power stroke line ....... 37
Pressure switch
Installing.................................................... 58
Product Identification ..................................... 20
Product overview
line-Q ........................................................ 25
Proportional pressure control valve
Pressure control in the power stroke line.. 39

Refilling
Oil .............................................................. 89
Repair
Dispatch .................................................... 55
Repairs........................................................... 94
Safety ........................................................ 94
Requirement
Maintenance.............................................. 87
Return stroke ................................................. 24

Draft

P

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

TOX_Manual_Powerpackage_line-Q_en104IndexPower stroke ............................................. 32

S

TOX_Manual_Powerpackage_line-Q_en

T
Target group .................................................... 8
Technical data ............................................... 50
Technical design data .................................... 27
Texts
Highlighting ............................................... 10
Tightening torques
Installation ................................................. 51
Piston rod .................................................. 51
Pneumatic screw fittings on the Powerpackage........................................................ 52
Tool installation
Instructions ................................................ 72
Transport........................................................ 54
Safety ........................................................ 54
Troubleshooting ............................................. 80
Safety ........................................................ 80
Type K, Z
Horizontal installation ................................ 34
Type plate ...................................................... 20

U

Draft

Safe
Construction.............................................. 19
Design....................................................... 19
Safety ............................................................ 12
Commissioning ......................................... 73
Disassembly ............................................. 95
Disposal .................................................... 95
Installation................................................. 56
Maintenance ............................................. 85
Operation .................................................. 78
Repairs ..................................................... 94
Transport .................................................. 54
Troubleshooting ........................................ 80
Safety requirements
Basic ......................................................... 12
Operating company .................................. 12
Selection
Personnel.................................................. 13
Selection of personnel ................................... 13
Set
Speed ratio between power stroke andpower stroke venting ...................... 31, 77
Setting
Control throttle 'X' ..................................... 75
Speed ratio between return stroke and fast
approach stroke ............................. 31, 77
Shutdown ...................................................... 96
Source of supply............................................ 11
Specification for hydraulic oil ......................... 52
Speed ratio between power stroke and powerstroke venting
Set ...................................................... 31, 77
Speed ratio between return stroke and fast approach stroke
Setting................................................. 31, 77
Speed reduction
Power stroke ............................................. 33
Speed reduction for power stroke
Installing.................................................... 71
Storage .......................................................... 54
Temporary storage ................................... 55
Stroke frequency optimization (ZHO)
Installing.................................................... 69
Stroke frequency optimization (ZHO) for drivewith integrated power stroke valve
Installing.................................................... 69
Stroke limitation

Use
Intended .................................................... 18

V
Validity
Document .................................................... 8
Venting
Drive .......................................................... 89

W
Warning signs .................................................. 9105

Index

Z

Draft

ZDK
Pressure regulation in power stroke line... 37
ZDO
Installing.................................................... 58
ZHO
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_en106