Design and installation guideline

Edition: 05/28/2020, Version: 2

TOX®-Powerpackage
Type T, RP

TOX® PRESSOTECHNIK GmbH & Co. KG
Riedstrasse 4D-88250 Weingarten
www.tox-pressotechnik.com

2

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Table of contents

Table of contents
1

Important information

1.1

Legal note ................................................................................................... 7

1.2

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

1.3

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

1.3.1

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

1.3.2

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

1.3.3

Contact and source of supply...................................................................... 8

1.4

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

1.5

Contact and source of supply...................................................................... 9

2
2.1

3

Product overview of Powerpackage Type T, RP
Product attributes of Powerpackage Type T, RP ...................................... 12

Optional equipment

3.1

Additional optional equipment ................................................................... 13

4

Function description of Powerpackage with mechanical fast approach
stroke spring

5

Function description of Powerpackage without fast approach stroke

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en3

Table of contents

6
6.1

Type sheet and data sheet........................................................................ 23

6.2

Compressed air quality and pneumatic connection .................................. 23

6.3

Tightening torques .................................................................................... 23

6.3.1

Tightening torques for flange mounting the drive...................................... 23

6.3.2

Tightening torques on the piston rod......................................................... 24

6.4

Press force table ....................................................................................... 25

6.4.1

Press force table type T ............................................................................ 25

6.4.2

Press force table type RP ......................................................................... 26

6.5

Specification for hydraulic oil..................................................................... 26

7
7.1

8

Design data
Data sheet................................................................................................. 29

Design guidelines

8.1

Design principles....................................................................................... 31

8.1.1

Air consumption ........................................................................................ 32

8.1.2

Cycle times................................................................................................ 33

8.2

Performance optimization ......................................................................... 34

8.3

Avoidance of dynamic oil leakage............................................................. 34

8.3.1

Setting speed ratio of return stroke to fast approach stroke ..................... 35

8.3.2

Set the speed ratio between power stroke and power stroke venting (optional) ........................................................................................................ 35

8.4

Stroke limitation of the power stroke ......................................................... 36

8.5Power limit of the power stroke ................................................................. 37

8.6

Speed reduction of the power stroke ........................................................ 37

94Technical data

Activation and pressure control

9.1

Design principles of activation................................................................... 39

9.1.1

Measuring connection and control connection.......................................... 40

9.2

Activation according to dynamic pressure method for Powerpackage...... 40

9.2.1

Powerpackage type T, RP ........................................................................ 41

9.3

Pressure control in the power stroke line (assembly ZDK) (optional) ....... 44

9.3.1

Powerpackage type T, RP ........................................................................ 44

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Table of contents

9.4

Pressure control in the power stroke line with proportional pressure control
valve (optional).......................................................................................... 46

9.4.1

Powerpackage type RP with mechanical spring ....................................... 47

9.5

External power stroke switch (assembly ZKHZ) (optional) ....................... 48

9.5.1

Powerpackage type RP with mechanical spring ....................................... 49

9.6

External power stroke deactivation (assembly ZKHD) (optional).............. 50

9.6.1

Powerpackage type RP with mechanical spring ....................................... 51

9.7

External power stroke release (assembly ZKHF) (optional)...................... 52

9.7.1

Powerpackage type RP with mechanical spring ....................................... 53

Index

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6

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Important information

1 Important information
1.1

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

1.2

Exclusion of liability
TOX® PRESSOTECHNIK has checked the contents of this publication toensure that it conforms to the technical properties and specifications of the
products or plant and the description of the software. However, discrepancies may still be present, 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 gratefulfor 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.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

7

Important information

1.3

Validity of the document

1.3.1

Content and target group
This design and installation guideline contains information and instructions
for the design and installation of the product.

1.3.2



All information in this design and installation guideline is up to date at
the time of print. TOX® PRESSOTECHNIK reserves the right to maketechnical changes that improve the system or increase the standard ofsafety.



The information is intended for the designer and operating company.

Other applicable documents
The following documents must also be observed in addition to the design
and installation guideline:

Data sheet TOX®-PowerpackageData sheet TOX®-Powerpackage Control units

Data sheet TOX®-Powerpackage Accessories



Any supplier documentation

See http://www.tox-pressotechnik.de.

1.3.3

Contact and source of supply
Please send any questions on the technical documentation (e.g. missing
documents, suggestions, corrections) by email to info@tox-de.com.

1.4

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 shouldin no way convey any gender discrimination or any violation of the principleof equality, however.

8

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Important information

1.5

Contact and source of supply
Only use original spare parts or spare parts approved by TOX® PRESSOTECHNIK.
TOX® PRESSOTECHNIK GmbH & Co. KG
Riedstraße 4
D - 88250 Weingarten
Tel. +49 (0) 751/5007-333
E-Mail: info@tox-de.com
For additional information and forms see www.tox-pressotechnik.com.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

9Important information

10

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Product overview of Powerpackage Type T, RP

2 Product overview of Powerpackage Type T, RP

6

4

T

5
2
7

1

4

RP

5
3
2

1
1
3
5
7

Working piston
Control throttle 'X'
Oil filling nipple
Power stroke valve

Fig. 12
4
6Compressed air supply return stroke [2]Compressed air supply for power stroke [4]Pressure valve (pneumatic spring)

Product overview Type T, Type RP

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

11

Product overview of Powerpackage Type T, RP

2.1

Product attributes of Powerpackage Type T, RP

Type

Product attributes

Type T










Type RP

12

Fast running drive with up to 550 strokes per minute.
Working process only with power stroke, no fast approach stroke.
Including power bypass ZLB.
Equipped with pressure control valve (pneumatic spring).
For use with embossing tools.
Including embossing cylinder with anti-rotation device and clamping tongs.
Equipped with mechanical spring in fast approach stroke.
Equipped with mechanical spring for return stroke of the intensifier piston.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Optional equipment

3 Optional equipment
3.1

Additional optional equipment
Type

Product attributes

ZDK

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.

ZKHZ

ZWK

ZDO

ZHO

ZPS

Tab. 1

Optional equipment

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

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13

Optional equipment

14

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Function description of Powerpackage with mechanical fast
approach stroke spring

4 Function description of Powerpackage withmechanical fast approach stroke spring
The drive works with a pneumatically operated cylinder with pneumohydraulic power stroke. At the same time, a closed oil cylinder and valve system is driven with compressed air, which is controlled in the same way as a
double-acting pneumatic cylinder.
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, theoil pressure acts on the working piston.
For the fast approach of the working piston to the working position (fast approach stroke) a mechanical spring is used.
Compressed air is used for the return to the home position (return stroke).

3

1
2

11
1
3
5
7
9
11

Fig. 2

10

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

9
2
4
6
8
10

8

7

6

5 4

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

Starting position of Powerpackage with mechanical fast approach stroke springIn home position, the drive is controlled via the main control valve in the
return stroke.

The working piston is retracted.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

15

Function description of Powerpackage with mechanical fast
approach stroke spring

Mechanically operated fast approach stroke

1

3
2

11
1
3
5
7
9
11

Fig. 316

10

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

9
2
4
6
8
10

87

6

5 4

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

Fast approach stroke Powerpackage with mechanical fast approach stroke springAfter the switchover of the main control valve the power stroke chamber is vented.

The power stroke valve is supplied with compressed air.



The working piston extends in the fast approach stroke with the power
generated by the mechanical spring.



The feed piston pushes hydraulic oil from the reservoir into the highpressure 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 a delay, depending on the air volume flowing out of the control
throttle 'X'.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Function description of Powerpackage with mechanical fast
approach stroke spring

Pneumohydraulic power stroke

1

3

2

11
1
3
5
7
9
11

Fig. 4

10

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

9
2
4
6
8
10

8

7

6 5

4

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

Power stroke Powerpackage with mechanical fast approach stroke spring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 theoil chamber into a working area and an oil reservoir.



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

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

17

Function description of Powerpackage with mechanical fast
approach stroke spring

Back stroke

1

3
2

11 10
1
3
5
7
9
11

Fig. 518

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

9
2
4
6
8
10

87

6

5 4

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

Return stroke Powerpackage with mechanical fast approach stroke spring

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, theworking piston moves back to the home position.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Function description of Powerpackage without fast approach
stroke5 Function description of Powerpackage without
fast approach stroke
The drive works with a pneumatically operated cylinder with pneumohydraulic power stroke. At the same time, a closed oil cylinder and valve system is driven with compressed air, which is controlled in the same way as a
double-acting pneumatic cylinder.
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, theoil pressure acts on the working piston.
Compressed air is used for the return to the home position (return stroke).
The connections [2] (return stroke) and [8] (pressure valve/pneumatic
spring) are continuously pressurized.

1 2

10

3

9

8

1
3
5

Return stroke chamberPower stroke valve
Intensifier piston

2
4
6

7
9

Storage piston
High-pressure chamber

810Fig. 67 6

5 4

Working piston
Power stroke chamberPressure valve (pneumatic
spring)Plunger
Fast approach stroke chamber

Starting position of Powerpackage without fast approach strokeIn the home position the drive is continuously pressurized.



The working piston is retracted.

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19

Function description of Powerpackage without fast approach
strokePneumohydraulic power stroke

2

3

1

10

8 7

1
3
5

Return stroke chamberPower stroke valve
Intensifier piston

2
4
6

7
9

Storage piston
High-pressure chamber

810Fig. 7

20

9

6

5

4

Working piston
Power stroke chamberPressure valve (pneumatic
spring)Plunger
Fast approach stroke chamberPower stroke Powerpackage without fast approach strokeCompressed air penetrates into the power stroke chamber of the intensifier piston after the switchover of the power stroke valve.

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



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

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Function description of Powerpackage without fast approach
strokeBack stroke

1 2

3

10

9

8

1
3
5

Return stroke chamberPower stroke valve
Intensifier piston

2
4
6

7
9

Storage piston
High-pressure chamber

810Fig. 87 6

5 4

Working piston
Power stroke chamberPressure valve (pneumatic
spring)Plunger
Fast approach stroke chamberPowerpackage return stroke without fast approach strokeThe power stroke valve is switched over to return stroke by a signal.

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, theworking piston moves back to the home position.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

21

Function description of Powerpackage without fast approach
stroke22

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Technical data

6 Technical data
6.1

Type sheet and data sheet
For technical data and installation dimensions see type sheet and data.
(https://www.tox-pressotechnik.com)

6.2

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):
Solids
Class
5

[μm]
40

Water dew point

Maximum Oil content

Class
4

Class
3

[°C]
3

6.3

Tightening torques

6.3.1

Tightening torques for flange mounting the drive
Thread size

Torque

M6
M8
M 10
M 16
M 20
M 24

17 Nm
40 Nm
80 Nm
340 Nm
660 Nm
1,130 Nm

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en[mg/m3]1

23

Technical data

6.3.2

Tightening torques on the piston rod
Tool coupling

Tightening torqueZWK
ZWK 001
ZWK 002
ZWK 004
ZWK 008
ZWK 015ZWK 030ZWK 050ZWK 075
ZWK 200

24

10 Nm
15 Nm
40 Nm
180 Nm
210 Nm230 Nm
290 Nm
500 Nm
500 NmTOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Technical data

6.4

Press force table
The effective press force is the ratio of the available press force at the
specified air pressure to the press force required for the pressing process.
Press force table see separate document.

6.4.1
Air pressure

[bar]
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0

Press force table type T

Oil pressure

Press
force

Oil pressure

Press
force

Oil pressure

Press
force

Oil pressure

Press
force

Poil

f

Poil

f

Poil

f

Poil

f

[bar]

[kN]

[bar]

[kN]

[bar]

[kN]

[bar]

[kN]

T 1.12
14
18
36
45
54
64
75
85
T 4.12
20
32
44
57
69
81
94
107

1.9
2.5
5.2
6.6
7.9
9.4
11.1
12.5
7.7
12.7
17.7
23.1
28.0
33.0
38.4
43.8

T 2.06
40
55
72
89
103
120
137
154
T 8.6
46
68
90
112
134
156
178
200

6.0
8.3
11.0
13.6
15.7
18.3
20.9
23.6
19.2
28.6
38.0
47.4
56.7
66.1
75.5
84.9

T 2.12
16
22
30
38
44
53
62
70
T 8.12
23
34
45
56
66
78
89
99

4.3
5.9
8.2
10.5
12.2
14.7
17.6
19.6
14.6
21.9
29.1
36.3
42.9
50.8
58.1
64.6

T 4.6
30
46
62
79
94
109
125
141
T 15.6
43
63
84
105
125
145
165
186

8.7
13.4
18.2
23.3
27.7
32.2
37.0
41.7
28.8
42.4
56.7
71.1
84.7
98.3
112.0
126.3

Tolerance of the technical specifications ±5%

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25

Technical data

6.4.2

Press force table type RP
Air pressure

Oil pressure

Press
force

Oil pressure

Press
force

Poil

f

Poil

f

[bar]

[bar]

[kN]

[bar]

[kN]

2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0

RP 8.32.3
32
59
90
114
142
170
198
225
253

11.0
18.0
28.0
36.0
44.0
53.0
62.0
70.0
79.0

RP 15.32.3
55
95
130
170
205
245
285
325
360

25.0
42.0
58.0
75.0
91.0
109.0
126.0
144.0
159.0

Tolerance of the technical specifications ±5%

6.5

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

The following hydraulic oils are approved with limitations for standard application:

26

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 canlead to 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 can lead 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 the seals.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

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

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en27

Technical data

28

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Design data

7 Design data
7.1

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

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29

Design data

30

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Design guidelines

8 Design guidelines
8.1

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)

No transverse forces may act on the piston rod.
If necessary, use a linear guide for the working piston: either a ram
plate and 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,
vent hole, high pressure measuring connection, control throttle‚X‘ andoil 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 oroil pressure monitor can significantly reduce the power stroke.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

31

Design guidelines

8.1.1

Air consumptionFor the air consumption, the fast and return stroke are calculated withthe available air pressure.

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



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

In general, the specification for the air requirement includes all filling processes required for a stroke. The information only refers to the specificdrive.
For hoses and valves - in particular for long hoses with large cross sections- which are filled and ventilated together with the drive, their consumption
must also be considered when selecting a compressor.
The following applies here: Short lines from the valve to the drive mean
economical energy.
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 per hour. Similarly, there might be air losses in the hose and valve
connections. In order to avoid air losses, e.g. at night, the drive can be depressurized during this time.

32

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Design guidelines

8.1.2

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
The line cross sections must at least match the connection sizes provided in order to achieve the calculated cycle time. This applies also to
the regulation valves and maintenance units installed upstream of thedrive.
Reduced line cross sections can considerably reduce the cycle time.

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 checkvalves in 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 a throttle in the power stroke line of the unit. The
drive can thus also be used for special applications, such as pressing inbushes, 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_Construction_Installation_Guideline_Powerpackage_RP_T_en

33

Design guidelines

8.2

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 returnstroke.



A balanced power stroke speed.

Adequately sized connection sizes (cross-section of hose, switchingvalves, maintenance unit) that prevent a reduction of the power stroke
speed.
For technical data and installation dimensions see data sheet.
(http://www.tox-pressotechnik.de)

8.3

Avoidance of dynamic oil leakage
The dynamic oil leakage is based on the physical effect of drag flow: thehigher the speed, the thicker the oil film dragged along. In the case of an
unfavorable speed ratio between the fast approach stroke and returnstroke, an oil film could get into the pneumatic chambers of the Powerpackage.
The following applies:

The ratio of the speed between the return stroke and the fast approach
stroke must be set.
–

A balanced power stroke speed.
–34

For setting the speed ratios, also the exhaust air dampers must be
installed on the fast approach stroke connections and the returnstroke connections.
For the attuned power stroke speed an exhaust air damper mustalso 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.

The power cross sections to the 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 the type sheet.
(https://tox-pressotechnik.com/)

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Design guidelines

8.3.1

Setting speed ratio of return stroke to fast approach stroke
The speed of the working piston in the fast approach stroke and returnstroke can be set with external exhaust air dampers on the forward stroke
and return stroke. The exhaust air dampers may have to be retrofitted.
Type

Type

T

RP
r

Necessary speed ratio Forward stroke equally fast as returnstrokeor Forward stroke faster than the returnstrokeTab. 2



Fast approach stroke equally fast as
return stroke
orFast approach stroke max. 20% fasterthan the return stroke

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.

8.3.2

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. 3

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_Construction_Installation_Guideline_Powerpackage_RP_T_en

35

Design guidelines

8.4

Stroke limitation of the power stroke
For applications for which a fixed end stop is required, the total stroke of
the Powerpackage can be limited.
For punch applications a limiting the travel of the power stroke must takeplace. 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).

Stroke limitation of the power stroke in the tool

2

1

A
a
1
3

Fig. 9Tool in starting position(UDC: Upper Dead Center
Stroke limitation
Minimum stroke

3

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).

36

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Design guidelines

8.5

Power limit of the power stroke
It is possible to monitor the press force of the power stroke by connecting
an oil pressure switch or an oil pressure monitor. Upon reaching the desired press force, the return stroke must be induced.
The press force can be reduced permanently by installing a pressure control in the power stroke line.
An oil pressure of at least 30 bar is necessary for pressure control in the
power stroke line (ZDK).

8.6

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.
See Installing speed reduction for power stroke.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en37

Design guidelines

38

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Activation and pressure control

9 Activation and pressure control
9.1

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 accountof the application (e.g. for fixing in place a spring-loaded holding-downclamp).



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

An 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.

The following applies for the activation of the compressed air supply during
venting:During venting, the return stroke and pressure valve (pneumatic spring)must be impinged with compressed air.



It must not be possible to activate the fast approach stroke and thepower stroke when doing so.

Attach drop protection if necessary.

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.

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en39

Activation and pressure control

9.1.1

Measuring connection and control connection
The oil pressure proportional to the press force is present on the measuring
connection and control connection.
This can be displayed, for example, by connecting a pressure gauge orused via transmission to a pressure switch for generating a switching pulse.
The following applies for the activation of the compressed air supply during
venting:During venting, the return stroke and pressure valve (pneumatic spring)must be impinged with compressed air.



It must not be possible to activate the fast approach stroke and thepower stroke when doing so.

Attach drop protection if necessary.

When depressurizing a pressure valve (pneumatic spring), the following applies:

9.2

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

Activation according to dynamic pressure method forPowerpackage
If the working piston meets a counterforce during the fast approach stroke,
it stops and the dynamic pressure acting on the piston surface falls. The
power stroke valve switches and the intensifier piston is impinged with compressed air.
The changeover time is controlled and adjusted with the control throttle X.
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 thefast approach stroke.

40

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Activation and pressure control

9.2.1

Powerpackage type T, RP
Powerpackage type RP with mechanical spring

Applicable for:Powerpackage type: RP

1V1

2

6.1

12 12 <-> 1
12

1 3
1

14

‘X‘ 2
1

Z1

HDM

6

X

RP
2

P

4

2

-?KYP1
1

2

1

5 1 3
1
1

3
1

Fig. 10

Activation according to dynamic pressure method for Powerpackage with mechanical spring

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en41

Activation and pressure control

Assembly
1V1

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
2
Return 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)

'X'
Z1

P

Powerpackage type T with pressure valve (pneumatic spring)

Applicable for:Powerpackage type: T

Z1

6

HDM

T
2

8

1V2
2
1

2

P
-?KYP

1

2

1

1

3
1

Fig. 1142

Activation according to dynamic pressure method for Powerpackage pressure
valve (pneumatic spring)

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Activation and pressure control

Assembly
1V1

Z1

P

Power stroke valve
2Power stroke output
6.1
Power stroke signal
14
Control connection
3
Muffler output
1
Power stroke input
12
Control connection
Drive
2
Return stroke input
8
Plunger return 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_Construction_Installation_Guideline_Powerpackage_RP_T_en

43Activation and pressure control

9.3

Pressure control in the power stroke line (assembly
ZDK) (optional)
A pressure 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.
For installing the pressure regulation, see the operating manual, chapter Installation.

9.3.1

Powerpackage type T, RP
Powerpackage type RP with mechanical spring

Applicable for:Powerpackage type: RP

1V1

2

6.1

12
12

13
1

14

‘X‘

2

1V5
2
1

Z1

6

1

HDM

X

RP
2

P

4

2

-?KYP2
1

1

2

5 13
1
1

3
1

Fig. 1244

Pressure control in the power stroke line (assembly ZDK)TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Activation and pressure control

Assembly
1V1

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
2
Return 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)

'X'
Z1

P

Powerpackage type T with pressure valve (pneumatic spring)

Applicable for:Powerpackage type: T

1V5

1V3

2
1

Z1

HDM

6

T
2

8

1V2
2
1

2

P
-?KYP
1

2

1

1

3
1

Fig. 13

Pressure control in the power stroke line (assembly ZDK)TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en45

Activation and pressure control

Assembly
1V1

Z1

P

9.4

Power stroke valve
2Power stroke output
6.1
Power stroke signal
14
Control connection
3
Muffler output
1
Power stroke input
12
Control connection
Drive
2
Return stroke input
8
Plunger return 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 withproportional pressure control valve (optional)
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.
For installing the pressure regulation, see the operating manual, chapter Installation.

46

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Activation and pressure control

9.4.1

Powerpackage type RP with mechanical spring
Applicable for:Powerpackage type: RP

1V1

2

6.1

12
12

13
1

14

1V5

T

-138YH1

P

‘X‘

2

G

1

6

Z1

HDM

X

RP
2

P

4

2

-?KYP2
1

1

2

5 13
1
1

3
1

Fig. 14

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

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

47

Activation and pressure control

Assembly
1V1

'X'
Z1

P

9.5

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
2
Return 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)
In the case of the external power stroke switch, the power stroke is initiatedafter reaching a particular distance or after a certain period of time.
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 strokeline.
The following is required:48

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_Construction_Installation_Guideline_Powerpackage_RP_T_en

Activation and pressure control

9.5.1

Powerpackage type RP with mechanical spring
Applicable for:Powerpackage type: RP

1V1

2

6.1

12 12 <-> 1
12

1 3
1

14

Z1
6

HDM

X

1V6

2

RP
1 3
2

P

4

2

-?KYP4
1

2

1

5 1 3
1
1

3
1

Fig. 15External power stroke switch (subassembly ZKHZ)

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en49

Activation and pressure control

Assembly
1V1

'X'
Z1

P

9.6

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
2
Return 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)
The power stroke can be deactivated with an electrical signal if necessary.
An external power stroke deactivation can also be fitted retrospectively.
The control system can be combined with a pressure regulator in the powerstroke line.
The following is required:

50

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

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Activation and pressure control

9.6.1

Powerpackage type RP with mechanical spring
Applicable for:Powerpackage type: RP

1V1

2

6.1

12 12 <-> 1
12

1 3
1

14
3

‘X‘ 2

2

1

1V7

1

HDM

6

2

1V6

1 3

X
RP
2

Z1

P

4

2

-?KYP5
1

2

1

5 1 3
1
1

3
1

Fig. 16

External power stroke deactivation (assembly ZKHD)TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

51

Activation and pressure control

Assembly
1V1

'X'
Z1

P

9.7

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
2
Return 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)
The power stroke can be released with an electrical signal if necessary.
An external power stroke deactivation can also be fitted retrospectively.
The control system can be combined with a pressure regulator in the powerstroke line.
The following is required:

52

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

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

Activation and pressure control

9.7.1

Powerpackage type RP with mechanical spring
Applicable for:Powerpackage type: RP

1V1

2

6.1

12 12 <-> 1
12

1 3
1

14
3

‘X‘ 2

2

1

1V7

1

HDM

6

2

1V6

1 3

X
RP
2

Z1

P

4

2

-?KYP5
1

2

1

5 1 3
1
1

3
1

Fig. 17

External power stroke release (assembly ZKHF)

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

53

Activation and pressure control

Assembly
1V1

'X'
Z1

P

54

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
2
Return 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_Construction_Installation_Guideline_Powerpackage_RP_T_en

IndexIndex
A

H

Activation
Design principles ...................................... 39
Dynamic pressure method........................ 40
Air consumption............................................. 32
Avoidance of dynamic oil leakage ................. 34

Hydraulic oil
Specification ............................................. 26

C
Compressed air quality.................................. 23
Contact ............................................................ 9Control connection ........................................ 40
Cycle times .................................................... 33

D
Data sheet ..................................................... 29
Design data ................................................... 29
Design principles ........................................... 31
Design principles of activation ....................... 39
Document
Validity ........................................................ 8
Documents
other applicable .......................................... 8
Dynamic oil leakage
Avoiding .................................................... 34
Dynamic pressure method
Activation .................................................. 40

EI
Important information ...................................... 7
information
Important..................................................... 7
Installation
Tightening torques .................................... 23

L
Legal note........................................................ 7

M
Measuring connection ................................... 40

N
Note
Gender........................................................ 8
Legal ........................................................... 7O
Oil leakage
Avoiding .................................................... 34
Optional
Equipment................................................. 13

Equipment
Optional .................................................... 13
Exclusion of liability ......................................... 7
External power stroke connection ................. 48
External power stroke deactivation ............... 50
External power stroke release ....................... 52F
Fast approach stroke..................................... 16
Function description ................................ 15, 19G
Gender note .................................................... 8

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en

55

IndexP

T

Piston rod
Tightening torques .................................... 24
Pneumatic connection ................................... 23
Power limit
Power stroke ............................................. 37
Power stroke ........................................... 17, 20
Power limit ................................................ 37
Speed reduction........................................ 37
Stroke limitation ........................................ 36
Press force table ........................................... 25
Type RP .................................................... 26
Type T....................................................... 25
Pressure control in the power stroke line with
Proportional pressure control valve .......... 46
Pressure regulation in power stroke line ....... 44
Product overview ........................................... 11
Proportional pressure control valve
Pressure control in the power stroke line.. 46

Target group .................................................... 8
Technical data ............................................... 23
Technical design data ................................... 29
Tightening torques
Installation................................................. 23
Piston rod.................................................. 24
Type RP
Press force table....................................... 26
Type T
Press force table....................................... 25

R
Return stroke ........................................... 18, 21

S
Set
Speed ratio between power stroke andpower stroke venting ............................ 35
Setting
Speed ratio between return stroke and fast
approach stroke ................................... 35
Source of supply.............................................. 9Specification for hydraulic oil ......................... 26
Speed ratio between power stroke and powerstroke venting
Set ............................................................ 35
Speed ratio between return stroke and fast approach stroke
Setting....................................................... 35
Speed reduction
Power stroke ............................................. 37
Stroke limitation
Power stroke ............................................. 36

56

V
Validity
Document ................................................... 8Z
ZDKPressure regulation in power stroke line... 44
ZKHD
External power stroke deactivation........... 50
ZKHF
External power stroke release .................. 52
ZKHZExternal power stroke connection............. 48

TOX_Construction_Installation_Guideline_Powerpackage_RP_T_en