TOX PRESSOTECHNIK Powerpackage Q Series User manual

Original operating instructions
TOX® Powerpackage line-Q
Type Q-S, Q-K
TOX® PRESSOTECHNIK
Riedstrasse 4
D-88250 Weingarten
www.tox-pressotechnik.com
Edition:05/25/2020, Version: 2
GmbH & Co. KG

2TOX_Manual_Powerpackage_line-Q_en

Table of contents
TOX_Manual_Powerpackage_line-Q_en 3
Table of contents
1 Important information
1.1 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
2 Safety
2.1 Basic safety requirements......................................................................... 11
2.2 Organizational measures .......................................................................... 11
2.2.1 Safety requirements for the operating company ....................................... 11
2.2.2 Selection and qualifications of personnel.................................................. 12
2.3 Fundamental hazard potential................................................................... 13
2.3.1 Electrical hazards...................................................................................... 13
2.3.2 Thermal hazards ....................................................................................... 13
2.3.3 Pneumatic hazards ................................................................................... 13
2.3.4 Contusions ................................................................................................ 14
2.3.5 Hydraulic hazards ..................................................................................... 14
2.3.6 Electromagnetic hazards........................................................................... 15
2.3.7 Laser ......................................................................................................... 15
2.3.8 Hazardous substances.............................................................................. 15
2.4 Safety device on the product..................................................................... 16
2.4.1 Safety device of system ............................................................................ 16

Table of contents
4TOX_Manual_Powerpackage_line-Q_en
3 About this product
3.1 Intended use ............................................................................................ 17
3.1.1 Safe and correct operation........................................................................ 17
3.1.2 Foreseeable misuse.................................................................................. 18
3.2 Product Identification................................................................................. 18
3.2.1 Position and content of the type plate ....................................................... 18
3.3 Function description of Powerpackage ..................................................... 18
3.4 Product overview of Powerpackage line-Q ............................................... 19
3.4.1 Product attributes of Powerpackage line-Q............................................... 19
3.5 Optional equipment ................................................................................... 20
3.5.1 Additional optional equipment ................................................................... 20
4 Technical data
4.1 Type sheet and data sheet........................................................................ 21
4.2 Compressed air quality and pneumatic connection .................................. 21
4.3 Tightening torques .................................................................................... 21
4.3.1 Tightening torques for flange mounting the drive...................................... 21
4.3.2 Tightening torques on the piston rod......................................................... 21
4.4 Press force table ....................................................................................... 22
4.5 Specification for hydraulic oil..................................................................... 22
5 Transport and storage
5.1 Safety during transport.............................................................................. 25
5.2 Lifting device ............................................................................................. 26
5.3 Temporary storages .................................................................................. 26
5.4 Dispatch for repair..................................................................................... 26
6 Installation
6.1 Safety during installation .......................................................................... 27
6.2 Installing drive ........................................................................................... 28
6.3 Installing accessories ................................................................................ 29
6.3.1 Installing electronic pressure switch (ZDO)............................................... 29

Table of contents
TOX_Manual_Powerpackage_line-Q_en 5
6.3.2 Installing position sensors of stroke monitoring for forward and return stroke
(ZHU) ........................................................................................................ 31
6.3.3 Installing the external linear position sensor (ZHW).................................. 33
6.3.4 Installing pressure control in the power stroke line (ZDK)......................... 35
6.3.5 Installing external power stroke connection (ZKHZ) ................................. 36
6.3.6 Installing external power stroke release (ZKHF) and power stroke deactiva-
tion (ZKHD) ............................................................................................... 37
6.3.7 Preparing external power stroke supply.................................................... 38
6.3.8 Installing the stroke frequency optimization (ZHO) ................................... 39
6.3.9 Installing the speed reduction for power stroke venting ............................ 41
6.3.10 Installing tool coupling (ZWK) ................................................................... 42
7 Commissioning
7.1 Safety during the commissioning .............................................................. 43
7.2 Requirements for the commissioning........................................................ 44
7.2.1 Measuring connection and control connection.......................................... 44
7.3 Avoidance of dynamic oil leakage............................................................. 45
7.3.1 Setting speed ratio of return stroke to fast approach stroke ..................... 46
7.3.2 Set the speed ratio between power stroke and power stroke venting (op-
tional) ........................................................................................................ 46
7.4 Setting control throttle 'X' .......................................................................... 47
7.5 Setting total length of stroke (optional)...................................................... 48
8 Operation
8.1 Safety in operation .................................................................................... 49
8.2 Requirements for operation....................................................................... 50
8.3 Operating drive.......................................................................................... 50
9 Troubleshooting
9.1 Safety during troubleshooting ................................................................... 51
9.2 Searching for causes of fault..................................................................... 52

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6TOX_Manual_Powerpackage_line-Q_en
Maintenance table of Powerpackage
10 Maintenance
10.1 Safety during maintenance ....................................................................... 57
10.2 Requirements for maintenance ................................................................. 59
10.2.1 Set system to maintenance position ......................................................... 59
10.3 Checking oil level ...................................................................................... 60
10.4 Refilling oil and venting drive .................................................................... 61
10.5 Lowering of oil level................................................................................... 64
10.6 Checking hydraulic hoses ......................................................................... 65
11 Repairs
11.1 Safety during repairs ................................................................................. 67
11.2 Changing seals ......................................................................................... 67
12 Disassembly and Disposal
12.1 Safety during disassembly and disposal ................................................... 69
12.2 Decommissioning...................................................................................... 70
12.3 Shutdown .................................................................................................. 70
12.4 Disassembling........................................................................................... 71
12.5 Disposal .................................................................................................... 71
13 Appendices
13.1 DECLARATION OF INCORPORATION ................................................... 73
Index

Important information
TOX_Manual_Powerpackage_line-Q_en 7
1 Important information
1.1 Legal note
All rights reserved.
Operating instructions, manuals, technical descriptions and software pub-
lished by TOX®PRESSOTECHNIK GmbH & Co. KG ("TOX®PRES-
SOTECHNIK") 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 ap-
proval in writing by TOX®PRESSOTECHNIK and may be subject to crimi-
nal and civil legal sanctions.
If this manual refers to goods and/or services of third parties, this is for ex-
ample only or is a recommendation by TOX®PRESSOTECHNIK.
TOX®PRESSOTECHNIK does not accept any liability or warranty/guaran-
tee with reference to the selection, specifications and/or usability of these
goods and services. The use and/or representation of trademarked brands
that do not belong to TOX®PRESSOTECHNIK are for information only; all
rights remain the 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 to
ensure that it conforms to the technical properties and specifications of the
products or plant and the description of the software. However, discrepan-
cies may still be present, so we cannot guarantee complete accuracy. The
supplier documentation included with the system documentation is an ex-
ception.
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®PRES-
SOTECHNIK 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 EU-declaration of conformity or installation declaration.

Important information
8TOX_Manual_Powerpackage_line-Q_en
1.4 Validity of the document
1.4.1 Content and target group
This manual contains information and instructions for the safe operation
and safe maintenance or servicing of the product.
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 oper-
ating and service personnel.
1.4.2 Other applicable documents
In addition to the available manual, further documents can be supplied.
These documents must also be complied with. Other applicable documents
can be, for example:
additional operating manuals (e.g. of components or of a whole sys-
tem)
Supplier documentation
Instructions, such as software manual, etc.
Technical data sheet
Safety data sheets
Data sheets
1.5 Gender note
In order to enhance readability, references to persons that also relate to all
sexes are normally only stated in the usual form in German or in the corre-
sponding translated language in this manual, thus e.g. "operator" (singular)
for male or female, or "operators" (plural) for male or female". This should
in no way convey any gender discrimination or any violation of the principle
of equality, however.

Important information
TOX_Manual_Powerpackage_line-Q_en 9
1.6 Displays in the document
1.6.1 Display of warnings
Warning signs indicate potential dangers and describe protective mea-
sures. 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.
èMeasures for remedial action and protection.
WARNING
Identifies a potentially dangerous situation!
Death or serious injury may occur if appropriate safety measures are not
taken.
èMeasures for remedial action and protection.
CAUTION
Identifies a potentially dangerous situation!
Injury may occur if appropriate safety measures are not taken.
èMeasures 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.
èMeasures for remedial action and protection.

Important information
10 TOX_Manual_Powerpackage_line-Q_en
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.
üIdentifies prerequisites that must be followed.
1. Action step 1
2. Action step 2: identifies an action step in an operating sequence that
must be followed to ensure trouble-free operation.
wIdentifies the result of an action.
uIdentifies the result of a complete action.
èIdentifies 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 facili-
tates distinction and orientation.
<In square brackets> identifies operating elements, such as buttons,
levers and (valves) stopcocks.
''with quotation marks'' identifies software display panels, such as win-
dows, messages, display panels and values.
In bold identifies software buttons, such as buttons, sliders, check-
boxes and menus.
In bold identifies input fields for entering text and/or numerical values.

Safety
TOX_Manual_Powerpackage_line-Q_en 11
2 Safety
2.1 Basic safety requirements
The product is state of the art. However, operation of the product may in-
volve danger to life and limb for the user or third parties or damage to the
plant and other property.
For this reason the following basic safety requirements will apply:
Read the operating manual and observe all safety requirements and
warnings.
Operate the product only as specified and only if it is in perfect techni-
cal condition.
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:
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 sup-
plemented by existing national regulations (e.g. for prevention of acci-
dents and for environmental protection).
Instructions for special operating features (e.g. work organization, work
processes, appointed personnel) and supervisory and reporting obliga-
tions must be added to the operating manual.

Safety
12 TOX_Manual_Powerpackage_line-Q_en
Take action to ensure safe operation and make sure that the product is
maintained 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. Ac-
tion contrary to the above will not be covered by the warranty or the op-
erating approval.
Make sure that the annual safety inspections are carried out and docu-
mented by an expert.
2.2.2 Selection and qualifications of personnel
The following safety requirements are applicable for the selection and quali-
fications of personnel:
Only appoint persons to work on the plant who have read and under-
stood the operating manual, and in particular, the safety instructions
before starting work. This is particularly important for persons who only
work on the plant occasionally, e.g. for maintenance work.
Only allow persons appointed and authorized for this work access to
the plant.
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.
visual and acoustic signals).
Ensure that assembly and installation work and the initial commission-
ing 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 ap-
prenticeship can only work on the plant under the supervision of an ex-
perienced person.
Have work on electrical equipment performed only by electricians or
trained persons under the direction and supervision of an electrician in
accordance with the electrotechnical regulations.

Safety
TOX_Manual_Powerpackage_line-Q_en 13
2.3 Fundamental hazard potential
Fundamental hazard potentials exist. The specified examples draw atten-
tion 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 compo-
nents in the area of all assemblies of the control system and motors of the
installation.
The following basically applies:
Have work on electrical equipment performed only by electricians or
trained persons under the direction and supervision of an electrician in
accordance with 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 in-
advertently.
Pay attention to the dissipation of residual energy from the control sys-
tem of the servomotors.
Make sure that the components are disconnected from the power sup-
ply when carrying out the work.
2.3.2 Thermal hazards
The drive works in continuous operation and can become hot and cause
burns when touched.
Wear individual protective equipment.
Before starting work, make sure that surfaces have cooled down suffi-
ciently.
2.3.3 Pneumatic hazards
Attention must be paid to pneumatic hazards particularly on the pneumatic
supply lines and connection points.
The following basically applies:
Allow work to be carried out on pneumatic equipment by authorized
service personnel only.
Wear individual protective equipment.

Safety
14 TOX_Manual_Powerpackage_line-Q_en
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.
2.3.4 Contusions
Contusions and hand injuries can occur in the radius of action of the prod-
uct.
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, clean-
ing), secure the system against unexpected, accidental and unautho-
rized activation.
Make sure that parts or tools cannot fall down or descend as a result of
stored energy. Use appropriate fuses.
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 ser-
vice 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.

Safety
TOX_Manual_Powerpackage_line-Q_en 15
2.3.6 Electromagnetic hazards
Electromagnetic hazards must be observed in the area of electromagneti-
cally vibrating or oscillating components.
Regular work on and with electromagnetically vibrating or oscillating com-
ponents can lead to disturbances in the blood circulation of the fingers as
well as neurological and motoric dysfunctions.
Basically applies:
Use antivibration gloves according to EN ISO 10819:1997 for neces-
sary work!
Electromagnetic fields can influence pacemakers (PM) and other im-
plants through indirect effects. Avoid possible malfunctions.
2.3.7 Laser
Depending on the model and features, lasers can be installed for the pur-
pose of recognition. There is a danger of looking into the laser in some situ-
ations. If this is not avoided, eye injuries may result.
2.3.8 Hazardous substances
The following safety requirements apply when handling chemical sub-
stances:
Observe the applicable safety regulations on handling chemical sub-
stances 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 con-
taminated 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 dis-
pose of them properly.

Safety
16 TOX_Manual_Powerpackage_line-Q_en
2.4 Safety device on the product
Safety devices are important components of the safety concept and help to
prevent accidents.
2.4.1 Safety device of system
A superordinate safety concept must be developed.

About this product
TOX_Manual_Powerpackage_line-Q_en 17
3 About this product
3.1 Intended use
The hydropneumatic drive performs the strokes that are generally defined
as fast approach stroke, power stroke and return stroke. The drive is in-
tended for installation in machines or robot tongs with the following techni-
cal applications:
Installing, pressing
Punching, pressing (of function elements)
Riveting, crimping, flaring
Punching, piercing
Embossing, marking
Tensioning, clamping, crimping
Pressing, compressing
Clinching, joining
This incomplete machine may not be commissioned until it has been ascer-
tained that the incomplete machine in which the component is to be in-
stalled 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 mainte-
nance work 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 au-
thorized for this purpose.
Any other use or application beyond this does not come under the scope of
intended use.

About this product
18 TOX_Manual_Powerpackage_line-Q_en
3.1.2 Foreseeable misuse
Use contrary to intended use includes the following foreseeable misuse:
Operation under conditions that deviate from the technical data.
Operation without fully assembled and functional connections.
Operation without fully assembled and functional safety devices.
Modifications to the product without prior approval by the TOX®PRES-
SOTECHNIK and the approving authority.
Incorrect parameterization.
Execution of activities by persons who are not qualified or authorized to
do so.
The operating company is exclusively responsible for all personal injury and
property damage resulting from non-intended use. Non-intended use will
not be covered by the warranty or the operating approval of the complete
plant.
3.2 Product Identification
3.2.1 Position and content of the type plate
Designation on the type plate Meaning
Type Product designation
No. Serial number
ΔV [ml] Lowering volume
Indicates the amount of oil that must be
discharged again after completely filling.
Pmax Maximum pressure
Type code structure
Type key Description
X-S 008. 3030. 100. 12
X-S 008. 3030. 100. 12 Identifies the series type such as X-S, S, K, etc.
X-S 008. 3030. 100. 12 Indicates the press force in [tons].
X-S 008. 3030. 100. 12 Indicates the version.
X-S 008. 3030. 100. 12 Indicates the length of the total stroke.
X-S 008. 3030. 100. 12 Indicates the length of the power stroke.
3.3 Function description of Powerpackage
See Design and installation guideline.

About this product
TOX_Manual_Powerpackage_line-Q_en 19
3.4 Product overview of Powerpackage line-Q
5
4
2
1
34
2
1
5
3
6
6
1 Working piston 2 Compressed air supply return stroke [2]
3 Control throttle 'X' 4 Compressed air supply fast approach
stroke [4]
5 Oil filling nipple 6 Power stroke valve
Fig.1 Product overview 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
a tension rod in a sandwich construction.
Intensifier and working part are connected with an
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.

About this product
20 TOX_Manual_Powerpackage_line-Q_en
3.5 Optional equipment
3.5.1 Additional optional equipment
Type Product attributes
ZHW Linear position sensor
The travel sensor indicates the absolute actual position
of the piston.
For external installation (for series line-Q and line-X to
Q-S/Q-K 30, X-SX-K 30).
ZHU Stroke monitoring
Determines the position of the working piston during
forward stroke and return stroke via the external sen-
sor.
ZDK Pressure regulation in power stroke line
Make possible the individual adjustment of the press
force with a manual pressure valve or electrical propor-
tional valve.
ZKHZ External power stroke connection
Enables the connection of the power stroke valve with
an electrically actuated 3/2-way valve.
ZWK Tool coupling
Connects the drive and tool flexibly to prevent trans-
verse forces from affecting the drive.
ZDO Electronic pressure switch
Records the oil pressure in the high-pressure part as
system pressure and visualizes it via a four-digit LED
display.
The set switching function allows 2 output signals to be
created.
ZHO Stroke frequency optimization
Reduces the cycle time.
Replaces the existing power stroke valve with one of
the next size.
ZPS Pressing force sensor
Measures the press forces in the direction of the pres-
sure.
Tab.1 Optional equipment
For optional equipment, see data sheet and brochure TOX®-Powerpack-
age.
http://tox-pressotechnik.com/