TOX PRESSOTECHNIK FinePress PFHL User manual

Original operating instructions
TOX®-FinePress
PFHL / PFHW
TOX® PRESSOTECHNIK
Riedstrasse 4
D-88250 Weingarten
www.tox-pressotechnik.com
Edition:09/01/2020, Version: 1
GmbH & Co. KG

2TOX_Manual_FinePress_PFHL-PFHW_en

Table of contents
TOX_Manual_FinePress_PFHL-PFHW_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
1.7 Contact and source of supply.................................................................... 11
2 Safety
2.1 Basic safety requirements......................................................................... 13
2.2 Organizational measures .......................................................................... 13
2.2.1 Safety requirements for the operating company ....................................... 13
2.2.2 Selection and qualifications of personnel.................................................. 14
2.3 Fundamental hazard potential................................................................... 15
2.3.1 Electrical hazards...................................................................................... 15
2.3.2 Thermal hazards ....................................................................................... 15
2.3.3 Pneumatic hazards ................................................................................... 15
2.3.4 Contusions ................................................................................................ 16
2.3.5 Hydraulic hazards ..................................................................................... 16
2.3.6 Electromagnetic hazards........................................................................... 16
2.3.7 Laser ......................................................................................................... 17
2.3.8 Hazardous substances.............................................................................. 17
2.3.9 Noise ......................................................................................................... 17
2.4 Safety symbols.......................................................................................... 18

Table of contents
4TOX_Manual_FinePress_PFHL-PFHW_en
3 About this product
3.1 Intended use ............................................................................................. 19
3.1.1 Safe and correct operation........................................................................ 19
3.1.2 Foreseeable misuse.................................................................................. 20
3.1.3 Substances harmful to the wetting properties of lacquers (LABS)............ 20
3.2 Product identification................................................................................. 20
3.2.1 Type plate ................................................................................................. 20
3.3 Product overview and function description................................................ 21
4 Technical data
4.1 Type sheet and data sheet........................................................................ 23
4.2 Compressed air quality and pneumatic connection .................................. 23
4.3 Compressed air press force table ............................................................. 23
5 Transport and storage
5.1 Safety during transport.............................................................................. 25
5.2 Storage when not in use ........................................................................... 26
5.3 Transport by lifting device ......................................................................... 27
5.4 Dispatch for repair..................................................................................... 28
6 Installation
6.1 Safety during installation ........................................................................... 29
6.2 Requirements for installation..................................................................... 31
6.2.1 Set-up location .......................................................................................... 31
6.3 Installing accessories ................................................................................ 32
6.3.1 Installing process monitoring (option) ....................................................... 32
6.3.2 Installing the stroke counter (optional) ...................................................... 33
6.3.3 Installing the force sensor (optional) ......................................................... 34
6.3.4 Installing travel sensor (option) ................................................................. 36
6.3.5 Installing the slide table (optional)............................................................. 38
6.3.6 Installing the tool holding fixture (optional)................................................ 39
6.3.7 Install the TDC sensor (option) ................................................................. 40
6.3.8 Install the BDC sensor (option) ................................................................. 42

Table of contents
TOX_Manual_FinePress_PFHL-PFHW_en 5
7 Commissioning
7.1 Safety during the commissioning .............................................................. 45
7.1.1 Safety device............................................................................................. 45
8 Operation
8.1 Safety in operation .................................................................................... 47
8.2 Requirements for operation....................................................................... 47
8.3 Process monitoring ................................................................................... 48
8.4 Setting the open height of the press head ................................................ 49
8.5 Fine adjustment of working stroke ............................................................ 52
8.6 Resetting the stroke counter (optional) ..................................................... 53
9 Troubleshooting
9.1 Safety during troubleshooting ................................................................... 55
9.2 Detecting faults ......................................................................................... 56
Maintenance table
10 Maintenance
10.1 Safety during maintenance ....................................................................... 59
10.2 Requirements for maintenance ................................................................. 61
10.2.1 Set system to maintenance position ......................................................... 61
10.3 TOX®-FinePress maintaining .................................................................... 62
10.3.1 TOX®-FinePress inspecting ...................................................................... 62
10.3.2 Inspecting the fastening of the press head ............................................... 63
10.3.3 Inspecting and cleaning movable parts and guides .................................. 64
11 Repairs
11.1 Safety and repairs ..................................................................................... 65

Table of contents
6TOX_Manual_FinePress_PFHL-PFHW_en
12 Disassembly and Disposal
12.1 Safety during disassembly and disposal ................................................... 67
12.2 Decommissioning...................................................................................... 67
12.3 Shutdown .................................................................................................. 68
12.4 Disassembling........................................................................................... 68
12.5 Disposal .................................................................................................... 69
13 Appendices
13.1 Declaration of conformity .......................................................................... 71
Index

Important information
TOX_Manual_FinePress_PFHL-PFHW_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_FinePress_PFHL-PFHW_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_FinePress_PFHL-PFHW_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_FinePress_PFHL-PFHW_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.

Important information
TOX_Manual_FinePress_PFHL-PFHW_en 11
1.7 Contact and source of supply
Only use original spare parts or spare parts approved by TOX®PRES-
SOTECHNIK.
TOX®PRESSOTECHNIK GmbH & Co. KG
Riedstraße 4
D - 88250 Weingarten
Tel. [phone]
E-Mail: [email protected]
For additional information and forms see www.tox-pressotechnik.com.

Important information
12 TOX_Manual_FinePress_PFHL-PFHW_en

Safety
TOX_Manual_FinePress_PFHL-PFHW_en 13
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
14 TOX_Manual_FinePress_PFHL-PFHW_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_FinePress_PFHL-PFHW_en 15
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
16 TOX_Manual_FinePress_PFHL-PFHW_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.
2.3.6 Electromagnetic hazards
Electromagnetic hazards are to be taken into account in the area of electro-
magnetically vibrating or oscillating components.
Regular work on and with electromagnetically vibrating or oscillating com-
ponents can cause disorders in the blood flow of the fingers as well as neu-
rological and motoric dysfunctions.

Safety
TOX_Manual_FinePress_PFHL-PFHW_en 17
The following applies generally:
Wear protective anti-vibration gloves when performing necessary work!
Electromagnetic fields can have an indirect effect on heart pacemakers
and other implants. Adhere to safety distances.
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.
2.3.9 Noise
Depending on the equipment, an increase in the noise level can arise in the
sphere of the product.
Keep the duration of the exposure at a minimum.
Wear individual protective equipment.

Safety
18 TOX_Manual_FinePress_PFHL-PFHW_en
2.4 Safety symbols
Safety symbols are important components of the safety concept and help to
prevent accidents. The safety symbols provide information about potential
hazards that could cause serious injuries.
The following safety symbols can be attached on the product:
Symbol Hazard Notes
Warning of suspended load Do not stay in the danger zone of the
suspended load.
Identifies fork-lift truck brackets.
Identifies attachment point.
Warning of hot surfaces In the area of motors, drives and
fans.
Warning of electrical voltage In the area of the entire control box.
Warning of crushing Risk of crushing in the working area.
Tab.1 Safety symbols

About this product
TOX_Manual_FinePress_PFHL-PFHW_en 19
3 About this product
3.1 Intended use
The press in conjunction with the designated tool is used for
Installing, pressing
Punching, pressing (of function elements)
Riveting, crimping, flaring
Punching, piercing
Embossing, marking
Tensioning, clamping, crimping
Pressing, compressing
Clinching, joining
of sheet metal or mechanical modules.
3.1.1 Safe and correct operation
Intended use includes the following conduct:
Only operate with the components for which it is specified.
Follow all instructions in this operating manual.
Comply with the specified maintenance intervals and perform 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
20 TOX_Manual_FinePress_PFHL-PFHW_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.
3.1.3 Substances harmful to the wetting properties of lacquers
(LABS)
No substances containing silicone, are knowingly processed and used.
3.2 Product identification
3.2.1 Type plate
The details on the type plate ensure clear identification of components and
the specific operating parameters.
The type plate is attached permanently on the component.