TOX PRESSOTECHNIK Powerpackage Q Series, Original Operating Instructions

Page 1: ...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 ...

Page 2: ...2 TOX_Manual_Powerpackage_line Q_en ...

Page 3: ...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...

Page 4: ...dditional 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 de...

Page 5: ...HO 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 betw...

Page 6: ...tion 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 INCORPORA...

Page 7: ...tion 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 prop...

Page 8: ...ents 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 ref...

Page 9: ...are not taken è Measures for remedial action and protection WARNING Identifies a potentially dangerous situation Death or serious injury may occur if appropriate safety measures are not taken è Measures for remedial action and protection CAUTION Identifies a potentially dangerous situation Injury may occur if appropriate safety measures are not taken è Measures for remedial action and protection W...

Page 10: ... to ensure trouble free operation w Identifies the result of an action u Identifies the result of a complete action è Identifies a single action step or several action steps that are not in an operating sequence The highlighting of operating elements and software objects in texts facili tates distinction and orientation In square brackets identifies operating elements such as buttons levers and va...

Page 11: ...liance 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 saf...

Page 12: ...point 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 ap...

Page 13: ...s 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 The...

Page 14: ...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 Th...

Page 15: ...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 manufactur...

Page 16: ...werpackage_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 ...

Page 17: ...missioned 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 maintena...

Page 18: ...amage 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...

Page 19: ... 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 positio...

Page 20: ...por 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 di...

Page 21: ...ed compressed air Lightly oiled compressed air is permitted Compressed air quality according to DIN ISO 8573 1 Solids Water dew point Maximum Oil content Class μm Class C Class mg m3 5 40 4 3 3 1 4 3 Tightening torques 4 3 1 Tightening torques for flange mounting the drive Thread size Torque M 6 17 Nm M 8 40 Nm M 10 80 Nm M 16 340 Nm M 20 660 Nm M 24 1 130 Nm 4 3 2 Tightening torques on the piston...

Page 22: ...5µm load rating 30 N mm2 Food grade oil Klüber Summit HySyn FG 32 The following hydraulic oils are approved with limitations for standard appli cation Hydraulic oil UCON LB 165 Synthetic oil ISOTEX 46 Synthetic oil Envolubric PC 46 NWL The use of hydraulic oils that have not been approved as standard can lead to an increase of maintenance intervals due to an increased intake of air The use of hydr...

Page 23: ...r and lifetime of the seals in case of the use of hydraulic oils that have not been approved as standard the granted warranty becomes extinct è Use hydraulic oils that have bee approved by TOX PRESSOTECHNIK as standard è Use other hydraulic oils only after the express approval of TOX PRES SOTECHNIK è Do not mix different hydraulic oils Negative effects such as flocculation cannot be excluded ...

Page 24: ...Technical data 24 TOX_Manual_Powerpackage_line Q_en ...

Page 25: ...hen transporting and setting down make sure that no parts of the body become jammed è Wear suitable personal protective equipment e g safety boots CAUTION Injury from toppling and falling products è Secure product from toppling falling accidentally moving è Store product horizontally or secure with dowels The transportation may only be carried out by authorized personnel The product may only be tr...

Page 26: ...è If there are no threaded holes suspend the ring bolt between the work ing part and intensifier è Lift up the product carefully 5 3 Temporary storages Use original packaging Make sure that all connections and threads are covered to prevent dust ingress and shocks Store the product only in closed dry dust free and dirt free rooms at room temperature 5 4 Dispatch for repair If the device is sent to...

Page 27: ...rmed by an electrician è Disconnect power supply è Wait for residual energy to disspate safely at least 3 minutes WARNING Ejecting parts and compressed air from compressed air conducting lines Serious injuries to eyes and body cavities è Always connect and disconnect lines without pressure è Pay attention to maximum permitted pressures è Wear individual protective equipment CAUTION Tripping points...

Page 28: ...he strength class 12 9 in accordance with ISO 4762 Torque wrench 1 WARNING Risk of crushing Attach lifting device ring bolts and use appropriate lifting gear Place and align drive on the fastening element provided 2 Tighten screws observe torques while doing so See Chap 4 3 Tightening torques Page 21 ...

Page 29: ...Electronic pressure switch ZDO 5 High pressure measuring hose ZHM 6 High pressure measuring con nection Material required Electronic pressure switch ZDO Assembly holder ZMP High pressure measuring hose ZHM NOTE Air trapped in the connecting line Air could get into the high pressure chamber impair the working process and distort the measuring result è Fill connecting line with oil and vent ...

Page 30: ... 1 Install assembly holder of pressure switch on the drive Make sure that display and operating elements are easily accessible 2 Fasten the pressure switch in the assembly holder 3 Install high pressure hose on the pressure switch and on the high pres sure measuring connection 4 Connect cable of the pressure switch on the control system according to circuit diagram See pressure switch ZDO operatin...

Page 31: ...ke ZHU Fig 2 Installing position sensors for stroke monitoring for forward and return stroke Material required Magnet sensitive proximity switch with LED ZHS 001 001 Holding angle for proximity switch Cable box 1 Installing holding angle 2 Installing proximity switch 3 Connect the proximity switch to the control See circuit diagram ...

Page 32: ... cylinder to the first switch on point w The LED lights up 2 Mark the edge of the proximity switch on the cylinder 3 Push the proximity switch further to the switch off point w The LED switches off 4 Push the proximity switch back to the 2nd switch on point w The LED lights up 5 Mark the edge of the proximity switch on the cylinder 6 Position and fix the proximity switch between the two markings ...

Page 33: ...r ZHW Material required Prerequisite for the installation of the external linear position sensor Powerpackage type line Q line X or RZS 20 mm stroke reduction either positioned inside in the Powerpackage or positioned outside the tool Linear position sensor ZHW Holding angle for linear position sensor ...

Page 34: ... of the operating manual of the manufacturer are to be adhered to 1 Installing holding angle 2 Insert the linear position sensor into the holding angle 3 Adjust the linear position sensor and fasten it with the set screws Tightening torque 2 Nm 4 Secure the set screws with the hexagon not 5 Connect the linear position sensor to the control See circuit diagram and operating instructions of the line...

Page 35: ...lling pressure control in the power stroke line ZDK 1 12 Fig 3 Installing pressure control in the power stroke line assembly ZDK Material required Manual pressure regulator ZDK Screw plug with collar size M 5 laterally on power stroke valve next to connection 12 ...

Page 36: ...nection 4 4 on the pressure regulator In addition install hose line and seal 5 Install pressure regulator on power stroke input 1 6 When installing a proportional pressure regulator connect it to the con trol See data sheet or circuit diagram 6 3 5 Installing external power stroke connection ZKHZ Material required Electrical switching valve power stroke switch ZKHZ Screw plug ü For connections see...

Page 37: ...g valve power stroke release and power stroke deactiva tion with OR valve on control connection 14 2 Connect line of the control throttle X to the OR valve 3 Connect pneumatic input 3 of the switching valve to compressed air supply Installing the external power stroke deactivation ZKHD ü For connections see External power stroke deactivation assembly ZKHD optional 1 Install switching valve power s...

Page 38: ...t to con nection 12 ü For connections see External power stroke supply optional 1 Remove the screw plug from the control connection 12 and screw the M 5 screw plug with collar fully in w Bore hole in power stroke valve is closed 2 Connect control connection 12 on the power stroke valve to output of fast approach stroke 4 1 In addition install hose line and seal 3 Install external power stroke supp...

Page 39: ...e fre quency ZHO 2 Slide valve 3 Plug 4 Circlip Fig 5 Installing the stroke frequency optimization ZHO Material required Stroke frequency optimization ZHO for drive with integrated power stroke valve Pneumatic supply line including all series connected valves in the size fitting to the connections 1 Remove circlip and plug 2 Remove the valve slide 3 Install the plug and circlip 4 Installing the st...

Page 40: ...lling the stroke frequency optimization ZHO Material required Installing the stroke frequency optimization ZHO for drive with exter nal power stroke valve Pneumatic supply line including all series connected valves in the size fitting to the connections 1 Dismantle the existing external power stroke valve 2 Install the stroke frequency optimization ZHO ...

Page 41: ...eduction for power stroke venting Material required Adjustable exhaust air damper ZD 1 Install the exhaust throttle between the power stroke valve output 3 and the muffler 2 Connect the compressed air supply connections 3 Set the exhaust air damper See Chap 7 3 2 Set the speed ratio between power stroke and power stroke venting optional Page 46 ...

Page 42: ...cal data dimensions are observed See data sheet or type sheet at https www tox pressotechnik com 1 Install the tool holding fixture on the thread of the working piston Ob serve tightening torques See Chap 4 3 Tightening torques Page 21 2 Secure the tool holding fixture screw locking compound 3 Wet the contact surface between the holding tray and tool holding fix ture with food grade grease 4 Insta...

Page 43: ...ning 7 1 Safety during the commissioning 1 The commissioning may only be carried out by trained and authorized personnel 2 Make sure that that no persons are located within the danger area of the machine 3 Observe technical data and limit values See Technical data ...

Page 44: ... 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 or used 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 va...

Page 45: ...tios also the exhaust air dampers must be installed on the fast approach stroke connections and the return stroke connections A balanced power stroke speed For the attuned power stroke speed an exhaust air damper must also be installed in the power stroke venting For the throttled power stroke speed the speed ratios between power stroke speed and venting of the power stroke must be set See Chap 6 ...

Page 46: ...ssary 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 7 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...

Page 47: ... by the system pressure and by setting an optional fast ap proach stroke throttle Fig 9 Setting control throttle X ü Working piston is retracted ü Compressed air supply is switched on 1 Close control throttle X when piston is retracted and impinged by turn ing clockwise 2 Extend working piston rod 3 Open control throttle X slowly by turning counterclockwise until the power stroke is noticeably act...

Page 48: ...ngth of stroke 1 Dismantle the protective covering on the working piston 2 Loosen clamping screws 3 Screw in or unscrew the adjustment sleeve until the desired total stroke length is adjusted The adjustment path can be read on a scale on the adjustment sleeve w Unscrew adjustment sleeve The total stroke length is extended w Screw in adjustment sleeve The total stroke length is shortened 4 Tighten ...

Page 49: ...ments Serious contusions and injuries è Make sure that that no persons are located in the danger area during operation CAUTION Noise during operation Hearing impairment è Wear individual protective equipment CAUTION Hazard from flying parts Injuries to eyes and body cavities è Wear individual protective equipment ...

Page 50: ...es are com plied with The main switch of the machine is switched on Compressed air supply is open The fault message on the machine are acknowledged There are no persons are located in the danger area A visual inspection is carried out especially Position of the oil level indicator when the working piston is re tracted oil level indicator flush with the surface of the cylinder No objects in the wor...

Page 51: ...erpackage_line Q_en 51 9 Troubleshooting 9 1 Safety during troubleshooting Troubleshooting may only be carried out by trained and authorized per sonnel Make sure that that no persons are located within the danger area of the machine ...

Page 52: ...essure Compressed air setting on pressure regulator in the power stroke line op tional is too low Increase air pressure in power stroke line Pneumatic spring pressure setting is too high or the pneumatic spring is faulty Check compressed air supply of the pneumatic spring Contact authorized service personnel Oil level is too low Checking oil level Page 60 Air is trapped in the hydraulic oil sys te...

Page 53: ...is faulty Contact authorized service personnel Pneumatic spring pressure regulator or pressure gauge pneumatic spring is faulty Check the compressed air pressure on the pressure gauge Contact authorized service personnel Frequent refilling of hydraulic oil is necessary Speed ratio of fast approach stroke to return stroke is set incorrectly Setting speed ratio of return stroke to fast approach stro...

Page 54: ...Troubleshooting 54 TOX_Manual_Powerpackage_line Q_en ...

Page 55: ...nly approximate values Depending on the area of application the actual values may differ from the guide values The ac tual intervals can be found in the system control Maintenance cycle Additional information according to counter flexible 10 3 Checking oil level 10 4 Refilling oil and venting drive Yearly 10 6 Checking hydraulic hoses ...

Page 56: ...Maintenance table of Powerpackage 56 TOX_Manual_Powerpackage_line Q_en ...

Page 57: ...least 3 minutes WARNING Hot surfaces on the drive and on the control box Injuries from burns è Allow hot surfaces and motors to cool down before touching them WARNING Ejecting parts and compressed air from compressed air conducting lines Serious injuries to eyes and body cavities è Always connect and disconnect lines without pressure è Pay attention to maximum permitted pressures è Wear individual...

Page 58: ... Use cleaning set such as industrial cleaner e g Loctite 7063 or Würth Montagekraftreiniger 0890 107 vacuum cleaner dry cloth and brush è Do not clean with compressed air but with suction è After cleaning protect bare outer surfaces from corrosion Coat sur faces with a cloth slightly moistened with anticorrosive fluid è Keep inside surfaces especially element carrying parts dry and free of grease ...

Page 59: ...rking piston retracted 2 Install a restraint device if necessary 3 Make sure that fast approach stroke and power stroke cannot be acti vated in maintenance position 4 Make sure that return stroke is impinged with compressed air 5 Make sure that the pressure valve pneumatic spring is impinged 6 Make sure that unauthorized accidental or unexpected starting up of the machine and initiation or dangero...

Page 60: ...enance position See Set system to maintenance position Page 59 è Check needle of the oil level indicator u The needle of the oil level indicator is flush with the surface of the cylin der Oil level is ok OR u The needle of the oil level indicator comes out Oil must be refilled See Refilling oil and venting drive Page 61 ...

Page 61: ... Vent screw 6 Vent screw 7 Vent screw 8 High pressure measuring connection 9 Oil filling nipple 10 Oil level indicator 11 Venting plate 12 Oil anti overfill safety device 13 Vent screw Fig 12 Refilling oil and venting drive Material required Oil filtered 5 µm load rating 30 N mm 2 in accordance with DIN 51524 2 HLP32 If different special oils are used see sticker Oil pump ZP 20 ...

Page 62: ...ccording to installation position WARNING Contusions caused by uncontrolled extending working piston Serious contusions and injuries on hand and fingers è Make sure that the return stroke is impinged with compressed air è Make sure that fast approach stroke and power stroke cannot be acti vated è Install a restraint device if necessary è If no valve block ZVX is installed turn off compressed air s...

Page 63: ...asuring connection cover see table Venting point according to installation position and push in with a blunt object e g a pin 6 Continue to fill until oil escapes from the open vent hole free of bubbles 7 CAUTION Risk of injury and risk of slipping from leaking oil Absorb oil immediately and without residue 8 Wait 10 min Afterwards repeat filling procedure until oil escapes from the open vent hole...

Page 64: ...red Oil pump ZP 20 ü System is in maintenance position See Set system to maintenance position Page 59 ü Drive is filled and vented See Refilling oil and venting drive Page 61 1 Remove venting plate with locking wire 2 Unscrew knurled cap of the oil filling nipple 3 Screw filling hose of the oil pump onto oil filling nipple 4 CAUTION Risk of slipping from leaking oil Absorb oil immediately and with...

Page 65: ...aintenance TOX_Manual_Powerpackage_line Q_en 65 10 6 Checking hydraulic hoses è Check hydraulic hoses regularly è Change hydraulic hoses after 6 years at the latest è Observe country specific guidelines ...

Page 66: ...Maintenance 66 TOX_Manual_Powerpackage_line Q_en ...

Page 67: ... Safety during repairs Repair work may only be carried out by trained and authorized service per sonnel For information and contact seeSources and contact to customer service 11 2 Changing seals Seals may only replaced by trained and authorized service personnel ...

Page 68: ...Repairs 68 TOX_Manual_Powerpackage_line Q_en ...

Page 69: ...ct power supply è Wait for residual energy to disspate safely at least 3 minutes WARNING Ejecting parts and compressed air from compressed air conducting lines Serious injuries to eyes and body cavities è Always connect and disconnect lines without pressure è Pay attention to maximum permitted pressures è Wear individual protective equipment CAUTION Sharp edges caused by material splintering Injur...

Page 70: ...that the system is shut down permanently and or is pre pared for removal 1 Stop system and wait for it to come to a standstill 2 Remove material if necessary 3 Switch off the system at the main switch and secure it against being switched on again 4 First disassemble or dismantle after switching off the power electricity pneumatics and after residual energy has safely dissipated at least 3 minutes ...

Page 71: ... properly è Regional disposal regulations must be observed 1 Strip the system down into its constituent parts 2 Dispose of greases and oils separately 3 Sort the constituent parts by material and dispose of according to the local regulations 12 5 Disposal When disposing of packaging consumables and spare parts including the machine and its accessories the relevant national environmental protection...

Page 72: ...Disassembly and Disposal 72 TOX_Manual_Powerpackage_line Q_en ...

Page 73: ...Appendices TOX_Manual_Powerpackage_line Q_en 73 13 Appendices 13 1 DECLARATION OF INCORPORATION ...

Page 74: ...Appendices 74 TOX_Manual_Powerpackage_line Q_en ...

Page 75: ......

Page 76: ......

Page 77: ...y 69 71 Safety 69 Dispatch Repair 26 Disposal 69 71 Safety 69 Document additional 8 Validity 8 Drive Install 28 Operating 50 Venting 61 Dynamic oil leakage Avoiding 45 E Equipment Optional 20 Exclusion of liability 7 External power stroke connection ZKHZ Installing 36 External power stroke release ZKHF Installing 37 F Function description 18 G Gender note 8 Guidelines 7 H Hazard Contusion 14 Elect...

Page 78: ...n sensors of stroke monitoring for for ward and return stroke ZHU 31 Pressure switch 29 Stroke frequency optimization ZHO 39 ZDO 29 ZHO 39 Installing accessories 29 Installing pressure control in the power stroke line ZDK 35 Installing tool coupling ZWK 42 Installing ZDK 35 Installing ZWK 42 Intended use 17 L Laser Hazard 15 Legal note 7 Lifting device 26 line Q Product overview 19 Lowering Oil le...

Page 79: ... S Safety 11 Disassembly 69 Disposal 69 Installation 27 Maintenance 57 Operation 49 Repairs 67 Transport 25 Troubleshooting 51 Safety device Product 16 safety requirements Basic 11 Operating company 11 Searching Causes of fault 52 Searching for causes of fault 52 Selection Personnel 12 Selection of personnel 12 Set Speed ratio between power stroke and power stroke venting 46 Setting Control thrott...

Page 80: ...ng torques Installation 21 Piston rod 21 Total length of stroke Setting 48 Transport 25 Safety 25 Troubleshooting 51 Safety 51 Type plate 18 U Use Intended 17 V Validity Document 8 Venting Drive 61 W Warning signs 9 Z ZDO Installing 29 ZHO Installing 39 ZKHD Installing 37 ZKHF Installing 37 ZKHZ Installing 36 ...