Completion

of the Operating Instructions

TOX®-Powerpackage

TOX® Special Powerpackages

and TOX® Powerpackage Accessories
TOX® Powerpackage type RZK

TOX® Powerpackage with press force sensor ZPS

TOX® Powerpackage with "Safety Rod Catcher" ZSL
e.g.. SSL, KSL, EKSL, ATSL

TOX® Powerpackage with adjustable end of stroke cushion ZSD

e.g.. EKSD, ATSD

TOX® PRESSOTECHNIK GmbH & Co. KG Riedstraße 4 D - 88250 Weingarten

Tel. +49 (0) 751/5007-0 Fax +49 (0) 751/52391 www.tox-de.com E-Mail: info@tox-de.com
 TOX® Special Powerpackages and Accessories

Content
1 About this manual ................................................................3
2 TOX®-Powerpackage Type RZK..........................................4
2.1 Function and characteristics ........................................4
2.2 Limitation of total stroke ...............................................5
2.3 Switching-OFF the powerstroke...................................5
2.4 Table press force-oil ....................................................5
2.5 Tightening torque.........................................................7
2.6 Oil refills / venting ........................................................7
2.7 Drawings / Parts list......................................................9
3 TOX® Powerpackage with Pressforce sensor ZPS ............13
3.1 Function and characteristics ......................................13
3.2 Recommendations for installation................................13
3.3 Mounting the pressforce sensor.................................14
3.4 Mounting the anti rotation lock ZPSV ....................15
4 TOX®-Powerpackage with "Safety Rod Lock" Type ZSL ...16
4.1 Function and characteristics ......................................16
4.2 Operating conditions / intended use...............................16
4.3 Actuation....................................................................17
4.4 Setting the proximity switches....................................17
4.5 Electric actuation .......................................................18
4.6 Inspection rules for the Safety Rod Lock ...................18
4.7 Maintenance / Repairs ...............................................18
5 TOX®-Powerpackage with Adjustable End of
Strike Cushion ZSD ...........................................................19
5.1 Function and characteristics ......................................19
5.2 Mounting the Powerpackage with BDC damping.......19
5.3 Adjusting the total stroke and the BDC damping,
operation....................................................................19
5.4 Inspection / Maintenance ...........................................20
5.5 Oil refill.......................................................................21
5.6 Drawings....................................................................22

TOX® PRESSOTECHNIK GmbH & Co. KG Riedstraße 4 D - 88250 Weingarten

Tel. +49 (0) 751/5007-0 Fax +49 (0) 751/52391 www.tox-de.com E-Mail: info@tox-de.com
 TOX® Special Powerpackages and Accessories
1 About this manual
These Operating Instructions serve as Comple-
tion of the Operating Instructions for the
TOX® Powerpackage. These instruction com-
prise the description of the TOX® Special
Powerpackages of type RZK, as well as the
TOX® Powerpackages with accessories like the
distance measuring system ZKW (e.g. KWE,
ATW, HZW), Pressforce sensor ZPS, the drop
protection ZSL "Safety Lock" (e.g. SSL, KSL,
EKSL, ATSL) or BDC damping ZSD (e.g. EKSD,
ATSD). The combination of several accessory
components in one TOX® Powerpackage is also
possible.
Please inform yourselves on the characteristic
features of the special Powerpackages and the
accessories described herein by reading those
parts of the Operating Instructions referring to
your TOX® Powerpackage and its accessories
(the delivered accessories are specified in the
shipping documents of the TOX® Powerpack-
age).
Observe the Operating Manual
TOX®-Powerpackage
In order to become familiarized with
this drive system, we ask you to
observe the Operating Manual of
the standard TOX®-Powerpackages
and especially chapter "Safety".
The Operating Instructions TOX® Powerpack-
age inform you in addition to general safety notes
on the functioning of the TOX® Powerpackage,
on planning and installation, and the handling
during all life cycles of a Powerpackage – trans-
port and assembly, setting and operation up to
maintenance and repair. But the Operating In-
structions of the TOX® Powerpackage also in-
clude chapter Trouble Shooting, Pressforce/Oil-
pressure tables, tables of tightening torques for
screwings, as well as drawings and parts lists.
Further information on the
TOX®-Powerpackage
If you have not received our Oper-
ating Instructions 'TOX® Power-
package', please contact us.
BA 11.0706.02
Copyright, warranty
These Operating Instructions as well as any
attached documents are protected by copyright.
They are entrusted to our customers and the
users of our products.
Copyright:
TOX® PRESSOTECHNIK GmbH & Co. KG
These operating instructions are current at the
date of issue.
Edition: 29.06.2007
Any modifications to the machine induced by the
employer are not comprised.
Damages to the
TOX®-Powerpackage
Report any failures as soon as
they are detected to the competent
representative or direct to
TOX® PRESSOTECHNIK:
TOX® PRESSOTECHNIK GmbH & Co. KG
Riedstrasse 4 D - 88250 Weingarten
Tel. +49 (0) 751/5007-0
Fax +49 (0) 751/52391
E-Mail info@tox-de.com
The TOX®-Powerpackages and the accessories
are designed and manufactured according to the
state of the art and the applicable German stan-
dards and specifications.
We reserve the right to make alterations result-
ing in technical improvements.
Legends of illustrations and position numbers
The illustrations in this part of the Operating
Instructions are provided with an illustration
number. Important system or appliance parts
shown on the illustrations are provided with
component numbers.
The reference in the text to a component allows
an easy allocation. Example:
(8/14) means: illustration 8, component part 14
3
 TOX®-Powerpackage RZK

2 TOX®-Powerpackage Type RZK

2.1 Function and characteristics Function
The TOX® Powerpackages of series RZK have Operating Instructions
been specially conceived as drive for the TOX® 'TOX® Powerpackage'
Robot and Machine tongs as well as for some This TOX® Powerpackage is a
TOX® frames. As specialities they are distin- variant of the TOX® Powerpack-
guished by the limitation of the total stroke, the ages of series K resp. EK with total
powerstroke switch-off, the add-on flange opti- stroke limitation.
mized for C-frames, as well as the compact con- For information on the functioning
struction. The TOX® Powerpackages of these of this Powerpackage, please refer
series can also be mounted to other machines. to the Operating Instructions for the
'TOX® Powerpackage',chapter 4.
Survey
1 Bores for fastening screws
1 2 1 3 4 5 6 7 8 2 Forcing screws
3 Air connection return stroke
4 Powerstroke switch-off
5 Air connection fast approach
stroke
6 HP measuring connection
7 Spacer sleeve (option,
for stroke reduction;
not illustrated)
8 Adjusting nut for total stroke
9 Vent plug
10 Oil refill nipple
11 Oil level indicator
12 Bleed plate
13 Air supply feed piston
(0.8 bar)
14 Return stroke plunger piston
(0.8 bar)
18 17 16 15 14 13 12 11 10 9 6 15 Air supply powerstroke
16 Powerstroke bleeding
17 Connection control throttle 'X'
18 Flange cover with mounting
groove

Ill. 1

4 BA 11.0706.02

Limitation of total stroke
Distance adjustable
sleeve adapter
Ill. 2
2.2 Limitation of total stroke
A spindle is attached to the working piston of the
TOX®-Powerpackage. An adjustable adapter is
provided on this spindle which serves to reduce
the stroke of the working piston and thus the
total stroke by 10 mm. Should a further limitation
be necessary, mount spacer blocks before the
adjustable adapter.
Adjustment of the total stroke
The protective cover in the rear part of the
TOX®-Powerpackage must not be removed for
the adjustment of the total stroke.
Release the locking screws securing the ad-
justable adapter against twisting.
Set the adjustable adapter in accordance with
the required total stroke.
• When turning the adjustable adapter in extreme
position in the rear: the whole stroke is available.
• When turning the adjustable adapter in extreme
position in front, the total stroke is reduced by 10
mm.
When the total stroke is set, secure the adjusting
nut again with the locking screws.
Pay attention to the torque!
Risk of piston breakage
Use the same torque to tighten the
locking screws of the adjusting nut
(Tightening torque see chapter 4,
table 'Screws DIN 912-12.9').
Screw down the locking screws
crosswise until the prescribed torque
is reached.
BA 11.0706.02
TOX®-Powerpackage RZK
Rotary lock switch
(here position I: powerstroke on)
Ill. 3
2.3 Switching-OFF the powerstroke
The powerstroke can be switched off with the
rotary lock switch on the TOX®-Powerpackage
flange with the help of a switch cabinet key:
Position 0: powerstroke off
Position 1: powerstroke on
The powerstroke is switched off when sup-
plied ex works (switch position 0).
2.4 Table press force-oil
Observe the operating pressure
Exceeding the max. permissible
operating pressure there could be
damages of the TOX®-Powerpackage,
the working part, the hydraulic cyl-
inders or the hydraulic tube as well
as danger to life and limb.
The nameplate shows the precise denomination
of the TOX® Powerpackage type. With the help of
this denomination you will find the relevant Oil-
pressure/Pressforce Table for the corresponding
Powerpackage type RZK on the following page.
5
 TOX®-Powerpackage RZK

TOX®-Powerpackage Type RZK with mechanical compression spring, 6 bar

RZK 05.xxx.100.07 (xxx = 031 / 032 / 033/ 034) RZK 08.xxx.100.08 (xxx = 031 / 032 / 033 / 034)
Air Oil pres- Press Fast ap- Retracting Oil pres- Press Fast ap- Retracting
pressure sure force proach force sure force proach force
(bar) [kN] force (N) (bar) [kN] force (N)
(bar) (N) (N)
2 100 15,2 441 625 130 27,2 904 1170
3 165 25,0 662 959 200 41,1 1350 1790
4 235 35,5 883 1290 280 58,5 1800 2410
5 300 45,3 1100 1620 355 74,1 2260 3030
6 360 54,3 1320 1960 435 90,7 2710 3650
* The press force is specified including the fast approach force
Tolerance for technical data ±5 %

TOX®-Powerpackage Type RZK with pneumatic spring, 6 bar

RZK 05.xxx.100.07 LF (xxx = 035 / 036 / 038/ 040) RZK 08.xxx.100.08 (xxx = 035 / 037)
Air Oil pres- Press Fast Retracting Oil pres- Press Fast Retracting
pressure sure force ap- force sure force ap- force
(bar) [kN] proach (N) (bar) [kN] proach (N)
(bar) force force
(N) (N)
2 70 10,7 441 561 87 18,5 904 1090
3 132 20,1 662 895 164 34,5 1350 1710
4 203 30,8 883 1220 240 50,4 1800 2330
5 274 41,4 1100 1560 319 66,8 2260 2950
6 345 52,1 1320 1890 394 82,4 2710 3570
* The press force is specified including the fast approach force and a pneumatic spring pressure of 0,8 bar.
Tolerance for technical data ±5 %

TOX®-Powerpackage Type RZK with mechanical compression spring, 10 bar

RZK 05.xxx.100.07 (xxx = 001 / 003 / 005 / 006) RZK 08.xxx.100.08 (xxx = 001 / 002 / 003 / 004 / 005)
Air Oil pres- Press Fast ap- Retracting Oil pres- Press Fast ap- Retracting
pressure sure force proach force sure force proach force
(bar) [kN] force (N) (bar) [kN] force (N)
(bar) (N) (N)
2 55 8,5 441 620 55 12,0 904 1180
3 95 14,6 662 954 95 20,6 1350 1800
4 130 20,0 883 1280 135 29,1 1800 2420
5 170 26,1 1100 1620 170 36,7 2260 3040
6 205 31,5 1320 1950 210 45,2 2710 3660
7 245 37,6 1540 2290 245 52,7 3160 4280
8 285 43,7 1760 2620 285 61,3 3610 4900
9 325 49,8 1980 2950 325 69,8 4070 5520
10 360 55,2 2200 3290 365 78,4 4520 6140
* The press force is specified including the fast approach force
Tolerance for technical data ±5 %

6 BA 11.0706.02
 TOX®-Powerpackage RZK

2.5 Tightening torque Adjustment of drive

TOX®-Powerpackage type RZK Should a correction of the center be necessary,
you may use tuning plates and tenon blocks with
KP-Type Outside di- Tightening torque tie rod offset.
transmission working transmission
part [mm] part part (pos. 29) Assembly instructions
(pos. 7) (pos. 16) nut DIN 980 Only tuning plates in pairs and of
with metal equal thickness must be installed.
sticking part
Take the offset side into considera-
RZK 05 85 mm 110 Nm 85 Nm tion when installing a tenon block.
RZK 05 110 mm 110 Nm 110 Nm
RZK 08 110 mm 240 Nm 110 Nm
RZK 08 135 mm 240 Nm 240 Nm 2.6 Oil refills / venting

Measuring couplings Trained personnel

Screws 1215 und 1620 (Pos. 30) The qualified repair of products
from TOX® PRESSOTECHNIK
Type Tightening torque
requires trained specialized per-
G 1/4" 50 Nm sonnel.
Secure measuring couplings with Loctite Always observe the applicable
safety regulations and legal condi-
Hydraulic screwing (Pos. 31) tions when operating the machine.
Screws DIN 912-12.9
Please refer to the notes in the Op-
Screwed sealing with elastic seal
erating Instructions of TOX®-
Thread Tightening Thread Tightening Powerpackage, chapter 2 'Safety'.
torque torque
G 1/2" 60 Nm M 4 5 Nm
Requirements
G 3/4" 90 Nm M 5 10 Nm
Powerpackage in initial position
M 6 17 Nm (working piston retracted).
M 8 40 Nm Return stroke line and, if appro-
M 10 80 Nm priate, pneumatic spring under
M 12 135 Nm pressure.
M 16 340 Nm
Thread and screw head contact have to be Operating Manual
greased before tightening.
TOX®-Powerpackage
Tightening moment for oil filling nipple Observe the instructions for oil refill
G1/8” = 15 Nm, secure with Loctite. and the oil specifications in chapter
13 of the Operating Instructions
TOX® Powerpackage.

BA 11.0706.02 7
 TOX®-Powerpackage RZK

5 6 1 7 3 4 6 2 9 1 7

8 5 6 8 7
1 HP measuring connection 5 Bleed screws HP cylinder
2 Oil refill nipple 6 Bleed screws intermediate ring
3 Bleed plate 7 Bleed screws transmission flange
4 Oil level indictor 8 Bleed screws HP cylinder cover
9 Vent plug

Bleed screws on the HP cylinder cover (4/8);

Tightening torques
For tightening torques please see
Operating Instructions for the
Powerpackage, chapter 'Spare
parts ordering / Repair'
1 Remove bleed plate (4/3) together with locking
wire and knurled cap of oil refill nipple (4/2). The
venting borehole (Ø 0,6 mm) becomes visible
under the bleed plate.
2 Vent completely the filling hose of oil pump (no
air bubbles in the hose).
3 Loosely connect the thread piece of the filling
hose to the oil filling nipple (4/2) of the
Powerpackage.
4 Pump oil until it emerges free of bubbles from
the borehole.
5 Bleed the Powerpackage:
Important : The bleeding depends on the
mounting position of the Powerpackage.
Bleed the Powerpackage at the highest bleed
screws of the following subassemblies:
– Bleed screws on the HP cylinder (4/5),
– Bleed screws on the intermediate ring (4/6),
– Bleed screw on the transducer flange (4/7);
should the HP measuring terminal (4/1) or
the vent plug (4/9) be situated at a higher
position, the venting must take place there
should the bleed plate (4/3) be in a higher
position, the bleeding must take place there.
Attention: unscrew carefully the bleed
screws! It might be possible that a Power-
package equipped with pneumatic spring is
pressurized with air.
Release the bleed screws by 2 turns max.
(wait until oil penetrates). Allow oil to continue
flowing until it emerges free of bubbles. Then
seal the bleed screw again.
If the HP measuring terminal is provided at
the highest position, press a pin of about 2
mm diameter in this terminal for bleeding until
the oil emerges free of bubbles. Pull the pin
out again.
6 After a rest period of about 10 minutes, pump
oil again and repeat the bleeding process.
7 When no more oil emerges from the borehole,
replace the knurled cap and the bled plate.
Ill. 4
8 Push oil level indicator (4/4) back into place.

8 BA 11.0706.02
 TOX®-Powerpackage RZK

2.7 Drawings / Parts list

Drawing TOX®-Powerpackage RZK with compression spring

Abb. 5

BA 11.0706.02 9
 TOX®-Powerpackage RZK

Drawing TOX®-Powerpackage RZK 05 / RZK 08 with pneumatic spring

(Zeichnung
nächste Seite)

Abb. 6

10 BA 11.0706.02
 TOX®-Powerpackage RZK

Drawing TOX®-Powerpackage RZK 05 / RZK 08 with pneumatic spring, part 2

Abb. 7

TOX®-Powerstroke valve RZK 05 / 08, flange size 85x85 / 110x110

Abb. 8

TOX®-Powerstroke valve RZK 08, flange size 135x135

Abb. 9

BA 11.0706.02 11
 TOX®-Powerpackage RZK

Parts list TOX®-Powerpackage RZK with compression spring / with pneumatic spring
Item Qty. Description Item Qty. Description Item Qty. Description
1 1 Intensifier piston 78 1 Aluminum sealing 341 1 Edge seal
2 1 Feed piston 79 1 Oil indicator pin 342 1 Edge seal
4 1 Adapter 80 2 SPR-B 353 1 Bearing busher
5 1 Barrel 81 1 Oil indicator needle 370 1 Retaining ring
7 1 Barrel 82 1 Piston seal 375 1 Air cylinder
8 1 HP-cylinder 93 1 Seal wiper 387 1 Rimseal
9 1 Flange 94 1 Retaining ring 398 1 Intermediate ring
10 1 Working rod 105 2 Usit ring 406 1 Pin
11 1 Plunger 106 2 Bleed screw 411 1 Cushion
12 1 HP-cylinder cover 110 1 Ring 419 1 Delrin ring
14 1 Adjusting sleeve 111 1 Ring 424 1 Locking wire
16 4 Tie rod 114 2 Guide belt 425 1 seal for locking wire
17 1 Bleed plate 115 1 O-ring 430 1 Label oil ventilation
19 2 Seal 117 1 Rod seal 435 1 Adapter
21 1 Cushion 120 1 Intermediate ring 443 1 Sintered washer
23 1 Adapter 123 1 Retaining ring 516 2 Set screw
25 4 Nut 138 1 O-ring 529 1 Edge seal
26 1 Transducer flange 139 1 O-ring 561 1 Sealing ring
27 1 Sleeve 140 1 O-ring 602 1 Int. valve complete
28 4 Nut 141 1 Bushing 605 1 HP-cylinder complete
29 4 Tie rod 165 1 Flange with integrated 609 1 Plunger
valve
30 1 HP-measuring connec- 205 1 Plug 612 1 Air cylinder FT
tion
31 1 Vent plug 206 1 Spool 637 1 Oil-level indicator
33 1 Nut 207 1 Lid 769 1 Ring
39 1 Bushing 209 1 Stop ring 770 1 Sealing ring
43 1 Nameplate 210 2 O-ring 771 1 Spool
44 2 Rivet 233 1 Delring 772 1 Compression spring
50 1 Compression spring 250 1 Set screw 997 1 Seal kit
54 1 Muffler 282 1 Compression plate 998 1 wear part set
complete
62 1 Oil filling nipple 286 1 Stop ring 999 1 standard part set
65 1 Piston seal 290 1 Round wire ring
66 1 Rod seal 302 1 Bushing
67 1 Piston seal 303 1 Valve slide overfill pro-
tection
68 1 Rod seal 304 1 Sintered washer
69 1 Rod seal 316 1 O-ring
70 2 O-ring 317 1 Compression spring
71 2 Edge seal 327 1 Cheese head screw
72 2 O-ring 336 1 O-ring
75 2 Edge seal 337 1 Wiper
76 2 O-ring 338 1 Rod seal
77 2 O-ring 339 1 Guide belt

12 BA 11.0706.02
 TOX® Press Force Sensor ZPS

3 TOX® Powerpackage with Pressforce sensor ZPS

3.1 Function and characteristics Elongation of working piston
With the Pressforce sensors of series ZPS,
the pressforces are measured in the direction of When mounting the pressforce
the pressure. The pressforce sensor is screwn sensor, the working piston will be
on the working piston of a TOX® Powerpackage elongated by measure C (see table
of the corresponding series. As accessories we type sheet ZPS).
offer an Anti-rotation lock ZPSV, a cable set In case of a later equipment of the
ZPSK, as well as various indication and evalua- Powerpackage, this dimensional
tion units (see brochure TOX®-Controls). change has to be taken into con-
sideration and a modification of the
Type sheet 10.00 'TOX® Powerpackage, chapter machine at customer's might be
'Accessories – TOX® pressforce sensor type ZPS' necessary.
includes the description, technical data as well as
a data sheet of the standard executions.
Anti rotation device for press-
Data sheet pressforce sensor
force sensor
The pressforce sensor is accompa-
When installing a pressforce sen-
nied by a data sheet with specifica-
sor, an anti-rotation lock to protect
tions. Please keep this data sheet.
the sensor cable must be installed.
Should the working piston already
Survey
be protected against rotation (e.g.
sensor anti rotation device by a guided tool), no anti-rotation
lock is necessary.

Appropriate anti-rotation devices are also of-

fered among the TOX® accessories (see type
sheet 'TOX® Powerpackage' chapter 'Accesso-
ries – Anti-rotation device ZPSV).

Load on power sensor

Overload: nominal value (max.
pressforce + 15 % (momentary).
When operating with overload, you
risk to damage the power sensor for
ever. Breaking load will destruct the
sensor.
Application temperature:
Tmin = -10°C and Tmax = 65°C.
Maximal tensile load:
Thread Connecting Fastening screw 25 % of nominal force.
for tool plug anti-rotation device

Ill. 16 Tilting and turning moments are

3.2 Recommendations for installation not admitted
Should turning or specially tilting
When ordering a TOX® Powerpackage with moments affect the pressforce sen-
pressforce sensor, the sensor will be supplied sor, this will cause wrong measuring
loose. When a TOX® machine is delivered ready results and perhaps also a damaging
for operation, the pressforce sensor will be al- of the sensor.
ready mounted.

13 BA 11.0706.02
 TOX® Press Force Sensor ZPS

Cable connection Special working environment

In order to avoid the parting of a The pressforce sensor must not get
cable, we recommend to lay the into touch with aggressive chemi-
cable in a cable guide (cable cater- cals, as this might damage the
pillar). The cable should be laid pressforce sensor. These chemi-
without tension for a maximum dis- cals comprise, for example, caustic
tance between cable fastening and or alkaline substances as well as
plug (provide a sufficient loop). solvents like alcohol etc. For further
information, please contact our
service department..
Recommendation for cabling
(when using the anti-rotation lock ZPSV):
3.3 Mounting the pressforce sensor
Screw the pressforce sensor direct on the
working piston of the Powerpackage. The
Kabelschlepp Zugentlastung working piston must not turn. Use the key
surface next to the counterpart for counter-
acting in order to avoid a torsion of the sen-
sor during fastening.
ZPS
Do not damage the pressforce
sensor during assembly
The pressforce sensor is protected
ZPSV by a sleeve / Elastomer coating
against dirt and dust. During
mounting, make sure the Elastomer
coating is not damaged.
Ill. 17 a
Stroke > 30 mm Should a tool holding fixture type ZWD be
mounted on the working piston, the press-
Schlaufe Zugentlastung force sensor must be mounted between
working piston and tool holding fixture.
ZPS Torques of the pressforce sensors
ZPS 001 ZPS 002 ZPS 004 ZPS 015
ZPSV
10 Nm 15 Nm 40 Nm 210 Nm

ZPS 030 ZPS 050 ZPS 100 ZPS 170

230 Nm 290 Nm 500 Nm 500 Nm

Ill. 17 b Secure the screwing of the pressforce sen-

sors with glue (e.g. Loctite 222 or of corre-
sponding quality) against loosening.
Stroke < 30 mm
Put the coupler plug into the connecting cable
and fasten the cable so that it will be without
tension in all positions of the working piston
(TDC and BDC).
The plugs in use from pin 1 to pin 4 are
stated in the data sheet.

14 BA 11.0706.02
 TOX® Press Force Sensor ZPS

3.4 Mounting the anti rotation lock
ZPSV
For mounting the anti rotation device, the
distance E must be precisely provided on
site according to the specifications in the type
sheet (+0.02 mm):
Mount the guide bar with the anti rotation de-
vice to the machine; when doing this, place the
pressforce sensor into the anti-rotation lock:
– the electric connection must be in the right
position,
– measure H (clamping range) must be
taken into consideration when mounting:

Anti- H Clamping range

rotation [mm]
device
ZPSV 001 37 sensor anti-rotation lock

ZPSV 002 49

ZPSV 004 59
Ill.18
ZPSV 015 75

Anti- E [mm] Anti- E [mm] ZPSV 030 85

rotation rotation
device lock ZPSV 050 105

ZPSV 001 52 ZPSV 030 170 ZPSV 100 –

ZPSV 002 52 ZPSV 050 180 ZPSV 170 – Ill. 19

ZPSV 004 80 ZPSV 100 on request
As soon as the pressforce sensor is correctly
ZPSV 008 105 ZPSV 170 on request
aligned, screw down the clamping (it is pos-
ZPSV 015 110 sible to change the screw/nut combination in
order to facilitate the assembly work).
Guide rod and anti-rotation lock are mounted
(eventually insert the guide rod in the anti- Torque of clamping – anti rota-
rotation lock and screw it down). tion device ZPSV
Please make sure the clamping is
Place the guide bush in the bore on the ma- not tightened too much, as this
chine. could influence the measuring
Grease slightly the guide rod. behaviour of the sensor.

Secure the nut with glue (e.g. Loctite 222 or

of corresponding quality).

BA 11.0706.02 15
 TOX® Press Force Sensor ZPS

4 TOX®-Powerpackage with "Safety Rod Lock" Type ZSL

4.1 Function and characteristics
The TOX® Safety Rod Lock type ZSL is primarily
a retaining device for static loads. The function
and operating principle of the Safety Rod Lock is
described in the type sheet 10.00 'TOX®-Power-
package'. This type sheet provides the dimen-
sions of the standard versions. Special versions
will be supplied with their particular dimensional
drawing.
On site the TOX® Powerpackage with Safety
Rod Lock must be connected by authorized per-
sonnel in conformity with the pneumatic dia-
grams.
The connection 'T' is plugged with a filter ele-
ment when supplied from the factory. If there is
a possibility that moisture or aggressive fluids
can be sucked into the housing through this port,
the 'T' should be connected with a line.

Ensure a sufficient air bleeding Technical Data:

Make sure the pressure space of – Unlocking pressure: mind. 2 bar
the clamping head and its pressure – Release pressure: 4 bar
feed are always sufficiently bleed- – max. operating pressure: 10 bar
ed.
4.2 Operating conditions / intended use
The Safety Rod Lock type ZSL has to be used
Survey for the mechanic safeguarding of the TOX®
Powerpackage with a tool up to the max. admit-
ted tool weight (see table on type sheet).
In case of other surroundings (for example:
TOX®- abrasive grit, chips, cooling liquid, water, other
Powerpackage fluids, ...) special modifications of the Safety
Catcher can be necessary. This could be for
example: additional wipers, wiper scraper, bel-
lows, sealing of the casing, surface treatment,
special paintings, stainless steal housing, oil
filling.
B
moving direction load

T
A

T port: pressure
compensation
B signal:
clamping released
A signal:
load secured
L port: release
Ill. 20 pressure

The connection and/or bores in the housing are

identified by embossed numbers.

16 BA 11.0706.02
 TOX® Safety Rod Lock ZSL

4.3 Actuation

Recommended: Not scope of supply

if shock noises occur
if pressure not constant

Ill. 21

The commonly used actuation of the Safety Rod
Lock is given in the drawing above.
During normal operation, the Safety Rod Lock
must be actuated so that it opens. In all other
operational conditions, as well as in cases of
power failure, emergency stop, etc. the clamping
device becomes effective, secures or even stops
the load. In case the pressure line should fail,
the load is secured in the same way.
If the pressure (p) is not sufficiently constant
(e.g. "pressure gap" when lowering movement
begins), we recommend installing a return valve
in the air pressure connection of the valve.
If shock noises occur at the release operation
due to excessive pressure, this effect can be
eliminated by fitting a choker valve in the p-line
(connection 'L')

4.4 Setting the proximity switches

The holes indicated by the characters 'A' and
'B', are provided for inductive proximity Protection against damages
switches. Any commercial proximity switches Proximity switches which are in-
may be used, which serted too far at connection 'B'
• have M12x1 outside threads will be damaged during hydraulic
actuation of the clamping device.
• are normally-open type
• and have a rated operating distance of 2 mm.
Proximity
The depth adjustment is equal for both switches switch setting
and is performed for both at connection 'A' by
inserting the proximity switch so far, that the 1 Housing
resistance exerted by the clamping jaw is 2 Clamping jaw
sensed. Then pull them back 0,5 - 1 mm and
secure them. 3 Proximity switch
4 Holding fixture

Ill. 22

BA 11.0706.02 17

4.5 Electric actuation
Observe safety regulations
The employer or the charged plant
constructor are responsible for the
observance of the prescribed
safety measures during planning,
installation and completion of the
plant. The electrical control system
has to be according to the prevail-
ing regulations.
It is the responsibility of the manu-
facturer of the electrical control sys-
tem to design the hard- and soft-
ware incompliance to the prevailing
safety regulations and to check all
relevant functions after the installa-
tion.
Here are the most important hints:
The Safety Rod Lock is prepared to provide two
signals with help of proximity switches (see Ill.
20).
A safe load secured condition is only achieved if
signal 'A' (load secured) is active. Thus this sig-
nal must be processed by the machine control
and must be visible for the machine operator.
Furthermore a cyclical auto-check of the function
of the signals is essential, for instance by cycli-
cal balancing with signal 'B' (clamping released).
By principle a downward movement is only pos-
sible if the clamping device is released (i.e. sig-
nal 2 "clamping released" is active). If this signal
2 (clamping released) is not active after pressur-
izing the Safety Catcher, the control has to initi-
ate an upward movement until this signal 2
(clamping released) appears.
4.6 Inspection rules for the Safety
Rod Lock
Obligatory safety checks
Please observe the specific pre-
scriptions of the country for the
execution of safety checks.
It has to be proved, that the actual holding force
has a sufficient surplus to the actual load. Test-
ing the static holding force the actual holding
force is at least 1.5 times of the actual load.
18
TOX® Safety Rod Lock ZSL
Various techniques for demonstrating this capa-
bility have been approved by the responsible
authorities. Please observe the specific prescrip-
tions of the country for the execution of safety
checks when selecting the test method.
The sequences specified here should be inte-
grated in the machine control, so that an auto-
matic run in an own operating mode is assured.
During the test, injuries due to the moving ma-
chine part must be avoided by the control (e.g.
two hand control).
Testing the static holding force
The press slide is protected by closing the safety
rod lock. Thereafter the press cylinder is pres-
surized with compressed air so that the total
force (including all weights) is 1.5 times the per-
missible load (see nameplate). The holding rod
must not slip under this load.
Depending on the design, the lowering dis-
placement for this operation will be 5 to 15 mm.
Other test methods
However, it is possible, that different solutions,
adapted to suit the particular system, can be
implemented as well, provided they prove, that
the holding capacity of the safety catcher is at
least 1.5 times the slide weight.
4.7 Maintenance / Repairs
The Safety Rod Lock require no maintenance. It
is nonetheless necessary to conduct a functional
test at regular intervals.
Immediate elimination of defects
Should the safety lock no longer
correspond to the required proper-
ties, the prescribed security for
working at the press or other ma-
chines is no longer granted. In this
case a qualified repair and accep-
tance of the clamping device by
TOX® PRESSOTECHNIK is
needed.
The TOX® Safety Rod Locks type ZSL are
safety devices, so any repair has to be done by
TOX®-PRESSOTECHNIK only. TOX®-PRESSO-
TECHNIK can not be held responsible for de-
vices that have been repaired unauthorized.
BA 11.0706.02

5 TOX®-Powerpackage with Adjustable End of Strike Cushion ZSD
5.1 Function and characteristics
The TOX® Powerpackage described herein with
adjustable BDC damping ZSD, serves for the
hydraulic damping of the Bottom Dead Center
(BDC), for example for the damping of punching
processes (damping of cutting impact) and for the
damped closing of machines at fast approach or
power stroke. Here the total stroke and the damp-
ing are continuously adjustable.
1
2 Mounting, setting, maintenance
3 be realized by authorized special-
4
Ill. 23
According to the setting, the adjusting sleeve
(total stroke setting) (23/1) drives against the
damping piston (23/2) at fast approach or power-
stroke. The damping piston displaces the hydrau-
lic oil via control needle (23/3). By setting this
control needle, a continuous adjustment of the
damping is possible. The hydraulic oil is dis-
placed to the “pressureless” back of the piston.
During the return stroke, the damping piston
(23/2) is returned to its initial position via a
pneumatic piston (23/4) and integrated bypass
valves. The maximum damping stroke is 7 mm
resp.10 mm.
All TOX® Powerpackages of type EK with total
stroke setting from size EK 02 can be equipped
with BDC damping ZSD.
The TOX® Powerpackage type EK with adjust-
able BDC damping is completely tubed and
hosed on delivery. The pneumatic actuation of
the BDC is effected by the TOX® Powerpackage
19
Adjustable End of Strike Cushion ZSD
The TOX® Powerpackage with BDC damping
must be connected on site by authorized staff
according to the pneumatic diagrams.
Operating instructions
The operating conditions correspond
with those of the standard Power-
packages, see Operating Instruc-
tions for TOX® Powerpackage.
Qualified staff
and repair work must exclusively
ists.
5.2 Mounting the Powerpackage with
BDC damping
A Powerpackage with BDC damping can be
mounted in any position. The adjustable BDC
damping operates in any mounting position.
For installation dimensions of the ZSD types,
see the corresponding table in type sheet 10.00
'TOX® Powerpackage'. You will find there also
the dimensions of the Powerpackage standard
types.
5.3 Adjusting the total stroke and the
BDC damping, operation
A threaded spindle (23/1) is attached to the work-
ing rod of the TOX®-Powerpackage. An adjusting
nut is threaded on the spindle and limits the stroke
of the working rod, and hence, the total stroke.
The damping effect is adjusted with the control
needle(23/3).
Do not adjust the BDC damping
during operation
In order to assure the operational
safety during production, the BDC
damping of the Powerpackage
must not be adjusted during opera-
tion.
BA 11.0603.01

Damping stroke
till Powerpackage EK 08 7 mm ± 0,5 mm
from Powerpackage EK 15:10 mm ± 0,5 mm
Adjustment
With all applications, the following
order must be followed:
1 setting the total stroke,
2 adjustment of damping effect.
Attention: The total stroke is ex-
tended by the damping stroke
(7 mm ±0,5 resp. 10 mm ±0,5). If
this is not taken into consideration
when calculating the total stroke,
you risk a tool rupture!
Adjustment of total stroke
Remove the safety guard on the rear section of
the Powerpackage: unscrew the setscrew of the
fastening ring and remove the ring with the pro-
tective tube. Release the locking screws (24/4)
securing the adjustable adapter (24/3) against
twisting.
Set the adjustable adapter in accordance with
the required total stroke:
• Turn the adjusting nut to the extreme rear
position: the entire stroke is available.
• Turn the adjusting nut to the extreme front
position: the total stroke is reduced to the
dampening stroke.
Adjust now the adjusting nut so that the re-
quired total stroke is reached, and secure the
adjusting nut with the clamping device.
Pay attention to the torque
Use the same torque to tighten the
locking screws of the adjusting nut.
Screw down the locking screws
crosswise until the prescribed
torque is reached.
Tightening torque for locking screws
Thread Tightening torque
M 4 5 Nm
M 5 10 Nm
M6 17 Nm
M 8 40 Nm
20
Adjustable End of Strike Cushion ZSD
Replace the safety guard
Risk of injury! Never operate the
TOX®-Powerpackage without
safety guard in place. Before start-
ing normal operation, replace the
safety guard.
Adjustment of dampening effect
The BDC damping is adjusted in the works to a
mean value.
The control needle (24/5) for the adjustment of
the end position damping is provided next to the
fastening ring on the cylinder cover.
unscrew the counternut at the external thread
of the control needle.
Turn the control needle in the desired direc-
tion:
– sugment damping effect:
turn to the right.
– teduce damping effect:
turn to the left.
Adjustment note: Already a quarter turn of
the screw may cause a perceptible change of
the damping. Make the adjustment step-by-
step till reaching the optimal BDC damping.
As soon as the control needle is adjusted so
that a damping effect is perceptible without
long delay, tighten the counternut again.
5.4 Inspection / Maintenance
For this TOX® Powerpackage, no fixed mainte-
nance intervals are determined.
Depending on the operating conditions, it can be
necessary to bleed the TOX® Powerpackage
regularly. This depends above all from the kind
of application, the load, and the environmental
conditions. The bleeding is described in the fol-
lowing chapter 6.5, 'Oil refill'.
Eliminate defects immediately
If a defect is stated, eliminate it
immediately and have the causes
removed by experts.
BA 11.0706.02

1 2
Ill. 24
5.5 Oil refill
® 4 Pump oil until it emerges free of bubbles from
TOX -Powerpackage EK with strike cushion ZSD
Requirements
Powerpackage is in initial posi-
tion(working piston retracted).
Compressed air is admitted to
the return stroke line and, if ap-
plicable, the pneumatic spring.
Operating Instructions
TOX® Powerpackage
Please follow the refilling instruc-
tions and the oil specifications in
chapter 13 of the Operating Instruc-
tions of the TOX® Powerpackage.
Tightening torques
For tightening torques see Operat-
ing Instructions of the Powerpack-
age, chapter “Ordering of spare
parts/Repair'
Venting of the TOX®-Powerpackage
1 Remove bleed plate (24/9) together with locking
wire and knurled cap of oil refill nipple (24/8).
The venting borehole (Ø 0,6 mm) becomes visi-
ble under the bleed plate.
2 Vent entirely the filling hose of the oil pump (no
air bubbles in the hose).
3 Loosely connect the thread piece of the filling
hose to the oil refill nipple of the Powerpack-
age (24/8).
BA 11.0706.02
Adjustable End of Strike Cushion ZSD
3 4 1 HP measuring connection
2 Damping piston
3 Regulating sleeve total stroke
4 Locking screws
5 Control needle
6 Oil refill nipple
BDC damping
7 Connecting hose to the
Powerpackage oil reservoir
8 Oil refill nipple Powerpackage
9 Bleed plate
Bleed screws (45),
(46), (47) and (55)
see illustration 25
Bleeding of BDC damping ZSD
the borehole.
5 To make sure that no air is contained in the
connecting hose (24/7), remove the oil refill
nipple of the BDC damping (24/6) and refill
about the quantity of oil existing in the con-
necting hose. Collect the oil penetrating from
the oil refill nipple of the BDC damping.
6 The bleed screws are identified in Ill.25 of
chapter 6.6 by positions (25/45), (25/46),
(25/47) and (25/55).
Attention : Loosen carefully the bleed
screws! A Powerpackage equipped with
pneumatic spring might be pressurized.
Important : Realize the bleeding step-by-
step, from top to bottom. Bleed all accessible
screws.
Release the bleed screws by 2 turns max.
(wait until oil penetrates). Allow oil to continue
flowing until it emerges free of bubbles. Then
seal the bleed screw again.
Repeat the bleeding
7 After a rest period of about 10 minutes, re-
peat the bleeding process starting with the
Powerpackage and followed by the BDC
damping.
8 When no more oil emerges from the borehole,
replace knurled cap and bleed plate.
9 Push oil level indicator back into place.
21
 Adjustable End of Strike Cushion ZSD

5.6 Drawings
Damping stroke
7 mm ±0,5 /
10 mm ±0,5

Ill. 25
Parts list adjustable end of strike cushion ZSD
Item Qty. Description Item Qty. Description Item Qty. Description
1 1 Backstroke housing 37 2 O-ring 53 1 Reduction
2 1 Pneumatic cap 38 1 Rod sealing 54 1 Threaded joint
3 1 Dampening piston 39 1 Rod sealing 55 2 Screw plug (venting)
4 1 Dampening cushion 40 1 Guide ring 56 1 Threaded joint
5 1 Needle plate 41 1 Support ring 57 1 Measuring coupling
9 1 pressure housing 42 2 Return valve 58 1 PA-tube
10 1 Control needle 43 div. Filter 59 1 Threaded joint
11 1 Counter nut 44 2 Sealing plug 60 1 Threaded joint
12 1 Top 45 4 Cap screw (venting) 61 2 Sealing ring
30 div. Sealing washer 46 div. Cap screw (venting) 62 2 Grease nipple
31 2 Rod sealing 47 div. Cap screw (venting) 63 2 Sealing ring
32 1 Rod sealing 48 2 Cap screw 64 div. Thrust piece PU-Elastomer
33 1 Sealing 49 2 Cap screw 65 1 Self-adhesive foil
34 1 Rod sealing 50 2 Cap screw 66 div. Sealing washer
35 1 Stripper 51 2 Threaded joint 67 1 Sealing ring
36 1 O-ring 52 1 Tube

22 BA 11.0706.02
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Subject to technical modifications

TOX® PRESSOTECHNIK
BA 11.0706.02

GmbH &
Co. KG

Riedstrasse 4
D - 88250 Weingarten
Tel. +49 (0) 751/5007-0
Fax +49 (0) 751/52391
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