TOX -Powerpackage X-KT-System

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1 TO -Powerpackage -KT-System The pneumohydraulic split system ata sheet / 06 TO GmbH & Pressotechnik o. KG Riedstrasse 8850 Weingarten / Germany Find your local contact at:

TO -Powerpackage -KT-System ustomized to individual needs The TO -Powerpackage -KT- System consists of the intensifier -ES and one or more drive cylinders.

rive cylinders can be selected from either the TO -Hydraulic ylinder HZL or the pneumohydraulic TO -Working ylinder -T.

-Hydrosplit oupling + + Easy colour-guided pneumatic plug-in-system Press with TO -Powerpackage -KT-System: intensifier and 6 drive cylinders.

2 TO -Powerpackage -KT-System ustomized to individual needs The TO -Powerpackage -KT- System consists of the intensifier -ES and one or more drive cylinders. epending on the required press force, dimensions and cycle-time each system is configured individually to customers needs. rive cylinders can be selected from either the TO -Hydraulic ylinder HZL or the pneumohydraulic TO -Working ylinder -T. dvantages of the -KT-System: + + Press forces 700 k + + Long power strokes + + ompact measurements + + Easy controls + + Use up to 6 drive cylinders per intensifier + + Low noise + + onnection via TO -Hydrosplit oupling + + Easy colour-guided pneumatic plug-in-system Press with TO -Powerpackage -KT-System: intensifier and 6 drive cylinders. TO -Pressure Intensifier -ES with fast approach stroke function The TO -Pressure Intensifier -ES is connected to the drive cylinders via hydraulic hoses and TO -Hydrosplit ouplings. The changeover from fast approach stroke to power stroke is performed automatically according to the dynamic principle. The speed of the changeover can be regulated via a control throttle. The unit is controlled by a / or 5/-way valve. s standard, the intensifiers are designed for air of 6 bar. Other air s or combinations on request. The TO -Pressure Intensifier -ES features: + + bsolute air-oil separation + + Integrated bypass for reliable operation of the system + + Ring reservoir for significantly reduced overall length + + an be mounted in any orientation + + ir spring included + + Simple pneumatic controls like for any double acting pneumatic cylinder + + losed oil system + + ll -KT-Systems with fast approach support High connection high measuring and control connection Oil filling nipple leed plate 5 ir connection fast approach stroke 6 ir connection return stroke 7 Return stroke air hose 8 Oil level indicator 9 Patented anti-overfill device 0 Intensifier piston Hydrosplit coupling Fast approach stroke hose (only for -T) 60 Power stroke valve 6 Valve block ZV T 0.05_0806.en

TO -Hydraulic ylinder HZL The TO -Hydraulic ylinder HZL features an absolute air-oil separation. Fast approach stroke and return stroke are conducted by the intensifier -ES.

dvantages of the TO - Hydraulic ylinder HZL + + ompact design + + Single-bearing working piston + + bsolute air-oil separation + + Fixed stop in approach stroke (elastomer cushioning optional) + +

system Return stroke chamber 5 bsolute air-oil separation 6 Flexible tie rod TO -Working ylinder -T The pneumatic TO -Working ylinder -T with double-bearing working piston and absolute air-oil

3 TO -Hydraulic ylinder HZL The TO -Hydraulic ylinder HZL features an absolute air-oil separation. Fast approach stroke and return stroke are conducted by the intensifier -ES. That allows the return stroke to be operated with air only (min. bar). Up to 6 TO -Hydraulic ylinders HZL can be connected by default to one intensifier (more on request). dvantages of the TO - Hydraulic ylinder HZL + + ompact design + + Single-bearing working piston + + bsolute air-oil separation + + Fixed stop in approach stroke (elastomer cushioning optional) + + Options: stroke monitoring ZHU and travel transducer ZKW + + udget solution + + lso available with total stroke adjustment (version 5) See pages High connection leed screw Special guiding system Return stroke chamber 5 bsolute air-oil separation 6 Flexible tie rod TO -Working ylinder -T The pneumatic TO -Working ylinder -T with double-bearing working piston and absolute air-oil separation provides fast approach stroke and return stroke by applying to the working cylinder. This results in high stroke forces, fast approach and return stroke forces. The power stroke is carried out by the TO -Pressure Intensifier -ES. Up to 6 TO -Working ylinders -T can be connected to one intensifier (more on request). dvantages of the TO - Working ylinder -T + + High fast approach and return stroke forces + + Short cycle-times + + Fixed stop with elastomer cushioning + + Prepared for stroke monitoring ZHU and external linear position sensor ZHW up to -T Hydraulic cushioning for return stroke + + ypass ZL and hydraulic end position cushioning ZH See page return stroke connection (closed) Oil high measuring connection Fast approach stroke connection (closed) Oil high port from -ES 5 leed screw 6 Special seals 7 bsolute air-oil separation 8 ouble-bearing working piston 9 Flexible tie rod 0 Elastomer cushioning Magnet ring for stroke monitoring ypass with hydraulic end position cushioning T 0.05_0806.en

4 esign of a TO --KT-System Example calculation of a combination of TO -Pressure Intensifier -ES and TO -Hydraulic ylinder HZL: To figure out what combination of TO -Pressure Intensifier -ES and TO -Working ylinders HZL is appropriate for you, we give you the following sample calculation. The values you have to provide are shown in red. That means: you define the required press force, total stroke and power stroke of the cylinder. Furthermore you have to determine the number of cylinders installed to one intensifier and the hose lengths. Following this sample calculation also combinations of TO-Hydraulic ylinders HZL with total stroke adjustment or TO -Pressure Intensifiers -ES with TO -Working ylinders can be specified. Example: You need 60 k press force, 00 mm total stroke, mm power stroke and you want HZL connected to one intensifier -ES. You need one hydrosplit coupling ZHK for each working cylinder (factor for calculation: ZHK 00 =.5) and one hose with 800 mm length. ( defined data data from table on page 5 calculated figures) a The required press force e.g. 60 k leads to the selection of a cylinder with max. 76 k press force. The calculation results in 97 bar required oil. ttention: max. 50 bar possible! alculation for system selection Max. oil bar Max. press Required press force x 60 = Required oil 97 force k for application k for application bar b The volume required in your case can be determined by multiplying the required power stroke (e.g. mm) by the type specific volume factor V (e.g..). The factors F +F are added to the previous result (whereby F depends on the hose length e.g. 800 mm). Then add a factor of.5 for each ZHK 00 hydrosplit coupling, equals Finally, this multiplied by the number of cylinders e.g., results in. cm oil volume. This leads to the selection of an intensifier -ES with cm, the -ES Required total delivery volume for power stroke Required delivery volume per mm power stroke Required power stroke for the application Factor depending on total stroke V F F Factor per 00 mm hose length. x mm ( 0.6 x 8 ) +.5 = 56.6 cm x =. cm (ZHK 00) Required delivery volume for power stroke mount cylinders Required total delivery volume for power stroke for the application c The stroke required for your application leads to the selection of a cylinder with a total stroke of 00 mm and defines the type of cylinder. Multiply the delivery volume factor V by the number of cylinders (e.g. ) equals in the total delivery volume of 60 cm. heck whether this is possible with the selected intensifier. This intensifier delivers e.g. 00 cm. Therefore it s enough. Required total delivery volume for fast approach stroke Required delivery volume per mm total stroke Total stroke of cylinder Required delivery volume for fast approach stroke mount cylinders V. x 00 mm = 0 cm x = 60 cm Required total delivery volume for fast approach stroke for the application d The oil calculated a e.g. 97 bar is devided by the oil produced by the intensifier at bar air (e.g. 0 ). The result is the required air (e.g..9 bar). In order to obtain high stroke frequencies, the air should always be about 0 % higher (e.g. 5.9 bar). aution: the maximum / press force of the cylinder must not be exceeded. alculated oil a 97 bar 0 =.9 bar Required air for application ote: When using different cylinders and different hose lengths, the calculation of the volume must be done individually for each cylinder. Then add the combined results. T 0.05_0806.en

5 TO -Hydraulic ylinder HZL max. 50 bar oil W M K G R E HZL 0 - HZL 9 HZL 8 HZL 7 HZL 9 - HZL 7 U F H L V Order no. Type Version Q Total stroke d Max. press force at 50 bar oil Fast approach force at 6 bar air Return force at 6 bar air per 00 mm hose length V F F Weight cm kg k da da E* F f7 G H K L M W V g6 R U HZL xM6x G/ Mx G/ HZL xM6x G/ Mx G/ HZL xM6x G/ Mx G/ HZL xM6x G/ Mx G/ HZL xM8x 5 G/ M6x G/ HZL xM8x 5 G/ M6x G/ 5 HZL xM8x 5 G/ M6x G/ 5 HZL xM8x 5 G/ M6x G/ 6 HZL xM8x6 65 G/ Mx G/ 7 HZL a b. b 6.9 b xM8x6 65 G/ Mx G/ 8 HZL xM8x6 65 G/ Mx G/ 9 HZL xM8x6 65 G/ Mx G/ 0 HZL xM0x6 68 G/ Mx G/ 0 HZL xM0x6 68 G/ Mx G/ HZL xM0x6 68 G/ Mx G/ HZL xM0x6 68 G/ Mx G/ HZL xM6x5 00 G/ M0x G HZL xM6x5 00 G/ M0x G HZL xM6x5 00 G/ M0x G 6 HZL xM6x5 00 G/ M0x G 9 HZL xM0x0 5 G/ M9x G 6 HZL xM0x0 5 G/ M9x G 9 HZL xM0x0 5 G/ M9x G 5 HZL xM0x0 5 G/ M9x G 57 HZL xM0x0 50 G/ M6x G 78 HZL xM0x0 50 G/ M6x G 8 HZL xM0x0 50 G/ M6x G 9 HZL xM0x0 50 G/ M6x G 97 HZL xMx0 00 G/ M6x G 5 HZL xMx0 00 G/ M6x G 6 HZL xMx0 00 G/ M6x G 7 HZL xMx0 00 G/ M6x G 80 otice: The specified press force includes the fast approach force. For mounting specifications see data sheet 0.8 TO -Powerpackage. Pressure tolerances ± 5 %. * Pneumatic supply at the intensifier -ES (connection sizes see -ES). imensions in mm TO -Pressure Intensifier -ES in combination with the TO -Hydraulic ylinder HZL V Y E G Pneumatic Hydraulic elivery elivery Oil Oil Maximum mount of connection connection volume volume number of hydrosplit [] [] high for fast for at bar at 6 bar hydrosplit couplings ZHK ZHK Fast ap- Return approach power air pressursure air pres- coupling with 00 0 proach / stroke stroke stroke direct adapter Weight Order no. E G H Q V max. max. Y power stroke cm cm bar bar 60 kg**** -ES G/ G/ G/ ** 55*** xzhk00-6 c b d -ES G/ G/ G/ 00 0** *** xzhk ES G G G 00 ** 59*** ES G G SE " ** 55*** xzhk ES G G SE " ** 55*** xzhk ote: Unless specified otherwise the max. permissible oil is 00 bar for all intensifiers of the type -ES. It must not imensions in mm be exceeded. ** ttention: Pressure and force values to be considered as calculation basis for preselection. The real values can differ. Pneumatic connection sizes *** Pressure tolerance ± 5% onnection ominal sizes / Inside-Ø hose **** Weight data for -ES including pneumatic control and hydrosplit coupling ZHK 00. G/ 7-8 mm G/8 8-9 mm G/ 0 - mm G/ 9-0 mm G 5 mm G / 8 mm H+0, T 0.05_0806.en 5

6 TO -Hydraulic ylinder HZL with total stroke adjustment max. 50 bar oil M K G R E K orresponding TO -Pressure Intensifier -ES see page 5. F H L V U HZL 0 - HZL 9 HZL 8 HZL 7 HZL 9 - HZL 7 U Order no. Type Version Total stroke d Max. press force at 50 bar oil Fast approach force at 6 bar air Return force at 6 bar air per 00 mm hose length V F F cm k da da E F f7 G H K L M W V g6 R U HZL xM6x G/ Mx G/ HZL xM6x G/ Mx G/ HZL xM6x G/ Mx G/ 5 HZL xM6x G/ Mx G/ 6 HZL xM8x 5 G/ M6x G/ 6 HZL xM8x 5 G/ M6x G/ 8 HZL xM8x 5 G/ M6x G/ 9 HZL xM8x 5 G/ M6x G/ HZL xM8x6 65 G/ Mx G/ 0 HZL a 6 8 b.5 b 6.5 b xM8x6 65 G/ Mx G/ HZL xM8x6 65 G/ Mx G/ HZL xM8x6 65 G/ Mx G/ 6 HZL xM0x6 68 G/ Mx G/ HZL xM0x6 68 G/ Mx G/ 6 HZL xM0x6 68 G/ Mx G/ 8 HZL xM0x6 68 G/ Mx G/ HZL xM6x5 00 G/ M0x G 8 HZL xM6x5 00 G/ M0x G HZL xM6x5 00 G/ M0x G 8 HZL xM6x5 00 G/ M0x G HZL xM0x0 5 G/ M9x G 56 HZL xM0x0 5 G/ M9x G 6 HZL xM0x0 5 G/ M9x G 7 HZL xM0x0 5 G/ M9x G 79 HZL xM0x0 50 G/ M6x G 9 HZL xM0x0 50 G/ M6x G 0 HZL xM0x0 50 G/ M6x G 6 HZL xM0x0 50 G/ M6x G 8 HZL xMx0 00 G/ M6x G 86 HZL xMx0 00 G/ M6x G 07 HZL xMx0 00 G/ M6x G 8 HZL xMx0 00 G/ M6x G 9 imensions in mm dapter for working piston (with internal thread to fit the piston rod end) Weight kg 6 Ø L V W M L SW Type fits to Ø L L M W V g6 SW HZZ HZL 0 0 M x.5 M6 x,5 5 9 HZZ HZL M6 x.5 M x HZZ HZL 07 / HZL 5 0 M x.5 M0 x HZZ HZL M0 x M9 x imensions in mm T 0.05_0806.en

7 TO -Working ylinder -T max. 00 bar oil -T T 00 -T 050 M W K G R S U F L H V E -T 00 -T 70 / -T 00 Order no. Type Version Total stroke d Max. press force at 00 bar oil Fast approach force at 6 bar air Return stroke force at 6 bar air Q per 00 mm hose length V F F cm E EH * Weight E RH * F f7 G H K L M R S V g6 W U hydr. kg k da da -T xM8x 5 G/ M6x G/ 9 -T xM8x 5 G/ M6x G/ -T xM8x 5 G/ M6x G/ 7 -T xM8x5 6 G/ Mx G/ 5 -T xM8x5 6 G/ Mx G/ -T xM8x5 6 G/ Mx G/ -T a 8 b b b xM0x6 88 G/ M0x G/ 8 -T xM0x6 88 G/ M0x G/ 7 -T xM0x6 88 G/ M0x G/ 57 -T xM6x5 00 G/ M0x G -T xM6x5 00 G/ M0x G 58 -T xM6x5 00 G/ M0x G 87 -T xM0x0 G/ M9x G / 77 -T xM0x0 G/ M9x G / 00 -T xM0x0 G/ M9x G / 5 -T xM0x0 50 G/ Mx G / -T xM0x0 50 G/ Mx G / -T xM0x0 50 G/ Mx G / 06 -T xmx0 00 G M6x SE " 6 -T xmx0 00 G M6x SE " 6 -T xmx0 00 G M6x SE " 90 -T xM0x55 0 G M80x 80 xø SE " 556 -T xM0x55 0 G M80x 80 xø SE " 6 -T xM0x55 0 G M80x 80 xø SE " 87 -T 00 on request otice: The specified press force includes the fast approach force. For mounting specifications see data sheet 0.8 TO -Powerpackage, tolerances ± 5 %. * Pneumatic supply at the intensifier -ES (connection sizes see -ES). ue to the flange connection SE, the -T 00 and -T 70 types can only be used with intensifiers of the sizes -ES 50 and -ES 00. imensions in mm TO -Pressure Intensifier -ES in combination with the TO -Working ylinder T E G Order no. E G H Q V ZHK ZHK 00 0 max. max. Y V Pneumatic connection [] [] Fast ap- Return proach / stroke power stroke -ES G/ G/ G/ ** 7*** xzhk00-6 -ES G/ G/ G/ ** 98*** xzhk ES G G G c 00 b 99 d 67** 05*** ES G G SE " ** 98*** xzhk ES G G SE " ** 67*** xzhk ote: Unless specified otherwise the max. permissible oil is 00 bar for all intensifiers of the type -ES. It must not imensions in mm be exceeded. Pneumatic connection sizes ** ttention: Pressure and force values to be considered as calculation basis for preselection. The real values can differ. onnection ominal sizes /Inside-Ø hose *** Pressure tolerance ± 5% **** Weight data for -ES including pneumatic control and hydrosplit coupling ZHK 00. G/ G/8 7-8 mm 8-9 mm G/ 0 - mm G/ 9-0 mm G 5 mm G / 8 mm H+0, Y Hydraulic connection high elivery volume for fast appr. stroke cm elivery volume for power stroke cm T 0.05_0806.en Oil at bar air bar Oil at 6 bar air bar Maximum number of hydrosplit coupling direct mount of hydrosplit couplings with adapter 60 Weight kg **** 7

8 TO -Hydrosplit oupling type ZHK Easy separation of intensifier and drive cylinder In order to ship the components already filled with oil and for easy installation, the TO -Hydrosplit oupling has been developed. This allows to connect all components without any introduction of air to the system and without leakage. The coupling is available as manual or electric switchable. TO -Hydrosplit oupling type ZHK manually switchable onnection hose side onnection intensifier side onnection hose side onnection intensifier side disconnected connected Hose Hose 6 7 Part Part oupling half hose side an be used with drives up to HZL 7 / -T 050. For bigger cylinders request the ZHK 0 (with SE connection.) TO -Hydrosplit oupling type ZHK with solenoid operated valve 7 5 oupling half intensifier side Threaded bushing do not open leed screw 5 oupling assembly screws 6 oupling mounting screws to intensifier 7 Valve stem to open or close valve Hose disconnected Part Part Hose connected 7 5 an be used with drives up to HZL 7 / -T 050. Features: Valve is operated with a drive cylinder. o drop ylinders can be activated independently. Return stroke position can be controlled One valve size can be used on all cylinders Improved cycle time Prepared for position feedback Technical data: Operating voltage Power consumption V /. W Includes solenoid I 650 (ISO 00) design, with LE 8 T 0.05_0806.en

9 TO -Hydrosplit oupling type ZHK ombinable with up to 6 drive cylinders Pressure Intensifier -ES with up to working cylinders 90 / 80 / 70 The intensifiers -ES 00 and -ES 5 allow direct mounting of to hydrosplit couplings ZHK 00. Pressure Intensifier -ES with and more working cylinders When mounting to 6 working cylinders to the intensifiers -ES 00 and -ES 5 with the hydrosplit coupling, the adapter 60 is used. 60 The adapter type 60 is always used when mounting hydrosplit couplings ZHK 00 to the intensifiers -ES 80, -ES 50 and -ES 00. Mounting variants Mounting variants of TO -Hydrosplit oupling with 6 hoses. Swivel fitting allows each hose to be independently oriented. Standard mounting sequence of the TO -Hydrosplit oupling ZHK 00 5 HZL - T HZL - T Hydrosplit oupling 6 -ES Hydrosplit oupling Hydrosplit oupling HZL - T Hydrosplit oupling -ES Variant HZL - T -ES -ES HZL - T Variant Variant T 0.05_0806.en Variant 9

10 Hydraulic hoses The connection between the drive cylinders and pneumohydraulic intensifier onnection variants Variant no. ylinder HZL / -T side Intensifier -ES side onnection Hmin. Rmin. Hmin. Rmin. x straight connection ZS 0 Hmin. ZS 0 Rmin. x 90 elbow on -ES x straight connection on HZL / -T Hmin. Rmin. x straight connection on -ES x 90 elbow on HZL / -T ZS 0 Hose length llocation of the hydraulic hoses to the drive cylinders ominal size Hoses Ø Hose dimensions Hose weight incl. oil* [kg / m] rive Standard hose lengths H min R min T / 000 / 500 / 000 / 500 / T 00 / -T / 000 / 500 / 000 / 500 / T / 000 / 500 / 000 / 500 / T / 000 / 500 / 000 / 500 / T 00 /-T / 000 / 500 / 000 / 500 / T 00 / -T / 500 / 000 / 500 / HZL / 000 / 500 / 000 / 500 / HZL / 000 / 500 / 000 / 500 / HZL 07 / HZL 500 / 000 / 500 / 000 / 500 / HZL 9 / HZL / 000 / 500 / 000 / 500 / HZL 8 / HZL / 000 / 500 / 000 / 500 / R min : smallest allowable bending radius *without screw-type fittings imensions in mm Ordering example: ZS hose length variant no. Other connection variants on request. Examples of the correct installation of hydraulic hoses right right right right wrong wrong wrong wrong Hoses must be installed so that it can be bled properly! 0 T 0.05_0806.en

11 dditional information Pneumatic control diagram Pneumatic control diagram (example): TO -Powerpackage -KT-System for up to 6 drive cylinders (-T or HZL) with pneumatic control, power stroke valve and hydrosplit coupling ZHK 00. Power stroke valve 6. <-> 6.. P istributor ledge ZVL Pressure regulator pneumatic spring 0.8 bar set permanently P ontrol throttle 6 HM ZHK 00 HZ/HZL H HM 8. ZHK 00 H T/-T. ot included in the scope of delivery! Maintenance unit required! onfiguration range: min. bar, max. 0 bar 5 ontrol system for -KT systems for - -T/HZL with power stroke valve, fast approach stroke support and control throttle. escription: Storage piston during fast approach pressurized with fast approach. Storage piston during return stroke pressurized with reduced air spring. Power stroke piston permanently pressurized with reduced air spring. T 0.05_0806.en

dditional information Ordering information The following ordering example (TO -Pressure Intensifier with TO -Hydraulic ylinders HZL) shows, how to order a TO -Powerpackage -KT system (either with

12 dditional information Ordering information The following ordering example (TO -Pressure Intensifier with TO -Hydraulic ylinders HZL) shows, how to order a TO -Powerpackage -KT system (either with working part -T or with hydraulic cylinder HZL): Ordering data: Example: Quantity: Order no. of the intensifier -ES -ES Order no. of either the TO -Working ylinder -T or the TO -Hydraulic HZL ylinder HZL Length and variant no. of the hydraulic hose ZS ZS Type of TO -Hydrosplit oupling and mounting variant ZHK , Mounting variant You will receive: x HZL incl. hoses and hydrosplit coupling x -ES incl. hydrosplit coupling (manually switchable) The TO -Powerpackage -KT-System will be delivered in detached condition but completely filled with oil. ll components are ready for connection including colour-guided pneumatic plug-in-system. T 0.05_0806.en Subject to technical changes.

TOX -Powerpackage Type X-S and X-K

TOX -Powerpackage Type X-S and X-K TX -owerpackage Type X-S and X-K ata sheet 0.30 0 / TX RESSTEHIK GmbH & o. KG, Riedstrasse 4, 0 Weingarten / Germany Find your local contact at: www.tox-pressotechnik.com TX -owerpackage line-x dvantages: