TOX Controls - Controls & Process Monitoring - Lang & Sin

TOX®-Controls TOX®-Controls TOX®-Process Monitoring TOX®softWare

TOX®-Controls

NETWORK TOX®-Controls – A Modular System

Pneumatic two-hand control console

Safety valve pneumatic or electric

Two-hand safety control console

A pneumatic air servicing unit is included with each TOX® control package.

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From simple, pneumatic basic controls, or electro-pneumatic controls, all the way to complex, custom programmable controls with nearly unlimited possibilities, we can provide you with all your control needs.

All TOX®-Controls meet the latest technical safety Norms and Guidelines from the German Occupational Safety and Health Administration as well as European Directive EN 13736 for pneumatic presses. With TOX®-Controls, you are always "on the safe side". We use only high-quality, tried and tested safety components and valves.

TOX®softWare Ethernet Interbus/ServiceNet/Profibus RS 232/485 PLC

TOX®-Monitoring The process at a Glance

Control Units for Monitoring of Clinching and Pressing Processes

The evaluation device can be selected according to each requirement. From 1- to 4-channel clinch monitoring all the way to continuous measuring in force-travel-pressing monitoring.

Various evaluation methods allow for different analysis of your processes. Diverse communication-interfaces allow for simple and quick data transfer to the data storage.

We provide: - customer optimized total solutions - single components - high quality sensors - shielded cables - user defined evaluation software - everything from one source, one system.

TOX®-Clinching Monitor CEP 400 30 25 20 KN

- Force monitoring of clinching processes - Trend monitoring - Process sequencing - Network capability over Ethernet TCP/IP - Expandable to userdefined processes - With and without display

15 10 5 0 7

6

5

4

3

2

1 0 Dimension X (mm)

TOX®-Pressing Monitor EPWL - Force-displacement monitoring of press-fit or joining processes - Various window configurations are possible - 8 different measuring programs - Standard RS 232

TOX®softWare

This specially developed software from TOX® integrates all appropriately equipped TOX® products. Programming, visualization and displaying, networking and archiving, all this can be done using a common platform.

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Signals from pneumatic controls for: – Pressure switch – Safety valves – Jog / sequencing valves – Other valves Supply and main switch

Junction box

Process Monitoring

Lift guards Rolling guards

Light curtains

Other Options per Customer Requirements

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Integration of Optional Machine Components

Process specific signals from the press for: – Top and bottom end position – Power stroke – Parts presence – Oil level – Oil pressure

Basic Components of the TOX®-Controls

Scope of the TOX®-Controls

Pulse Controls

Straight pneumatic controls

TOX®-Controls The modular system for our presses, machine and robotic units controls 2-Hand Controls STP 03-11 Control module according to EN 574 IIIC with main directional valve to drive pneumatic and pneumo-hydraulic cylinders and presses with a tool opening ≤ 6 mm. 2-Hand Safety Controls STP 03-10 Simple basic controls to drive pneumatic and pneumo-hydraulic cylinders and presses without additional functions.

External Pulse Controls STE 075-00 Main directional valve and required accessories (flow controls, air servicing unit, etc.), pneumatic components only, cycle initiation to be provided by customer using an external input from their controls.

Foot Pedal Controls with Operator Safety Module STE 317-00 Safe cycle initiation of pneumatic and pneumoSTE 317-01 hydraulic cylinders by a foot pedal including an STE 317-02 operator safety module to provide guarding.

Electric Controls

2-Hand Safety Controls STE 003-200 From simple cycle initiation of pneumo-hydraulic STE 325-200 cylinders to complex, standardized, programmable STE 336-200 controls with established, limited additional functions.

2-Hand Safety Controls with Additional “Jog” Function STE 327-00 Basic jog mode controls for cycle initiation of pneumatic and pneumo-hydraulic cylinders. With established additional functions.

Hand Safety Controls with PLC STE 326-00 Variable and customizable cycle initiation of STE 328-00 pneumatic and pneumo-hydraulic cylinders and presses. The process sequence can be customized to meet customer requirements. Jog mode is available as an option.

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STE 075-00-..

1/4” 1/2” 3/4” 1”

STE 317-00-.. 1/2” STE 317-01-..

STE 325-200-.. STE 336-200-..

1/4”

1/2” 3/4” 1”

Electric

STE 317-02-.. STE 03-200-..

2-Hand safety controls. Basic function, forward/ retract strokes actuated by finger sensors. Main directional valve with required accessories, requires customer supplied signal for cycle initiation, only for automated lines. Foot pedal controls. Requires mechanical guarding of work area prior to start of cylinder cycle. (See TOX®-Powerpackage Presses catalog for type CLX). 2-Hand safety controls series 200. Cycle initiation by finger sensors, from simple to complex program sequencing (STE 336 with basic PLC).

Signal for return stroke

Safety valve

1/2” 1/4”

External signal

STP 03-10-..

Straight pneumatic

1/2”

Safety functions

2-Hand controls to drive main directional valves. (Enclosure per EN 574).

Cycle initiation approach stroke

1/4”

Functionality

Size variants

STP 03-11-..

Controls

Ordering Description

Scope of the TOX®-Controls

Finger sensors 2-Hand controls Finger sensors 2-Hand controls External signal from pressure switch Pressure switch

–

–

yes

yes

–

–

yes with CLX

yes

Finger sensors 2-Hand controls

Pressure switch

yes

yes

Finger sensors 2-Hand controls Finger sensors 2-Hand controls External signal

Foot pedal

STE 327-00-..

1/4” 1/2” 3/4” 1”

2-Hand safety controls with jog mode, basic version.

Finger sensors 2-Hand controls

Pressure switch

yes

yes

STE 326-00-..

1/4” 1/2” 3/4” 1”

2-Hand safety controls with PLC. Comprehensive, flexible and customizable controls.

Finger sensors 2-Hand controls

Pressure switch

yes

yes

STE 328-00-..

All Controls includes: Air servicing unit and Speed flow controls Glossary: Locking function when the cylinder has switched into the powerstroke, and the sensor signaling “tool closed” has been met, the finger sensors can be released. The cylinder develops the preset pressure and then retracts. Single step mode used for setup of the machine. Momentary activation of the 2-hand buttons results in single step sequencing of the cylinder. Jog mode is similar to the single step mode, but the cylinder can be stopped at any desired position. Technical Data: electric: all required electric components, emergency reset, in-feed, function keys etc. are included. pneumatic: includes all required valves as well as an air servicing unit, as well as flow controls for approach and return speed. Stand-alone: Controls ordered without a press will be delivered with 3 meter long hoses and wiring.

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Electric controls in 2-Hand enclosure

Enclosure for electric components

–

–

2-Hand controls –

–

–

–

–

–

–

–

–

–

–

2-Hand controls –

–

–

–

yes 340x340

yes 380x380 x210

–

–

–

yes

–

–

–

–

–

–

yes 340x340

yes 380x380 x210

–

–

–

yes

yes

–

–

yes incl. ZDA

yes

yes 380x600 x210

–

–

–

yes

–

– Foot pedal, CLX, automaticand setup ZDA Foot pedal, CLX, automatic mode Foot pedal, CLX 2-Hand controls 6) – 8)

–

yes

–

yes 340x340

yes 380x380 x210

–

yes

yes 560x560

yes 600x600 x210

–

yes

yes 340x340

yes 380x380 x210 600x800 x210

Jog / setup mode

yes

1) – 11)

Optional enclosure

In-feed and main switch in separate enclosure

Pneumatic mounting plate without enclosure

Locking function powerstroke

Additional functions (optional)

Peak Load oil press. switch

–

Inclusive

Interface CEP 400 / EPWL possible

–

Sequencing mode

–

yes

yes

yes

yes

–

–

yes

yes

1) – 11), 13), 15), 16) – 2-Hand controls 1) – 9)

–

–

yes

yes

yes

2-Hand controls 1) – 16)

–

yes yes 560x560 Additional functions for approach resp. connection 1) 2) 3) 4) 5) 6) 7) 8)

External input signal Additional retract signal for external input Proximity switch Foot pedal Finger sensors Oil level monitoring Counter Preset counter

9) Light curtain 10) Manually operated side hinged guarding 11) Pneumatic operated lift guarding; travel: 250 mm / width: 400 mm 12) Remote access for Siemens S7 13) A function with end position feedback and separate control possibility 14) Interface for monitoring unit 8 E/A 15) Interface for monitoring unit 3 E/1A 16) External release

Ordering example: STE 326-00-3/4” + Description of additional functions Size of pneumatic supply Ordering description

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Additional Information on the TOX®-Controls

Basic operation of the electric TOX®-2-Hand-Controls when used with the TOX®Powerpackage-Presses The cycle is initiated using the two finger sensing devices on the 2Hand safety module. Both sensing devices must be activated within 0.5 seconds. The working rod will advance through the fast approach stroke until it meets resistance. This resistance will shift the sequence valve and initiate the power stroke. The TOX®-Powerpackage remains pressurized as long as the sensing devices are activated. Once the preset oil pressure is reached, the pressure switch sends a signal to the directional valve to retract the working rod. Controls with the self locking function initiate the return stroke automatically regardless of whether the safety sensing devices are still activated. The working rod will retract as soon as the preset oil pressure has been reached.

If any or both of the sensing devices are released prematurely, the TOX®Powerpackage will retract immediately. After completing a cycle, a new one can only be initiated after the 2Hand safety sensing devices have been released during the return stroke of the previous cycle. Depending on the type of controls, additional signals can be used, such as parts presence sensors. Complete process sequencing can be realized using our PLC controls.

Safety: Activating the integrated emergency reset button will introduce the return stroke immediately in any operating mode. In case of a loss in air pressure, the working rod will not retract and could drift down slowly. Optional: It is recommended to implement a rod safety catcher whenever installing a die set or moving platen in the press. This provides a safe means of catching the tooling in the event of a sudden loss in air pressure.

Standard execution of the TOX® safety controls • Flow control valves to regulate speed during approach and return strokes, air servicing unit, oil pressure switch to signal return stroke (not included with straight pneumatic controls) • For machines without a base or for orders without a PC press, the control elements will be supplied separately including 3 m of connecting power lines. This applies also to controls which are ordered with a TOX®-Powerpackage and are to be mounted by the customer.

All controls are supplied according to TOX® PRESSOTECHNIK specifications, which can be obtained directly from us or over the internet. Password will be provided on request. The buyer must ensure that any presses and controls supplied by TOX® PRESSOTECHNIK conform to all applicable national and local Occupational Safety Hazard Guidelines.

TOX® PRESSOTECHNIK shall not be held liable for any damage or injuries resulting from neglect or misapplication. The buyer guarantees to TOX® PRESSOTECHNIK that they will comply with all applicable national and local safety regulations prior to use of the equipment. By definition, any pinch points along the return stroke of the tooling area must be properly guarded.

Safety recommendations for press controls with self locking function For presses with 2-Hand safety controls and using tooling with an opening > 6 mm, a sensor for “tool closed” must be installed (see operating manual) according to the

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guidelines provided in the DIN EN 13736 standards. The sensor must be installed in such a way that it will provide a signal once the tooling is closed. If the tool opening is ≤ 6 mm

or the tooling area is guarded (e.g. perimeter guarding), then this sensor is not required. The sensor serves as a fail safe method of the command for the self locking function.

TOX®-Monitoring Monitoring units for clinching processes CEP 400 1- to 4-channel units The Control Monitor without display

Monitoring Unit wall mount unit IP 54

CEP 400-31-1, 1-channel version CEP 400-32-2, 2-channel version CEP 400-32-4, 4-channel version

CEP 400-21, 1-channel version CEP 400-22, 2-channel version

Control Monitor Panel mount version

4-channel Control Monitor Panel mount version

CEP 400-01, 1-channel version CEP 400-02, 2-channel version

CEP 400-04, 4-channel version

Advantages of the Series 400 Units: • Reduced programming costs • Optimum price / performance ratio • User friendly • Many optional interfaces • Comprehensive product family

Ordering example: CEP 400-31-1 Channel Type

Function of the CEP 400 • Monitors clinching and joining processes • Provides important data about process status • Special clinching monitoring using window technique • Up to 64 check programs can be selected • Real names for program memory, up to 40 characters • 64 sensor configurations per channel • 4 password levels: operator, setup technician, integrator, end user • 8 digital I/O’s • Status indicator menu of digital I/O ports • Stores up to 100 values with time stamp

• Includes TOX®softWare for parameterization and data recording • Display of TOX® Control Dimension “X” (absolute value) • Choice of mounting style or with IP65 enclosure for 1 + 2 channels • Backlit display • Membrane keyboard with password protection for up to 4 channel units • RS 232 for parameterization

Optional Expansion: • Ethernet interface allows for network communication unlimited • Profibus interface DP • Can Open Gateway for implementation of all standard Bus systems, Interbus, Profinet, … • Process sequence control for TOX® clinching processes • Service modules such as - Remote modem access - Test control unit to check measuring cycle • Analog output 0 – 10 V • Evaluation unit for bench top presses TOX®-FinePress

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TOX®-Pressing Controls The Safety Window for Your Process

The windows can read and evaluate 4 positive a negative curve directions. In the example shown below, the windows 1 to 4 are positive.

positive

X = Travel, Y = Force

Application: The pressing monitoring system EPWL checks processes where a precisely defined functional correlation between force and distance must be checked. The EPWL is used widely to monitor joining, riveting, pressfit and staking processes. The EPWL can be used in fully automated production lines, as well as in manual processes such as acceptance sampling in shipping and receiving. Quick component part changes are no problem for the EPWL. Up to 8 component part specific parameter settings are available and can be controlled by PLC or by menu. The windows for the work process are determined and defined according to customer requirements.

Ordering description: EPWL

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The TOX® pressing control EPWL checks continuously your pressing operation providing quality control during production: - it monitors pressing- and forming processes, as Force-Distance - controls windows: threading, progression, block measure/ block force - 8 different component part types in 8 measuring programs - provides most important data about process status - RS 232 standard - RS 485 optional

Sensors TOX®-Position Sensor • End position sensors ZHU mounted on the TOX®-Powerpackage • external precision limit switch see page 12 TOX®-Travel sensors • Travel sensor ZKW integrated in the TOX®-Powerpackage • External travel sensors see page 13 Oil pressure sensors Oil pressures from 0 – 400 bar • Analog output see page 14 TOX®-force sensors • Built-in sensors • Strain sensors see page 16 Please contact us to help you select the sensors best suited to your individual requirements.

TOX®softWare Overview of the Process Network

Every CEP Process Monitor and our electric servo systems TOX®-ElectricDrive includes our TOX®SoftWare. This software allows you to set parameters, edit, save and evaluate your process in a simple, user friendly manner.

Clinching-ProcessMonitoring CEP 400

TOX®-Axis Controller EDC

TCP/IP

TOX®softWare

Data backup

Internet

Parameterization Profibus Interbus

I/O

RS 232/ RS 485

Signal processing

The TOX®softWare is organized as follows: • Project overview to visualize and parameterize clinching processes. • Status report provides a clear display of primary parameters for one or several processes. • Process overview for parameterization of individual processes. A separate force sensor can be defined for each process (e.g. for change of TOX® tools or for TOX® clinching units with different parameters).

• End value overview for a quick control of the last 100 clinch points. These values can be recalled and exported at any time with help of the TOX®softWare. • Server archiving for continuous and complete archiving of all clinch data over the Ethernet connection. The data is saved as a CSV file and can be easily evaluated using MS-Excel, for example.

Project Assistant The WORX-Module has pre-configured, ready to use process function blocks which can be customized to the individual application. A dialog based project-wizard will aid in the initial setup and assist in the project layout. Projects can be saved and copied as templates for future use.

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TOX® Accessory, electrical Position Sensors

End position sensing ZHU of approach and retract strokes for the TOX®-Powerpackage A permanent magnet is mounted on the working rod and detected by the external position sensors. Technical data: Operating voltage: UB 10 - 30 V DC Residual ripple: ≤ 15 % Max. allow. current: 200 mA Switch-on time: ≤ 0,5 ms Switch-off time: 20 - 50 ms Hysteresis: 0,5...1 mm Connection: with LED, M8 per DIN 43 650 IP 65

Accessories for TOX®-Powerpackage, to be ordered separately: - Proximity switch with LED, ZHS 001.000 - Mounting bracket for proximity switch ZHU (S/K 1) - Mounting bracket for proximity switch ZHU (S/K 2-15) - Mounting bracket for proximity switch ZHU (S/K 30) - Cable set with M8x1 plug and 5 m cable, straight, without LED

Caution This option reduces the total stroke of the TOX-Powerpackage cylinder (S /K /AT) by 10 mm and for the TOX®-Hydraulic cylinder HZ by 20 mm. This option is available only for TOX®-Powerpackage cylinders S/K/ AT 01-30 and HZ 02-48 with total stroke up to 200 mm.

This option can not be retrofitted. Please note when ordering a TOX®Powerpackage cylinder. Ordering example: S 1.32.6 - ZHU Position sensing option without sensors and brackets Order No. for TOX®-Powerpackage

Precision limit switch ZWE for monitoring of X-Dimension Technical data: Operating voltage: Switching current min. at 1 mV: Operating point accuracy: Mechanical life: Actuating force: Mounting position: Connection:

This precision limit switch can be used to monitor electrically the XDimension for clinching applications.

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Wire colors: PIN 1 + excitation PIN 4 – switching signal

1 mA ± 0,01 mm ≥ 10 million 10 N optional M12 round plug

Ordering example: ZWE 001.000 Variant Type Description

2,5 Operating point 0,8 Differential travel 0,5 End position

Dome plunger R2

M12x1

Ø15,8 M14x1 Ø6

Other position/travel measuring systems from other manufacturers and other measuring methods (such as inductive, capacitive, resistance, incremental) can be also implemented. Please contact us.

18 ... 30 V DC

3

Wiring diagram

4 34 64

TOX® Accessory, electrical Travel sensors

Integrated, analog absolute value position transducer ZKW for the TOX®-Powerpackage type K The displacement transducer indicates the absolute instantaneous position of the TOX®-Powerpackage working rod, even during power failure. The measurement system is contact-less, and, therefore, wear-free and not sensitive to dirt or interference. The end values are adjustable. CANopen and PROFIBUS-DP interfaces are available on request. Technical data: Repeatability: Operating voltage:

33

49

Ø45

Ø70

Sw46

≤ ± 0,01 mm 24 V DC ± 20% (stable) ≤ 150 mA

Power consumption: Voltage capacity GND against housing: 500 V Exits: Outputs: Output voltage 0 ... 10 and 10 ... 0 V Load current: ≤ 5 mA Ripple: ≤ 5 mV Protection: IP 67

123,5 74,5

TOX®-Powerpackage End cap

Plug connector S32 for shielded cable max. 20 m, Ø 6 to 8 mm

Wire colors: PIN 2 – output signal 0 V PIN 5 + output signal 0 – 10 V PIN 6 – excitation 6 V PIN 7 + excitation 24 V DC

Ordering example: K 2.100.6 - ZKW Position transducer Order No. for TOX®- Powerpackage

Adaptable to all TOX®-Powerpackages type K, AT, HZ except for K1, AT1 and HZ 2 – 5.

External, analog absolute value position transducer ZWW for installation in die sets Technical data: Repeatability: Operating voltage: Resistance: Linearity: Connection: Protection: Scope: The displacement transducer indicates the absolute instantaneous position of the working rod or ram, even during power failure. The measurement system is almost wear-free, and it is not sensitive to dirt or interference. The sensor is mounted externally in a die set or on the working rod. B 15 30 55 115

C 32 32 40 40

10 V DC 1 kΩ – 5 kΩ 0,1 – 0,3% full scale plug, 5 pin, Binder 10-09-2013-00-05 IP 54 Sensor Plug Bracket

15

Wire colors: PIN 1 – excitation PIN 2 + output signal PIN 3 + excitation Ordering example: ZWW 100.00 Variant Travel 100 mm Description

D 108 138 196 307

13 + clearance for travel

11 A

B

C

22

18

45 29 Ø10

Ø4

15

M4

Ordering Measurdescription ing range A ZWW 010.000 10 mm 48 ZWW 025.000 25 mm 63 ZWW 050.000 50 mm 88 ZWW 100.000 100 mm 138

Caution A means of connecting to the ram is required.

± 0,01 mm

41 Wiring diagram

D

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TOX® Accessory Oil Pressure Switch ZDO and Mounting bracket ZMP

Monitoring the oil pressure in the TOX®-Powerpackage

Programming keys 48

For analog switch ZDO.01.400A, the second setpoint can be additionally set at 4-20 mA or 0-10 V. Additional programming menu LED display unit (bar, psi, Pa) Switching logic (PNP, NPN) Peak hold memory LED-display can be flipped 180° LED-display can be turned off

Wiring diagram: ZDO.01.400 Standard brown black white

blue

ZDO.01.400A with analog output brown black white

blue

The oil pressure in the high pressure chamber of the TOX®-Powerpackage is registered in the electronic pressure switch as the system pressure and displayed by a 4 digit LED display. According to the selected switch function, two output signals are generated. With the help of the programming keys, an electronic setting of switch point, switch back point (in 1% increments over the nominal range), the corresponding time delays (from 0 to 50 sec), switch functions for the output, rise time (damping), as well as locking/unlocking is possible.

Ordering example: ZDO.01.400A - with SP2 as analog output max. pressure 400 bar version 01 electronic pressure switch External mounting to the tie rods on the TOX®-Powerpackage is possible with the optional bracket. Switch includes protective cap for the display and programming keys and the high pressure connector.

Accessories to be ordered separately: - split mounting bracket with two M5 screws, mounting holes spaced In addition, a malfunction signal is 44 mm displayed if: - ZMP - 001.002 - the system pressure > 10% of the Mounting bracket for max. nominal pressure. attachment to tie rods - a short circuit occurs in switch on the TOX®-Poweroutputs 1 or 2. package - high pressure hose ZHM 630: The pressure switch is specifically ZHM 630-90 matched to the pressure characte90° hose end ristics of the TOX®-Powerpackage. 630 mm long end connection 1x90°, completely Technical data: assembled, filled with oil, bled and Pressure sealed (optional hose lengths 400, Order-No. range Increment 1000, 1500, 2000 mm) ZDO 01.010 0,5 - 10 bar 0,01 bar - electric cable 5 m long ZDO 01.400 0 - 400 bar 1 bar - micro plug M12 ZDO 01.400A 0 - 400 bar 1 bar (M12 plug-type connector) ZDO 01.600 0 - 600 bar 1 bar Repeatability: Accuracy: Display: - 7-segment LED

± 0,1 % FS ± 1,5 % FS

Mounting bracket for ZDO ZMP 001.002

50

Switch function per setpoint Output: Hysteresis/ Normally open Hysteresis/ Normally closed Window function/ Normally open Window function/ Normally closed

35

Display

A window programming is also possible. Installation of the ZDO is simple and takes only a few minutes. The programmed values are safely stored in the EPROM independent of the supply voltage.

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15

18 - 30 V DC IP 67

,2

e.g. tie rod of TOX®Powerpackage

In addition, for ZDO.01.400A: Output 2: Analog output 4-20 mA / 0 -10 V Operating voltage: Protection:

27

40

Electronic pressure switch and pressure sensor ZDO

TOX® Accessory, electrical Oil Pressure Sensor ZDS with Display Unit ZDA

Pressure sensor ZDS

Analog display unit ZDA

M12x1

Please specify TOX®-Powerpackage type when ordering. Ordering example: ZDA-115/230 V AC supply voltage pressure display unit

95 SW30

G 1/4”

The oil pressure in the high pressure part of the TOX®-Powerpackage is registered by the pressure sensor as system pressure and indicated by 5 digits on the pressure indicator with integrated sensor supply. The measured value „pressure“ is displayed in “bar”. It is possible to change the pressing force into kN on site. A freely programmable microprocessor controls the evaluation of the signal. The function keys on the front part of the processor measuring device serve for programming. The function „instantaneous value storage“ is available for receiving variable measuring signals. Further investigations are possible with the peak value memory. A freely selectable analog output (4...20 mA, 0...10 V) is available for connection with a PLC. As option, a serial interface for the transmission of the measured data to a PC is offered as well.

Display unit and accessories: - Pressure indicator ZDA - Pressure sensor ZDS, attachment by mounting plate to service side of TOX®-Powerpackage - Mounting plate ZMP, adapted to TOX®-Powerpackage - HP measuring hose ZHM 630, connection 1 x 90°, compl. assembled, filled and bled, secured against leaking of oil - electric connection cable between pressure sensor and pressure indicator (5000 mm)

Scope of delivery: - pressure sensor ZDS 0 - 400 bar - cable 5 m long - high pressure hose ZHM 630, 1x90° - mounting bracket ZMP

ZDA technical data: - 5 digit display 2-color - peak hold memory - analog input two programmable limit contacts Reading rate: 10/sec Power: 90 ... 264 V AC 50/60 Hz Dimensions: (WxHxD): 96 x 48 x 187 mm Switchboard: Panel cutout: 92+0,5 x 45+0,5 mm Option: - serial interface - analog output for PLC

ZDS technical data: Pressure range: 0 - 400 bar Connection: M12 plug Analog output: 4-20 mA Accuracy: 1% FS Repeatability: 0,1% FS Power: 12 - 30 V DC/ by processor

Wire colors: PIN 1 + excitation PIN 2 + signal output

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TOX® Accessory, electrical Rod End Load Cell ZPS directly mounted on the working rod of the TOX®-Powerpackage Technical data: Rated output: Temperature range: Zero balance: Excitation voltage: Insulation resistance: Nominal impedance: Electric connection: Combined error: Overload:

1,1 mV/V +10°C to 65°C ± 2% 10 V DC (max. 15V) 1GΩ 760 Ω M8 x 1 < ± 0,5% 115%

The rod end load cell ZPS can be mounted directly on the working rod of the TOX®-Powerpackage cylinder. C

D

A

B H

SW

G

E

B Fg6

The load cell ZPS measures forces in the direction of the applied force. It is sealed against dirt and moisture. The load cells are available in various sizes to fit each TOX®Powerpackage. The sensor should be applied with an antirotation device, to avoid damage of the connection cable (see next page).

I

Advantages: - highly precise - robust - compact

J

Wire colors: PIN 1 + excitation PIN 2 – excitation PIN 3 + signal output PIN 4 – signal output Cable: 5 m long with M8 x 1 plug

Order-No. ZPS ZPS ZPS ZPS

001 002 004 015

Press force max. kN 13 21 42 160

ZPS 030 ZPS 050 ZPS 100

325 500 1.030

ZPS 170

1.700

Fits TOX®-Powerpackage type S 1/K 1 S 2/K 2 S 4/K 4 S 8/K 8 S 15 / K 15 S 30 / K 30 S 50 / K 50 S 75 / K 75 S 100 / K 100 S170 / K 170

Please order accessories separately

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A 20 25 30 48 58 68 100

B

C

D

E

Fg6

G

SW

H

I

J

M12x1,5 M16x1,5 M22x2 M30x2

60 75 90 115

12 15 20 25

7 7

18 26

53 68 83 105

16 21 26 41

8 12 14 15

14 16 14 19

10 13 16 22

M39x2 M42x2 M64x2

130 150 180

35 40 60

-

-

120 136 155

50 55 85

20 20 22

36 42 63

36 59 66

on request

TOX® Accessory, mechanical Antirotation Device ZPSV for Rod End Load Cell ZPS

C + Total stroke

Antirotation device Prevents damage to the load cell cable. Please note the tight tolerance for dimension E. The bushing and guide pin are supplied with this option.By ordering, please advise the model number of the TOX®-Powerpackage cylinder. A

D

B

K

G

H

F

I

L

J

2 E±0,0

Order-No. ZPSV ZPSV ZPSV ZPSV ZPSV ZPSV ZPSV ZPSV ZPSV

001 002 004 008 015 030 050 100 170

fits load cell type ZPS 001 ZPS 002 ZPS 004 ZPS 008 ZPS 015 ZPS 030 ZPS 050 ZPS 100 ZPS 170

A

B

C

D

E

F

G

14 14 18 23 23 28 28

12 12 16 20 20 25 25

70 85 100 90 90 150 150

17 17 19 24 24 24 24

52 52 80 105 110 170 180

18 18 24 30 30 38 38

19 21 23 32 32 37 42

H

I

17 17 20 23 23 27 27

22 25 30 48 48 58 68

J

K

49,14 49,14 77,46 102,45 107,57 167,84 177,96

L

58,14 58,14 89,46 117,45 122,57 186,84 238,96

26 26 32 38 38 46 46

on request

Please observe the corresponding mounting instructions described in our Operating Manual “TOX®-Powerpackage”.

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TOX® Accessory, electrical Press Force Sensor

TOX® Press Force Sensor CKN, In-Die sensor for TOX®-Punch or TOX®-Die

+0,07

Force sensor mounting plate

ØA-0,1

+0,15

ØC +0,1

This force transducer specially developed by TOX® PRESSOTECHNIK allows measurement of relatively high forces under critical space requirements. Technical data: Rated output:

8 mV at 12 mA excitation Temperature range: +10°C to 65°C Zero balance: ± 3% Excitation current: 12 mA Insulation resistance:>5x109 Ω Nominal impedance: 350 Ω Combined error: ≤ ± 2% Overload: 120%

Order No.

Pressure plate

Raded capacity kN

CKN CKN CKN CKN CKN CKN CKN CKN CKN

027.000 040.000 055.000 072.000 091.000 112.000 140.000 150.000 190.000

27 40 55 72 91 112 140 150 190

Requirements: - press force + 20% < rated capacity of the sensor - mounting guidelines - included 5 pin connector - cable 2 m long - Sensor must be installed in such a way that no side-, torsion-, or pre- loads are present.

Ø3 2

4

L -0,02

P +0,05

5,05 +0,02

+0,07 (D) +0,05

Guide length = ® min. 0.4 x (TOX tool length)

Sensor dimensions

Mounting dimensions

ØA mm 13 15 17 19 21 23 26 27 30

ØC mm 13 15 17 19 21 23 26 27 30

ØB mm 3 3 3 3 3 3 3 3 3

L mm 25 25 30 30 35 35 35 40 40

D mm 30 30 35 35 40 40 40 45 45

P mm 25 25 30 30 35 35 35 40 40

Ordering example: CKN 040.000 Version Rated capacity (40 kN) Description

Wire colors: black + excitation red – excitation white + signal output green – signal output

TOX® Press Force Sensor ZKNW, miniature sensors for use in die sets

M

F I

H

ØC ØK

ØD1

ØD2 A

Example: sensor under TOX -Die ®

Extremely compact sensor for universal use.

OrderNo.

Technical data: Rated output: Temperature range: Zero balance: Recommended excitation voltage:

ZKNW ZKNW ZKNW ZKNW ZKNW ZKNW ZKNW

1,5 mV/V +10° to 65° ± 1%

3 V DC (max. 5 V DC) Insulation resistance: >10 MΩ Nominal impedance: 350 Ω Combined error: ≤ ± 0,5% Overload: 150%

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100.0704.02

001.000 002.000 005.000 010.000 020.000 050.000 100.000

Measuring range [% FS] 0 ... 1 kN 0 ... 2 kN 0 ... 5 kN 0 ... 10 kN 0 ... 20 kN 0 ... 50 kN 0 ... 100 kN

Wire colors: white + excitation brown – excitation yellow + signal output green – signal output

Dimensions in [mm] Ø D1 6,4 6,8 7,7 10,0 14,0 19,7 26,5

Ø D2 F 12,7 3,05 12,7 3,05 12,7 3,05 12,7 3,05 15,9 6,0 22,4 6,0 44,0 15,0

A 42,5 42,5 42,5 42,5 43,3 43,4 52,5

H 9,6 9,6 9,6 9,6 16,0 16,0 38,0

I 0,25 0,25 0,25 0,25 0,25 0,25 0,5

ØC 1,9 1,9 1,9 1,9 1,9 1,9 3,0

ØK 3,5 3,5 3,5 3,5 3,5 3,5 3,5

M 1,6 1,6 1,6 1,6 3,1 3,1 7,5

Ordering example: ZKNW 010.000 Version Rated capacity (10 kN) Description

TOX® Accessory, electrical Press Force Sensor, Strain Sensor ZKN, bolt-on type

13,6

Ø6,6

92,5 76

12

25 14,5

6,5

The surface sensor measures the strain between two bolted locations. The measured signal is proportional to the elongation of the structure. The sensor can measure elongation and compression.

Mounting recommendations: The strain sensor must be mounted on a machined surface with a minimum ISO surface finish of N9 and a maximum flatness tolerance of 0.05 mm. The tightening torque should be 14 + 1 Nm. Use mounting screws M6x25 with a grade of 10.9 or higher.

Wire colors: Standard passive (pull and press): brown + excitation geen – excitation yellow + signal output white – signal output

Standard active (pull or press): brown + excitation green – excitation (GND) yellow + signal output white – signal output (OV)

Technical data: Standard passive: Rated output:

1,25 mV/V (250 µE) Temperature range: +10°C to 65°C Zero balance: ± 100% possible Excitation voltage: 5 V DC (max. 10 V DC) Insulation resistance: > 10 MΩ Nominal impedance: 350 Ω Combined error: ≤ ± 2% Overload: 120% Standard cable length: 2m

Standard active: Rated output:

10 V (250 µE)

Temperature range: +10°C to 65°C Zero balance: ± 100% possible Excitation voltage: max. 24 V DC ≤ 30 mA Insulation resistance: >10 MΩ 52 ≤ ± 2% 120%

Combined error: Overload: Standard cable length:

2m

Ordering example: ZKN 103.xxx.200

Ordering example: ZKN 103.xxx.200

Cable length Sensor type upon request Description

Cable length Sensor type upon request Description

Other force sensors from different manufacturers are available on request. Please contact us.

100.0704.02

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100.0704.02

& TOX® PRESSOTECHNIK GMBH CO. KG Riedstraße 4 D-88250 Weingarten Tel. +49 (0) 751 / 50 07-0 Fax +49 (0) 751 / 5 23 91 E-Mail: [email protected] www.tox-de.com

Subject to technical alteration.

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