FAQs about the TOX^® Powerpackage

A list of approved hydraulic oils for use in Powerpackages and X-KT Systems can be found in the operating manual of each TOX^® Powerpackage.

Other oils are possible on request. In general, synthetic and brake fluids can not be used.

Yes, operation with nitrogen/CO2 is possible. The general requirements as for the use of compressed air must be observed.

TOX^® Powerpackages must generally not be loaded with radial forces on the piston rod.

Powerpackages and X-KT Systems fall under Article 4 (3) according to the Pressure Equipment Directive DGRL 2014/68EU. Thus, TOX^® Pressure Intensifiers are not subject to CE marking and an involvement of a notified body is not required. The safety requirements prescribed in the PED 2014/68/EU are not necessary and do not have to be proven.

The following applies for the operator: For TOX^® Powerpackages, no inspection periods for pressure vessels according to the Ordinance on Industrial Safety and Health have to be observed.

The TOX^® Powerpackage is considered as an "incomplete machine", since it cannot fulfill a certain function on its own.

For partly completed machinery, TOX^® PRESSOTECHNIK as manufacturer supplies a suitable "Declaration of Incorporation" (see

Operating Instructions of the TOX^® Powerpackage). The declaration of incorporation is made in Germany and the European Union according to the Machinery Directive (2006/42/EC), Annex II 1.B.

For TOX^® Powerpackages there is no classification and marking according to ATEX Product Directive 2014/34/EU or Directive 94/9/EC. Accordingly, Powerpackages are not approved for use in potentially explosive atmospheres.

TOX^® Powerpackages can nevertheless be suitable for use in various ATEX zones. An assessment is the responsibility of the operator. If TOX^® Powerpackages are used in potentially explosive areas, the risk and responsibility for the use lies with the operator.

TOX^® Powerpackages can also be stored for a longer period of time. The position of the Powerpackage (horizontal or vertical) is irrelevant.

After a TOX^® Powerpackage has been stored for a longer period of time, the seals may adhere to the metallic mating surfaces under certain circumstances, resulting in initial sluggishness when moving the pistons. However, this sluggishness should be eliminated with the first stroke of the cylinder.

Seals, wearing part sets and hydraulic hoses must be stored in a cool, dry, low-dust, low-ozone and UV-protected environment. Direct sunlight and UV radiation as well as storage temperatures below -10°C must be avoided.

For the fast approach and return stroke, the Powerpackages may generally be operated with an air pressure up to 10 bar.

For the power stroke, it must be ensured that the maximum permissible oil pressure is not exceeded. This is indicated in the oil pressure table of the respective Powerpackage.

If you would like to operate your TOX^® Powerpackage with a higher air pressure than specified in the pressure table, please contact us.

Yes, this is possible. For more information see the Operating Instructions of the TOX^® Powerpackage.

The classification of the quality class for compressed air quality is done according to DIN ISO 8573-1.

Solids: Class 5, particle size 40 µm

Water dew point: Class 4, dew point 3°C

Max. Oil content: Class 3, oil content 1 mg/m³

TOX^® Powerpackages and X-KT-Systems are designed for use over many millions of cycles and will not exhibit oil leakage if used correctly. However, if oil leakage does occur on your Powerpackage, the causes could include the following:

• Damaged seals: Seals in the Powerpackage can be damaged due to dirt on the piston rod and particles in the supply air. Therefore, ensure that the moving piston rod is shielded from dirt if there is a lot of dirt. Also ensure that the compressed air quality class is maintained. Similarly, high humidity can lead to corrosion on the running surfaces of the Powerpackage, and corroded running surfaces can damage seals. Therefore, high humidity in the interior of the Powerpackage must be avoided.

• Incorrect speed ratio between forward and return stroke: Care must be taken to ensure that the speed ratio between the forward and return stroke of the working piston is set correctly. This must be observed in particular with high tool weights, when the return stroke speed is slowed down considerably. Large differences between forward and return stroke speed can lead to dynamic oil carryover from the hydraulic chamber to the pneumatic chamber and thus to oil leakage in the long term. For information on the speed ratio, refer to the Operating Instructions .

• Insufficient pneumatic supply: An insufficient pneumatic supply, in particular due to valves and hose cross-sections that are too small, can lead to the speed ratio in the power stroke not being correct. As in the forward and return strokes, this can lead to dynamic oil carryover due to speed differences. It is therefore essential to observe the required pneumatic cross-sections for valves and connecting lines specified in the relevant data sheet. If the required pneumatic cross-sections cannot be realized, the correct speed ratio must be set by installing throttle valves. In this case, please contact us .

• X-S / X-K / RZS / Q-S / Q-K / X-AT series: With internal fixed stop and integrated elastomer damping in the pre-stroke. The full stroke can be used up to the end stop in the power stroke and for punching.

• S- / K- / EL- / EK- / AT series: Equipped with elastomer damping disc on the working piston. The damping disk must not be used as an end stop in the power stroke/punching stroke. If Powerpackages of these series are to be used up to the internal fixed stop, please contact us .

• Hydraulic cylinder type HZ/HZL/RZHL: With internal fixed stop in the pre-stroke. The full stroke can be used up to the end stop. Version with additional elastomer damping elements optionally available.

By mounting or retrofitting the stroke frequency optimization module ZHO . This makes it possible to reduce the cycle time of the power stroke and power stroke venting time by approx. 20%.

The main control valve, maintenance unit (one size larger if possible) and air lines must have at least the same connection size as on the power pack.

The main control valve should be mounted as close as possible to the power pack, short hose lines with a sufficiently large cross-section are preferable.