alkitronic EFCip User manual

Operation and Maintenance Manual
Electric Torque Multiplier Series E
EFCip

2
Operation and Maintenance Manual
Foreword
Congratulations on your purchase of an alkitronic® electric
torque multiplier. This high quality product sets unique
international standards and satises high safety levels. In
order to preserve these features, your assistance by regular
maintenance is required. Please read this operation and
maintenance manual carefully and observe the following
information and instructions.
Maintenance and repair of the alkitronic® torque multiplier
must be performed by the alki TECHNIK GmbH or certi-
ed workshops adequately trained and instructed by alki
TECHNIK GmbH.
Improper maintenance may endanger your health and
damage the unit. In addition, non-compliance of any
above items will void all warranty claims!
This operation and maintenance manual includes basic
information and instructions which must be observed dur-
ing operation and maintenance. The operator must read
and understand the basic precautions before operation
or performing maintenance. It must always be available
on site.
This operation and maintenance manual applies only to
the alkitronic® torque multiplier.
Do not only observe the“Safety instructions”mentioned in
“Denition of symbols“, but also all other special instruc-
tions and hints in other sections.
Denition of Symbols
Safety instructions, which by non-compliance
may result in personal injury or death.
Safety instructions, which by non-compliance
may result in damage to the alkitronic® torque
multiplier, its functions or the environment.
Information for proper and safe operation.
Practical advice and information to make work
easier.
Content Table Page
A Reception Control and Packaging 3
B General Description 3
B1 Model Description 3
1. Technical Data 5
2. Safety Instructions 5
2.1 Intended use 5
2.2 Operators responsibilities 5
2.3 Possible hazards 5
3. Operation 5
3.1 Placing tool in operation 5
3.2 Preparing for bolting 6
3.3 Blocking the rotating motor/handle 6
4. Electric Operation 6
4.1 Primary operation 6
4.2 Operation panel with OLED Display 6
4.3 Overview bolting programs 6
4.4 Bolting programs 7
4.4.1 Bolting with torque methode 7
4.4.2 Bolting with torque/angle procedure 8
4.4.3 Error messages 9
4.4.4 General warnings 9
5. Mechanic Operation 10
5.1 Tightening and loosening 10
5.1.1 Models with axial drive 10
5.1.2 Models with radial/tangential drive 11
6. Ending or Interrupting the Work 12
7. Functional and Operational Tests 12
7.1 Optical and mechanical inspection 12
8. Service / Storage / Maintenance 12
8.1 Accessories change 12
8.2 Storage 12
8.3 Taking out of operation 13
8.4 Maintenance intervals 13
9. Technical Notes 13
10. Acoustic Emission and Vibration 13
11. Declaration of Conformity 13
12. Appendix
Replacing the power cord plug 14
Technical data 15

3
electric torque multipliers
alkitronic® EFCip - torques up to 6,500 Nm*
alkitronic® ECWip angle tools for restricted access - high op-
erating comfort. Torque values are the same as model EFCip
with additional equipment: OLED-Display, menu guidance
and bolting programmes as for example combined torque/
angle procedure.
Innovative motor protection with automatic switch-o to
secure the bolting quality.
A Reception control and packaging
Visually inspect all components for possible
damage. If shipping damage is found, notify the
forwarding alkitronic® Partner immediately. Re-
turn components and alkitronic® electric torque
multiplier in original package to avoid additional
damage. Therefore, please keep the packaging.
B General description
alkitronic® electric torque multiplier are strength power-
operated torque multipliers for continuously tightening or
loosening heavy duty bolt connections.
The torque multiplier turns o with achievement of a de-
manded value or nal torque.
The drive is done by a maintenance-free, low-wear synchro-
nised motor without brushes and excellent eciency, large
torque range and high assembly speed.
Consistent torque accuracy in all international power sup-
plies. Precise shut-off torque at operation with voltage-
controlled portable generators.
B 1 Model description
alkitronic® electric torque multiplier with axial drive.
The 360 degree rotating handle ensures comfortable opera-
tion. Robust motor housing of cast aluminium, electric protec-
tion class IP 54 for safe work in any weather (moisture, rain).
* approx. values / torque values are dependent on model
alkitronic® ECip-N - torques up to 3,000 Nm *,
All models with overload protection.
alkitronic® electric torque multiplier with axial drive, for heavy
goods vehicles and low seated boltings. 360 degree rotat-
ing handle for comfortable use, housing of cast aluminium,
electric protection class IP 54.
alkitronic® EFCip-SG, protection class IP 54 standard,
constructively integrated reaction absorber, torques up to
3,780 Nm*.
alkitronic® EFCip-R / EFCip-SG with radial/tangential gear-
ing e.g. for use with spindles or long threaded bolts in plate
heat exchangers. Robust motor housing of aluminium or cast
aluminium, electric protection class IP 54.
alkitronic® EFCip-R,protection class IP 54 standard, torques
up to 3,600 Nm*.

4
Operation and Maintenance Manual
alkitronic® STA
Standard adaptor, for a smaller
spanner width (AF).
alkitronic® STA
Standard adaptor
Reaction pin
Reaction pin
alkitronic® accessories
for torque multiplier
with axial drive.
alkitronic® accessories
..R / ..SG torque multiplier
alkitronic® accessories
For each fastening the original
accessories.
alkitronic® STACO
Standard socket
alkitronic®STABI
Standard con-
nector
alkitronic® DMA
Torque reaction
absorber
1. Technical Data
Supply voltage 100 V - 253 V
Supply frequency 45 Hz - 66 Hz
Nominal power max. 1100 W
Ambient temperature -20OC to +50O C
Repeat shut-o accuracy ± 2%
2. Safety Instructions
2.1 Intended use
alkitronic® torque multipliers are designed to tighten or loos-
en heavy duty bolt connections continuously. Do not use the
torque multiplier for any other purpose than its intended use.
For other applications please consult alki TECHNIK GmbH.
2.2 Operators responsibilities
The operator must have read and understood the instructions
of this operation and maintenance manual before using or
servicing the alkitronic® torque multiplier. Minimum age of
the operator must be 18 years.
Operation and service may not be performed, if the con-
cerned person does not understand purpose, consequences
and precise performance of each procedure. For questions
regarding the safety measures and areas of application, your
alkitronic® Partner will be pleased to assist.
Improper operation, incorrect application, abuse
or use by unqualied personnel may be hazardous
to other persons, operator, torque multiplier and
other property.
The operator is responsible to third parties within
the work area. Keep children and bystanders away
while operating the torque multiplier.
Do not operate alkitronic® torque multipliers in
explosive atmospheres, such as in the presence
of ammable liquids, gases, or dust. For operation
outdoors or in humid rooms, observe the relevant
regulations.
Non-authorised alterations and modications of
the torque multiplier are not permitted.
2.3 Possible hazards
Maintain the alkitronic® electric torque multiplier.
Check breakage of parts/accessories, damaged
power supply cord and any other condition that
may affect the tool operation. In case of dam-
ages the torque multiplier must immediately be
inspected by a qualied technician for electrical

5
electric torque multipliers
safety and mechanical defects (repairs may only be
performed by an alkiTECHNIK GmbH certied and
authorised personnel). All safety and mechanical
defects must be resolved before resuming opera-
tion.
For the avoidance of electric shocks or malfunc-
tions admitted and accordingly marked extension
cords are to be used outside only.
3. Operation
Prior to electric power connection, it must be
ensured that the indicated technical data on the
tool type plate as well as in the operation manual
corresponds with the power supply and environ-
mental conditions. Deviating values could lead to
malfunctions or severe damages.
All alkitronic® torque multipliers are delivered
with a three-wired power cord with ground con-
ductor. A possible exchange of the power cord
plug (caused by nationally dierent electricity
supply or net plugs) may be performed only by an
authorised electrician. See appendix “Replacing
the power cord plug“.
alkitronic® electric torque multipliers without
“Protection class IP54“ must not be operated in
moist or humid environment otherwise an addi-
tional rain protection must be provided on site.
In case of machine malfunction or loss of elec-
tricity switch o power button immediately and
disconnect the plug from the power source.
3.1 Placing tool in operation
alkitronic® STACO/STABI/STA/DMA (specic nuts, connectors,
adaptors and reaction absorbers) available as accessories, are
needed in accordance with a specic bolt joint.
The torque multiplier must be disconnected from
the power source before making any adjustments
or changing accessories.
• Accessories may be placed on the tool drive side. Make
sure every part is placed correct and secured (in compli-
ance with item 3.2 Preparing for bolting).
• Replace worn or damaged accessories immediately. F or
replacement use original alkitronic® accessories only.
This rule will reduce the risk of malfunction and serious
personal injury.
• Put STACO / STABI (2)/(3) on square drive (both boreholes,
adaptor and square must correspond).
• Insert safety pin (7), secure with rubber ring (6).
• STABI: screw in safety screw (8) completely.
alkitronic® STABI
3
8
alkitronic® STACO
2
6
7
For a DMA without safety screw a safety ring DMAR is obtai-
nable as accessory. The safety ring prevents the DMA from
loosening and can be put additionally on the toothing and
be screwed together.
1
DMA Safety screw
DMAR Safety ring (accessories)
alkitronic® DMA
4
3.2 Preparing for bolting - Models with axial gearing
• Place the alkitronic® torque multiplier on a at surface.
• If the DMA is secured with a safety screw, screw out safety
screw completely (the position of the screw can vary de-
pendent on type).
• Insert DMA reaction absorber (1) onto toothing (4);
• Screw in safety screw completely again - the DMA is
secured.

6
Operation and Maintenance Manual
4.1 Primary operation
Power switch On/O
(Luminous button)
CW direction:
Tap operation or
quick run
CCW direction:
Tap operation or quick run
Rocker button
Bolting process with the rocker button
Action point below: CW direction - tap operation
Action point above: CCW direction - tap operation
In case the rocker button is pressed down continuously the
torque multiplier changes over to standard operation (quick
run). When releasing the rocker button the tool stops.
The torque multiplier shuts o precisely when reaching
the required torque or value.
Never block the rocker button. A proper opera-
tion is not possible any more!
4. Electric Operation
Decreasing values / row descending
Mode selection / conrmation of input
Increasing values / row ascending
4.2 Operation panel with OLED-Display
4.3 Overview bolting programs (Modi)
Standard program M1 (scope of delivery)
Mode Description
M 1 Bolting according to the torque methode,
automatic release with adjustable angle degrees.*
Modular software solutions for the upgrading of
userspecic applications.
M 2 Bolting according to the torque/angle method,
automatic release with adjustable angle degrees.*
* Caused by high torsional force it is often impossi-
ble repositioning the torque multiplier on the next
screw joint. Therefore use the automatic release
function to relieve stresses within the multiplier.
The setting of angle degrees enables a “run free“
of the reaction absorber DMA.
Program e.g. Mode 1
Torque
Realise angle
Unit
„run“ is displayed only
when the motor is running

7
electric torque multipliers
4.4.1 Bolting according to the torque method
Adjustment mode 1 - with/without automatic release function
4.4 Bolting programs
Place on next bolt/nut and start
bolting process.
Conrm resp. the acknowledgment is automatically.
Start Display
Once the values have been checked -
start bolting process.
“OK” signalisation (bolting pro-
cess was awless, nal torque is
reached).
“nOK”signalisation ashes (faulty
bolting).
Check settings, repeat bolting.
Take into account relevant provisions of bolting.
Use e.g. new bolts etc.
After a short time, the display
jumps to the next image.
Correction procedere:
push button and
return to step 1.
Step 1
No automatic release function:
Set angle to zero“0“.
Enter
nal torque
Enter
bolting program
Enter
release angle
Conrm input
Conrm input
Conrm input
Step 2
Step 3

8
Operation and Maintenance Manual
4.4.2 Bolting according to the combined torque/angle procedure (option)
Adjustment mode 2 - with/without automatic release function
Step 1
Probable reason: rotation angle is not reached. Bolted joint ex-
ceeds torque range of the used torque multiplier.
Check settings, repeat bolting.
Take into account relevant provisions of bolting. Use e.g. new
bolts etc.
Step 2
Step 3
Step 4
Start Display
Once the values have been checked -
start bolting process.
After a short time, the display
jumps to the next image.
Correction procedere:
push button and
return to step 1.
No automatic release function:
Set angle to zero“0“.
Conrm input
Conrm input
Conrm input
Conrm input
Conrm resp. the acknowledgment is automatically.
Enter
pre torque
Enter
bolting program
Enter
angle of rotation
Enter
release angle
Place on next bolt/nut and start
bolting process.
“OK” signalisation (bolting pro-
cess was awless, e.g. rotation
angle is reached).
“nOK”signalisation ashes (faulty
bolting).

9
electric torque multipliers
4.4.3 Error messages
Temperature errors cannot be reset using the “M” button.
Resetting is done automatically when temperature thresholds
fall again below the limit.
To assure safe operation various temperature levels of the
torque multiplier are controlled. A switch-o during a bolting
process is however possible if the preset max. temperature
limits are exceeded.
Reactions
A - TEMP Error:
The bolting process is blocked/cancelled.
B - TEMP Warning during bolting:
Finish the bolting process in progress.
C - TEMP Warning prior to a bolting process:
The bolting process is blocked until the tempera-
ture is back to normal.“TEMP”warning will then no
longer show.
Error messages are always displayed ashing and inversely.
Error message as
hexadecimal gure
General error Message
Error display electrical
supply
General error display
excessive temperature
Errors can be reset by using the “M” button, pro-
vided the cause is eliminated. If this fails, your
alkitronic® partner will be pleased to help you.
Please take a note of the error code and report it
to our customer service.
Warning initiated due to faulty power/voltage supply or
frequency.
E.g. by undervoltage or overvoltage (<100 V or >253 V).
TEMP-warning display
„TEMP“ warning is ashing
Service warning, see
8.4 Maintenance intervals
Under excessive use/high loads or in case of many
operation hours we recommend that calibration
and service is carried out at shorter intervals
than the recommended 12 months. In this case
a service warning appears in the display. You can
acknowledge the message with the “M” button.
From this time on the information is shown at
every restart of the torque multiplier.
4.4.4 General warnings

10
Operation and Maintenance Manual
Always place STACO/STABI completely on the bolt/
nut. Provision of a safe and stable counter mount-
ing is essential. For individual DMA solutions, your
alkitronic® Partner will be pleased to assist you.
In addition, non-compliance of any above items
will void all warranty claims.
Improper bolting connection or incorrect reaction
support may cause:
- Strain breakage in STACO / STABI adaptors,
bearing or output square drive;
- Bruises or even life-threatening injuries (parts
splintering o);
- “Shut-o“ torque failures.
incorrect
correct
Correct torque reac-
tion point in marked
area only
incorrect
5. Mechanic Operation
5.1 Tightening and loosening
Safety hints
Comply with all applicable local, state and national
electrical and safety regulations.
Always carry out a function inspection and safety
check - no working with damaged parts!
Keep your hair, clothing, and gloves away from
moving parts. Loose clothes, jewellery or long hair
can be caught in moving parts (alkitronic® DMA/
STACO/STABI/STA).
Maintain a safety distance when tightening bolts or
nuts. Do not leave the torque multiplier unattended
during use. A rapid“switch o”in case of emergen-
cy must be always ensured.
Keep proper footing and balance at all times. This
enables better control of the torque multiplier in
unexpected situations.
5.1.1 Tightening and loosening - Models with axial drive
Operation steps
• Connect the torque multiplier to the power supply.
• Place the alkitronic® torque multiplier with alkitronic®
STACO/STABI completely on bolt/nut.
• The DMA or torque-on recipient of the torque multiplier
must be at the same height as the socket/adaptor to take
the reaction moment.
• A sure, stable counter-mount (2) must be ensured.
• Always keep the torque multiplier in axis line to the bolt
during bolting process.
• Push power switch and start bolting process.
• The drive stops when achieving the desired torque or
value. Switch off machine and place on next bolt/nut.
If the torque multiplier is not removable of the
bolted joint (torsional forces caused):
• Press rocker switch above (rotation direction CCW)
shortly.
This measures leading to a“run free“ of the reaction
absorber DMA.
• Active automatic release function the DMA is automati-
cally “relieved“.
• Place on next bolt/nut and start bolting process.
Note to bolting program mode 2:
If bolting process was awless (“OK” signalisation in the
Display), conrm rst bolting process .
2
1
Never place your hand or ngers between the DMA
and support point to avoid injuries by bruises!
Directions of rotation
Reaction moment
Bolting direction