alkitronic EF Series User manual

Operation and
Maintenance Manual
Electric Torque Multiplier
Serie EF
EF

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® electric 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® electric 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® electric
torque multiplier, its functions or the environ-
ment.
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 4
2. Safety Instructions 4
2.1 Intended use 4
2.2 Operators responsibilities 4
2.3 Possible hazards 4
3. Operation 5
3.1 Placing tool in operation 5
3.2 Preparing for bolting 5
4. Electric Operation 6
4.1 Operation unit EF - all models 6
4.2 Operating area with OLED display 6
4.3 Overview bolting programs (Modes) 6
4.4 Bolting programs 7
4.4.1 Bolting according to the torque method 7
4.4.2 Bolting according to the combined torque/angle
procedure (option) 8
4.4.3 Bolting according to the combined torque/angle
procedure - Premium 9
4.4.4 Bolting with specication of turns 10
4.4.5 Documentation bolted joint and Bluetooth
activation 11
4.4.6 The alkitronic® APP 12
4.4.7 Error messages in the alkitronic® EF
operating area 15
5. Mechanic Operation 16
5.1 Handles and Operating Handles 16
5.1.1 Mounting Operating Handle 16
5.2 Remote Control (FB-EF) 17
5.3 Tightening and loosening 18
5.3.1 - Models with axiale drive 18
5.3.2 - Models with radial-/tangential drive 19
6. Ending or Interrupting the Work 20
7. Functional and Operational Tests 20
7.1 Optical and mechanical inspection 20
8. Service / Storage / Maintenance 20
8.1 Accessories change 20
8.2 Storage 21
8.3 Taking out of operation 21
8.4 Maintenance intervals 21
9. Technical Notes 21
10. Acoustic Emission and Vibration 21
11. Declaration of Conformity 22
12. Appendix 22

3
electric torque multipliers
alkitronic® EF-S - torques up to 42,000 Nm (30,980 ft.lbs).*
alkitronic® EF-A angletoolsforrestrictedaccess- high operat-
ing comfort. Torques up to 9,800 Nm (7,230 ft.lbs).*
Models with OLED-Display, menu guidance and bolting pro-
grammes as for example torque/angle procedure.
All models with overload protection.
B 1 Model Description
alkitronic® electric torque multiplier with axial drive.
The 360 degree rotating handle ensures comfortable opera-
tion. Robust motor housing of an aluminium alloy.
* approx. values / torque values are dependent on model
alkitronic® EF-SG
Constructively integrated reaction absorber, torques
up to 3,780 Nm (2,790 ft.lbs)*
alkitronic® EF-R/ EF-SG with radial-/tangential gearing e.g.
for use with spindles or long threaded bolts in plate heat
exchangers. Robust motor housing of aluminium. All models
with overload protection.
alkitronic® EF-R
Torques up to 3,780 Nm (2,790 ft.lbs)*
A Reception Control and Packaging
Visually inspect all components for possible
dam age. If shipping damage is found, notify the
forward ing 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 syn-
chroniced 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.

4
Operation and Maintenance Manual
1. Technical Data
Supply voltage / frequency 100 V - 253 V / 45 Hz - 66 Hz
Nominal power max. 1,400 W
Ambient temperature -20OC to +50O C / -4OF to +122OF
Repeat shut-o accuracy ± 2%
Housing Protection category I, IP-code 20
2. Safety Instructions
2.1 Intended use
alkitronic® electric torque multipliers are designed to tighten
or loosen 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® electric 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® electric torque mul-
tipliers 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-authorized 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
safety and mechanical defects (repairs may only
be performed by authorized personnel).
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
EF-R / EF-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

5
electric torque multipliers
All safety and mechanical defects must be resolved
before resuming operation.
For the avoidance of electric shocks or malfunctions
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® electric torque multipliers are deliv-
ered with a three-wired power cord with ground
conductor. A possible exchange of the power cord
plug (caused by nationally different electricity
supply or net plugs) may be performed only by an
authorized electrician. See appendix “Replacing
the power cord plug“.
alkitronic® electric torque multipliers must not
be damp, neither operated nor stored in moist or
humid environment. Otherwise an additional rain
protection must be provided on site.
In case of machine malfunction or loss of electricity
immediately switch o power button and discon-
nect 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.
alkitronic® STABI
3
8
alkitronic® STACO
2
6
7
1
4
3.2 Preparing for bolting - Models with axial gearing
• Place the alkitronic® electric 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 se-
cured.
DMA Safety screw
DMAR Safety ring (accessories)
alkitronic® DMA
• 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.
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.

6
Operation and Maintenance Manual
4. Electric Operation
4.1 Operating unit (all alkitronic® EF.. Models)
Power switch
On/O
(Luminous
button)
Direction
of rotation CW
Metal pushbutton
Direction of rotation CCW
Handle
Operating
handle
Operating handle
For special applications are
two convenient operating handles
included in delivery and
can be installed if required.
Direction of rotation pushbuttons for tap and continuous
operation
The operation of one of these buttons (see drawing above)
makes it easier to place the alkitronic® EF... on a bolt or nut
as well as the preturning.
If the button is pressed down, the bolting process starts;
when it is release, the bolting process stops.
The torque multiplier shuts o precisely when reaching the
required torque or value.
Decrease value / line down
Mode selection / input conrmation
Increase value / line up
4.2 Operating area with OLED display
Key-Symbols
4.3 Overview bolting programs (Modes)
Mode Description
M 1 Bolting according to the torque method, automatic
release with adjustable angle degrees.*
Already included in the scope of delivery.
Optional programs:
M 2 Bolting according to the torque/angle method,
automatic release function with presettable angle
degrees. *
M 2
Premium Additional adjustable torque limits
M 3
Bolting with presetting of revolutions and adjustable
torque limitation.
M 4 Bolting parameters according to individual customer
requirements.
M 5 Documentation of the bolting operations (target/
actual status recording for each bolting operation
performed).
Bluetooth transmission via alkitronic® APP.
* 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.
Bolting programs
e.g. Mode 1
Torque
Release angle
Unit
„run“ is displayed as soon
as the motor is
running

7
electric torque multipliers
4.4.1 Bolting according to the torque method
Settings mode 1 - with/without automatic release function
4.4 Bolting programs
Step 1
If no automatic release function is desired,
set release angle to„0“.
Remove the torque multiplier, place it on
the next bolt/nut and continue with the
bolting process.
Set nal torque
Set bolting method
Set release angle
Conrm
Conrm
Conrm
Conrm resp. the acknowledgment is automatically.
Start Screen
Once the values have been checked -
start bolting process.
Successful bolting is signaled by
„OK“.
“nOK”signalisation ashes (faulty
bolting).
Check the setting values. Repeat the bolting
operation, observing the relevant regulations for
the bolting operation, e.g. use new bolts or new
bolting material.
Step 2
Step 3
After a short time, the display jumps
to the next image (example).
Correction procedere:
push key and return
to step 1.
Application description:
Bolted connections are bolted with a torque specication and monitored at the same time. During the bolting process, the currently applied
torque is always shown on the display and reaching the SET value is signaled by an „OK“. The maximum actual torque applied is stored. If
required, an automatic release angle can be set.This function enables a fast, secure“run free“ of the DMA and also relieves torsional stresses
within the torque multiplier.
Note on the procedure for the loosening angle:
This is not intended for loosening a bolt/nut, here
only the release of tension between the torque
multiplier and the bolted joint is established!
*
*
The setting steps of the
torque values are in incre-
ments of 10 Nm (10 ft.lbs).

8
Operation and Maintenance Manual
4.4.2 Bolting according to the torque/angle method (option)
Settings mode 2 - with / without automatic release function
Step 1
If no automatic release function is desired,
set release angle to„0“.
Remove the torque multiplier, place it on
the next bolt/nut and continue with the
bolting process.
Set Pre-torque
Set bolting method
Set release angle
Set angle of rotation
Correction procedere:
push key and return to
step 1.
Conrm
After a short time, the display jumps
to the next image (example).
Conrm
Conrm
Conrm
Conrm resp. the acknowledgment is automatically.
Start Screen
Once the values have been checked -
start bolting process.
Successful bolting is signaled by
„OK“.
“nOK”signalisation ashes (faulty
bolting).
Possible causes: The angle of rotation was not reached. The
torque output of the alkitronic® EF is not sucient for the bolted
joint. Check the setting values. Repeat the bolting operation,
observing the relevant regulations for the bolting operation, e.g.
use new bolts or new bolting material. verwenden.
Step 2
Step 3
Step 4
Note on the procedure for the loosening angle:
This is not intended for loosening a bolt/nut, here
only the release of tension between the torque
multiplier and the bolted joint is established!
Application description:
Bolted connections are tightened using a torque specication and additional rotation angle specication and at the same time monitored.
In the torque specication, the currently applied actual torque is shown in the display. When the preset target torque value is reached, the
torque multiplier automatically switches to the rotation angle function (the pushbotton must remain permanently activated).
The currently measured rotation angles are shown in the display and upon reaching the preset angle of rotation, an„OK“ is shown in the display.
The maximum applied actual torque and the actual rotational angle are stored and evaluated with an„OK“ or„nOK“ in the display.
*
*
The setting steps of the
torque values are in incre-
ments of 10 Nm (10 ft.lbs).

9
electric torque multipliers
4.4.3 Bolting according to the torque/angle method - Premium
Settings mode 2 PREMIUM - torque limitation min / max. and with / without automatic release function
Step 1
If no automatic release function is desired,
set release angle to„0“.
Limitation of max. torque
Remove the torque multiplier, place it on
the next bolt/nut and continue with the
bolting process.
Set Pre-torque
Set bolting method
Set Torque max.
Set Torque min.Limitation:
Limitation:
Set release angle
Set angle of rotation
Correction procedere:
push key and return to
step 1.
Conrm
Aftera short time,the displayjumps
to the next image (example).
Conrm
Conrm
Conrm
Conrm
Conrm
Conrm resp. the acknowledgment is automatically.
Start Screen
Once the values have been checked -
start bolting process.
Successful bolting is signaled by
„OK“.
“nOK”signalisation ashes (faulty
bolting).
Possible causes: The angle of rotation was not reached.
Termination due to exceeding the torque limit. The torque output
of the alkitronic® EF is not sucient for the bolted joint.
Check the setting values. Repeat the bolting operation, observing
the relevant regulations for the bolting operation, e.g. use new
bolts or new bolting material. verwenden.
Step 2
Step 3
Step 4
Step 5
Step 6
Note on the procedure for the loosening angle:
This is not intended for loosening a bolt/nut, here
only the release of tension between the torque
multiplier and the bolted joint is established!
Application description:
The bolting process is identical to mode 2, but a minimum and maximum torque value can be stored to protect the bolt/nut or the bolting
process in general from overload and damage. The bolting process in the torque/rotation angle method is monitored and simultaneously
limited with an adjustable minimum and maximum torque. The maximum selectable value corresponds to the maximum power range of the
respective machine. If this torque value is exceeded during the bolting process, the process is aborted and evaluated with an„nOK“ in the display.
*
*
The setting steps of the
torque values are in incre-
ments of 10 Nm (10 ft.lbs).

10
Operation and Maintenance Manual
4.4.4 Bolting with specication of turns
Settings Mode 3
Step 1
Remove the torque multiplier, place it
on the next bolt/nut and continue with
the bolting process.
Set
torque limitation
Set
bolting method
Set
revolutions
Correction procedere:
push key and return to
step 1.
Conrm
After a short time, the display jumps
to the next image (example).
Conrm
Conrm
Conrm resp. the acknowledgment is automatically.
Start screen
Once the values have been checked -
start bolting process.
The SET number of revolutions
reached is signaled by„OK“.
“nOK”signalisation ashes (faulty
bolting).
Possible causes:
Exceeding the torque limit or the torque output of the alkitronic®
EF is not sucient for the bolted joint. Check the setting values.
Repeat the bolting process in compliance with the relevant regula-
tions for the bolting process.
Step 2
Step 3
Application description:
A certain number of revolutions is specied for the output drive. The torque limiter monitors the process at the same time.
The currently measured number of revolutions is shown in the display. As long as the pushbutton is held down, the alkitronic® EF counts the
revolutions already made until the set number of revolutions is reached.
It is possible to pause the output. The currently measured number of revolutions is stored temporarily. When the pushbutton is pressed again,
the counter continues to run until the SET number of revolutions is reached.
Note:
However, the temporary storage is deleted when the mode is changed or the device is restarted.
When the number of revolutions is reached, the process is evaluated with an„OK“ in the display then recorded. If the set torque limit is
exceeded, the process is aborted and a„nOK“ is shown then saved.
*
*
The setting steps of the
torque values are in incre-
ments of 10 Nm (10 ft.lbs).