alkitronic VELOX User manual

Operation and Maintenance Manual
Electric Hydraulic Pump VELOX
VELOX

Operation and Maintenance Manual
2
Contents page
A Reception control / packaging 4
B General description 4
1. Technical Data 4
2. Safety Information 4
2.1 Operation of the equipment 4
2.2 Operators responsibilities 4
2.3 Possible risks (hydraulic hoses and couplings) 5
2.4 General electrical and mechanical risks 5
3. Starting Procedure 6
4. Operation 7
4.1 Setting the torque 7
4.2 Manual operation with remote control 7
5. Inspections and Maintenance 8
5.1 Visual inspection 8
5.2 Check for sealing and soiling 8
5.3 Meeting the deadline 8
5.4 Meeting the deadline - hydraulic hoses 8
6. After Operation 8
6.1 Storage 8
6.2 Taking out of operation 8
7. Technical Hints 9
7.1 Automatic Switch O 9
7.2 Oil temperatur 9
8. Disposal of Hydraulic Oil 9
9. VELOX Special Version DUO 9
10. Operating Notes 9
11. Diagrams 10
12. VELOX Modules, CANBus 10
Foreword
Congratulations on your purchase of an alkitronic® VELOX
Hydraulic Pump. This product sets the highest international
standards for quality and safety. To maintain these stand-
ards, please read and follow the information and instruc-
tions found in the operation and maintenance manual.
Maintenance and repair of the alkitronic® VELOX Hydraulic
Pump must be performed by alki TECHNIK GmbH or certied
workshops trained and instructed by alki TECHNIK GmbH.
Improper maintenance may endanger you and damage the
unit. Non-compliance with any of the above items voids all
warranty claims!
The operation and maintenance manual contains all basic
information and instructions. The operator must read, un-
derstand, and observe this material together with the basic
precautions before either using or attempting to maintain
the alkitronic® VELOX Hydraulic Pump.
The manual must always be available on site.
This operation and maintenance manual applies only to the
alkitronic® VELOX Hydraulic Pump.
Observe the“Safety information”found in section 2, and all
other special instructions in other sections.
Safety instructions.
Non-compliance may result in personal injury
or death.
Safety instructions.
Non-compliance may result in damage to the
alkitronic® VELOX Hydraulic Pump, its functions,
or the environment.
Information for proper and safe operation.
Practical advice and information to make work
easier.
Denition of Symbols

VELOX electrical hydraulic pump
3
alkitronic® VELOX
VELOX remote control
For precise, reliable bolting and a wide torque range we
recommend our alkitronic® Hydraulic Wrenches AT and AX.
alkitronic® Accessories
Due to the specic selection of
our wide range of accessories,
the operator can apply these to
a broader workeld.
For individual solutions your
alkitronic®Partner or alki
TECHNIK GmbH will gladly
advise you.

Operation and Maintenance Manual
4
A Reception Control / Packaging
Inspect all components for possible damage. If
shipping damage is found, notify the forwarding
agent immediately. Return components in the
original package to avoid additional damage.
Therefore, please keep the packaging.
B General Description
The frequency controlled motor produces a corre-
sponding hydraulic pressure using a radial piston
pump. The pressure is then being transferred to
the user via hydraulic hoses.
The alkitronic® VELOX Hydraulic Pump has been
especially designed for hydraulic tools with cylin-
ders / pistons, which activate a lever to generate
a corresponding torque.
1. Technical Data
Driving power : electrical
Voltage : 110 / 230 V und 50/60 Hz
Nominal
sensitivity : 1,6 kW max.
Oil ow : mid. pressure
6 l/min to 140 bar
high pressure
0,75 l/min to 700 bar
Tank capacity : approx. 4 l
Weight, kpl. : approx. 24 kg
Measures : 360 x 260 x 560 mm
with frame : 390 x 310 x 570 mm
(L x W x H)
Hydraulicoil : HLP 46, Vitan GF 32
(additional hydraulic-oil
grades resp. organic oil upon
request)
Emission
Continuous sound pressure level LpA < 75 dB(A).
Measurement according to DIN 45635.
Maximum pressure for advance and return
stroke are xed, if desired, the pressure can be
adjusted by the manufacturer.
2. Safety Information
2.1 Operation of the equipment
The alkitronic® VELOX Hydraulic Pump may only be used to
runhydraulic torquewrencheswhich areoperatedwith atwin
line hydraulic system rated for 700 bar pressure with this tool.
No other pneumatic oil grades than those specied in this
manual may be used.
All hydraulic connection equipment must be rated for 700
bar pressure.
Any other use of equipment is not in accordance with the
pump safety requirements.
2.2 Operators responsibilities
The operator must have read and understood the
instructions in this operation and maintenance
manual before using or servicing the alkitronic®
VELOX Hydraulic Pump. Minimum age of the opera-
tor must be 18 years.
Operation and service may not be performed, if the
concerned person does not understand the pur-
pose, 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 you.
Improper operation, incorrect application, abuse or
use by unqualied personnel may be hazardous to
other persons, operator, Hydraulic Power Unit and
other property.
The operator is responsible to third parties within
the work area.
The VELOX Hydraulic Pump must not be used in
explosion-endangered areas. For operation out-
doors or in humid rooms, observe the relevant
regulations.
The VELOX Hydraulic Pump must be protected from
moisture. In case of damage to the unit, harnesses
or the electric connections, stop operating the
hydraulic pump.
Non-authorized alterations and modications of
the VELOX Hydraulic Pump are not permitted.

VELOX electrical hydraulic pump
5
Do not mix alkitronic® products with substitute
copies!
The interface between the coupling and the nipple
is crucial. alkitronics unique tolerances and preci-
sionmustnotbetampered with. An improper solu-
tion caused by using non-alkitronic devices, may
lead to an incorrect connection, or even worse an
accidental disconnection which results in hydrau-
lic oil shooting out at high pressure.
Do not extend hydraulic hoses without interme-
diate coupling.
Reversing the couplers for extension results in
reverse ow and reverse control of the hydraulic
tool. Non-compliance with these regulations may
lead to faulty functions and damage to the tool or
serious injuries to the operator.
If a uid injection injury occurs, it must always
be treated as a medical emergency that requires
prompt and accurate diagnosis and treatment.
Possible leaking oil is hazardous to the environ-
ment. It must be safely collected and properly
disposed of.
2.4 General electrical and mechanical risks
The alkitronic® VELOX Hydraulic Pump may only
be operated, if the power supply matches the
electric performance specifications of the unit
and all hydraulic connections to the load (motor,
cylinder or hydraulic torque wrench) are tight and
non-reversible. The load should comply with the
minimum requirements for safe operation.
In case of damage and repair, the hydraulic pump
must be separated from the power supply and im-
mediately be checked by a qualied technician for
electrical safety and mechanical defects. All safety
and mechanical defects must be resolved before
resuming operation.
In case of a power failure or malfunction, shut-o
the hydraulic pump immediately via the power
switch, seperate the pump from the power supply
and put the torque wrench in a safe position.
To avoid the risk of tilting or falling, the VELOX
Hydraulic Pump must always be set-up securely. If
working in high places, it should be secured.
Never remove the transport frame.
2.3 Possible risks (hydraulic hoses and couplings)
Correct hose connections see page 10, g. 6.
Hazards due to hose failure & oil leakage
Hose assemblies may fail abruptly and unexpect-
edly due to a variety of reasons. Hydraulic oil shoot-
ing out at high pressure and/or at high speed can
cause serious personal injury and severe damage
to objects as well as pollution of the environment.
Examples of potential hazards
 • Burstinghosecomponents
 • Whippinghoseends
 • Oilsprayleakage
 • Couplingblow-o
Make sure that:
The design and operation of tools and machines
complies with the existing safety regulations.
Inspect hose assemblies for damage and wear at
regular intervals; if possible, before each use.
Inspect hose sets in unpressurised condition; use
implements when necessary.
Defective or damaged hose assemblies must be
replaced immediately. Do not attempt to repair
them. Always use new components.
Never try to locate a leak with your hands!
If leakage occurs, shut down the hydraulic pump
immediately. Never try to locate the leak with
any part of the body when the hose set is pres-
surised. Use a suitable implement to inspect the
hose for damage.
To avoid hydraulic oil escaping under high pressure,
make sure all hydraulic hoses (coupling and nipple)
are properly connected and secured with the VELOX
Hydraulic Pump and the load (motor, cylinder or
torque wrench).
Distortion or loosening of
screws or the setting of
screws (S) may considerably
impair the functions of the
hydraulic pump and result
in damage to the tool.
Screws are secured with
lacquer resp. sealed. If this
equipment is serviced by
any other than an authorized
person, this guarantee is
rendered null and void.
S

Operation and Maintenance Manual
6
3. Starting Procedure
K
3
Fig. 1
Fig. 2
1. Attach the hydraulic hoses to the hydraulic torque wrench
andtothe VELOXHydraulicPump(K). See connection scheme
page10, item 11.
2. Attach remote control (F). Make sure that all couplings
are fully engaged to avoid hydraulic oil shooting out and to
ensure that the hydraulic oil can ow.
Check the oil level in the
showcase. The red mark
indicates the minimum
which the oil level must
not fall below.
If required, the Hydraulic
Oil (Oil grades see item
1. Technical Data) can be
relled after removing
the Vent cap (5).
Note!
Regularly check high pressure hoses and all
couplings as well as ttings and connections
before operating the tool. Make certain hydraulic
couplings are free of dirt before operating the tool.
Particles of dirt within the hydraulic system may
result in disturbances, faulty functions, and break
down of the motor.
Make certain the hydraulic hoses are placed in a
large radius to avoid injuries. The hoses must not
be bent, twisted, or damaged.
Gauge (2)
Pressure adjusting valve (3)
Vent cap (5)
2
5
Hydraulic hoses must be equipped in pairs with
alternating couplers and nipples to regulate pre-
(pressure) and reverse running to the piston or to
the pole side of the hydraulic cylinder (see page 9,
item 7. Technical hints).
An interruption on the return line will cause
excessive overpressure on the rod end of the
hydraulic cylinder. This may result in damage to
the tool or major injuries to the operator.
Please observe local laws and regulations when
drawing up bolt connections.
When using a hydraulic torque wrench, you must
adhere to the corresponding operation manual.
Before putting the VELOX Hydraulic Pump into
operation check the working order using a pres-
sure of max. 100 bar (procedure see item 4 and 4.1).
F

VELOX electrical hydraulic pump
7
4.2 Manual operation with remote control
- Manual operation with button (man)
After turning on the motor and determining the
desired torque (using the enclosed torque chart), a
rotating movement of the hydraulic torque drive is
reachedbypressingandlooseningtheremotecontrol
button (man), resulting in the corresponding torque.
Keep pressing the remote control button (man) until
the drive of the hydraulic wrench stops turning and
the pre-set pressure is reached. Please note display
of gauge (2).
Then press the remote control button (man)once or
twice again,until the pre-set pressure is reached to
make sure that the nal torque is achieved at the bolt
connection and the hydraulic torque wrench does not
stop until it reaches the stop of the hydraulic piston.
Note hint, page 9, item 10
Please note display of gauge (2) on the VELOX
Hydraulic Pump to make sure the pre-set pressure
has been reached (Fig 3).
The bolting connection will be loosened completely
by loosening the bolting connection repeatedly.
4. Operation
Switching on the pump
Pressing the ON / OFF button (1, Fig. 3) switches
the VELOX Hydraulic Pump on or o.
ON =
OFF =
3Fig. 3
4.1 Setting the torque
Use the enclosed torque chart to determine the
necessary pressure of the VELOX Hydraulic Pump.
Turn on the motor (1), press the remote control button
(man) and hold.
Simultaneously adjust the spindle (3) until the desired
pressure is displayed on the gauge (2). Depress the
remote control button (man), block spindle (3) and
thus secure it against independent twisting (Fig. 3-4).
Fig. 4
2
(man) Manuell
Pressure adjusting
valve (spindle)
ON /
OFF
Gauge
1
O
I

Operation and Maintenance Manual
8
Adjust the hydraulic torque wrench according to
the required torque LOOSENING or TIGHTENING
of bolted connection. (See Operation Manual for
the corresponding hydraulic torque wrench.)
If remote control is not activated, the VELOX
Hydraulic Pump turns o automatically after a few
seconds. Restart the tool by pressing the remote
control button (man) (Fig. 4).
5. Inspections and Maintenance
5.1 Visual inspection
Check connections see page 10, Fig. 6 - correct
connection scheme
5.2 Check for sealing and soiling
Regularly check high pressure hoses and all cou-
plings as well as ttings and connections before
setting the tool into operation.
Make certain hydraulic couplings are free of dirt
before operating the tool.
Particles of dirt within the hydraulic system may
result in disturbances, faulty functions and break
down of the motor. Faulty parts must be replaced
by authorized personnel only.
5.3 Meeting the deadline
To ensure torque precision, an inspection of the
gauge precision by a test gauge must be per-
formed at least once a year.
When the VELOX Hydraulic Pump is used fre-
quently we recommend an oil change and an oil
quality check once a year (see Technical Data:
recommended oil grades).
According to legal regulations a mechanical and
electrical safety inspection is required once a
year. Under high stress/high loads/high operating
hours, inspect more frequently.
5.4 Meeting the deadline - hydraulic hoses
For safety, all hydraulic hoses used regularly must
be replaced at the latest after ve years (additional
max. two years of storage). For increased require-
ments (multiple shift operation, short cycle times,
hand tools) replace the hoses after two years. Ad-
ditional regulations by the legislator (DIN 20 066/
BGR 237) must be observed.
Operating and service requirements prescribed
in this Operation and Maintenance Manual must
be observed.
6. After Operation
After nishing operation with the VELOX Hydraulic
Pump,disconnect the systemfromthe mains.Store
it in a dry, clean place. Remove hydraulic hoses and
hydraulic wrench. Also read the following.
6.1 Storage
Always store the dry, clean VELOX hydraulic pump
in the alkitronic®transportation case or in any lock-
able box.
Moisture leads to oxidation on both housing and
interior parts. As a result malfunction and further
damages may occur.
Hydraulic hoses
For storage, make sure the hydraulic hoses are
disconnected and that the ends of the hose
lines and the connecting components
(couplings/nipples) are plugged with protect-
ing caps.
Store the hydraulic hoses in a cool, dry, and
dust-free location.
Avoid direct solar and UV radiation, ozone-
generating lighting (i.e. uorescent sources of
light, mercury vapor lamps), and storage tem-
peratures below – 10°C.
Hydraulic hoses must not come into contact
with acids, lyes, or solvents.
Store hoses stress-free and at. When stored in
circles, observe the minimum bend radius
specied by the manufacturer.
Temperatures between +15°C and +25°C, a rela-
tive humidity under 65% are considered favorable
storage conditions.
Intrusion of ozone or other harmful air compo-
nents can be prevented by packing in foil.
6.2 Taking out of operation
If the VELOX Hydraulic Pump is stored for a long
time, store the cleaned tool in a closeable and dry
room, out of the reach of children. Moving tool
parts are to be protected against oxidation.
Additionally note item 6.1 Storage.
•
•
•
•
•

VELOX electrical hydraulic pump
9
10. Operating Notes
(page 7, item 4.2.1 Remote Control operation)
Tips on how to avoid downtimes:
As soon as the hydraulic piston of the torque wrench
stops, release button (M). This avoids an overload of
the pump motor, leading to a possible safety-related
shut-down.
7. Technical Hints
7.1 Automatic temperature shut-o
An automatic temperature switch o is inte-
grated in the VELOX Hydraulic Pump to avoid a
rise in temperature.
When the Hydraulic Pump has turned o due to
high temperature, the tool is ready for use again
after a short of cooling period.
7.2 Oil temperature
To avoidfaulty bolt connections and/ordamage
tothetool, the oil temperature should not exceed
+65°C.
8. Disposal of Hydraulic Oil
Dispose of used hydraulic oil properly. It must
not get into the earth or into the sewerage
system under any circumstances. Before
opening the outlet screw (S), make sure a
suitable oil pan is provided. Clean up spilled oil
immediately.
(man) manual
9. VELOX Special Version„DUO“
For simultaneous operation of two hydraulic torque
wrenches.
sOutlet screw

Operation and Maintenance Manual
10
Return (R)
Return (R)
HD hose pair
Hydraulic tool
HD hose pair
Advance (A)
Advance (A)
alkitronic®VELOX
11. Diagrams
12. VELOX Modules, CANBus
Correct connection diagrams:
Hydraulic pump - High pressure hose - Hydraulic torque wrench
Fig. 6a
Fig. 6b
Advance (A)Coupling
Nipple
Nipple
Coupling Return (R)
Connections of
hydraulic unit
Connections of
hydraulic wrench
(A)
(R)
Non-authorized alterations and modications
of the VELOX equipment or modules are not
permitted.
For repairs, the pump must be disconnected
from the mains; otherwise there is danger to life.
The pump can also be seriously damaged.
Field bus (CAN Bus)
For service personnel only:
CAN Bus interface for LED error analysis or for reading with a
laptop via USB or RS 485.
A special software provides a graphical user interface and
is used for commissioning, diagnostics, and testing settings.

VELOX electrical hydraulic pump
11
Notes
© alki TECHNIK GmbH/GBA VELOX/2/09.03.20/4Pdesign Materials and specications are subject to change without notice.

alki TECHNIK GmbH
Development, Production and Distribution of Bolting Systems
Unterlettenweg 4 – 85051 Ingolstadt/Germany – fon [phone] – fax [phone]
[e-mail] – www.alkitronic.com
Increased quality
Premium production
Highest quality materials
Long product life cycles
Experience in bolting technology since 1984
Made in Germany – international patents
Increased productivity
Quicker tightening without reworking
No environmentally caused failures (IP54, ATEX)
High work safety
Easy to use: clear, simple instructions
Low maintenance and cost ecient
Increased precision
Precise, customer-specic torques
High repeatability
Reliability in permanent operation
Dokumentation of tightening results
Automatic shut-off
Better service
Technical advice on site
Training offers
Manufacturer’s calibration and certication
Lifecycle support
Spare part and repair service
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