OETIKER ELK 02 Series User manual

Electronically controlled
pneumatic pincer
OETIKER ELK 02 V2.X
Original instruction manual
Issue May 2021
Item no. 08903352
OETIKER Horgen, Switzerland
Instruction manual

OETIKER ELK 02 V2.X
Issue 05.2021 08903352 1-2
Contents
Contents
1 Information about this manual....................................................................................................................... 1-6
1.1 Symbols and means of representation used........................................................................................... 1-6
1.2 Scope....................................................................................................................................................... 1-6
1.3 New features.............................................................................................................................................1-7
1.3.1 The ELK 02 V1.X ..........................................................................................................................1-7
1.3.2 The ELK 02 V2.X.......................................................................................................................... 1-8
1.4 Abbreviations........................................................................................................................................... 1-9
1.5 Labels on the ELK 02.............................................................................................................................. 1-10
2 Basic safety instructions...............................................................................................................................2-11
2.1 Using the instruction manual.................................................................................................................. 2-11
2.2 Use for the intended purpose................................................................................................................. 2-11
2.3 General safety instructions..................................................................................................................... 2-11
2.4 Special safety instructions .....................................................................................................................2-12
2.5 Safe working practices ...........................................................................................................................2-12
2.6 Modifications, changes...........................................................................................................................2-12
2.7 Qualified personnel.................................................................................................................................2-13
2.8 Maintenance work ..................................................................................................................................2-13
3 Design of the ELK 02 system ........................................................................................................................3-14
3.1 Optional extras .......................................................................................................................................3-15
3.2 Design of the HO EL pincers ..................................................................................................................3-15
3.3 Connections on the ELK 02 control unit.................................................................................................3-16
4 Process description ...................................................................................................................................... 4-18
4.1 Closing force...........................................................................................................................................4-18
4.2 Procedure ...............................................................................................................................................4-19
4.3 Sequence of operations ........................................................................................................................ 4-20
4.3.1 Test level.................................................................................................................................... 4-20
4.3.2 The closure level........................................................................................................................ 4-22
5 Assembling and connecting the ELK 02..................................................................................................... 5-23
5.1 Connecting the control unit ................................................................................................................... 5-23
5.2 Compressed air and pneumatic pincer................................................................................................. 5-24
5.2.1 General information and requirements...................................................................................... 5-24

OETIKER ELK 02 V2.X
Issue 05.2021 08903352 1-3
Contents
5.2.2 Connecting the compressed air................................................................................................ 5-24
5.3 Aligning the pincer head........................................................................................................................ 5-25
6 Working with the ELK 02............................................................................................................................... 6-26
6.1 General instructions for handling .......................................................................................................... 6-26
6.2 Switching on the ELK 02........................................................................................................................ 6-26
7 Menu navigation in the PC program.............................................................................................................7-27
7.1 System requirements and installation ....................................................................................................7-27
7.2 Installing the PC program.......................................................................................................................7-28
7.2.1 Installing the program automatically ..........................................................................................7-28
7.2.2 Installing the program manually .................................................................................................7-29
7.2.3 Installing the USB driver.............................................................................................................7-29
7.3 PC program structure.............................................................................................................................7-30
8 Structure of the PC program........................................................................................................................ 8-31
8.1 Preparing to read and send data........................................................................................................... 8-32
8.2 File menu ............................................................................................................................................... 8-32
8.2.1 Closure data table new.............................................................................................................. 8-33
8.2.2 Pincer type overview ................................................................................................................. 8-38
8.2.3 Backup/Restore......................................................................................................................... 8-39
8.2.4 ELK 02 firmware update............................................................................................................ 8-40
8.2.5 Quit ........................................................................................................................................... 8-40
8.3 Pincer test.............................................................................................................................................. 8-40
8.4 Measure ................................................................................................................................................. 8-42
8.5 Options .................................................................................................................................................. 8-44
8.5.1 Statistics menu.......................................................................................................................... 8-45
8.5.2 Password menu......................................................................................................................... 8-49
8.5.3 Screen scaling menu................................................................................................................. 8-51
8.5.4 System settings menu............................................................................................................... 8-51
8.5.5 Languages..................................................................................................................................8-72
8.5.6 Help ............................................................................................................................................8-72
9 Menu navigation in the ELK 02 .................................................................................................................... 9-73
9.1 Description of the display.......................................................................................................................9-73
9.1.1 Symbols and abbreviations in the display..................................................................................9-74

OETIKER ELK 02 V2.X
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Contents
9.2 Menu structure........................................................................................................................................9-74
9.3 The test level...........................................................................................................................................9-75
9.3.1 Button functions A to D enabled................................................................................................9-75
9.3.2 Button functions A to D disabled (ELK 01-Mode) ......................................................................9-76
9.3.3 Key functions enabled and disabled (ELK 01 mode) ................................................................ 9-77
9.3.4 Pincer test...................................................................................................................................9-79
9.4 The closure level.................................................................................................................................... 9-84
9.4.1 The closure ................................................................................................................................ 9-85
9.4.2 Closure function ........................................................................................................................ 9-90
9.4.3 Pincer type................................................................................................................................. 9-94
9.4.4 Verification ................................................................................................................................. 9-95
9.4.5 Initiating closure with “START”.................................................................................................. 9-96
9.4.6 Singular closure......................................................................................................................... 9-98
9.4.7 Chaotic closure.......................................................................................................................... 9-99
9.4.8 Sequential closure....................................................................................................................9-100
9.4.9 Closure step-by-step................................................................................................................9-103
9.4.10 Closing with hold......................................................................................................................9-104
9.4.11 Closure with detect ..................................................................................................................9-105
9.4.12 Closure with contact detection ................................................................................................9-106
10 Maintenance and repairs...........................................................................................................................10-107
10.1 General safety instructions for maintenance and repair work ...........................................................10-107
10.2 Maintenance .......................................................................................................................................10-107
10.2.1 Before maintenance work.......................................................................................................10-107
10.2.2 After maintenance work .........................................................................................................10-107
10.2.3 Weekly preventive maintenance jobs.....................................................................................10-108
10.2.4 Annual preventive maintenance jobs .....................................................................................10-108
10.2.5 Other preventive maintenance ...............................................................................................10-108
10.3 Repairs................................................................................................................................................10-109
10.3.1 Changing the pincer jaws.......................................................................................................10-109
10.3.2 Changing the pincer head ...................................................................................................... 10 -112
11 Decommissioning, storage, recommissioning ....................................................................................... 11-114
11.1 Decommissioning and storage............................................................................................................11-114
11.2 Recommissioning ................................................................................................................................11-114

OETIKER ELK 02 V2.X
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Contents
12 Disposal ....................................................................................................................................................... 12-115
13 Technical data.............................................................................................................................................13-116
13.1 Electrical connection and interfaces .................................................................................................. 13-116
13.1.1 Main plug ................................................................................................................................ 13-116
13.1.2 X1 interface............................................................................................................................. 13-117
13.1.3 X2 interface ............................................................................................................................ 13-117
13.1.4 X3 interface (RS232) ............................................................................................................... 13-120
13.1.5 X20 interface........................................................................................................................... 13-125
13.1.6 USB interface ......................................................................................................................... 13-128
13.2 Technical data..................................................................................................................................... 13-128
13.2.1 Fluidics.................................................................................................................................... 13-128
13.2.2 ELK 02 housing ......................................................................................................................13-129
13.2.3 Accuracy within the working temperature range ...................................................................13-129
13.2.4 Temperature ...........................................................................................................................13-129
14 Troubleshooting..........................................................................................................................................13-130
14.1 General notes on faults....................................................................................................................... 13-130
14.2 What to do, when...? ...........................................................................................................................13-130
14.3 Error messages and error correction measures.................................................................................13-130
15 Checklists – repair forms...........................................................................................................................14-133
15.1 Checklist for ELK 02, control unit ....................................................................................................... 14-133
15.2 Pincer checklist repair form................................................................................................................15-135
16 Warranty conditions...................................................................................................................................15-137
16.1 Warranty period .................................................................................................................................. 15-137
16.2 Conditions........................................................................................................................................... 15-137
16.3 Warranty claims .................................................................................................................................. 15-137
16.4 Consequential damage.......................................................................................................................16-138
16.5 Costs...................................................................................................................................................16-138
17 Declaration of Conformity ........................................................................................................................ 16-139

OETIKER ELK 02 V2.X 1 Information about this manual
Issue 05.2021 08903352 1-6
1 Information about this manual
1.1 Symbols and means of representation used
Safety notices are used in this manual to warn of the risk of personal injury or property damage.
Always read and observe these safety notices.
Observe all notices that are flagged with a safety alert symbol and signal word.
The following symbols are used in this instruction manual:
Symbol Meaning
DANGER Hazardous situation.
Failure to observe this notice will lead to death or serious injury.
WARNING Hazardous situation.
Failure to observe this notice may lead to death or serious injury.
CAUTION Hazardous situation.
Failure to observe this notice may lead to minor injury.
NOTICE Information on the avoidance of property damage.
INFO Information relating to the understanding or optimization of working practices.
One-step instruction
1. ...
2. ...
3. ...
Multi-step instruction
Carry out the steps in the order shown.
üRequirement
Necessary or labor-saving steps for the successful execution of an action
1.2 Scope
This instruction manual applies to all HO-EL pincers with the ELK 02 V2.x control unit.

OETIKER ELK 02 V2.X 1 Information about this manual
Issue 05.2021 08903352 1-7
1.3 New features
1.3.1 The ELK 02 V1.X
Hardware
• Hardware compatible with ELK 01
The hardware and CAL 01 connectors are identical to the ELK 01. Therefore the ELK 01 hardware can be used with
the ELK 02.
• Power supply range 85 - 265 V, 47 - 63 Hz
• USB interface, type B, galvanically isolated
• X20 interface, extended inputs and outputs
• Bus options, e.g. PROFINET / PROFIBUS
• X3 RS232 interface, galvanically isolated
• Graphic display unit, 65x35 mm, with 4 control buttons, display-driven for ease of use
Software
INFO
ELK 01 software and data sets cannot be migrated to the ELK 02.
• All pincer types are stored in the ELK 02
• Storage capacity for 99 active program numbers (APNs)
• Nominal force input directly on the ELK 02 (without PC)
• Closure with detection to prevent double closures
• Force and gap priority with verification for the qualification
• Measurement screen can be called directly from the individual closure data view
• Compressed air input pressure monitoring, static and dynamic
• Function key “i”: displays the compressed air input pressure and the pincer type
• Software updates for ELK 02 online via PC
• PC backup function, data and settings
• PC restore function, data and settings
• Pincer test in 3 dierent modes
• Pincer test documentation
• New password structure
• Maintenance instructions

OETIKER ELK 02 V2.X 1 Information about this manual
Issue 05.2021 08903352 1-8
1.3.2 The ELK 02 V2.X
• 4 user keys on the graphical display can be disabled (switched o).
The ELK 02 then behaves like an ELK 01.
• Dual closure: improved gap priority closure
• Improved gap priority closure
• OK pulse output at the interface X2 in the pincer test
• Alphanumeric text field in the measurement screen
• Individual closure data simplified;
Because of the implementation of DUAL closure and for better overview and easier operation, the individual
closure data viewing screen has been revised:
In the closure functions there remain only
- Force priority
- Gap priority
- Dual closure
Verification is switched on and o via a þ (e.g. þ Open, þ Hold etc.).
The closure function and verification are determined by the pincer type.
Even after pincer type, closure function and verification have been selected, the individual closure data view
screen still permits changes.
The data contents are compatible with earlier firmware issues.

OETIKER ELK 02 V2.X 1 Information about this manual
Issue 05.2021 08903352 1-9
1.4 Abbreviations
APN Active program number (max. 99)
D Closure function code for dual closure
d Closure function code for dual closure with
verification
DS Detection gap
DK Detection force
F Closure function code for force priority
f Closure function code for force priority with
verification
HK Holding force
HK-T Holding force tolerance
HS Holding gap
HS-T Holding gap tolerance
HS-SK Closing time between holding gap – closing
force
HS-SS Closing time between holding gap – closing gap
KK Contact force
KS Contact gap
NO Not ok (refers to “Not ok” closure)
OF Open
OF-SK Closing time between opening – closing force
OF-SS Closing time between opening - closing gap
OF-Z Removal time
OS Opening gap
OS-SK Closing time between opening gap – closing
force
OS-SS Closing time between opening gap – closing
gap
OS-T Opening gap tolerance
pE Compressed air supply pressure
pA Compressed air output to pincer
S Closure function code for gap priority
s Closure function code for gap priority with
verification
SK Closing force
SK-HZ Closing force holding time
SK-T Closing force tolerance
SS Closing gap
SS-HZ Closing gap holding time
SS-T Closing gap tolerance
UK Changeover force from force priority to gap
priority
VK Verification force
VK-HZ Verification force holding time
VK-T Verification force tolerance
VW Verification value
VW-T Verification value tolerance
ZT Pincer test

OETIKER ELK 02 V2.X 1 Information about this manual
Issue 05.2021 08903352 1-10
1.5 Labels on the ELK 02
Fig.1 Labels on the ELK 02
1 Warning labels (on the back of the control unit)
2 Warning label
3 Risk of crushing
4 Rating plate

OETIKER ELK 02 V2.X 2 Basic safety instructions
Issue 05.2021 08903352 2-11
2 Basic safety instructions
2.1 Using the instruction manual
• Make sure that this instruction manual is always kept close at hand ready for use.
• Pass on this instruction manual to the next owner.
• Please read through the instruction manual carefully before operating the ELK 02 unit. Familiarize yourself
with all settings and their functions. Anyone involved in setting up, commissioning, maintaining or repairing
the unit must have read and understood the instruction manual and in particular the safety instructions.
2.2 Use for the intended purpose
The unit may only be used for the intended purpose and under technically safe and fault-free conditions.
The ELK 02 and associated OETIKER pincers are intended solely for the controlled closure of OETIKER clamps and
Low Profile Clamps.
Use for the intended purpose also covers observance of this instruction manual and compliance with the technical
data.
Any use not in accordance with the intended purpose is regarded as incorrect.
Use other than for the intended purpose
The ELK 02 has been developed in accordance with the best available technology and is safe for use. Residual
dangers remain if it is used incorrectly or by untrained personnel. The operator of the ELK 02, not the manufacturer,
shall be held responsible for any personal injury or property damage arising from incorrect usage.
2.3 General safety instructions
• Observe all operating and maintenance instructions.
• Maintenance and repair work should always be carried out by qualified specialists.
• The ELK 02 unit may only be used by people who are familiar with its use and have been informed of the
risks.
• All relevant accident prevention regulations and other generally recognized health and safety rules must
be complied with. The manufacturer shall not be held liable for damage resulting from unauthorized
modifications to the ELK 02.

OETIKER ELK 02 V2.X 2 Basic safety instructions
Issue 05.2021 08903352 2-12
Spare parts
In order to ensure the fast and accurate delivery of spare parts, a clear purchase order is essential. It must include
the following information:
• Product name, software version
• Type designation
• Serial number
• Name of spare part and number of units required
• Spare part number
• Shipping method
• Full address
Details can be found in the OETIKER tools catalog.
Improvements to the machine
In our endeavor to continuously improve the quality of our products, we reserve the right to make improvements
without changing the instruction manual. Details of dimensions, weights, materials, performance ratings and names
may therefore be subject to necessary changes. Regarding electrical diagrams, the diagram supplied with the
machine takes precedence in all cases.
2.4 Special safety instructions
Only specially trained personnel are authorized to carry out maintenance and repair work on pneumatic equipment.
Depressurize the machine’s pneumatic equipment before starting maintenance or repair work.
Check hoses for wear as part of the preventive maintenance routine and replace them if necessary.
2.5 Safe working practices
Before each start of production, check the ELK 02 for visible damage and only use it if it is in perfect
working order.
Any defects must be reported to a supervisor immediately.
Do not continue to use the ELK 02 if defects have been identified.
2.6 Modifications, changes
• No design or safety modifications may be made to the ELK 02 without our express authorization. We
shall not be held liable for damage resulting from any modifications. In particular, repairs of any kind are
prohibited.
• The securing screws on the control unit and the ELK 02 pincer are sealed with lacquer. If the lacquer is
damaged, OETIKER cannot accept any claims under warranty.
• Use only original spare parts and accessories.
• Do not dismantle any safety equipment.

OETIKER ELK 02 V2.X 2 Basic safety instructions
Issue 05.2021 08903352 2-13
2.7 Qualified personnel
Only authorized and qualified personnel are permitted to use this machine, subject to compliance with the technical
data and the following safety rules and regulations. Qualified personnel are people who are familiar with setting up,
assembling, commissioning and operating the product and who have the qualifications appropriate to their job role.
2.8 Maintenance work
The inspection and maintenance intervals specified in the instruction manual must be complied with. Maintenance
and repair instructions must be followed accordingly.

OETIKER ELK 02 V2.X 3 Design of the ELK 02 system
Issue 05.2021 08903352 3-14
3 Design of the ELK 02 system
The ELK 02 electronically controlled pneumatic pincer system comprises the following main components:
Fig.2 Design of the ELK 02 system
1 Status lamp *)
2 Pre-filter
3 Accumulator
4 Control unit
5 Pneumatic pincer EL
6 PC with installed software
7 Closing force sensor SKS 01 *)
8 Calibrator CAL 01 *)
*) optional extra

OETIKER ELK 02 V2.X 3 Design of the ELK 02 system
Issue 05.2021 08903352 3-15
3.1 Optional extras
A number of additional items are available for the automation process, including
• Test equipment CAL 01, comprising the calibrator CAL 01 and closing force sensor SKS 01, for measuring
the pincer jaw force (closing force) and for calibrating the ELK 02
• Status lamp X2L01 for the visual detection of OK and NO closures and for the audible detection of NO
closures
3.2 Design of the HO EL pincers
Fig.3 HO EL pincers
1 Rotary adapter
2 EL trigger unit (“optional” extended trigger not
shown)
3 Possible mounting surfaces
4 Pincer plate
5 Pincer jaw
6 Grease nipple
7 Union nut
8 Lock nut
9 Pincer body
10 Vent holes
11 START button
12 LED light
13 Suspension loop
NOTICE
Risk of pincer jaw damage
When using the HO 10000 pincer model, make sure that the compressed air supply pressure pE does not
exceed 5 bar.
NOTICE
The vent holes (Fig.3/10) must not be blocked.

OETIKER ELK 02 V2.X 3 Design of the ELK 02 system
Issue 05.2021 08903352 3-16
3.3 Connections on the ELK 02 control unit
INFO
For details of the inputs and outputs on the control unit please refer to section 13.1, from p. 13-116.
Fig.4 Control unit, connections
Item in Fig. 4 Name of interface Type/use
1pA Compressed air output to pincer
2X1 9-pin SUB-MIN-D (male)
Pincer connection
3X2 15-pin SUB-MIN-D (HD) (male) Inputs/outputs
4X3
9-pin SUB-MIN-D (female)
• Computer connection RS232
• Connection CAL 01 RS232
5X20 25-pin SUB-MIN-D (male) Inputs/outputs
6X5/6/7 Option

OETIKER ELK 02 V2.X 3 Design of the ELK 02 system
Issue 05.2021 08903352 3-17
Item in Fig. 4 Name of interface Type/use
7 USB USB interface
8 Optional bus interface
9 Optional bus interface
10 Vent
11 Vent
12 3-pin IEC connector (male)
13 On/O switch
14 pE Compressed air supply pressure (see safety notice below)
Table1
Connections to the control unit
NOTICE
Risk of pincer jaw damage
When using the HO 10000 pincer model, make sure that the compressed air supply pressure pE does not
exceed 5 bar

OETIKER ELK 02 V2.X 4 Process description
Issue 05.2021 08903352 4-18
4 Process description
The ELK 02 is used for closing OETIKER clamps and Low Profile Clamps under the following conditions:
• quantified
• qualified
• verified
Quantification
Corresponds to the definition of gap and closure values.
Qualification
Corresponds to the definition of tolerances for gap and closure values and monitoring time profiles during closure.
Verification
Closure of the pincer jaws at the verification force VK, a reduced force for determining the verification value VW.
Detection
Detection identifies a second closure on the same clamp or Low Profile Clamp and reports it as NO.
All physical values necessary for the function can be input via the PC using the ELK 02 software. The PC can then
be used if required for recording the closure data and for inputting the nominal force.
Contact detection
The contact detection function determines the contact position of the corresponding clamp with the material being
clamped at the start of compression.
4.1 Closing force
OETIKER clamps and Low Profile Clamps must be closed with a recommended and uniform closing force
(force priority). This results in a consistent, reproducible and permitted tensile load on the strip material, without
overloading the individual components, the parts being clamped and the clamps.
The recommended closing forces for each OETIKER product group are listed in the technical data sheets.
The closing force can be altered by changing the parameters in the ELK 02 control unit.
It is critical to use the clamping force established for both the clamp and the specific application.
The closing force test device (i.e. test equipment CAL 01) is used for determining and setting the closing force.

OETIKER ELK 02 V2.X 4 Process description
Issue 05.2021 08903352 4-19
4.2 Procedure
1. Insert the ear of an OETIKER clamp (Fig.5/1) into
the clamping area on the pincer head (Fig.5/2).
For OETIKER Low Profile Clamps:
2. Position the pincer jaws on the tensioning hooks
of the Low Profile Clamp.
2. Press the START button (Fig.6/3).
Closure is initiated and the ear (Fig. 7/4) of the clamp is
closed.
In the case of Low Profile Clamps, initiating closure
reduces the clamp diameter to the required size for
engagement. Depending on the product, the clamp is
either engaged automatically or by applying contact
pressure on reaching the engagement position.
On reaching the predefined parameter values the jaws on the pincer head are opened.
INFO
The closure sequence is dependent on the closure data and on the predefined system data. It is initiated by
pressing the START button, for example.
A further closure operation can be performed.
If special heads are used – e.g. for closing OETIKER Low Profile Clamps – the details will dier from those shown in
the diagrams in Fig.5 to Fig. 7.
Fig.5 Insert clamp
Fig.6 Start closure
Fig.7 The ear is closed

OETIKER ELK 02 V2.X 4 Process description
Issue 05.2021 08903352 4-20
4.3 Sequence of operations
The sequence of operations when working with the ELK 02 system is divided into two sections:
• Test level
• The closure level
4.3.1 Test level
Fig.8 The test level
ELK 02 einschalten
System-Test
Regelungseinheit und Peripherie
bei erreich. Schließungen
(gem. System-Einstellung)
Zangentest-Auorderung
extern (gem. System Einst.)
über V24 (X3)
CAL 01 / PC
keine Autorisierung notwendig FUNKTION
Zangentest APN
Autorisierung
Zangentest
Fehlermeldung
F1...F4, F15
Fehlerbehebung
Fehler Quittierung
(gem. System-Einstellung)
Überspringen
Schließ-Ebene