OETIKER ELK 02 User manual

Electronically Controlled
Pneumatic Pincer
OETIKER ELK 02 V1.x
Original instruction manual
Issued June 2012
Instruction Manual
Item no. 08902266
OETIKER Horgen, Switzerland

OETIKER ELK 02 V1.x Contents
Issued 03.12 08902266 1-2
Contents
1Information about this manual................................................................................................................1-6
1.1 Symbols and means of representation used ..............................................................................1-6
1.2 Scope ..........................................................................................................................................1-6
1.3 New features on the ELK 02 V1.0 ..............................................................................................1-7
1.3.1 Hardware ...............................................................................................................................1-7
1.3.2 Software.................................................................................................................................1-7
1.4 Abbreviations ..............................................................................................................................1-8
1.5 Labels on the ELK 02..................................................................................................................1-9
2Basic safety instructions.......................................................................................................................2-10
2.1 Using the instruction manual.....................................................................................................2-10
2.2 Correct usage............................................................................................................................2-10
2.3 General safety instructions .......................................................................................................2-10
2.4 Special safety instructions ........................................................................................................2-11
2.5 Safe working practices..............................................................................................................2-11
2.6 Modifications, changes .............................................................................................................2-11
2.7 Qualified personnel ...................................................................................................................2-12
2.8 Maintenance work.....................................................................................................................2-12
3Design of the ELK 02 system................................................................................................................3-13
3.1 Optional extras..........................................................................................................................3-14
3.2 Design of the HO EL pincers ....................................................................................................3-14
3.3 Connections on the ELK 02 control unit ...................................................................................3-15
4Process description...............................................................................................................................4-17
4.1 Closing force .............................................................................................................................4-17
4.2 Procedure..................................................................................................................................4-18
4.3 Sequence of operations ............................................................................................................4-19
4.3.1 Test level..............................................................................................................................4-19
4.3.2 Closure level ........................................................................................................................4-20
5Assembling and connecting the ELK 02..............................................................................................5-21
5.1 Connecting the control unit .......................................................................................................5-21
5.2 Connecting the compressed air and pneumatic pincer ............................................................5-22
5.2.1 General information and requirements ................................................................................5-22
5.2.2 Connecting the compressed air ...........................................................................................5-22

OETIKER ELK 02 V1.x Contents
Issued 03.12 08902266 1-3
5.3 Aligning the pincer head ...........................................................................................................5-23
6Working with the ELK 02 .......................................................................................................................6-24
6.1 Switching on the ELK 02...........................................................................................................6-24
7Menu navigation in the PC program.....................................................................................................7-25
7.1 System requirements and installation.......................................................................................7-25
7.2 Installing the PC program .........................................................................................................7-26
7.2.1 Installing the program automatically ....................................................................................7-26
7.2.2 Installing the program manually...........................................................................................7-27
7.3 PC program structure................................................................................................................7-27
8Layout of the PC program.....................................................................................................................8-28
8.1 Preparing to read and send data ..............................................................................................8-29
8.2 File menu ..................................................................................................................................8-29
8.2.1 New close data table............................................................................................................8-30
8.2.2 Pincer type overview............................................................................................................8-35
8.2.3 Backup/Restore ...................................................................................................................8-36
8.2.4 ELK 02 firmware update ......................................................................................................8-37
8.2.5 Quit ......................................................................................................................................8-37
8.3 Pincer test .................................................................................................................................8-37
8.4 Measure ....................................................................................................................................8-39
8.5 Options......................................................................................................................................8-41
8.5.1 Statistics menu.....................................................................................................................8-42
8.5.2 Password menu ...................................................................................................................8-46
8.5.3 Screen scaling menu ...........................................................................................................8-48
8.5.4 System settings menu..........................................................................................................8-48
8.5.5 Languages ...........................................................................................................................8-66
8.5.6 Help......................................................................................................................................8-66
9Menu navigation in the ELK 02.............................................................................................................9-67
9.1 Description of the display..........................................................................................................9-67
9.1.1 Symbols and abbreviations in the display ...........................................................................9-68
9.2 Menu structure ..........................................................................................................................9-68
9.3 Test level...................................................................................................................................9-69
9.3.1 Pincer test ............................................................................................................................9-70
9.4 Closure level .............................................................................................................................9-74
9.4.1 Closure.................................................................................................................................9-75

OETIKER ELK 02 V1.x Contents
Issued 03.12 08902266 1-4
9.4.2 Force priority ........................................................................................................................9-80
9.4.3 Gap priority ..........................................................................................................................9-81
9.4.4 Force priority with verification ..............................................................................................9-82
9.4.5 Gap priority with verification.................................................................................................9-84
9.4.6 Force priority for PG 192 / 168T1 ........................................................................................9-86
9.4.7 Initiating closure with “START” ............................................................................................9-87
9.4.8 Single closing.......................................................................................................................9-89
9.4.9 Chaotic closing.....................................................................................................................9-90
9.4.10 Sequential closing................................................................................................................9-91
9.4.11 Step-by-step closing ............................................................................................................9-93
9.4.12 Closing with hold..................................................................................................................9-94
9.4.13 Closing with detect...............................................................................................................9-95
9.4.14 Closing with contact detection .............................................................................................9-96
10 Maintenance and repairs.....................................................................................................................10-97
10.1 General safety instructions for maintenance and repair work ................................................10-97
10.2 Maintenance............................................................................................................................10-97
10.2.1 Before maintenance work ..................................................................................................10-97
10.2.2 After maintenance work .....................................................................................................10-97
10.2.3 Weekly maintenance jobs..................................................................................................10-98
10.2.4 Annual maintenance jobs ..................................................................................................10-98
10.2.5 Maintenance jobs as and when required...........................................................................10-98
10.3 Repairs....................................................................................................................................10-99
10.3.1 Changing the pincer jaws ..................................................................................................10-99
10.3.2 Changing the pincer head................................................................................................10-102
11 Decommissioning, storage, recommissioning ...............................................................................11-104
11.1 Decommissioning and storage..............................................................................................11-104
11.2 Recommissioning..................................................................................................................11-104
12 Disposal...............................................................................................................................................12-105
13 Technical data.....................................................................................................................................13-106
13.1 Electrical connection and interfaces .....................................................................................13-106
13.1.1 Main plug .........................................................................................................................13-106
13.1.2 X1 interface......................................................................................................................13-107
13.1.3 X2 interface......................................................................................................................13-107
13.1.4 X3 interface (RS232) .......................................................................................................13-110

OETIKER ELK 02 V1.x Contents
Issued 03.12 08902266 1-5
13.1.5 X20 interface....................................................................................................................13-114
13.1.6 USB interface...................................................................................................................13-116
13.2 Technical data.......................................................................................................................13-117
13.2.1 Fluidics.............................................................................................................................13-117
13.2.2 ELK 02 housing................................................................................................................13-117
13.2.3 Accuracy in the working temperature range ....................................................................13-118
13.2.4 Temperature ....................................................................................................................13-118
14 Troubleshooting.................................................................................................................................14-119
14.1 General notes on faults.........................................................................................................14-119
14.2 What to do, when...? .............................................................................................................14-119
14.3 Error messages and error correction measures ...................................................................14-119
15 Checklists............................................................................................................................................15-122
15.1 Checklist for ELK 02, control unit..........................................................................................15-122
15.2 Pincer checklist .....................................................................................................................15-124
16 Warranty conditions...........................................................................................................................16-126
16.1 Warranty period.....................................................................................................................16-126
16.2 Conditions .............................................................................................................................16-126
16.3 Warranty claims ....................................................................................................................16-126
16.4 Consequential damage .........................................................................................................16-126
16.5 Costs .....................................................................................................................................16-127
17 Declaration of Conformity.................................................................................................................17-128
18 Index....................................................................................................................................................18-129

OETIKER ELK 02 V1.x 1 Information about this manual
Issued 03.12 08902266 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.
CAUTION Information on the avoidance of property damage.
NOTICE 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.
Requirement
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 control unit, item no. 136 00 289 (85 -
265 V / 47 - 63 Hz, V1.0).

OETIKER ELK 02 V1.x 1 Information about this manual
Issued 03.12 08902266 1-7
1.3 New features on the ELK 02 V1.0
1.3.1 Hardware
• Hardware compatible with ELK 01
The hardware and the peripheral 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
1.3.2 Software
NOTICE
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 of product-dependent relative movements
• Measurement screen can be called directly from the close data individual view
• Intake pressure monitoring, static and dynamic, for qualified NO analysis
• Intake pressure display
• Software updates for ELK 02 online via PC
• PC backup function, data and settings
• PC restore function, data and settings
• Pincer test documentation
• New password structure
• Service interval

OETIKER ELK 02 V1.x 1 Information about this manual
Issued 03.12 08902266 1-8
1.4 Abbreviations
APN Active program number (max. 99)
DS Detection gap
DK Detection force
HK Holding force
HK-T Holding force tolerance
HS Holding gap
HS-T Holding gap tolerance
HS-SK Closing time between holding gap and closing
force
HS-SS Closing time between holding gap and closing
gap
KK Contact force
KS Contact gap
OF Open
OF-SK Closing time between open and closing force
OF-SS Closing time between open and closing gap
OF-Z Removal time
OS Opening gap
OS-SK Closing time between opening gap and
closing force
OS-SS Closing time between opening gap and
closing gap
OS-T Opening gap tolerance
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
VK Verification force
VK-HZ Verification force holding time
VK-T Verification force tolerance
VW Verification value
VW-T Verification value tolerance

OETIKER ELK 02 V1.x 1 Information about this manual
Issued 03.12 08902266 1-9
1.5 Labels on the ELK 02
Fig. 1: Labels on the ELK 02
1 Warning label
2 Risk of crushing
3 “Do not loosen bolts” warning label
4 Rating plate

OETIKER ELK 02 V1.x 2 Basic safety instructions
Issued 03.12 08902266 2-10
2 Basic safety instructions
2.1 Using the instruction manual
• Make sure that this instruction manual is always kept close to 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 Correct usage
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.
Correct usage also covers observance of this instruction manual and compliance with the technical data.
Any use not in accordance with the prescribed usage shall be regarded as incorrect usage.
Non-prescribed usage
The ELK 02 has been developed in accordance with the best available technology and is safe for use. Residual
dangers remain if it 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 its incorrect
usage.
2.3 General safety instructions
• Observe all operating and maintenance instructions; they are a prerequisite for many years’ trouble-free use
of the ELK 02.
• 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 V1.x 2 Basic safety instructions
Issued 03.12 08902266 2-11
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 if necessary.
2.5 Safe working practices
Before the start of each production run 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.
• Only use original spare parts and accessories.
• Do not dismantle any safety equipment.

OETIKER ELK 02 V1.x 2 Basic safety instructions
Issued 03.12 08902266 2-12
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 V1.x 3 Design of the ELK 02 system
Issued 03.12 08902266 3-13
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 V1.x 3 Design of the ELK 02 system
Issued 03.12 08902266 3-14
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 (with optional extended
trigger)
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
CAUTION
Damage caused by broken pincer jaws
When using the HO 10000 pincer model, make sure that the compressed air intake pE does not exceed
5 bar.

OETIKER ELK 02 V1.x 3 Design of the ELK 02 system
Issued 03.12 08902266 3-15
3.3 Connections on the ELK 02 control unit
NOTICE
For details of the inputs and outputs on the control unit please refer to section 13.1, page 13-106.
Fig. 4: Control unit, connections
Item
in Fig. 4 Name of interface Type/use
1 pA Compressed air output to pincer
2 X1 9-pin SUB-MIN-D (male)
Pincer connection
3 X2 15-pin SUB-MIN-D (HD) (male) Inputs/outputs
4 X3 9-pin SUB-MIN-D (female)
• Computer connection RS232
• CAL 01 connection RS232
5 X20 25-pin SUB-MIN-D (male) Inputs/outputs
6 X5/6/7 Option
7 USB USB interface

OETIKER ELK 02 V1.x 3 Design of the ELK 02 system
Issued 03.12 08902266 3-16
Item
in Fig. 4 Name of interface Type/use
8 Optional bus interface
9 Optional bus interface
10 Vent
11 Vent
12 3-pin IEC connector (male)
13 On/Off switch
14 pE Compressed air intake (see safety notice below)
Table 1: Control unit connections
CAUTION
Damage caused by broken pincer jaws
When using the HO 10000 pincer model, make sure that the compressed air intake pE does not exceed
5 bar.

OETIKER ELK 02 V1.x 4 Process description
Issued 03.12 08902266 4-17
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
Corresponds to checking the defined values in compliance with the tolerances and an output record.
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 entered via the PC using the ELK 02 software. The PC can
then be used if required for recording the close data and for entering the nominal force.
4.1 Closing force
OETIKER clamps and Low Profile Clamps have to 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.
The closing force test device, i.e. test equipment CAL 01, is used for determining and setting the closing force.

OETIKER ELK 02 V1.x 4 Process description
Issued 03.12 08902266 4-18
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.
Fig. 5: Insert clamp
3. Press the START button (Fig. 6/3).
Fig. 6: Start closure
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.
Fig. 7: Ear is closed
On reaching the predefined parameter values the jaws on the pincer head are opened.
NOTICE
The closure sequence is dependent on the close 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 differ from those
shown in the diagrams in Fig. 5 to Fig. 7.

OETIKER ELK 02 V1.x 4 Process description
Issued 03.12 08902266 4-19
System test
Control unit and peripherals
with successful closures
(as per system settings)
Pincer test prompt
external (as per system
settings)
via V24 (X3)
CAL 01 / PC
Error message
F1-F4
,
F15
no authorization
necessary
Error correction
Error
acknowledgement
(as per system
settings)
FUNCTION
Pincer test APN
Pincer test
Authorization Skip
Closure level
Switch on ELK 02
4.3 Sequence of operations
The sequence of operations when working with the ELK 02 is divided into two sections:
• Test level
• Closure level
4.3.1 Test level
Fig. 8: Test level

OETIKER ELK 02 V1.x 4 Process description
Issued 03.12 08902266 4-20
Force or gap priority
with/without
verification
with or without hold,
detect,
contact detection
external Pincer button
APN pre-
selection external
Start
chaotic single sequential
NO OK
Error messages during
closure F1-F24
Data record
Measurement results
Error messages
4.3.2 Closure level
Fig. 9 Closure level