Product Information

• General Information
  • Symbols on the Tool
  • Safety Signal Words
  • Warranty
  • Website
  • ServAid
  • Safety Data Sheets MSDS/SDS
  • Product Safety Video for Nutrunners
  • Country of Origin
  • Dimensional Drawings
• Overview
  • The Tensor System
  • Technical Product Data
• Service Overview
  • Service Recommendations

General Information

WARNING

Risk of Property Damage or Severe Injury

Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.

• Read all Safety Information delivered together with the different parts of the system.

• Read all Product Instructions for installation, operation and maintenance of the different parts of the system.

• Read all locally legislated safety regulations regarding the system and parts thereof.

• Save all Safety Information and instructions for future reference.

Symbols on the Tool

The symbols on the tool have the following meanings:

Safety Signal Words

Warranty

• Product warranty will expire 12 months after the product is first taken into use, but will in any case expire at the latest 13 months after delivery.

• Normal wear and tear on parts is not included within the warranty.

  • Normal wear and tear is that which requires a part change or other adjustment/overhaul during standard tools maintenance typical for that period (expressed in time, operation hours or otherwise).

• The product warranty relies on the correct use, maintenance, and repair of the tool and its component parts.

• Damage to parts that occurs as a result of inadequate maintenance or performed by parties other than Atlas Copco or their Certified Service Partners during the warranty period is not covered by the warranty.

• To avoid damage or destruction of tool parts, service the tool according to the recommended maintenance schedules and follow the correct instructions.

• Warranty repairs are only performed in Atlas Copco workshops or by Certified Service Partners.

Atlas Copco offers extended warranty and state of the art preventive maintenance through its ToolCover contracts. For further information contact your local Service representative.

For electrical motors:

• Warranty will only apply when the electric motor has not been opened.

Website

Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on the Atlas Copco website.

Please visit: www.atlascopco.com.

ServAid

ServAid is a portal that is continuously updated and contains Technical Information, such as:

• Regulatory and Safety Information

• Technical Data

• Installation, Operation and Service Instructions

• Spare Parts Lists

• Accessories

• Dimensional Drawings

Please visit: https://servaid.atlascopco.com.

For further Technical Information, please contact your local Atlas Copco representative.

Safety Data Sheets MSDS/SDS

The Safety Data Sheets describe the chemical products sold by Atlas Copco.

Please consult the Atlas Copco website for more information www.atlascopco.com/sds.

Product Safety Video for Nutrunners

Learn more about safety features on Atlas Copco nutrunners and what measures the operator has to take for a safe operation. Click the link or scan the QR code below to view the video:

https://www.youtube.com/watch?v=FAh6yttvUpw

Country of Origin

For the Country of Origin, please refer to the information on the product label.

Dimensional Drawings

Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.

Please visit: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.

Overview

• The Tensor System
• Technical Product Data

The Tensor System

The Tensor system consists of a range of tightening tools powered by brushless electric motors and different drive units.

Motors are available in different sizes. All tools are protected from overheating of the motor. Electrical protection system is based on an earth fault circuit brake, Earth Fault Protector (EFP). The EFP senses small current leakage (>30mA) and if leakage occurs, the drive is switched off (30ms). Changing, interfering or tampering with the protection system voids all warranty and obligations from Atlas Copco. Trouble-shooting and re-start of the system may only be carried out by an authorized person. Check the function of the EFP on a regular basis by pressing the trip-button. The EFP should switch off accordingly.

Technical Product Data

Technical Product Data can be found on either ServAid, or the Atlas Copco website.

Please visit: https://servaid.atlascopco.com or www.atlascopco.com.

Service Overview

• Service Recommendations

Service Recommendations

Preventive maintenance is recommended at regular intervals. See the detailed information on preventive maintenance. If the product is not working properly, take it out of service and inspect it.

If no detailed information about preventive maintenance is included, follow these general guidelines:

• Clean appropriate parts accurately

• Replace any defective or worn parts

Installation

• Installation Requirements
  • Tool display
  • Socket release function
  • Connecting the tool
  • Grounding
• Installation Instructions
  • Installation
  • Fitting of the tool cable
  • Fixtures for Tensor angle type models
    • Fixtures provided by Atlas Copco
      • Extension for fixturing
      • Reaction plate
      • Angle tool holder
      • Universal tool holder (< 50 Nm)
    • Customer-developed fixturing equipment
      • For all tools equipped with a Torque Multiplier
      • For torque less than 100 Nm
      • For torque between 100 and 200 Nm
      • For torque above 200 Nm
  • Clamping the Tensor tool to a fixture

Installation Requirements

• Tool display
• Socket release function
• Connecting the tool
• Grounding

Tool display

The tool display is turned on from the controller.

On Power Focus 4000:

• Push the Prog button

• Use the navigation buttons to follow the path > Tool > Configuration > Accessory bus > ST bus > Mode

Socket release function

It is recommended to use the socket release function on all the ETP ST101 tools. When the function is enabled, the socket rotates backwards 3° after a completed tightening. The aim is to reduce tension on the reaction bar and to make it easier to remove the tool.

The socket release function is turned on from the controller.

On Power Focus 4000:

• Push the Prog button

• Use the navigation buttons to follow the path > Pset > Programming+ > Options > Socket release > Mode On

Connecting the tool

The tool should, via its correct Power Focus drive unit, be connected to the mains, 230V/50Hz alternatively 115V/ 60Hz, single phase. See instructions for your Power Focus drive unit.

Grounding

If the tool is mounted in a handheld or hand guided fixture, the fixture should be connected to the drive using a separate 2.5mm² grounding cable.

Installation Instructions

• Installation
• Fitting of the tool cable
• Fixtures for Tensor angle type models
  • Fixtures provided by Atlas Copco
    • Extension for fixturing
    • Reaction plate
    • Angle tool holder
    • Universal tool holder (< 50 Nm)
  • Customer-developed fixturing equipment
    • For all tools equipped with a Torque Multiplier
    • For torque less than 100 Nm
    • For torque between 100 and 200 Nm
    • For torque above 200 Nm
• Clamping the Tensor tool to a fixture

Installation

The tool should, via its correct POWER FOCUS/drive unit, be connected to the mains, 230V/ 50Hz alternatively 115V/ 60Hz, single phase. See instructions for your POWER FOCUS/ drive unit.

Fitting of the tool cable:

• Security check that the cabletype is correct

• Align the cable connector using the two asymmetrically positioned heads on the connector to fit in the slots in the tool handle.

• Tighten the lock nut.

• Security check that the connection is correct by pulling, pushing and turning the cable connector (there should be no movement).

The tool has a built in electronic memory chip that will transmit the torque transducer calibration value and angle pulses to the POWER FOCUS/drive unit. Any changes made of these values in the POWER FOCUS while the tool is connected will be stored in the tool memory.

Fitting of the tool cable

• Make sure that the tool cable is of correct type.

• Align the cable connector using the two asymmetrically positioned heads on the connector to fit in the slots in the tool handle.

• Tighten the lock nut.

• Make sure that the connection is correct by pulling, pushing and turning the cable connector (there should be no movement).

The tool has a built in electronic memory chip that will transmit the torque transducer calibration value and angle pulses to the POWER FOCUS/drive unit. Any changes made of these values in the POWER FOCUS while the tool is connected will be stored in the tool memory.

Fixtures for Tensor angle type models

Atlas Copco provides several separate fixtures for the Tensor angle type models.

• Make sure that accessories, such as bar code scanners and different types of selectors, do not interfere with the fixtures.

The ordering number for all ready-made fixtures are found att http://servaidweb.atlascopco.com:

1. Select Tools Accessories.

2. Enter product number or name for the tool.

3. Click Search.

Note that more solutions may be available at a later date.

Fixtures provided by Atlas Copco

• Extension for fixturing
• Reaction plate
• Angle tool holder
• Universal tool holder (< 50 Nm)

Extension for fixturing

The extension for fixturing is mounted directly on the tool between the angle head and the gearbox.

Atlas Copco recommends this solution.

This fixture can be used for all Tensor STB/ST/STR/ES61 models, regardless of size.

To fit the fixture onto the tool, the front part of the tool must be dismantled and then assembled again. An extra front mounting nut is required.

Reaction plate

The reaction plate fixture allows changes to the position of the reaction bar for different applications.

This fixture can be used for all Tensor STB/ST/STR/ES61 models, regardless of size.

Angle tool holder

The tool holder is primarily developed to fit Atlas Copco Torque arms. It can be mounted in several ways depending on the application.

This fixture can be used for all Tensor ST/STR models, regardless of size.

Universal tool holder (< 50 Nm)

The universal tool holder is suitable for all SL/SR models.

Customer-developed fixturing equipment

• The guidelines differ depending on the separate torque ranges for the tools, and if the tool is equipped with a Torque Multiplier.

• Never put a clamp holding the fixture on the surface covering the torque transducer!

• Avoid point loads.

• Clamping load must not exceed 2 kN.

There are no restrictions on the following:

• Materials used for the clamps

• Bearing or swiveling arrangement for the fixture

• Overall thickness of the clamp

For all tools equipped with a Torque Multiplier

Primarily, place the fixture on the spline at the tip of the multiplier.

If this is not possible, the fixture should be placed on the multiplier or on the mounting plate. This is because the tool is not dimensioned for the high torque that the multiplier can deliver.

For torque less than 100 Nm

• The clamping area shall be as large as possible

Avoid clamping on the angle head and cap nut.

STB/ST/ES/SL/SR equipment:

• Fit the clamp around the motor.

• Clamp on the sides of the tool.

STR equipment:

• Preferably, choose a solution that Atlas Copco provides.

• If not possible, fit the clamp around the motor. Cover the inside of the clamp using a rubber cloth to protect the marking plates and plastic cover of the motor.

• Clamp on the top and bottom of the tool.

• Keep the clamping load as low as possible.

For torque between 100 and 200 Nm

ST/STR equipment primarily:

• Fit the clamp holding the equipment around the gearbox.

• The clamp should be located as close as possible to the front nut of the tool.

• The clamp width should be between 15 and 20 mm.

ES equipment primarily:

• Fit the clamp around the motor.

For torque above 200 Nm

Atlas Copco recommends that the holes at the front of the tool are used for the fixture.

If this is not possible, place the clamps further back on the tool.

For tools below 300 Nm, place the clamp on the gearbox.

If this is not possible, place the clamp on the motor.

For tools from 300 Nm and upwards, use one clamp around the gearbox and one clamp around the motor.

Make sure that the center axes for the two clamps are aligned.

Clamping the Tensor tool to a fixture

To clamp the tool to a fixture, only the areas marked grey on the figure can be used. However, be careful not to damage the rubber coating when clamping the rubber handle.

Operation

• Ergonomic Guidelines
• Operating Instructions
  • Operating

Ergonomic Guidelines

Consider your workstation as you read through this list of general ergonomic guidelines to identify areas for improvement in posture, component placement, or work environment.

• Take frequent breaks and change work positions frequently.

• Adapt the workstation area to your needs and the work task.

  • Adjust for a convenient reach range by determining where parts and tools need to be located to avoid static load.

  • Use workstation equipment such as tables and chairs appropriate for the work task.

• Avoid work positions above shoulder level or with static holding during assembly operations.

  • When working above shoulder level, reduce the load on the static muscles by lowering the weight of the tool, using for example torque arms, hose reels or weight balancers. You can also reduce the load on the static muscles by holding the tool close to the body.

  • Take frequent breaks.

  • Avoid extreme arm or wrist postures, particularly during operations requiring a degree of force.

• Adjust for a convenient field of vision that requires minimal eye and head movements.

• Use appropriate lighting for the work task.

• Select the appropriate tool for the work task.

• In noisy environments, use ear protection equipment.

• Use high-quality inserted tools and consumables to minimize exposure to excessive levels of vibration.

• Minimize exposure to reaction forces.

  • When cutting:

    A cut-off wheel can get stuck if the cut-off wheel is bent or not guided properly. Use the correct flange for the cut-off wheel and avoid bending the cut-off wheel during operation.

  • When drilling:

    The drill might stall when the drill bit breaks through. Use support handles if the stall torque is high. The safety standard ISO11148 part 3 recommends using a device to absorb a reaction torque above 10 Nm for pistol grip tools and 4 Nm for straight tools.

  • When using direct-driven screwdrivers or nutrunners:

    Reaction forces depend on the tool settings and joint characteristics. Strength and posture determine the amount of reaction force that an operator can tolerate. Adapt the torque setting to the operator's strength and posture and use a torque arm or reaction bar if the torque is too high.

• In dusty environments, use a dust extraction system or wear a mouth protection mask.

Operating Instructions

• Operating

Operating

Make sure that the tool is in correct working order and that the controller is correctly programmed to avoid unexpected behaviour from the tool, which may result in operator injury.

Check that the tool is in the correct running direction by looking at the function light situated above the tool handle, by turning the reverse ring (only for ETV/ETD DS or by turning the arm on the trigger knob (only for ETP DS).

The soft-start function facilitates entering the screw head and thread.

The duration of the soft start is adjustable, see the manual for the drive unit.

The tool is equipped with signal lights,

• Green = OK tightening

• Yellow = Warning – low torque (not for ES)

• Red = Warning – high torque

• Orange = Function indicator (only for SL and DL)

• Blue = Function indicator (only for SL)

Service

• Preventing ESD Problems
• Maintenance Instructions
  • Overhaul
  • Service Recommendations
• Lubrication Instructions
  • Lubricant Guide
  • Lubrication
• Repair Instructions
  • Repair

Preventing ESD Problems

The components inside the product and controller are sensitive to electrostatic discharge. To avoid future malfunction, make sure that service and maintenance is carried out in an ESD approved work environment. The figure below shows an example of an appropriate service work station.

Maintenance Instructions

• Overhaul
• Service Recommendations

Overhaul

Service must only be carried out by qualified personnel who have access to the Service instruction and/or have been trained for service on Tensor tools.

The electric motor is a sealed unit and may under no circumstances be opened by anyone else than Atlas Copco Industrial Technique AB!

If you decide that the electric motor is defect or in need of service, return the complete motor unit to Atlas Copco Industrial Technique for replacement.

Motors which have been opened by anyone else than Atlas Copco Industrial Technique will not be serviced.

Overhaul and preventive maintenance is recommended at regular intervals once per year or after maximum 250.000 tightening depending on which occurs sooner. More frequent overhaul may be needed if the machine is used in heavy-duty operations. If the machine not is working properly, it should immediately be taken away for inspection.

When dismantling the tool always use the specially designed service tool 4080 0848 80, (two service tools are required).

Service Recommendations

Preventive maintenance is recommended at regular intervals. See the detailed information on preventive maintenance. If the product is not working properly, take it out of service and inspect it.

If no detailed information about preventive maintenance is included, follow these general guidelines:

• Clean appropriate parts accurately

• Replace any defective or worn parts

Lubrication Instructions

• Lubricant Guide
• Lubrication

Lubricant Guide

Lubrication

Lubricate according to the Lubrication Guide at each service occasion.

For more information, see Spare Parts section in ServAid - https://servaid.atlascopco.com.

Repair Instructions

• Repair

Repair

Repair must only be carried out by qualified authorised personnel. For further information contact your local Atlas Copco sales representative.

Troubleshooting

• If the tool becomes very hot
• Power Focus 3000/4000
• Power Focus 600/6000

If the tool becomes very hot

With proper adjustment the tool can handle any normal line jobs that an operator sustains. What can cause overheating are combinations of some factors: torque above rated, too low speed, too long ramp time (motor has to give high torque for a long time), very high prevailing torque, very soft joints, short cycle time. To correct, look over speed, ramp time, tightening strategy. One stage and Ergoramp are most heat conserving when applicable. Please refer to the User Guide of your POWER FOCUS. If the above corrections are not enough, choose a tool of the next higher capacity.

Power Focus 3000/4000

Is the POWER FOCUS switched on and in RUN mode? Check that the correct POWER FOCUS is used (ST31/ST32/ST61/STR31/STR61-Tensor3-7, ST81-Tensor8-9). Check the fuses for the drive part. Check Drive parameters, refer to the User Guide of the POWER FOCUS/ drive unit. Check the earth fault circuit breaker on the backside of the drive. Should it have tripped, make sure to find the primary fault before resuming operation. Check that the wiring on the remote start connector is correct. For further information see 9836 2258.

Power Focus 600/6000

Is the unit switched on? Check the earth fault circuit breaker behind the front door. Should it have tripped, make sure to find the primary fault before resuming operation. Check that the wiring on the remote start connector is correct. For further information see 9836 4954/9836 7446.

Recycling

• Environmental Regulations
• Recycling information

Environmental Regulations

When a product has served its purpose it has to be recycled properly. Dismantle the product and recycle the components in accordance with local legislation.

Batteries shall be taken care of by your national battery recovery organization.

Recycling information