Atlas Copco ETV S7 (ETV S7-200 13CTADS, 40-200 Nm) electric angle nut tightening machine

Important Pre Quality Tips

After any event that affects the tightening process occurs, the tightening torque result must be verified. Trigger verification scenario: initial installation of the system; Parts/bolts/tools/software/configuration/environmental changes; Electrical connection modification; Production line technology, personnel replacement, etc. Verification requirements: must be carried out after initial installation, maintenance and repair; At least once per shift or at an appropriate frequency.

Security Information

1. General safety rules

Only for use in industrial indoor dry environments, explosive environments are prohibited; Only compatible sleeves can be used.

Keep hands and long hair away from the rotating sleeve, and do not wear gloves when operating; Check the integrity and fastening of the suspension ears before use.

Tool work will generate reactive forces, and operators need to take protective measures; Before use, confirm that the tool status and controller program are correct to prevent accidental actions from causing injury.

When using the reaction bar model, confirm the spindle direction before starting, and strictly prohibit hands from approaching the working reaction bar to prevent squeezing injuries.

Power supply: single-phase 230V/50Hz (optional 115V/60Hz); The controller box must be locked; Before plugging or unplugging tool cables, be sure to turn off the power supply of the controller; Disconnect the tool from the controller before making internal adjustments.

Installation and maintenance are only carried out by qualified personnel.

2. Electrical protection system

The tool belongs to the TENSOR system and is divided into S4/S7 motor specifications. The tool and controller specification numbers must be consistent (S7 with S7) and cannot be mixed across specifications.

Motor overheating protection: automatic power-off due to abnormal temperature rise; The temperature will automatically reset when it drops.

Dual independent electrical protection

Passive: grounding of the entire machine;

Active: Ground fault circuit breaker EFP, detects leakage>10mA, cuts off the drive unit<30ms.

It is prohibited to tamper with the protection system, and tampering will directly void the warranty.

At least once a month, test the grounding fault protector and check the continuity of the grounding circuit from the equipment body to the ground; Fault reset requires authorized personnel holding the controller box key to operate.

3. Compliance Statement

CE compliance: Meets the 2006/42/EC Machinery Directive, 2004/108/EC Electromagnetic Compatibility, 2006/95/EC Low Voltage Directive, and is compatible with the EN series of coordinated standards.

RoHS: Complies with the EU Hazardous Substances Restriction Directive 2011/65/EU.

WEEE Waste Electrical and Electronic Equipment Directive 2012/19/EU: marked with a forked garbage bin, related components need to be specially recycled and cannot be discarded as ordinary garbage. They can be sent to a customer service center for processing.

Installation

Connect single-phase mains power through a matched POWER FOCUS drive controller.

Tool cable assembly

Operate in the power-off state of the controller; Align the asymmetric positioning pin with the handle interface, insert the long plastic pin into the connector hole, and insert the connector into the steel pin for positioning; Tighten the locking nut.

Pull, push, and rotate cable joints to confirm no looseness or displacement.

Built in storage chip: The tool comes with an electronic storage chip that automatically transmits torque sensor calibration values and angle pulses to POWER FOCUS; Modifying parameters on the controller will be written back to the tool’s built-in memory.

Grounding: If the tool is assembled to a handheld/hand guided fixture, the fixture needs to be connected to the drive unit using an independent 2.5   mm ² grounding wire.

Operation usage

Steering settings

ETV/ETD models: rotating reversing ring; Clockwise=forward tightening, counterclockwise=reverse loosening.

ETP model: Pull the trigger knob to swing the lever; Upward forward, downward reverse.

Soft start function: facilitates the import of screw heads and threads, and the start time can be adjusted within the POWER FOCUS controller.

status indicator light

Green: Tighten OK and qualified;

Yellow: Warning – Low torque;

Red: Warning – High torque.

ESD electrostatic protection: Tools and internal components of controllers are sensitive to static electricity, and ESD anti-static workstations (anti-static mats, anti-static wristbands) must be used for disassembly, assembly, and maintenance.

Maintenance and upkeep

1. Lubrication

When repairing planetary gears, needle roller bearings, and ball bearings, molybdenum disulfide grease must be used; Recommend Molykote BR 2 Plus; The amount of lubricant must be accurate, too much or too little can cause malfunctions.

Lubricating Oil Comparison Table

Recommended grease for components

Universal parts Almagard 3751

Cable nut CRC lithium grease No.3020

Gear and Angular Gear Molykote Longterm 2 Plus

2. Major repairs and preventive maintenance

Only qualified personnel who have received Tensor-S tool training and hold maintenance manuals are accepted for operation.

The motor is a seal assembly, and it is strictly forbidden for non Atlas Copco personnel to disassemble it; The motor malfunction will be directly returned to the manufacturer for replacement as a whole; Disassembling the motor without authorization will result in the loss of all warranty.

Cycle: Tighten once a year, or a total of 250000 times. Perform major repairs when the condition is met first; Heavy load conditions require a shortened cycle; Stop the machine immediately for inspection if the tool is abnormal.

Special maintenance tools with part numbers 4080-0848-80 are required for disassembly, and two are needed.

3. Spare parts and warranty

Parts without an order number and parts in the repair kit are not supplied separately; Using non original spare parts will reduce performance and increase maintenance, and the manufacturer has the right to void the warranty.

Prerequisite for effective warranty: Strictly follow the manual to complete installation, operation, lubrication, and major repairs; If the motor is detected to be disassembled, the warranty will be invalidated.

ServAid tool software: official website/CD access; You can refer to safety instructions, disassemble explosion views, order spare parts tools, support multiple languages, and include discontinued product information.

Guidelines for Human Machine Engineering Operations

Used to optimize workstations and reduce the risk of operator injury:

Frequent rest and changing of operating posture; Adapt workstations to job requirements and reduce static muscle load.

Try to avoid working at heights above the shoulders as much as possible; Use torque arms, balancers, and tools close to the body to reduce weight during high-altitude operations.

Avoid extreme force postures on the arms and wrists; Lighting adaptation work.

Wear hearing protection in noisy environments; Use high-quality sleeves to reduce vibration; Try to minimize the reactive force.

According to the ISO11148-03 standard, pistol tools with a torque greater than 10 Nm and straight handle tools with a torque greater than 4 Nm must be equipped with a reaction force absorption device; High torque operating conditions require matching torque arms/reaction bars.

Install dust removal equipment or protective masks in dusty environments.

Troubleshooting

1. The tool does not start

Confirm that POWER FOCUS is in RUN mode; Confirm that the controller matches the tool model S7;

Check the fuse of the drive unit; Verify controller parameters;

Check the internal grounding fault circuit breaker. If it trips, first identify the root cause of the fault and then restart the equipment.

2. Abnormal overheating of tools

Causes: Exceeding the rated torque, low speed, long ramp time, high preset torque, soft connection thread pair, short cycle time combined.

Handling: Adjust the speed, ramp time, and tightening strategy; Prioritize single segment strategy and Ergoamp (with lower heat loss); Use larger capacity tools when ineffective.

Scrap and Recycling

After scrapping the equipment, dismantle it and recycle the parts according to local regulations; The battery will be handed over to the national battery recycling agency for disposal.

Noise and Vibration Explanation

The instruction manual only provides testing standards and does not fill in specific values; The laboratory test values are only used for comparison between tools and cannot be used for on-site risk assessment. Actual on-site values may be higher. This tool can induce arm hand vibration syndrome; Suggest establishing employee health monitoring and early identification of vibration related physical injuries.