Tensor DL screwdrivers - Atlas Copco

Tensor DL screwdrivers
Where every fastener counts!

Choose Tensor DL and get it right…
Light, powerful, intelligent, Tensor DL is the screw tightening
system that will keep you ahead. Its unmatched performance
in terms of speed, accuracy and process control will raise
productivity to a new level in your plant, while helping you to
cut assembly costs.
SECURITY
PRODUCTIVITY
FLEXIBILITY
Controlled tightening cuts
assembly costs
• Elimination of common assembly problems
• Monitoring of process and tightening cycle
• Operator is guided by the system
• High accuracy ensures end-product quality
High performance boosts productivity
• System performance enables shorter cycle times
• Through programming, the tool is always optimized
to the process
• Better power-to-weight ratio than comparable air
and electric tools
• Excellent ergonomic properties help improve health
and safety in the workplace
• Fast payback on initial tool investment due to high
productivity and process security
One tool for several applications
• Up to 10 parameter sets can be programmed
to handle different torques and types of joint
• Replace up to 10 conventional tools with
one Tensor DL
• System is easily reprogrammed to allow for
changes in production

…first time, every time!
3

Security
Where every
fastener counts…
Controlled tightening cuts assembly costs by detecting errors. Tensor DL
will bring you closer to zero fault production than ever before. By alerting
the operator to the most common errors before they continue down
the line, the system ensures high quality end-products, and saves you a
fortune in reworking costs. Most important of all, controlled tightening
helps avoid warranty claims and badwill that could jeopardise future sales.
No more missed screws
A missing screw can effectively
sabotage product quality.
While a conventional tool gives
no indication that a screw is
missing, Tensor DL counts the
screws and signals Batch OK.
Correct torque every time
with fewer tools
Tensor DL always applies the
correct torque, thus avoiding
loose screws or broken parts.
Up to 10 parameter sets can
be programmed to handle
different torques and types of
joint. A bit selector can be
used to select the correct
torque setting automatically
when the operator picks a
screw bit.
4
Premature shut-off,
a thing of the past
Every assembly process involves
the risk of human error.
Shutting off the tool before
reaching the correct torque
is a typical example. Unlike
conventional tools, Tensor DL
helps the operator detect early
shut-off by means of lamps on
the tool and on the DL Drive.
Tightening is correct only when
the green signal lamp lights.
The right screws and
washers every time
An assembly station usually
has a variety of different
screws and washers. If they
are mixed up or a washer goes
missing, Tensor DL identifies
Are electric tools worth the investment?
Absolutely, and we can prove it! During their long
working lives, Tensor DL screwdrivers will pay for
themselves many times over and raise the profitability
of your operation. You can also replace as many as
10 conventional tools with one Tensor DL.
the error by detecting variations
in the tightening angle.
The tool then signals a NOK
tightening, preventing a defective
product from leaving
the factory and reaching the
end-customer.
Forget stripped screws
When working with sheet
metal screws, if a self-tapping
screw enters the hole at the
wrong angle, or the thread
gets stripped, Tensor DL
signals that the screw has not
been correctly tightened.
Good repeatability
For consistent tightening
results on both hard and soft
joints day after day, it is often
necessary to use two conventional
tools, one for each type
of joint. Tensor DL gives
good repeatability by using a
different parameter set for
each type of joint. Since torque
is determined electronically,
there is no extra wear on
mechanical components even
after years of service.

…let Tensor DL do the counting!
5

Productivity
Tensor DL leads the way…
Keep ahead of the game – raise the productivity of your small-screw
assembly operation! The Tensor DL system comprises a state-of-the-art
Tensor screwdriver and a DL Drive. Unbeatable performance and a range
of unique features make it the optimum tool for small-screw assembly
operations on the work bench or production line.
Fast, accurate tightening
Tensor DL is fast – so fast
that you will notice a marked
increase in your overall productivity.
Unlike a pneumatic tool,
Tensor DL maintains a given
speed even under increasing
torque load. High torque precision
gives high quality endproducts
with fewer rejects.
Tune the system
to the process
All assembly processes are
different, so why should the
tool always operate within
6
Carbon fibre torque arm
Lightweight carbon fibre arm gives
operator optimum performance
the same parameters? Using
programming software, Tensor
DL can easily be configured
for optimum performance in a
specific application.
A better working
environment
Tensor DL’s electric motor is
significantly quieter than that
of a pneumatic tool. In addition,
there is no risk of the
workpiece being damaged by
oil contamination from the
exhaust air. Work-related
operator health and safety
issues will also be reduced
thanks to the ergonomic soft
action of the Tensor DL.
Fast payback
With Tensor DL, superior
productivity, combined with
process security and low
operating costs, mean a fast
payback of the initial tool
investment.
Configurable
push-to-start
For fast, accurate
tool triggering.
Ready for screw-feeding
For increased productivity
Tool front lights
Powerful lights
guide the operator.

…others follow!
Tensor DL Drive – the brain of the system
The DL Drive powers the screwdriver, controls the
tightening process, monitors the assembly process and
guides the operator to ensure the task is performed
“right first time”. The DL Drive communicates easily
with external sensors and PLCs for line control
functionality, and is designed to interface with accessories
such as bit selectors and audible and visible alarms.
ESD certified
Tensor DL is certified against
electrostatic discharges, ESD.
This is your guarantee against
damage to electrical components
caused by ESDs from
the tool in your plant.
High-performance motor
High speed Tensor motor
with wide torque range
gives shorter cycle times.
Low noise level:

Flexibility
One tool – several
applications!
One Tensor DL can be used for a variety of applications.
This reduces operating costs and allows a cleaner design
of the work area.
Replace up to 10
conventional tools
By using different torque
settings or parameter sets
on the Tensor DL, you can
work with the ideal torque
setting for every application.
Thus, you can use one
Tensor DL system where
you previously used several
conventional tools.
8
Guiding the operator
The bit selector guides the
operator by automatically
selecting the correct torque
setting when the operator
selects a bit. This prevents
incorrect assembly and speeds
up the time it takes for the
operator to learn the task.
The bit selector is available in
two versions: four or eight bit
capacity.
True flexibility in production
With product life-cycles continuously decreasing, flexible
production resources are essential. Tensor DL is easily
reprogrammed to handle changes in production.
Auto Set
The simplest and fastest
way to configure the system.
Select the final torque on the
DL Drive and, after 5-8 tightenings,
the Auto Set function will
automatically determine the
optimum settings.
ToolsTalk
All tool functions can easily be
configured by using ToolsTalk,
Atlas Copco’s programming
software. A computer is
Bit selectors, 4 or 8 positions.
connected to the Drive and
the intuitive software allows
the user to configure the entire
system in a short time.

Tensor DL – the ideal tool
for your assembly operation
Electronics
Designed to meet the demands of the electronics
industry, the Tensor DL system can be used for selftapping
screws and ESD applications. A batch counting
function eliminates missed screws and the tool top
speed ensures a high level of productivity.
White goods
By replacing conventional hand-held screwdrivers in the
white goods industry, Tensor DL will speed up production
and raise end-product quality. It matches up to the
industry’s high demands in terms of production flexibility
and tool commonality.
Motor vehicle industry
The motor vehicle industry is often seen as leading
development in the assembly field. With its communication
and advanced error proofing possibilities, Tensor DL
meets the requirements of this demanding industry.
Aerospace industry
The aerospace industry is characterized by its intense
focus on safety. Tensor DL helps aerospace manufacturers
achieve their goal of zero fault production. The tool
can also be equipped with special attachments to handle
many aerospace specific joints.
9

Cutting costs and improving quality at Johnson Controls
Tensor DL ensures process
security at Viessmann
Among the first to use the
new Tensor DL screwdriver is
German heating component
manufacturer Viessmann. At
the company’s assembly plant
in Allendorf/Eder (north of
Marburg), Tensor DL is used
to fit 80 burners per shift to
condensing boilers.
10
Manfred Pinhard, responsible
for design and resource planning
at Viessmann Werke
GmbH & Co., chose the
Tensor DL “in order to ensure
process security even at low
torques”. He also appreciates
the fact that the screwdriver
configuration can “easily be
programmed or reprogrammed
on a laptop at any time”.
Johnson Controls is a major
supplier of integrated seating
and interior systems for the
automotive industry. At Lakewood
in Michigan, USA, the
company produces headliners
for large car manufacturers.
Prevailing torque, different
screw lengths, and varying
joint types are typical
challenges the production
engineers face when planning
the assembly process. “This
previously led to problems
such as cross threads, missing
components and damaged
parts,” states manufacturing
engineer Phil Green.
Several Tensor DL systems
were introduced, allowing for
integration to the line. Johnson
Demag Cranes & Components is the world
market leader for cranes and hoists. Its Wetter/Ruhr
facility manufactures both electric
hoists and other hoist and crane types. In an
effort to reduce the large amount of pneumatic
tools needed to assemble the many
different models, the company invested in
several Tensor DL systems. High uptime and
Controls now has full line
control and feedback.
Six conventional tools were
replaced with only three
Tensor DL systems per
station.
Phil Green explains that the
new tools have improved
quality control and taken away
the need for final inspections.
The investment paid off in less
than eight weeks by eliminating
assembly problems, cutting
preventive maintenance
service costs by 70%, and
reducing downtime. “The
ability to change rundown
speed and torque settings
with the tool has given me
the flexibility we never had
before,” he says.
Four sets of screws, comprising 15 Allen screws in four
sizes, are tightened to a specific angle and torque within
±10% over 6 Sigma. The screws are tightened using
just one Tensor DL at different torques of 5.1 Nm and
below. The bit selector tells the operator which tightening
parameters apply as each respective screw bit is selected.
Lifting quality and lowering costs
at Demag
lowest “total” cost are of great importance
for Demag when investing in tools. Atlas
Copco also provides regular preventive
maintenance on the tools, giving Demag no
unexpected or costly repairs. In addition
Demag has significantly reduced downtime,
lower inventory costs and higher quality in
their production processes.

Tensor DL Drive
Atlas Copco supports a pay-perfunction
philosophy for our Drive
technology. Therefore, the DL Drive
is available in two different versions,
depending on the user requirements.
The Advanced Drive features error
proofing, line control capabilities,
and the possibility to connect
accessories for expanded operator
guidance. The Advanced Drive can
be programmed to handle 10 different
parameter sets (P-sets).
For users not requiring the functionality
of the Advanced Drive,
Atlas Copco also offers the Basic
Drive. This version carries all the
functionality of the Advanced Drive,
except for line control and the connection
of accessories such as
socket selectors and RE-alarms.
One P-set can be programmed on
the Basic Drive.
Tightening strategies
The DL has a variety of tightening
strategies to handle different joint
characteristics. The rotate spindle
function of the Advanced Drive
enables the tool to spin a predetermined
number of turns.
External communication
PLCs and other auxiliary systems
are easily connected using the digital
inputs and outputs (I/O) of the DL.
The I/O bus is used to connect
accessories such as the Socket
Selector or RE-alarm.
DL Functionality Basic Advanced
Number of P-sets 1 10
Batch count X X
OK relay X X
NOK relay X X
nxOK relay X X
Reset batch input X X
Decrement batch input X X
Autoset X X
Real time programming X X
Quick programming X X
Torque tuning X X
Tool signal lights X X
Tools service indicator X X
CCW tightening direction X X
Rundown monitoring X X
Lock on reject X X
Socket tray/selector X
RE-alarm X
Strategies and options Basic Advanced
Two step X X
Quick step X X
Ergoramp X X
Auto Zoom step X X
Self tap X X
High speed rundown X X
Rotate spindle X
Self tap/PVT monitoring X X
Torque ctrl/angle monitoring X X
Rundown angle monitoring X X
Communication Basic Advanced
Up to 8 I/O’s X
PLC functions X
Line control X
I/O bus X
RS 232 X X
4 dig I/O X X
Remote start X X
Model Ordering number
D303-DL Basic 8433 4850 48
D313-DL Advanced 8433 4850 33
11

Tensor DL screwdrivers
Torque range Speed Weight Length CS distance Stroke
Model
STRAIGHT TOOLS
Lever start
Nm in lbs r/min kg lb mm mm mm Ordering no.
ETD DL21-04-I06 1–4 8.8–35.4 1 600 0.6 1.3 235 18/19.5 (1)
- 8433 4014 25
ETD DL21-07-I06 2.2–7.5 19.5–66 970 0.6 1.3 235 18/19.5 (1)
- 8433 4017 31
ETD DL21-10-I06 3–10 26.6–88.5 720 0.6 1.3 235 18/19.5 (1)
- 8433 4019 10
Push-to-start and front lights
ETD DL21-01-I06-PS 0.3–1.2 2.6–10 2 200 0.6 1.3 243 18/19.5 (1)
ETD DL21-04-I06-PS 1–4 8.8–35.4 1 600 0.6 1.3 242 18/19.5 (1)
ETD DL21-07-I06-PS 2.2–7.5 19.5–66 970 0.6 1.3 242 18/19.5 (1)
ETD DL21-10-I06-PS 3–10 26.6–88.5 720 0.6 1.3 242 18/19.5 (1)
Fixtured tools (lever start or remote start)
ETF DL21-01-I06 0.3–1.2 2.6–10 2 200 0.7 1.5 328 18/19.5 (1)
ETF DL21-04-I06 1–4 8.8–35.4 1 600 0.7 1.5 328 18/19.5 (1)
ETF DL21-07-I06 2.2–7.5 19.5–66 970 0.7 1.5 328 18/19.5 (1)
ETF DL21-10-I06 3–10 26.6–88.5 720 0.7 1.5 328 18/19.5 (1)
1) x/y; x=CS distance without handle, y=CS distance with handle
All models: • Are reversible • Female hexagon drive for bits: 1/4" • Have quick change chuck
RIGHT ANGLE TOOLS
Lever start
ETV DL21-04-I06 1–4 8.8–35.4 1 600 0.7 1.5 268 9 (2)
ETV DL21-04-I06-QC 1–4 8.8–35.4 1 600 0.7 1.5 268 9 (2)
ETV DL21-04-06 1–4 8.8–35.4 1 600 0.7 1.5 268 9 (2)
ETV DL21-07-I06 2.2–7.5 19.5–66 970 0.7 1.5 268 9 (2)
ETV DL21-07-I06-QC 2.2–7.5 19.5–66 970 0.7 1.5 268 9 (2)
ETV DL21-07-06 2.2–7.5 19.5–66 970 0.7 1.5 268 9 (2)
ETV DL21-10-I06 3–12 26.6–106.2 610 0.7 1.5 281 11 (2)
ETV DL21-10-I06-QC 3–12 26.6–106.2 610 0.7 1.5 281 11 (2)
ETV DL21-10-06 3–12 26.6–106.2 610 0.7 1.5 281 11 (2)
2) CS distance over angle head
Accessories
Tool cable 3 m 4220 2604 03
5 m 4220 2604 05
10 m 4220 2604 10
Selector 4 8433 0610 04
Selector 8 8433 0610 08
RE-alarm 8433 0560 03
I/O expansion box 8433 0564 38
Extension cable 3 m 4220 2795 03
5 m 4220 2795 05
10 m 4220 2795 10
Pistol grip handle 4220 2743 90
Can be fitted on all straight models.
I/O bus cable 0.5 m 4222 0470 00
1 m 4222 0470 01
3 m 4222 0470 03
5 m 4222 0470 05
10 m 4222 0470 10
15 m 4222 0470 15
ToolsTalk DS/DL software 8092 1138 62
(includes programming cable)
I/O termination plug 4222 0443 00
Rotary selector 8433 0606 15
Selector adapter cable 4222 0417 00
- 8433 4010 89
- 8433 4014 91
- 8433 4017 69
- 8433 4019 25
- 8433 4040 04
- 8433 4042 13
- 8433 4043 22
- 8433 4044 11
- 8433 4004 47
- 8433 4004 73
- 8433 4004 91
- 8433 4007 66
- 8433 4007 79
- 8433 4007 94
- 8433 4009 34
- 8433 4009 61
- 8433 4009 77
PISTOL GRIP TOOLS
Lever start
ETP DL21-04-I06 1–4 8.8–35.4 1 600 0.6 1.3 235 18/19.5 - 8433 4024 19
ETP DL21-07-I06 2.2–7.5 19.5–66 970 0.6 1.3 235 18/19.5 - 8433 4027 26
ETP DL21-10-I06 3–10 26.6–88.5 720 0.6 1.3 235 18/19.5 - 8433 4029 13
Pistol grip (push-to-start and front lights)
ETP DL21-01-I06-PS-H 0.3–1.2 2.6–10 2 200 0.6 1.3 243 18/19.5 - 8433 4020 77
ETP DL21-04-I06-PS-H 1–4 8.8–35.4 1 600 0.6 1.3 243 18/19.5 - 8433 4024 66
ETP DL21-07-I06-PS-H 2.2–7.5 19.5–66 970 0.6 1.3 243 18/19.5 - 8433 4027 53
ETP DL21-10-I06-PS-H 3–10 26.6–88.5 720 0.6 1.3 243 18/19.5 - 8433 4029 28
Tool key
Electric shut-off
• ETD = In line
• ETV = Right angle
Torque [Nm]
ETD DL 2 X 07 Y 06 Z
Technology
• D = DigiTork control
• L = Low voltage Motor size Generation
Front part
• I = Female Hex
Square drive size
• 06 = 1/4
• 10 = 3/8
Options
• QC = Quick change chuck
• PS = Push-to-start
• H = Handle
www.atlascopco.com
9833 1440 01 BOARDWALK 2007:1 Strokirk-Landströms AB