Tensor DL screwdriversWhere every fastener counts!

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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

Choose Tensor DL and get it right…

SECURITY

PRODUCTIVITY

FLEXIBILITY

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 programmedto handle different torques and types of joint

• Replace up to 10 conventional tools with one Tensor DL

• System is easily reprogrammed to allow forchanges in production

Light, powerful, intelligent, Tensor DL is the screw tighteningsystem that will keep you ahead. Its unmatched performancein terms of speed, accuracy and process control will raise productivity to a new level in your plant, while helping you tocut assembly costs.

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…first time, every time!

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Where every fastener counts…

Controlled tightening cuts assembly costs by detecting errors. Tensor DLwill bring you closer to zero fault production than ever before. By alertingthe operator to the most common errors before they continue down the line, the system ensures high quality end-products, and saves you afortune in reworking costs. Most important of all, controlled tighteninghelps avoid warranty claims and badwill that could jeopardise future sales.

No more missed screws

A missing screw can effect-ively sabotage product quality.While a conventional tool givesno indication that a screw ismissing, Tensor DL counts thescrews and signals Batch OK.

Correct torque every timewith fewer tools

Tensor DL always applies thecorrect torque, thus avoidingloose screws or broken parts.Up to 10 parameter sets canbe programmed to handledifferent torques and types ofjoint. A bit selector can beused to select the correcttorque setting automaticallywhen the operator picks ascrew bit.

Premature shut-off, a thing of the past

Every assembly process in-volves the risk of human error.Shutting off the tool beforereaching the correct torque is a typical example. Unlikeconventional tools, Tensor DLhelps the operator detect earlyshut-off by means of lamps onthe tool and on the DL Drive.Tightening is correct only whenthe green signal lamp lights.

The right screws and washers every time

An assembly station usuallyhas a variety of differentscrews and washers. If theyare mixed up or a washer goesmissing, Tensor DL identifies

the error by detecting varia-tions in the tightening angle.The tool then signals a NOKtightening, preventing a de-fective product from leavingthe factory and reaching theend-customer.

Forget stripped screws

When working with sheetmetal screws, if a self-tappingscrew enters the hole at thewrong angle, or the threadgets stripped, Tensor DLsignals that the screw has notbeen correctly tightened.

Good repeatability

For consistent tightening results on both hard and softjoints day after day, it is oftennecessary to use two conven-tional tools, one for each typeof joint. Tensor DL gives good repeatability by using adifferent parameter set foreach type of joint. Since torqueis determined electronically,there is no extra wear onmechanical components evenafter years of service.

Secu

rity

Are electric tools worth the investment?

Absolutely, and we can prove it! During their longworking lives, Tensor DL screwdrivers will pay for themselves many times over and raise the profitabilityof your operation. You can also replace as many as10 conventional tools with one Tensor DL.

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…let Tensor DL do the counting!

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Fast, accurate tightening

Tensor DL is fast – so fast that you will notice a markedincrease in your overall produc-tivity. Unlike a pneumatic tool,Tensor DL maintains a givenspeed even under increasingtorque load. High torque pre-cision gives high quality end-products with fewer rejects.

Tune the system to the process

All assembly processes aredifferent, so why should thetool always operate within

the same parameters? Usingprogramming software, TensorDL can easily be configured for optimum performance in aspecific application.

A better working environment

Tensor DL’s electric motor issignificantly quieter than thatof a pneumatic tool. In addi-tion, there is no risk of theworkpiece being damaged byoil contamination from theexhaust air. Work-related operator health and safety

Tensor DL leads the way…

Keep ahead of the game – raise the productivity of your small-screwassembly operation! The Tensor DL system comprises a state-of-the-artTensor screwdriver and a DL Drive. Unbeatable performance and a rangeof unique features make it the optimum tool for small-screw assemblyoperations on the work bench or production line.

Prod

uctiv

ity

Ready for screw-feeding

For increased productivity

Tool front lights

Powerful lightsguide the operator.

Configurable push-to-start

For fast, accurate tool triggering.

issues will also be reducedthanks to the ergonomic softaction of the Tensor DL.

Fast payback

With Tensor DL, superiorproductivity, combined withprocess security and lowoperating costs, mean a fastpayback of the initial toolinvestment.

Carbon fibre torque arm

Lightweight carbon fibre arm givesoperator optimum performance

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Industrial electrical contact, small diameter cable

Maximum flexibility of movement for the operator. Robust electricalcontact does not weaken and break.

Excellentergonomics

High power-to-weightratio. A 10 Nm toolweighs only 0.6 kg.Operator-friendlytrigger and soft-griphandle.

High-performance motor

High speed Tensor motorwith wide torque rangegives shorter cycle times.Low noise level: <70 dBA.

Signal lights

Red light ensures imme-diate detection of NOKtightenings by the operator.

DigiTork™

The highly accurate,patented digital torquecontrol concept has a verysoft action, preventingshock damage to com-ponents, screws and bits.

Tensor DL Drive – the brain of the system

The DL Drive powers the screwdriver, controls thetightening process, monitors the assembly process andguides the operator to ensure the task is performed“right first time”. The DL Drive communicates easilywith external sensors and PLCs for line controlfunctionality, and is designed to interface with access-ories such as bit selectors and audible and visible alarms.

ESD certified

Tensor DL is certified againstelectrostatic discharges, ESD.This is your guarantee againstdamage to electrical compo-nents caused by ESDs fromthe tool in your plant.

Function button

The configurable functionbutton can be set up fordifferent reverse modesand toggling betweenparameter sets.

…others follow!

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One tool – severalapplications! One Tensor DL can be used for a variety of applications.This reduces operating costs and allows a cleaner designof the work area.

Replace up to 10 conventional tools

By using different torquesettings or parameter sets on the Tensor DL, you canwork with the ideal torquesetting for every application.Thus, you can use one Tensor DL system where you previously used severalconventional tools.

Guiding the operator

The bit selector guides theoperator by automaticallyselecting the correct torquesetting when the operatorselects a bit. This preventsincorrect assembly and speedsup the time it takes for theoperator to learn the task. The bit selector is available intwo versions: four or eight bitcapacity.

True flexibility in production With product life-cycles continuously decreasing, flexibleproduction resources are essential. Tensor DL is easilyreprogrammed to handle changes in production.

Auto Set

The simplest and fastestway to configure the system.Select the final torque on theDL Drive and, after 5-8 tighten-ings, the Auto Set function willautomatically determine theoptimum settings.

ToolsTalk

All tool functions can easily beconfigured by using ToolsTalk,Atlas Copco’s programmingsoftware. A computer is

Bit selectors, 4 or 8 positions.

Flex

ibili

ty

connected to the Drive and the intuitive software allowsthe user to configure the entiresystem in a short time.

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White goodsBy replacing conventional hand-held screwdrivers in thewhite goods industry, Tensor DL will speed up produc-tion and raise end-product quality. It matches up to theindustry’s high demands in terms of production flexi-bility and tool commonality.

ElectronicsDesigned to meet the demands of the electronics industry, the Tensor DL system can be used for self-tapping screws and ESD applications. A batch countingfunction eliminates missed screws and the tool topspeed ensures a high level of productivity.

Aerospace industryThe aerospace industry is characterized by its intensefocus on safety. Tensor DL helps aerospace manufactu-rers achieve their goal of zero fault production. The toolcan also be equipped with special attachments to handlemany aerospace specific joints.

Motor vehicle industryThe motor vehicle industry is often seen as leadingdevelopment in the assembly field. With its communica-tion and advanced error proofing possibilities, Tensor DLmeets the requirements of this demanding industry.

Tensor DL – the ideal tool for your assembly operation

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Tensor DL ensures processsecurity at ViessmannAmong the first to use thenew Tensor DL screwdriver isGerman heating componentmanufacturer Viessmann. Atthe company’s assembly plantin Allendorf/Eder (north ofMarburg), Tensor DL is used to fit 80 burners per shift tocondensing boilers.

Manfred Pinhard, responsiblefor design and resource plan-ning at Viessmann WerkeGmbH & Co., chose the Tensor DL “in order to ensureprocess security even at lowtorques”. He also appreciatesthe fact that the screwdriverconfiguration can “easily beprogrammed or reprogrammedon a laptop at any time”.

Cutting costs and improving quality at Johnson Controls

Johnson Controls is a majorsupplier of integrated seatingand interior systems for theautomotive industry. At Lake-wood in Michigan, USA, thecompany produces headlinersfor large car manufacturers.

Prevailing torque, differentscrew lengths, and varyingjoint types are typical challenges the productionengineers face when planningthe assembly process. “Thispreviously led to problemssuch as cross threads, missingcomponents and damagedparts,” states manufacturingengineer Phil Green.

Several Tensor DL systemswere introduced, allowing forintegration to the line. Johnson

Controls now has full linecontrol and feedback. Six conventional tools were replaced with only three Tensor DL systems per station.

Phil Green explains that thenew tools have improvedquality control and taken awaythe need for final inspections.The investment paid off in lessthan eight weeks by eliminat-ing assembly problems, cuttingpreventive maintenance service costs by 70%, andreducing downtime. “Theability to change rundownspeed and torque settings with the tool has given methe flexibility we never hadbefore,” he says.

Four sets of screws, comprising 15 Allen screws in foursizes, 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 andbelow. The bit selector tells the operator which tighteningparameters apply as each respective screw bit is selected.

Demag Cranes & Components is the worldmarket leader for cranes and hoists. Its Wet-ter/Ruhr facility manufactures both electrichoists and other hoist and crane types. In aneffort to reduce the large amount of pneu-matic tools needed to assemble the manydifferent models, the company invested inseveral Tensor DL systems. High uptime and

lowest “total” cost are of great importancefor Demag when investing in tools. AtlasCopco also provides regular preventivemaintenance on the tools, giving Demag nounexpected or costly repairs. In additionDemag has significantly reduced downtime,lower inventory costs and higher quality intheir production processes.

Lifting quality and lowering costsat Demag

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Atlas Copco supports a pay-per-function philosophy for our Drivetechnology. Therefore, the DL Driveis available in two different versions,depending on the user requirements. The Advanced Drive features errorproofing, line control capabilities, and the possibility to connect accessories for expanded operatorguidance. The Advanced Drive can be programmed to handle 10 differ-ent parameter sets (P-sets).

For users not requiring the func-tionality of the Advanced Drive, Atlas Copco also offers the BasicDrive. This version carries all the functionality of the Advanced Drive,except for line control and the con-nection of accessories such assocket selectors and RE-alarms. One P-set can be programmed onthe Basic Drive.

Tightening strategies

The DL has a variety of tighteningstrategies to handle different jointcharacteristics. The rotate spindlefunction of the Advanced Driveenables the tool to spin a predeter-mined number of turns.

External communication

PLCs and other auxiliary systems are easily connected using the digitalinputs and outputs (I/O) of the DL.The I/O bus is used to connect accessories such as the SocketSelector or RE-alarm.

Tensor DL Drive

DL Functionality Basic AdvancedNumber of P-sets 1 10Batch count X XOK relay X XNOK relay X XnxOK relay X XReset batch input X XDecrement batch input X XAutoset X XReal time programming X XQuick programming X XTorque tuning X XTool signal lights X XTools service indicator X XCCW tightening direction X XRundown monitoring X XLock on reject X XSocket tray/selector XRE-alarm X

Strategies and options Basic AdvancedTwo step X XQuick step X XErgoramp X XAuto Zoom step X XSelf tap X XHigh speed rundown X XRotate spindle XSelf tap/PVT monitoring X XTorque ctrl/angle monitoring X XRundown angle monitoring X X

Communication Basic Advanced

Up to 8 I/O’s XPLC functions XLine control XI/O bus XRS 232 X X4 dig I/O X XRemote start X X

Model Ordering number

D303-DL Basic 8433 4850 48D313-DL Advanced 8433 4850 33

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www.atlascopco.com

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I/O bus cable 0.5 m 4222 0470 001 m 4222 0470 013 m 4222 0470 035 m 4222 0470 05

10 m 4222 0470 1015 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 15Selector adapter cable 4222 0417 00

Accessories

Tensor DL screwdrivers

Tool cable 3 m 4220 2604 035 m 4220 2604 05

10 m 4220 2604 10

Selector 4 8433 0610 04Selector 8 8433 0610 08

RE-alarm 8433 0560 03

I/O expansion box 8433 0564 38

Extension cable 3 m 4220 2795 035 m 4220 2795 05

10 m 4220 2795 10

Pistol grip handle 4220 2743 90Can be fitted on all straight models.

Torque range Speed Weight Length CS distance StrokeModel Nm in lbs r/min kg lb mm mm mm Ordering no.

STRAIGHT TOOLSLever startETD DL21-04-I06 1–4 8.8–35.4 1 600 0.6 1.3 235 18/19.5(1) - 8433 4014 25ETD DL21-07-I06 2.2–7.5 19.5–66 970 0.6 1.3 235 18/19.5(1) - 8433 4017 31ETD 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 lightsETD DL21-01-I06-PS 0.3–1.2 2.6–10 2 200 0.6 1.3 243 18/19.5(1) - 8433 4010 89ETD DL21-04-I06-PS 1–4 8.8–35.4 1 600 0.6 1.3 242 18/19.5(1) - 8433 4014 91ETD DL21-07-I06-PS 2.2–7.5 19.5–66 970 0.6 1.3 242 18/19.5(1) - 8433 4017 69ETD DL21-10-I06-PS 3–10 26.6–88.5 720 0.6 1.3 242 18/19.5(1) - 8433 4019 25

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) - 8433 4040 04ETF DL21-04-I06 1–4 8.8–35.4 1 600 0.7 1.5 328 18/19.5(1) - 8433 4042 13ETF DL21-07-I06 2.2–7.5 19.5–66 970 0.7 1.5 328 18/19.5(1) - 8433 4043 22ETF DL21-10-I06 3–10 26.6–88.5 720 0.7 1.5 328 18/19.5(1) - 8433 4044 111) 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 TOOLSLever startETV DL21-04-I06 1–4 8.8–35.4 1 600 0.7 1.5 268 9(2) - 8433 4004 47ETV DL21-04-I06-QC 1–4 8.8–35.4 1 600 0.7 1.5 268 9(2) - 8433 4004 73ETV DL21-04-06 1–4 8.8–35.4 1 600 0.7 1.5 268 9(2) - 8433 4004 91ETV DL21-07-I06 2.2–7.5 19.5–66 970 0.7 1.5 268 9(2) - 8433 4007 66ETV DL21-07-I06-QC 2.2–7.5 19.5–66 970 0.7 1.5 268 9(2) - 8433 4007 79ETV DL21-07-06 2.2–7.5 19.5–66 970 0.7 1.5 268 9(2) - 8433 4007 94ETV DL21-10-I06 3–12 26.6–106.2 610 0.7 1.5 281 11(2) - 8433 4009 34ETV DL21-10-I06-QC 3–12 26.6–106.2 610 0.7 1.5 281 11(2) - 8433 4009 61ETV DL21-10-06 3–12 26.6–106.2 610 0.7 1.5 281 11(2) - 8433 4009 772) CS distance over angle head

PISTOL GRIP TOOLSLever startETP DL21-04-I06 1–4 8.8–35.4 1 600 0.6 1.3 235 18/19.5 - 8433 4024 19ETP DL21-07-I06 2.2–7.5 19.5–66 970 0.6 1.3 235 18/19.5 - 8433 4027 26ETP 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 77ETP DL21-04-I06-PS-H 1–4 8.8–35.4 1 600 0.6 1.3 243 18/19.5 - 8433 4024 66ETP DL21-07-I06-PS-H 2.2–7.5 19.5–66 970 0.6 1.3 243 18/19.5 - 8433 4027 53ETP DL21-10-I06-PS-H 3–10 26.6–88.5 720 0.6 1.3 243 18/19.5 - 8433 4029 28

ETD DL 2 X 07 Y 06 Z

Torque [Nm]Front part• I = Female Hex

Options• QC = Quick change chuck• PS = Push-to-start• H = Handle

Technology• D = DigiTork control• L = Low voltage Motor size Generation

Square drive size• 06 = 1/4• 10 = 3/8

Electric shut-off• ETD = In line• ETV = Right angle

Tool key

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