HydrAulic tigHtening tecHnology for All fAstening

Transcription

Perfect tightening solutions
Hydraulic tightening technology
for all fastening elements
Fast.
Safe.
Accurate.
ANSI B18.22
ANSI B16.5
ASTM A193
ASTM A194
EN14399
DIN2510
ISO4762
ISO4014
ISO4017
DIN976
DIN939
2
3
Bolts are by far the most important detachable joints in mechanical and
plant engineering and the automotive industry. More than two thirds of
all detachable joints are tightened by means of bolts. In Germany alone,
more than 50 billion bolts are used every year. The vast majority of
these bolts are smaller than M12; however, the number of large bolts is
constantly increasing, because the trend of the past decade is towards
ever larger machines and plants for economic reasons.
Nowadays, construction machines, airplanes, power plants, turbines and
even bridges and multistory buildings are designed at magnitudes that
would have been impossible only a few years ago. For these magnified
dimensions, correspondingly larger fastening elements are required and
the existing bolted joints must have a higher performance and therefore
a higher and more accurate preload.
HYTORC, the world's leading manufacturer of bolting technology,
develops ever new and more efficient tools, fastening elements and
tightening processes in order to offer higher efficiency, profitability,
safety and quality to its customers around the world.
Contents
b Assembly of flange joints
compliant with TA Luft using
the DISC washer for sustainably
tight flange joints.
page
Bolting Technology made by HYTORC
4
Perfect Bolting Technology
6
Industries and Applications
8
Hydraulic Square Drives – Type AVANTI
10
Hydraulic Square Drives – Type ICE
14
Hydraulic Square Drives – Type MXT
16
Hydraulic Square Drives – Type EDGE
18
Hydraulic Exchangeable Link Drives – Type STEALTH
20
Hydraulic Exchangeable Link Drives – Type XLCT
24
Hydraulic Exchangeable Link Drives – Type VERSA
26
Accessories for Hydraulic Wrenches
28
Cleaners for Male and Female Threads
32
HYTORC Lubricants
34
Standard Fastening Elements – Bolts, Nuts, Studs
35
Innovative Fastening Elements – SmartDISK zWasher,
DISC hexagon washer, CLAMP tension nut, SmartSTUD, JustBolt
36
Field-Tested Hydraulic Power Packs
38
Innovative Hydraulic Aggregates with Eco2Touch Control
40
Overview of Bolting Methods
44
HYTORC Services
48
HYTORC Trainings
52
HYTORC Industrial Bolting
54
4
4
Bolting technology
made by HYTORC.
• Comprehensive range of products
• Many years of application expertise
• Innovative, customized fastening
solutions for any application
• Certified according to ISO 9001 and
regulation 1401 by KTA
• Customer-oriented sales
• Services and solutions
Hytorc Bolting Technology
5
The best solution:
Innovative technology and
intelligent processes for
perfect fastening quality.
HYTORC is the leading manufacturer of bolting technology and a reliable
partner of many industries. With our wide range of products, highest
quality standards, unique services and valuable expertise, we find the
best solution to your bolted connections, even to the most demanding
applications.
HYTORC develops and manufactures innovative
solutions to detachable joints. By providing
reliably fast tools and assembly systems, we
make an important contribution to the highest
compatibility in the industries of mechanical and
plant engineering, automotive, energy,
chemistry, petro chemistry and wind power.
We identify the perfect solution for you from the
world's most comprehensive range of bolting
technology equipment and customize it to meet
your requirements:
•Hydraulic torque wrenches
•Pneumatic torque wrenches
•Electric torque wrenches
•Patented fastening elements
•Innovative bolting processes
•Intelligent system control
b AVANTI-10 SIMULTORC during flange assembly
Thanks to the portfolio listed above and our
core competences – product development,
engineering and system consulting – our
expertise in industrial bolting is unparalleled
and unique worldwide.
With safe and user-friendly systems and
practice-oriented solutions, we help you design
perfect bolted connections with regards to costs,
quality, productivity and machine availability
during the planning phase. This gives you a
decisive advantage and is the reason why many
leading companies have valued us as a partner
for many years.
Make HYTORC part of your solution
in bolting technology!
6
The best bolting technology
Made by HYTORC
HYTORC offers the entire range of hydraulic bolting technology with all tightening processes
according to VDI2230, innovative fastening elements and customer-oriented services.
Fast, safe, innovative.
HYTORC offers the entire range of hydraulic bolting technology with all
tightening processes according to VDI2230 (Systematic calculation of
high duty bolted joints – joints with one cylindrical bolt), innovative
fastening elements and customer-oriented services.
Fast, safe, innovative.
c Awarded as Top Innovator
in 2013
The HYTORC headquarters for Germany, Austria, Switzerland as well
as Turkey and Azerbaijan is located in Krailing near Munich, Germany.
Since 1985, HYTORC has been marketed by the trading company
Barbarino & Kilp GmbH, a company with a successful history of more
than 275 years that has consistently developed the HYTORC brand.
Our team currently comprises approx. 40 employees in the
headquarters in Krailing and distribution and service sites. This team
structure allows the highest efficiency in engineering, administration,
processing and logistics from the headquarters as well as individual
customer services on site from the various local offices.
c Certified according to ISO 9001 and ISO 29990
Our customers value our strictly customer- and service oriented
working methods. For example, HYTORC has its own calibration
center for pressure, torque and preload force. Our CAD center which
supports our customers already during the planning phase, allows us
to make customized designs and provide constructive support during
planning. Our perfectly equipped training center for theoretical and
practical training for management, construction, quality assurance
and assembly in Augsburg, Germany, generates certified fastening
expertise within companies. Our portfolio is topped off by our unique
services such as on-site service and flexible financing services.
Welcome to the world of HYTORC!
c A large number of patents demonstrate
that HYTORC develops innovative products
7
HYTORC offers unique services:
. Many years of application expertise since 1968
.
Fast and safe bolting, with a constant friction value
without support-/reaction arm.
Hands-free bolting by remote control also for overhead
applications, in explosion risk zones (ATEX certified)
and for fastening under water.
.
Intelligent hydraulic bolting technology in the sense
of Industry 4.0
The HYTORC system meets all the minimum
requirements from VDI/VDE 2862-2 and more:
Safe assembly processes thanks to optimum
supervision, transparency of systems, system analysis,
bolt administration and visualization of process data.
.
Sustainably tight flange connections with especially
low leakage rates
Instead of a product loss of 14.2 kg per year and meter
when tightening manually, a product loss up to 0.1 kg
per year and meter is now possible thanks to
simultaneous use of several hydraulic torque wrenches
at the same time and one of our five fastening
elements with a constant friction value.
.
No-maintenance bolt connections Nominal preload forces can be increased effortlessly
by using one of our five fasteners with a constant
friction value and/or intelligent, reliable bolting
processes such as the stretch-to-yield or the torqueangle controlled tightening method.
. Comprehensive portfolio of products
in the fields of hydraulics, pneumatics, electric and
cordless wrenches from 60 Nm to 190,000 Nm.
.
Standard bolted connections
such as high-quality galvanized screwdriver sets,
anchor bolts, rolled bolt threads up to M200 and up to
18 m length with certificates for any branch of industry.
c HYTORC headquarters in Krailling near Munich, Germany
. Fastening elements with a constant friction value
that do not turn
. Lubricants, anti-seize and metal cleaners
. Cleaners for male and female threads as well as
nut splitters and lifting devices
. Customer-oriented sales
.
On-site service
HYTORC supports you on site with revision and
shut-down support as well as on-site inspections,
tests and recalibrations of your fastening tools for
sustainable improvement of your occupational safety,
ergonomics and quality.
.
Trainings
As a certified provider of training services,
we offer various training modules, e.g. according to
EN 1591-4:2013, ASME-PCC1:2013 or OSHA-7110
at our training center in Augsburg, Germany,
or on your premises.
HYTORC is a one-stop shop for everything
concerning bolted connections.
8
HYTORC fastening solutions
for applications in many industries
With its innovative mobile fastening technologies, HYTORC makes
an important contribution to any branch of industry.
Chemistry / petro-chemistry
Power plants / energy
Wind power
Innovative fastening solutions for
sustainably tight flange connections
in accordance with TA Luft. To the
benefit of the environment and
machine performance.
Fast. Safe. Tight.
Accurate fastening results for all
bolted connections with uninterrupted documentation in order to
reduce down times, revisions and
maintenance works.
Fast. Safe. On the grid.
The fastest torsion-free and most
preload-accurate assembly processes
for the wind energy sector.
From 0 kN to 500 kN in 45 sec. for
fastening incl. documentation.
Fast. Safe. Accurate.
Examples of application:
• Pressurized flanges
• Blowout preventers
• Compressors
• Apparatuses
• Reactors
• Fittings
• Heat exchangers
• Hydrogenation plants
• Catalysts
• Pumps
• Cyclonic separators
• Carburetors
and many more
• Pressurized flanges
• Blowout preventers
• Compressors
• Apparatuses
• Reactors
• Fittings
• Heat exchangers
• Hydrogenation plants
• Catalysts
• Pumps
• Cyclonic separators
• Carburetors
and many more
• Gears
• Tower flange
• Mainframe
• Yaw drive
• Rotor blade
• Foundation bolt
• Main frame
• Clamp set
• Brake pads
• Clamp ring
and many more
9
HYTORC offers unique fastening solutions for various
industries and sectors. We can, for example, pave new
ways in order to save a significant amount of time in
down-times and revisions. In order to make the fastening
process safer for mechanics, HYTORC provides special
tools for hands-free bolting and tensioning without
support arm. This also protects your machines and helps
prevent damage on components and coatings.
Furthermore, flanges can be fastened quickly, safely and
technically tight thanks to HYTORC. With plane-parallel
flange connections we ensure that the TA Luft is met.
This benefits the environment and your business.
Users of HYTORC products can master any challenges with
our unique bolting processes and fastening elements and
can document all of their precise work.
Machine and plant engineering
Automotive
Other branches of industry:
Safe, process-controlled and
documented fastening solutions
in accordance with VDI 2230 for
maximum capacity and perfectly
dimensioned bolt connections.
Fast. Safe. Compliant with standards.
Reliable hydraulic fastening systems in
accordance with VDI/VDE 2862-2 even
for limited clearing applications with
a high risk assessment: hazard for life
and limb or the environment.
Fast. Safe. Documented.
Mining
• Roadway support elements
• Tunnel excavation technology
• Vertical drilling rigs
Shipbuilding and harbor facilities
• Marine diesel engines/large engines
• Shaft couplings in the drive train
• Marine propellers
Steelworks
• Guide- and stability roller fastening
on mill trains
• Cylinders
• Bending presses
• Roll train cassettes on the rolling mill stand
• Forging box, cooling bed
• Containers
• Presses
• Variable displacement pumps
• Cathode and electrolysis furnaces
• Cab fastening
• Support fastening
• Roller slewing rings
• Motor fastening
• Shredding facilities
• Cylinder bolts
• Couplings
• Bucket wheels
and many more
• Wheels and chains
• Module fastening
• Swing gears
• Roller slewing rings
• Chassis
• Drive and output flanges
• Pitman arms
• Transverse control arms
• Sprocket drums
• Towing hitches
• Operating cylinder fastening
• Articulated joints
• Engine mounting
• Crane fastening
and many more
Construction companies
• Construction of buildings, halls
and bridges
Industrial service providers
Elevators and cableways
Public sector customers
• Research institutes
• Universities
• Municipal works
• Military
• Public service providers
10
10
HYTORC hydraulic
square drive tools
These are individually applicable tools
up to 190,000 Nm for any assembly
process in compliance with VDI 2230
and beyond. No matter which assembly
process and fastening elements you
chose – HYTORC square torque wrenches
allow for axial fastening without
support arm – for best performances
and maximum occupational safety.
AVANTI – square drive hydraulic Wrench
11
AVANTI square drive hydraulic wrench
multifunctional and user-friendly
The AVANTI is multifunctional and can be used for torque and tension applications.
With its compact dimensions and robust housing, the AVANTI can be used in any
working environment.
AVANTI – Productivity benefits
• Seven different fastening processes
• Hands-free and safe fastening in combination
with one of five friction-optimized fastening
elements
• Accurate torque transmission to the
connection and optimized initiation of preload
force by reducing the bending moments
• Automatically operating rotation angle control
for constant preload forces
• Continuously variable torque adjustment from
150 Nm to 190,000 Nm
• Reaction arms 360° adjustable around
square axis
• Wide range of applications thanks to
maximum ease of use and compact dimensions.
Also fit for applications under water and in
explosion risk zones.
b Maximum occupational safety
is especially important for overhead fastening
a AVANTI with adjustable
inline reaction fixture
12
c Flange bolting by means of 2x AVANTI-3
c Safe overhead fastening by means of AVANTI-5
c Torque-angle tightening process by means of AVANTI-5
c Torsion-free tensioning of case screws
c Simultaneous flange bolting under water
c Axial torque-controlled tightening by means of AVANTI-10
AVANTI – square drive hydraulic Wrench
13
b Fast, safe, tight: Only one mechanic is needed for
fastening flange connections simultaneously, hands-free
and even overhead in a very short time using several AVANTI.
The DISC washer or the CLAMP tension nut protects the
flange surfaces and ensure perfect transmission of the
required torque value.
AVANTI sets high standards in terms of occupational safety
as it operates on the fitting at the push of a button on a
remote control. Therefore, it eliminates the need to
manually hold the tool in place. Of course this also holds
true for overhead fastening. Thus, even complex flange
connections can be safely closed and opened by only one
mechanic. Calibrated preload forces can be accurately and
easily achieved with the highest repeatability.
H
AVANTI – Features
• Hydraulic connection rotatable by 360° x 180°
• Single-piece, robust tool housing
• Square with integrated pressure cap
• Reaction arm can be positioned at the push
of a button
• Drive pawl system
• Safety screw and plug couplings with dust caps
• Calibration certificate for new deliveries
c AVANTI – Equipment variants
R
L
B
AVANTI – Facts & figures
Model
Torque min.
Torque max.
Square drive
Torque precision
Tool weight
Radius [R]
Length [L]
Height [H]
Width [B]
Nm
Nm
inch
%
kg
mm
mm
mm
mm
AV-0.7
135
1.024
¾
± 2,5
1,8
25,1
77,5
80,5
45,5
AV-1
257
1.767
¾
± 2,5
2,0
28,7
91,2
91,4
55,4
AV-3
584
4.090
1
± 2,5
4,1
38,1
117,9
116,8
73,7
AV-5
1.004
7.013
1½
± 2,5
6,6
45,7
141,2
134,1
85,9
Technical changes are reserved. 3D models in STEP format are available upon request at [email protected]
AV-8
1.508
10.682
1½
± 2,5
9,0
50,0
160,0
157,2
98,0
AV-10
1.893
15.720
1½
± 2,5
12,2
57,2
176,8
167,9
110,0
AV-20
3.618
24.626
2½
± 2,5
21,2
66,0
211,8
192,5
128,8
AV-35
6.496
46.884
2½
± 2,5
37,4
81,0
260,6
229,4
158,2
AV-50
9.413
58.391
2½
± 2,5
57,8
100,3
294,4
255,5
178,8
14
ICE square drive hydraulic wrench
multifunctional, fast and compact
The ICE is based on the AVANTI, features several improvements and sets trends for
hydraulic fastening tools. The ICE is multifunctional and can be used for tightening
to a torque value as well as for expanding to preload force.
ICE – Productivity benefits
• ICE is the world's fastest hydraulic wrench
• Seven different bolting methods
• Hands-free, safe tightening with one of five
friction-optimized fastening elements
• Accurate transmission of torque to the
connection and optimized initiation of preload
force by reducing the bending moments
• Automatically operating rotation angle control
for constant preload forces
• Continuously variable torque adjustment
from 150 Nm to 190,000 Nm
• ide range of applications thanks to its
maximum ease of use, ergonomic design and
compact dimensions. Fit for applications
under water and in explosion risk zones
a ICE bolting machine with
standard support arm for
seven tightening processes
ICE – square drive hydraulic Wrench
15
c ICE torque wrench with SmartDISK zWasher
drive for axial torque-controlled tightening
of bolts according to ISO 4014, ISO 4017 and
ISO 4762
c ICE torque wrench with CLAMP drive for
torsion-free tensioning in the smallest
installation spaces. The CLAMP tension nut
receives reaction force is axially and free
from lateral forces
c ICE torque wrench with DISC drive for safe
tightening without support arms and free
from lateral forces
The ICE torque wrenches in combination with our newly
developed hydraulic aggregates significantly increase
labor and installation speed, because in addition to the
delivery of the hydraulic aggregate, the technology of
the tool used is most decisive for tightening speed.
By optimizing frictional resistances in the overall system,
HYTORC succeeded in transforming the given delivery into
fastening speed and productivity. In addition, our new
housing design offers high stability even in tough working
environments for reliable operation.
R2
variants
H1
X
H1
ICE – Features
• Hydraulic jack in two levels, rotatable by 360°
and foldable by 180°
• Square wrench with integrated pressure cap
• Reaction arm can be positioned at the push
of a button
• Calibration certificate with new deliveries
c ICE – Equipment
R1
L
B
D
ICE – Facts & figures
Model
Torque min.
Torque max.
Square drive
Torque precision
Tool weight
Radius [R1]
Radius [R2]
Width [D]
Width [B]
[X]
[L]
Height [H1]
Height [H2]
Nm
Nm
inch
%
kg
mm
mm
mm
mm
mm
mm
mm
mm
ICE-1
257
1.767
¾
± 2,5
2,4
28,7
59,7
34,0
55,4
39,1
112,5
127,5
93,9
ICE-3
584
4.090
1
± 2,5
4,8
38,1
76,2
47,0
73,4
52,1
141,0
166,3
124,7
ICE-5
1.004
7.013
1½
± 2,5
7,3
47,2
83,1
63,0
86,1
62,7
163,8
193,0
151,1
ICE-11
2.173
15.210
1½
± 2,5
13,8
60,4
101,3
67,8
110,5
80,0
211,8
241,8
192,0
ICE-21
4.150
29.050
1½
± 2,5
23,5
66,1
112,3
96,0
144,8
95,3
245,1
273,6
223,5
ICE-35
6.496
46.884
2½
± 2,5
39,8
81,1
127,0
99,1
165,4
117,1
296,7
325,4
275,4
16
MXT square drive hydraulic wrench
original, tried and tested, powerful, robust
The MXT is the compact and proven square tool for traditional torque-controlled
tightening with cylinder-sided reaction arm for applications with a confined radius.
MXT – Productivity benefits
• The MXT screwdriver is a tool that has been
field-proven all around the world for
traditional tightening with a reaction arm
of 75 Nm to more than 72,000 Nm
• Compact, ergonomic design
• 60 positions for the support arm in
lightweight design with central locking
• Drive pawl system for safely removing the
wrench from the work piece
• Automatic rotation angle control for a constant
rotating angle of 24° per stroke
• Short set-up times
a Small to large MXT
with torque outputs from
155 Nm to 51,061 Nm
a MXT with
rotation angle sensor
MXT – square drive hydraulic Wrench
17
c Tightening process: Torque-angle with MXT-1 in gear manufacturing
c Perfect for bolts ISO4762: the small head radius of the MXT
The MXT is sophisticated, easy to use and robust.
The low-wear ratchet system with large teeth and drive
pawl system ensures a stable torque angle of 24° per
piston stroke even under high pressure, for a direct
transmission to preload force. The reaction arm has
60 positions and can be securely positioned by means
of the quick lock. A comprehensive range of accessories
tops off the variety of applications of the proven MXT
models.
c MXT – Equipment variants
L1
H3
H4
MXT – Features
• Hydraulic hose connection rotatable by 360° x 180°
• Single-piece tool housing
• Torsion-free power head
• Constant rotation angle of 24° per stroke
• Low-wear toothed gear bearing
R1
L3
H1
R2
L2
H2
MXT – Facts & figures
Model
Torque min.
Torque max.
Square drive
Torque precision
Tool weight
Radius [R1]
Radius [R2]
Length [L1]
Length [L2]
Length [L3]
Height [H1]
Height [H2]
Height [H3]
Height [H4]
Nm
Nm
inch
%
kg
mm
mm
mm
mm
mm
mm
mm
mm
mm
MXT-0,7
155
1.131
¾
± 2,5
2,4
20,5
84,3
100,6
151,8
23,6
41,1
64,2
76,2
108,9
MXT-1
262
1.845
¾
± 2,5
4,8
24,8
97,7
122,2
178,3
33,2
50,2
71,8
92,2
124,4
MXT-3
629
4.446
1
± 2,5
7,3
28,7
135,4
159,5
243,5
36,8
66,8
98,8
125,2
155,2
MXT-5
1.095
7.695
1½
± 2,5
13,8
39,6
162,5
190,5
284,9
44,4
76,2
123,4
146,0
183,4
MXT-10
2.301
15.857
1½
± 2,5
23,5
49,5
195,3
239,8
355,8
55,1
100,3
148,8
199,1
223,5
MXT-15
2.866
21.388
2½
± 2,5
19,8
55,5
219,2
268,4
388,1
63,4
111,1
177,3
204,6
243,6
MXT-20
3.880
27.200
1½
± 2,5
23,5
66,0
260,3
285,7
444,5
57,2
120,1
181,1
223,7
259,8
MXT-35
7.078
51.061
2½
± 2,5
39,8
75,7
322,0
353,3
538,9
81,7
147,8
218,8
276,8
313,9
18
EDGE square drive hydraulic wrench
simple, solid, cost-effective
The EDGE is a simple and cost-effective basic square drive torque wrench
that carries out its work with power and reliability.
EDGE – Productivity benefits
• Powerful standard drive for traditional bolting
with a reaction arm of 95 Nm to more than
40,000 Nm
• Drive ratchet with fine teeth with only three
moving parts
• 60 positions for the reaction arm, lightweight
construction with a centered catch
• Hydraulic hose connection rotatable by 360°
• Short set-up times
edge – square drive hydraulic Wrench
19
c EDGE-2 during flange fastening
c EDGE-4 on the housing flange of a metal-forming machine
The EDGE is the perfect basic hydraulic wrench for simple
applications. Due to its solid and simple design, its small
radii and its short set-up times, this hydraulic power pack
is perfectly suited for bolting with a torque output between
116 Nm and 40,200 Nm. With standard sockets/hexagon
sockets it is a reliable tool in the hands of experienced
mechanics.
c EDGE – Equipment variants
EDGE – Features
• Single-piece aluminum tool housing
• Standard square drive
• Drive ratchet with fine teeth
• Many high-quality accessories
H2
L1
L4
L3
H1
L2
EDGE – Facts & figures
Model
Torque min.
Torque max.
Square drive
Torque precision
Tool weight
Radius [R]
Length [L1]
Length [L2]
Length [L3]
Length [L4]
Height [H1]
Height [H2]
Nm
Nm
inch
%
kg
mm
mm
mm
mm
mm
mm
mm
EDGE-0,5
116
820
¾
± 2,5
7,3
70,4
101,9
128,5
84,3
24,9
41,7
74,9
EDGE-2
223
1.559
¾
± 2,5
4,8
85,6
125,5
158,2
104,6
30,0
50,0
89,7
EDGE-4
584
4.088
1½
± 2,5
4,8
115,6
162,6
206,8
135,6
39,6
66,8
119,6
EDGE-6
1.211
8.475
1½
± 2,5
4,8
137,2
193,4
246,8
162,0
46,1
80,9
153,5
EDGE-8
1.657
11.599
1½
± 2,5
13,8
154,2
220,2
290,8
194,1
53,6
90,7
166,9
EDGE-12
2.162
15.131
1½
± 2,5
23,5
154,4
242,8
308,1
202,7
59,4
100,3
179,6
EDGE-30
5.743
40.199
2½
± 2,5
19,8
227,1
348,2
434,6
291,6
84,6
143,3
256,5
20
HYTORC exchangeable
torque wrenches
The three types of our especially slim
click-in torque wrenches are suitable for
all assembly procedures according to
VDI2230. Thanks to the quick exchange
of ratchet links and the variety of
accessories, these tools can quickly be
extended to any assembly conditions.
Please note: All ratchet links are fast,
safe and precise, as they are designed
for the full torque power of the tool.
STEALTH – exchangeable Hydraulic torque wrench
21
STEALTH exchangeable torque wrench
multifunctional, precise and extremely slim
STEALTH is the multifunctional and especially slim click-in torque wrench
for tightening and tensioning in one system.
STEALTH – Productivity benefits
• Compact, ergonomic design and a torque
output of up to 48,000 Nm
• Very slim design – power head and ratchet
link of the same height without protruding
parts
• All ratchet links are designed for the full
torque power of the tool
• Hydraulic dual piston system for higher
working speed
• Quick click-in link exchange
• All wrench widths are available in metric or
inch dimensions, also for all special variants
c Click-in system:
The technology revolution
with extra-slim dimensions for
automatic and quick link interlock
b STEALTH – The right solution
to long protruding threads
b Light and
ergonomic
22
c STEALTH-2 in operation on the NYC Freedom Tower
c The STEALTH is perfect for limited clearance bolting
c Slim and fast: Application on a wind turbine
c SIMULTORC assembly system with Eco2Touch
c STEALTH-2 with DISC washer on container cover
c The STEALTH is perfect for hexagon bolting
STEALTH – exchangeable Hydraulic torque wrench
23
b Plane-parallel, simultaneous bolting by concurrent
transfer of preload force on at least four positions
and with constant rotation angles. The nuts are thus
tightened in a torque- and path-controlled way and
ensure constant load on the gasket.
c STEALTH – Equipment variants
STEALTH – Features
• Single-piece, robust power head
• Constant rotation angle during each stroke
H
The STEALTH is the advanced hydraulic exchangeable
torque wrench with super slim ratchet links with very
small head radii and a high torque output. The power
head and the ratchet links are of the same height; it is
equipped with a dual piston system which increases
the fastening speed at the push of a button.
SW
R
L
B
STEALTH – Facts & figures
Model
Torque min.
Torque max.
Wrench width
Torque precision
Tool weight
Length [L]
Height [H]
Width [B]
Nm
Nm
mm
%
kg
mm
mm
mm
STEALTH-2
364
2.573
19 - 60
± 2,5
STEALTH-4
787
5.508
36 - 80
± 2,5
140,5
106,9
32,0
166,7
138,0
43,0
STEALTH-8
1.572
10.990
50 - 100
± 2,5
STEALTH-14
2.760
19.622
70 - 120
± 2,5
STEALTH-22
4.261
30.110
75 - 145
± 2,5
STEALTH-36
6.446
47.795
90 - 165
± 2,5
274,2
233,2
74,0
322,8
274,6
87,0
depending of the wrench size
203,1
162,5
54,0
237,5
201,7
64,0
24
XLCT exchangeable torque wrench
original, compact, tried and tested, robust
The XLCT is the proven exchangeable torque wrench that can be used universally
with hexagon ratchet or square drive links.
XLCT – Productivity benefits
• Torque output of more than 110,000 Nm
• Exchangeable square ratchet or ratchet links
available – with hex or double-hex sockets
optionally and a great variety of applications
• Drive pawl system for a constant rotation
angle
• All wrench widths are available in metric or
inch dimensions
• Many customized solutions available
a XLCT for cutting
ring pipe couplings
c Customized tool for foundation bolts
in limited heights
XLCT – exchangeable Hydraulic torque wrench
25
c Spherical valve fastening with halfway open but lockable rigid box
wrench
c XLCT-2 with lateral support on the flange
The XLCT is a universal bolting tool and, thanks to
its various adaption- and tool-customized solutions,
it can be used very flexibly. The basis is its torsion-free
power head and ratchet standard hex links or square
ratchet links in different sizes.
The XLCT operates quickly, extremely precise and
completely reliable. With its many expansion varieties,
the XLCT leaves nothing to be desired in practical
applications.
H
XLCT – Features
• Torsion-free power head
• Constant rotation angle during each stroke
• Safety screw and plug couplings
• Calibration certificate with every new delivery
c XLCT – Equipment variants
L
B
XLCT – Facts & figures
Model
Torque min.
Torque max.
Wrench width
Torque precision
Tool weight
Length [L]
Height [H]
Width [B]
Nm
Nm
mm
%
kg
mm
mm
mm
XLCT-2
364
2.573
19 - 65
± 2,5
XLCT-4
787
5.508
36 - 80
± 2,5
XLCT-8
1.572
10.990
50 - 100
± 2,5
186,2
128,3
32,0
256,2
166,2
43,0
306,8
197,3
54,0
XLCT-14
2.760
19.622
70 - 120
± 2,5
XLCT-18
4.261
30.110
75 - 145
± 2,5
XLCT-30 XLCT-45
6.446
8.994
47.795
62.958
90 - 155 100 - 190
± 2,5
± 2,5
XLCT-60
7.120
49.860
85 - 165
± 2,5
359,2
235,3
64,0
366,1
270,7
74,0
426,8
310,7
85,0
389,5
336,5
99,8
397,2
339,5
105,8
26
VERSA exchangeable torque wrench
simple, solid, cost-effective
The VERSA is a simple, cost-effective and slim basic exchangeable torque wrench
that operates powerfully and reliably.
VERSA – Productivity benefits
• Slim and quick – perfect for confined spaces
• Compact design for a torque output from
150 Nm up to 49,000 Nm
• Drive ratchet with fine teeth with only three
moving parts
• Exchangeable ratchet links from 24 mm to
165 mm with hexagon or double-hex and
a wide range of adaptions
• Hydraulic hose connection either inflexible or
rotatable by 360°, or rotatable by 360° and
foldable by 120°
• Low weight in operation and short set-up
times
Versa – exchangeable Hydraulic torque wrench
27
c Fastening of a bearing with VERSA-2
c Small, light and safe: the VERSA-3
In terms of its price, equipment and wide range of
high quality accessories, the VERSA is the perfect tool
for traditional bolting to a precise torque value. Due
to its simple design and its small radii it is especially
designed for hard-to-access and very confined spaces.
Short set-up times and quick switching from tightening
to loosening mode as well as accurate bolting to a torque
value of more than 47,000 Nm make it the perfect basic
exchangeable link torque wrench.
c VERSA – Equipment variants
and foldable by 120°, or rotatable by 360° and
inflexible
H
VERSA – Features
SW
R
L
B
VERSA – Facts & figures
Model
Torque min.
Torque max.
Wrench width
Torque precision
Tool weight
Length [L]
Height [H]
Width [B]
Nm
Nm
mm
%
kg
mm
mm
mm
VERSA-1
156
1090
24 - 46
± 2,5
VERSA-2
370
2.590
24 - 60
± 2,5
108,5
79,5
24,0
186,2
128,3
32,0
VERSA-4
849
5.940
36 - 80
± 2,5
VERSA-8
1.779
12.450
50 - 100
± 2,5
VERSA-14
2.905
20.350
70 - 120
± 2,5
VERSA-20
4.041
28.290
70 - 130
± 2,5
VERSA-30
7.120
49.860
85 - 165
± 2,5
366,1
270,7
74,0
366,1
270,7
74,0
256,2
166,2
43,0
306,8
197,3
54,0
359,2
235,3
64,0
28
HYTORC – Your partner for
high-quality accessories
and customized solutions
In the best interest of our customers,
we place a high value on very high quality
standards when selecting, manufacturing
and processing our original accessories.
Our quality assurance in accordance with
ISO 9001 and our own process controlling
ensure that these standards are always met.
This is especially important when it comes
to customer-specific individual solutions.
Accessories for hydraulic wrenches
29
Entire range of products
High-quality accessories by HYTORC
The wide range of our excellent torque wrenches is topped off
by an expansive portfolio of unparalleled accessories.
HYTORC offers a wide range of accessories –
socket wrenches, back-up wrenches, hoses
and more.
Highest quality standards are met thanks to
quality assurance according to the guidelines
of our quality assurance process as required
by ISO9001 quality process and in-house
assurance. Thus, we meet both national and
international standards such as ISO 2725-2
and the German standard DIN 3129.
Thanks to this solid basis, we are able to
promote our own innovations and technological
projects. Upon request, we also manufacture
customized accessories. True to our motto
"Everything is possible", we are your strong
partner in the field of accessories.
Standardized sockets according to the German standard
DIN 3129:2012-03
For the secure transmission of high torques with sockets, highest
standards in terms of the manufacturing process, durability and
safety have to be met. This includes the precise and customized
construction of important power transmission components, taking
into account international standards such as ISO 1174-2, 1703,
1711-2, 2725-2 and 2725-3.
Our standard range of stock for sockets covers all dimensions up
to 2.5 inches in square drive and up to 200 mm in metric dimensions.
This enables HYTORC to deliver the accessories you need within a
few hours.
Standard sockets for head cap screws according to ISO 4762
Choosing the right socket primarily influences work safety. Head
cap screws, also called Allen screws, are connecting elements which
require special care during loosening. Therefore, HYTORC has
launched its own product range, in which all hexagonal sockets of
the same square head cap screws have the same total length.
This ensures that the reaction arm with all wrench widths always
dissipates the counter-torque on the same reaction level. However,
long hexagonal sockets and change adapters are also available for
all cylinder cap screws i.a.w. ISO 4762, both in metric and inch sizes.
b Quality accessories made by HYTORC
Stack sockets for bolted connections with long protruding bolts
Stack sockets are special solutions which have stood the test of time
for several years for all wrenches with exchangeable links. They are
female-male hexagon adapters. HYTORC delivers load free hex stack
sockets in customized sizes, through holes matching the respective
thread sizes and smaller dimensions than those of standardized
exchangeable links. Of course, HYTORC also offers corresponding
support arms.
30
Accessories for square drive hydraulic wrenches
• Sockets for wrench sizes of up to 200 in mm or inch
• Square drives ½“ to 2½“
• Direct-drive sockets for all wrench sizes
• Direct-drive hex sockets for all wrench sizes
• Hex sockets for wrench sizes of up to 100 in mm
Accessories for box torque wrenches
• Customized stack sockets
• Hex adapters
• Square drive extensions
• Hex click-in links
• Double hex sockets
Reaction fixtures
• Customized design for all torque wrenches
• Axial reaction arm extensions
• Inline reaction arms
• Adjustable 360° rotation reaction arms
• TWINTORC fixtures
Back-ups
• Hydraulic back-up wrenches of up to 5,000 Nm
• Exchangeable double hex sockets
• Mechanical back-ups for all torque ranges
• Versions with double hex sockets
• Customized solutions available
Limited clearing system with click-in link
• With exchangeable hex adapters
• Rotation to the left / right possible
• Variable torque stages
• For use with jGUN, FLASH, ICE and AVANTI
• Available as all-in-one system in mm or inch
Accessories for hydraulic wrenches
FieldCheck – torque testing system
• Simple testing method for your building site
• Adjusted to torque ranges
• For square drive hydraulic wrenches
• Accessories for limited clearance hydraulic wrenches
• For hydraulic and pneumatic torque wrenches
Cup fixture extensions
• Made from aluminum or steel
• Single piece, welded or bolted
• For all STEALTH, XLCT and VERSA tools
• Also suitable for ICE, AVANTI, MXT and EDGE
• Customized lengths available
Hydraulic hoses and accessories
• Available with original couplings by all manufacturers
• Manometer of 1.0 and 0.25 category
• Hoses with a length of 5 or 10 m
• Tested in accordance with regulation BGR 237 by the
German employer's liability insurance association
• 2,800 bar burst pressure (fourfold safety)
• Customized lengths available upon request
Hydraulic lifting cylinders
• Four different types
• Several matched lifting classes
• Maximum operating pressure of 700 bar
• Available with original couplings by all manufacturers
Hydraulic bolt tensioning cylinders
• Three standard types
• Operating pressure of 700 bar, 1350 bar or 1500 bar
• Also available with stroke counter
• With high-pressure plug couplings
• Comes with calibrated tensile force table
31
32
HYTORC thread cleaning system
For male and female threads
Clean threads are an essential precondition for accurate tightening.
Accurate tightening and the required assembly preload
cannot be achieved if threads are not clean.
This is especially true for inner sleeves and their contact
surfaces as well as for the bolts external thread and its
shank.
Automatically adjustable cleaners for
external and internal threads
• Simple, easy and fast
• Solid and ergonomic design
• Safe brushing wheels with spring suspension
c Cleaner for internal threads with
automatic suction of particles
• Almost no wear
• Low servicing and maintenance costs
• Fixed and adjustable cleaners for
internal threads
• Optional suction
• Available as complete box
b Cleaner for external threads
with automatic thread setting
thread cleaning system
33
Cleaners for external threads
Achieve optimal cleaning of threaded bolts of sizes M8 to
M230 with our cleaners for external threads. Our patented
brushing system allows for an automatic adjustment to the
thread diameter without steps in the respective adjustment
range. Simultaneous cleaning of the thread's pitch and
shank is possible. During the process, rust and particles at
the upper and lower threads are removed and the bolt is
excellently cleaned and smoothened. In this way, a
constant thread friction value is achieved. The stainless
steel brushes featuring spring suspension are protected by
a robust aluminum casing. By turning the adjustment ring,
the pressure on the brushes is variably adjusted within the
entire adjustment range. This guarantees that the cleaners
achieve optimal cleaning results for each individual task.
Cleaners for internal threads
Achieve optimal cleaning of threaded holes of sizes M60 to
M210 with our cleaners for internal threads. Our proprietary
technology allows for an automatic adjustment to the
thread diameter without steps in the respective adjustment
range. A set featuring special individual brushes is
available for the sizes M8 to M72. During the process, rust
and particles at the upper and lower threads are removed
and the hole is excellently cleaned and smoothened. In this
way, a constant thread friction value is achieved. The
attachment for the stainless steel brushes is made from
aluminum. After the bolts have been loosened and the
adjustment ring has been turned, the brushes are adjusted
to the desired thread diameter (of the respective
adjustment range) without steps.
You may either use a mobile cleaning system immediately
at your plant or a fixed cleaning system which may, for
example, be attached to your vise. No additional
accessories are necessary for cleaning threaded bolts with
a length of up to 200 mm. A particle filtering device is
available for all our cleaning systems for external threads.
It adds 40 mm to the working space. Various vise
attachments are available for fixed applications. The
cleaners come with a foot switch which make fixed
applications more comfortable. The cleaning system for
external threads can also be combined with optionally
available throughput drive. With the drive moved to the
side, this allows cleaning of any bolt length.
c Cleaners for internal threads
may be adjusted without steps
starting with M56
Cleaners for external threads
Model
DEV-ARG 10-27
DEV-ARG 20-55
DEV-ARG 35-70
DEV-ARG 50-90
DEV-ARG 90-120
Area of application
M10-M27
M22-M54
M36-M68
M52-M88
M86-M120
External ø max.
100 mm
150 mm
160 mm
185 mm
212 mm
Particle suction
optionally available
Cleaners for internal threads
Brush type
Single brushes
DEV-IK-6070
DEV-IK-7080
DEV-IK-8090
DEV-IK-9011
DEV-IK-1113
DEV-ISK-1027
DEV-ISK-0872
Area of application
Brush ø max.
Particle suction
M8-M56
Depending on thread
M60-M72
3x30mm
M72-M80
3x30mm
M80-M90
3x30mm
M90-M110
3x40mm
M110-M130
3x40mm
Box with sets for inner threads with drive from M8 to M27
Box with sets for inner threads with drive from M8 to M72
Clearance min.
62- 79 mm (M10-M27)
99-133 mm (M22-M54)
118-150 mm (M36-M68)
147-183 mm (M52-M88)
194-228 mm (M86-M120)
34
HYTORC lubricants
Enable perfect connections
HYTORC offers expert advice and excellent service in the field of
lubricants and application.
The lubricants recommended by our experts are perfectly
geared for all components of bolted connections and, thus,
make sure that the required loads are definitely reached.
As our customer, you benefit from more than just one
advantage of our lubricants: One the one hand, we offer a
one-stop solution and on the other hand our high-quality
lubricants are customized to match your respective area of
application. We have been in the field of industrial bolting
for decades now and have experienced many challenging
situations which helped us develop very broad and indepth expertise in this sector. We have used our expertise
to help develop our lubricants, which is why they are
suitable for all your requirements.
Cleaners and lubricating pastes
• HY.50 Special lubricating paste μmin. 0,08
is especially suitable for the clean and
damage-free assembly and smooth rotation
of high-duty bolts
• HY.52 Special lubricating paste, white
μmin. 0,09 is the obvious choice for the
assembly as well as smooth rotation of
machine parts with low rotational speeds
(also for non-ferrous metal and stainless steel)
• HY.55 High temperature lubricating paste
μmin. 0,10 is the ideal lubricating paste for
applications in the temperature range of up
to +1,200 °C
• HY.56 High temperature paste μmin. 0,12
Is a lubricating paste for applications in
the temperature range of up to +1,000 °C;
it has been developed for application in
flange connections
• HY.61 Liquid loosening lubricant
• HY.73 Metal cleaner
• DISC.08 Anti-friction coating spray
Air-drying anti-friction coating spray
for constant friction coefficients;
perfect for hexagonal nuts used
in combination with the DISC
Fastening elements
35
Standard fastening elements
High-quality components from HYTORC
HYTORC is a one-stop shop which offers all the acceptance inspection documents
required i.a.w. EN 10204.
The importance of bolts, nuts, discs and other fastening
elements is often underrated. However, it is quite clear
that these parts are integral parts of properly working
plants.
cd Our entire high-quality product range
of standardized bolted connections with
all available surface coatings
That is why, at HYTORC, these components are always of
the highest quality. For the quality of fastening elements
plays a decisive role for excellent tightening, i.e. for the
safe and smooth operation of your plant. For these reasons,
we help you procure all fastening elements – from detailed
design through customized manufacturing to quality
assurance and certification. At HYTORC, the term "one-stop
shop" covers everything from desired EN 10204 anticorrosives to suitable lubricants and testing methods.
What we can manufacture for you:
• External and internal threads up to M200 and up to
a length of 18 m
• All threads with inch dimensions
• Bolts i.a.w. ISO4014, ISO4017, ISO4762, EN14399
• Studs and tension bolts i.a.w. various national and
international standards (DIN, ASTM, AISI and UNS)
• Hexagonal nuts i.a.w. the standards DIN934, DIN2510
and ASTM A193
• Certification i.a.w. EN 10204
• Heat treatment
• Hot and cold working
• Surface coating (zinc flake coated, galvanized or
hot-dip galvanized)
• Proprietary laboratory for all testing methods
The testing methods we can offer:
• Chemical analysis (up to 20 elements)
• Charpy impact test to -150 °C
• Surface-crack testing (two methods)
• Spectrum analysis
• Tensile testing (testing device up to 600 kN)
• Hardness testing HRC and HRB
• Determination of surface roughness (measuring device)
• Determination of coating thickness
• Measurement of bolt load up to M90 and 3000 kN
36
Innovative fastening elements
for reaction arm free bolting
HYTORC offers innovative fastening elements for any assembly and any application:
SmartDISK zWasher, DISC, CLAMP, SmartSTUD and justBolt. High tenacity connections,
connections in high-temperature surroundings, perfect surface protection with full
bolt utilization: HYTORC can do it all.
SmartDISK zWasher
The no-rotation SmartDISK zWasher puts action and reaction on the
square drive axis and provides a defined friction coefficient below the
bolt head. Thanks to its design, it can be used for the axial clamping
of all standard bolts i.a.w. ISO 4014, ISO 4017 and ISO 4762.
This significantly simplifies the preloading of bolts in threaded holes
which can be done axially now. The calibrated torque of the assembly
tool is transformed into a preload which can clearly be reproduced
since these no-rotation washers do not rotate on the component.
Relevant regulations, such as ASME-PCC 1 or VDI-220-2007-07
already require the use of washers to minimize friction.
c The no-rotation SmartDISK zWasher is suitable for
axial tightening in all bolted connections – and does
not incur additional material expenses.
c Hexagon washer DISC for no-rotation
and friction-optimized bolting
DISC hexagon washer
Our DISC hexagon washer significantly simplifies the preloading of
bolted connections featuring hexagonal nuts. Thanks to constant
friction coefficients of the no-rotation DISC, the calibrated torque
of the assembly tool is transformed into a preload which can be
reproduced – even in axial bolting with short grip lengths.
Our DISC eliminates damage at all components – immediately
and in the long term. This means that maintenance intervals may
significantly be shortened and be planned and carried at smaller
costs. The DISC ensures that neither the bolted component nor the
nut can rotate during tightening and axial preload. Back-up wrenches,
which have been used up to now, are no longer necessary and
assembly tools may directly be "attached" to the DISC – even for
overhead bolting.
Fastening elements
CLAMP tension nut
The CLAMP tension nut is a mechanical preload system which can
be calibrated and used for almost any application:
The CLAMP replaces traditional nuts but does not rotate at the
bolt thread! The CLAMP tension nut makes preloading in bolted
connections much simpler, easier and safer. For the first time, the
torque may directly be transformed into a reproducible preload.
The CLAMP's proprietary spline thread is slightly larger but features
a significantly smaller pitch. This means that the required preload
torque may be reduced and smaller assembly tools may be used.
This, in turn, allows for torsion-free preload with a preloading scatter
of less than ±5 %.
37
c CLAMP tension nut for torsion-free clamping
SmartSTUD
Our SmartSTUD is a three-piece fastener which is fastened without
any torsion. The fastener is designed in the form of a clamping shank
or compact stud shank. The round outer sleeve of the SmartSTUD
system serves to replace the nut; a washer is also integrated. By
this simple system design, axial and torsion-free clamping becomes
possible for the first time. The dimensions of the SmartSTUD have
been minimized to such an extent that the outer diameter corresponds
to that of a hex bolt. Any movement takes place within the SmartSTUD
which means that this system may be calibrated to exactly match
assembly preload for any application. As the SmartSTUD has been
adapted to the dimensions of jacket nuts in accordance with the
German standard DIN 2501, it is creep resistant up to 600 °C.
c SmartSTUD – the first fastener for torsion-free
clamping especially at high temperatures > 350 °C
justBolt
The threaded bolt justBolt includes a support profile in the form of
an external hexagon which is roughened on one side and/or toothing.
They fixate the assembly tool which means that no external support
arm is necessary during assembly or disassembly.
JustBolts, which are available in sizes M20 and larger, allow for
precise axial preloading. During assembly, the tool drive is fixed by
mans of the reaction fixture provided by justBolts which support the
assembly tool. Thanks to axial fastening, the friction coefficient is
considerably more constant and steady than in case of traditional
assembly of bolted connections. This assembly method is especially
suitable for limited-clearance applications. Operators may also
replace connections featuring hexagonal bolts by justBolts if they
desire safe, fast, precise and reaction arm free fastening.
c Threaded bolts justBolts for axial tightening with
support element (external or internal hexagon)
Perfect to replace hexagonal bolts.
38
Field-tested hydraulic power packs
Sturdy, reliable, compact and fast
HYTORC's hydraulic power packs leave nothing to be desired.
HYTORC's hydraulic power packs have specially been
designed to match HYTORC's hydraulic wrenches. Sturdy,
reliable, compact, precise and fast – these are the most
important features of these hydraulic drives. The noise
emission of these models is considerably lower than 80 dB.
MiniJet and JetPro 5.3 focus on profitability. The models of
our JetPro series feature an automated three-phase pump
which ensures that engine power is ideally used over the
entire pressure range and adapted to the rotational speed
of the fastening application. Their cooling systems
guarantee high stability. Comfort electronics support the
operator, automatically switch off the power pack in case of
brief interruptions and automatically discharges pressure
from all valves before the system is switched off.
Safety
All of our electrically driven power packs comply with
CE requirements, VDE 0/700 and EN 60445 and their
electromagnetic compliance has been tested by the
Swiss Electrotechnical Association. The casings and
electrical appliances are of protection class IP 54.
ATEX certifications
EPS 12 ATEX 2 489 X and EX II 2 G EX c IIB T4
(A tightening system in accordance with ATEX consists
of at least three retrofit elements: a hydraulic wrench
by HYTORC, the JetAir 12 and a twin line hose with a
nominal width of 6 mm).
MiniJet – 230 Volt (50 + 60 Hz)
• 2-phase hydraulic power pack
• Compact, small, and lightweight design
• Suitable for 50 Hz and 60 Hz
• Standard remote control 5 m
• Glycerin-filled analogous manometer of category 1.0
• Output of electric motor: 0.6 kW
• Low-pressure volume flow rate: 4 l/min.
• High-pressure volume flow rate: 0.4 l/min.
• Weight (without oil): 14 kg
JetPro 5.3 – 230 Volt
• 2-phase hydraulic power pack
• Compact, small, and lightweight design
• Suitable for 50 Hz
hydraulic power packs
Standard-Eco-Pumpe – 230 Volt / 400 Volt (50 + 60Hz)
• Customized upgrade possible thanks to modular design
• Volume flow from 5 to 15 liters thanks to quickly
exchangeable pump elements
• Manual or automatic control
• May be upgraded to Eco2Touch system
• May be upgraded to display remote control for safe
fastening in accordance with DGA, DDW and DGD
(no documentation required)
• Use of control and reference parameters possible
• The visualization of the process allows for parametric
representation of the application
JetPro 9.3 – 230 Volt (50 + 60Hz)
• 3-phase, compact, high-performance hydraulic power pack
• Also available with a digital manometer
• Low-pressure volume flow rate: 2.2 l/min.
JetPro 18.3 – 400 Volt
• Suitable for 50 Hz
• Also available with a digital manometer
• Low-pressure volume flow rate: 6.0 l/min.
JetAir 12.3-4T (Luft)
• Medium-pressure volume flow rate: 2.5 l/min.
39
40
High power which also
controls: HYTORC's
Our product portfolio comprises cutting-edge
standard, semi- and fully automatic as
well as automatically controlled hydraulic
power packs. This enables us to provide our
customers with the right hydraulic power
pack for each application and specification.
EcoPUMP models may be upgraded at any
time for optimized profitability.
41
Advanced hydraulic power packs
EcoPUMP with Eco2Touch control
HYTORC presents the world’s first hydraulic power pack within the meaning
of industry 4.0 with intuitive Touch control.
The Eco2Touch control has been developed in the context
of industry 4.0 and is an innovation based our successful
SmartPUMP. Moreover, all process parameters have been
integrated into the new system in order to meet, among
others, the requirements of VDI / VDE 2862 sheet 2.
The basis of the hydraulic system is the EcoPUMP,
an especially reliable and powerful hydraulic power pack
that has successfully been used for several years already.
The new HYTORC Eco2Touch control is the corresponding
electronic control unit at the cutting edge of processor
technology. It is positioned on the EcoPUMP and is
operated via a Touch display. This unique control method
allows tightening any bolt safely and to the maximum by
using an intuitive and simple Touch control. The operator
does not have to enter complicated tightening or other
parameters: The hydraulic power pack is controlled via
icons on the Touch control, just as on a smartphone. The
parameter settings are carried out independently from
other operating systems and without a laptop or PC.
42
With the Eco2Touch control, HYTORC does not only meet
the minimum requirements described in VDI / VDE 2862
sheet 2 for applications of fastening systems and tools in
plant construction and mechanical engineering, but goes
much further. Due to its modular design, the Eco2Touch
control offers individual, flexible and user-oriented
solutions to processes and documentation. For the
specified redundant measurements, rotation angle sensors
which measure and monitor the rotation angle during the
tightening process are attached to the HYTORC torque
wrenches.
The torque value is measured at the EcoPUMP.
The Eco2Touch control now monitors pressure and torque
increase during the tightening process. The bolt is within
the elastic range as long as the torque and rotation angle
value increase proportionally. The maximum tension force
of the bolt is reached when the torque value no longer
increases proportionally to the rotation angle. At this
point, the system switches off and confirms the bolted
connection. The tightening process has then been
successfully carried out and is documented.
c The Touch display of the Eco2Touch: modern and clear
c The new hydraulic power pack Eco2Touch
takes the entire VDI/VDE 2862 sheet 2 and much
more into account. The entire mobile device has been
especially developed with a view to industry 4.0.
43
c Graphic representation of the tightening process with all process
parameters
c Automatically generated documentation (PDF) tracking time and date
The HYTORC Eco2Touch meets the technical minimum
requirements for bolted connections of category A and B
from the VDI/VDE 2862 sheet 2 and more.
Tightening methods possible with the Eco2Touch:
DGA: Torque-controlled tightening
• Directly measured control value
(e.g. torque value, rotation angle, stretching, pressure)
• Directly measured reference values (e.g. torque value,
rotation angle, stretching, and pressure)
• Control and reference value may not be identical
DGD: Torque-controlled,
angle monitored tightening
DGS:Torque-controlled,
yield point monitored tightening
DDW: Torque and Angle controlled tightening
• Provision of bolting results for further processing
• The Eco2Touch control monitors the accurate data
recording thanks to the intermittent operating method
of the hydraulic torque wrench
SGA: Yield point controlled tightening
• Evaluation of each fastening process
SGD: Yield point controlled,
angle monitored tightening
• Provision of process parameters as text (CSV)
and graphic (PDF) files
ADA: Axial torque controlled tightening
with HYTORC fastening elements
• System monitoring by means of a self-test of all
components relevant for control and reference values
EXT: Externally controlled tightening with random measuring sensors with standard industrial
interface 0..10V / 0..20mA / 4..20mA
• Redundant measurement by means of optional
industrial interfaces
SEQ: Sequencer – combination of all named
methods in random, automated order
ANA: Torque analysis tool for controlling the
further rotation angle in torque-controlled
bolts (with rotation angle sensor)
44
Expert connections
Overview of bolting methods
Bolted connections are by far the most important detachable joints for the industry.
Ever larger machines and plants require ever larger fastening elements and the
existing bolted joints must have a higher and more precise preload.
HYTORC has the right solutions.
Nowadays, more than 90% of all bolted connections are
preloaded by rotation. The method which is mostly used is
torque-controlled tightening. In addition, torque-controlled,
angle monitored tightening and yield point controlled
tightening are becoming more and more established.
Nowadays, engineers use ever improving methods to
calculate the required minimum preload force of a bolted
connection; HYTORC developed the right processes to
meet the increased requirements. The most important and
common methods will be presented in the following.
DGA
Hydraulic
torque-controlled
tightening
In hydraulic torque-controlled tightening, the torque
wrench stops when it reaches the pre-set torque value or it
signalizes that the torque value has been reached. For this
method, knowledge about friction is of great importance.
Lubricants as well as the quality of the components and
their surfaces influence friction behavior.
In order to prevent adding inaccuracies to the torque on top
of the scattering of friction, HYTORC developed particularly
precise torque wrenches. The alteration of the tightening
torque value in hydraulic torque wrenches results mostly
from the variation of the lever arm during tightening.
With the reaction pawl, direct preload transmission to the
bolt is optimized by the pre-set torque value. Furthermore,
the fastening speed of the HYTORC hydraulic torque
wrenches has been increased significantly by means of the
reaction pawl.
As the tightening torque value directly increases together
with increasing hydraulic pressure, the bolted connection
is tensioned in intervals. The entire tightening process of
each bolt can be documented by the Eco2Touch. With the
fastening elements DISC, SmartDISK zWasher, CLAMP
tension nut, SmartSTUD and justBolt, even axial tightening
that is free from lateral forces and without reaction arm is
possible featuring preload precision of ±5%.
Torque-controlled tightening can be used for any bolted
connections with torque values of up to approx. 200,000
Nm. On the basis of torque value calculations, suitable
lubricants must be used in order to prevent grinding or
fretting. When used on flange connections, it should be
used in the form of a SIMULTORC assembly system with
no-rotation discs in Order to prevent damages on the flange
contact surfaces.
VDI2230 conventional tightening factor:
αA 1,4 -1,6
VDI2230 friction-optimized tightening factor: αA 1,1 -1,2
VDI2230 friction-controlled tightening factor: αA 1,0 -1,1
bolting methods
DDW
Hydraulic
torque and angle controlled
tightening
The hydraulic torque and angle controlled tightening
method indirectly measures the stretching of the bolt.
Using the thread pitch, a defined elongation of the bolted
connection can be allocated to an exact rotation angle. In
doing so, the compression strain within the fastened parts
and the elastic and plastic deformations occurring within
the interfaces before full surface contact is reached are
measured.
However, this method can only be used for
the determination of preload force if the rotation angle
is actually transformed into elongation of the bolted
connection. Therefore, it must be ensured that all
interfaces with a defined snug torque are exactly on top
of each other, and the parts to be bolted can absorb the
required surface pressure. Accurate calculations are
indispensable here.
The hydraulic torque and angle controlled tightening
method developed by HYTORC not only monitors snug
torque and rotation angle, but also final torque. The system
does not confirm the tightening process as correctly
terminated until the required rotation angle and the final
torque are within the determined parameter range.
An even higher accuracy can be achieved when the bolted
connection is tightened up to the super-elastic range. Here,
the Eco2Touch controls, documents and files all process
parameters.
45
SGA
Hydraulic
Yield point controlled
tightening
Hydraulic yield point controlled tightening is a super-elastic
tightening method in which the start of yielding of the bolt
serves as control value for the preload force value.
Independently of the friction under the head, the bolt is
tightened until the yield point is exceeded as a result of the
exposure to tension and torsion stress.
As is the case with hydraulic torque-angle controlled
tightening, the components must first be preloaded with
a snug torque. During further tightening of the bolted
connection, torque value and rotation angle are continuously measured and the gradient is calculated. The applied
measuring technology detects the limit of the elastic range
and ends the bolting process at the pre-determined change
of gradient. As the bolt is plastically strained only to a very
small extent, bolted connections with short grip lengths
can also be tightened with the yield point controlled
method. During the tightening process, all process
parameters are controlled, documented and filed by the
Eco2Touch control.
The plastic elongation that takes place in the bolted
connection during assembly is very small; thus, reusability
of bolted connections that are tightened with the yield
point controlled method is hardly impaired. The rigidity of
the application, the snug torque and the criteria for
disconnection should be adjusted to the corresponding
bolted connection.
This tightening method is especially suitable for bolted
connections with short grip lengths and in production
processes / production lines. It may only be applied when
bolted connections are tightened in threaded holes (blind
holes) in accordance with ISO 4014, ISO 4017 and ISO 4762.
Furthermore, suitable lubricants must be used in order to
avoid grinding or fretting.
This tightening method is especially suitable for bolted
connections with short grip lengths and when using bolting
systems on construction sites. It may only be applied when
bolted connections are tightened in threaded holes (blind
holes) in accordance with ISO 4014, ISO 4017 and
ISO 4762. Furthermore, suitable lubricants must be
provided in order to prevent grinding or fretting.
VDI2230 tightening factor: αA 1,2 -1,4
VDI2230 tightening factor: αA 1,2 -1,4
46
DGD
Torque-controlled,
angle monitored
tightening
In this assembly method, the nominal torque value is
the control value and the achieved rotation angle is the
reference value for termination of the process.
The method can be used for:
Applications of category A: high risk assessment,
risk for life and limb or the environment
Applications of category B: medium risk assessment,
malfunction / system downtime
Applications of category C: low risk assessment, not critical
DGS
Torque-controlled,
yield point monitored
tightening
In this assembly method, the nominal torque is the control
value and the linear lead progression is the reference value
for termination of the process. If there is a deviation from
the linear course due to detection of the yield point, the
process is stopped. This means that the bolts no longer
break.
SEQ
Sequencer –
random combination
of all named methods
In this module, all available assembly methods can be
combined at random. For the standard version “without
external sensor technology”, the category classification
must be made in correspondence with the type of
combination.
ANA/DAT
Torque analysis tool for controlling the
further rotation angle in torque controlled
bolting with rotation angle sensor
This analysis module determines the further rotation
angle of a bolt from a defined snug torque to reaching
the defined nominal torque value. In this assembly
method, the nominal torque is the control value.
bolting methods
SGD
Yield point controlled
and angle monitored
tightening
In this assembly method, the nominal torque value is the
control value and linear lead progression and achieved
rotation angle are the reference values for termination
of the process.
EXT
Externally controlled tightening
with random measuring sensors
with industry interface
This assembly method features the control value nominal
torque and another, optional external physical measuring
parameter, which is continuously measured at the current
or voltage loop and is graphically depicted in its physical
entity and documented.
ADA
Axial torque controlled tightening
with the five HYTORC
fastening elements
In this indirect process the preload force is the control
value. The process is terminated by the nominal torque
value. As a standard, termination is conducted on the basis
of parameterized timing values.
The process is only possible in combination with our five
no-rotation fastening elements with a constant friction
value: SmartDISK zWasher, DISC hexagon washer,
CLAMP tension nut, SmartSTUD or justBolt.
47
48
Absolutely customerfocused – that's HYTORC.
HYTORC is all about satisfying your
requests quickly and according to
scheduled. From our on-site service
through to expert advice, our calibration
and repair service to trainings:
Our service adds value to your business.
We are happy to provide you with
excellent service!
Services
49
HYTORC services
We always focus on our customers
You would like to buy or rent tools? We will make sure you receive
the service you need on time and even on-site.
HYTORC customers especially appreciate HYTORC's
service modules which may ideally be adapted to their
individual requirements.
HYTORC's service range:
• 24/7 repair service
• Project and system planning
24/7 repair service
The best tools deserve to receive the best service; which
will be provided reliably and fast by our headquarters as
well as on-site by our field service.
• Measurement and testing center
• On-site service
• CAD design
Measurement and testing center
Aligning theory and practice: We determine even high
preload forces of bolted connections simply and precisely
and verify torque and angle with all available fastening
methods. On-site or at our measurement and testing center.
• Calibration service
• Trainings
• Calculation program for
appropriate bolting
Project and system planning
Large projects require good cooperation and trusting
business relations. Our service packs and broad range of
services make us a reliable partner for the industry. We
guarantee optimized data protection – confidential,
systematic and discreet.
Calculation program for appropriate bolting
In order to detect errors in the calculation of bolted
connections, HYTORC offers a simple, database-assisted
torque calculation program which is available for free upon
request. If you would like to obtain it, please send an email
to [email protected] and copy "Torque Calculation Program"
into its subject line.
b Find everything you need:
The entire HYTORC product range for fastening
• Flange connection certification
• Rentals
• 24/7 Service hotline:
+49 800-500 58 88
50
c The CAD draft and...
c ... its successful implementation
CAD design
We visualize customized solutions in advance. Our CAD
design department which cooperates with our customers’
design departments has almost ten years of experience.
By including your design department into the designing
process of machines and plants at an early stage,
considerable savings are possible. In this way, the shape
of components can be matched with the standard tools
to be used and expensive customized solutions can be
avoided later on.
Cutting-edge 3D printers enable us to visually implement
specialized solutions which may then be used for prototype
design, even before any special tools are made. This saves
time and money.
c Available anywhere and at any time – HYTORC's on-site service
On-site service
Tightening systems are only as good as their servicing.
In addition to our service and repair departments at the
HYTORC site in Krailing, Germany, our trained service
technicians are happy to render services at your site, too.
• On-site service: Spare parts
Our on-site service technicians have spare parts and tool
gaskets with them in their vehicles. This ensures fast
service and an optimum supply of spare parts – even on
weekends.
• On-site service: Repair
Thanks to our on-site service technicians, standard repairs
as well as inspections and maintenance works can be
carried out at your site.
Services
51
Revision / upgrade support
In order to achieve a sustainable improvement of
occupational safety, ergonomics and quality, HYTORC
experts are happy to support your employees and your
contractors prior to and during a revision/upgrade.
Technical preparations prior to revision/upgrade:
• Analysis of drawings and parts lists
• Analysis to choose most appropriate fastening method
• Creation of flange tightening certificates including
operating instructions for mechanics
• Verifying torques, preloads, required clearance and
accessibility
Technical support during revision/upgrade:
• On-site provision of spare tools/accessories
• On-site advice on spare parts
• Provision of staff on-site to ensure that the operators are
able to use the supplied bolting equipment efficiently
and according to occupational and plant safety.
• Documentation of pre-set parameters as specified
Calibration service
Calibrating hydraulic torque tools is absolutely indispensable in terms of a continuous preload. However, not only
torques but also the pressure gauges, i.e. manometers,
have to be checked.
Regular testing and calibrations may be carried out at our
site in Krailing, Germany, or at your site.
All vehicles of our on-site technicians are equipped with
mobile calibration devices. Our on-site service team is
happy to carry out calibrations up to 5,000 Nm, 25,000 Nm
and even 50,000 Nm fast and reliably – even after hours,
if necessary.
HYTORC generally calibrates all its hydraulic pneumatic
and electric torque wrenches; we also calibrate products
by other manufacturers.
c LoadCERT – Proof i.a.w. TA Luft
LoadCERT flange tightening certificate
Both standards, TA Luft and EN 1591, require that flange
connections are proven to be leak-free and tight.
In order to ensure such quality, HYTORC offers LoadCERT,
an on-line certification software for the automatic creation
of flange tightening certificates. After having registered
via www.hytorc.de, you will be able to benefit from the
free-of-charge HYTORC flange tightening certificate, too.
Benefits of the HYTORC flange tightening certificate:
• Proof i.a.w. TA Luft and EN 1591
• Operating instructions for tightening the flange
• Helps you take the right decision when problems occur
• Can be integrated into existing quality management
systems
• Additional feature of tender documents to prepare for
downtimes
• Resource planning in terms of lubricant, bolt, gasket
and tool stocks
• Minimization of weak points thanks to automated
plausibility checks during creation
• Increases plant and occupational safety
52
Professional training at the highest level
HYTORC is a certified training service provider
Professional training programs with specialized course content for individual
and demand-oriented training in small groups of up to 20 participants.
Well trained personnel lets you keep your competitive
edge and increases your company's occupational and plant
safety. Our customized trainings offer many advantages.
HYTORC is a certified training service provider and, as
such, offers fastening trainings and courses for engineers
and mechanics. They take place at our trainings center or at
your premises. During trainings for individuals or groups,
our competent trainers impart theoretical and especially
practical expertise. We enhance the capabilities and skills
of your employees and train them to become experts.
The HYTORC training center in Augsburg, Germany, is our
training base when it comes to industrial bolting and at
the focus of our certified quality management system.
It is a cutting-edge training facility and we conduct all
our internal trainings here.
c Trainings at our center of excellence in Augsburg, Germany
If you are interested in receiving training at your company,
this can also be arranged: We will provide you with a trainer
as well as the material required to conduct hands-on
trainings and you provide the location for the theory and
practical part of the training. After having passed the test,
all successful candidates immediately receive their
certificate.
HYTORC is flexible and happy to organize the entire
certification of your employees.
c Customized trainings on-site
Trainings
53
We always keep our training program up-to-date and
adapt it to the industry's requirements.
We offer customized trainings modules which comply
with standards such as EN 1591-4, ASME-PCC1:2013
and OSHA-7110:
Safe operation of hydraulic, electric and pneumatic
torque wrenches
Occupational safety in maintenance –
Basic requirements
Training contents:
• General requirements to on-site operation
• Safety precautions before, during and after operation
• Quality accessories for increased occupational safety
• Training with a view to practical applications
c Room for theoretical training
Tightening methods i.a.w. VDI2230
Basic requirements to selection and proper operation
Training contents:
• VDI2230 and its assembly methods according to table 8A
• Selection of tightening methods i.a.w. VDI/VDE 2862
Sheet 2
• Set-up and mode of operation as well as setting
parameters and selection
• Operation and analysis in practice
EN1591-4 – Flanges and their joints
Certification of personnel's ability to assemble bolted
connections
c Room for practical training
Training contents:
• 8.2.2 Basic certification level
• 8.2.3 Tightening by means of hydraulic clamping tools
• 8.2.4 Tightening by means of hydraulic torque tools
• 8.3 Responsible engineer
Please send your inquiries for staff trainings to
[email protected] via email and copy "Training" into
its subject line.
c Practical training i.a.w. EN 1591-4, module 8.2.2
54
Together, we will find
the best solution
Our comprehensive range of products
and valuable expert knowledge helps
us find customized solutions – even to
most demanding applications.
Continuous innovation, the constantly
high quality of our products and years
of experience have made us the reliable
partner we are for our customers today.
No matter which challenge you hold in
stock for us – together with you, we will
find the best solution!
HYTORC industrial bolting
55
HYTORC –
The world's leading
partner and supplier
in industrial bolting.
• Comprehensive and unique range of products
• Innovative technology and solutions
• Service at our customers' doorsteps
• Training center in Augsburg, Germany
• Fast and customer-centric services
HYTORC boasts innovative products, unique
fastening elements, intelligent bolting methods
and years of application and engineering
expertise in the field of industrial bolting.
Thanks to a wide sales and service network
in Germany and Europe, we are always at our
customers' doorsteps and are able to give
fast support thanks to the best tools and our
expert knowledge.
That is why we can always provide you with the
best solutions at the cutting-edge of industrial
bolting. We look forward to the challenges you
have in stock for us!
KMore information can be found by visiting:
www.hytorc.de
HYTORC | BARBARINO & KILP GmbH
Justus-von-Liebig-Ring 17
D-82152 Krailling / germany
Telefon: +49 (0)89/230 999-0
Internet: www.HYTORC.de
03 2015 | 1
All information in this printed catalog correspond to our current level of knowledge and is
intended to inform you about our products and their possible applications. Therefore, it does
not guarantee that particular products have certain characteristics necessary for a specific
application. We warrant impeccable quality within the scope of our General Terms and Conditions.

HydrAulic tigHtening tecHnology for All fAstening

Transcription

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