Apex Tool Group Cleco BD Series User manual

For additional product information, visit our website at www.clecoTools.com
Installation Manual
P2585JH-EN
2022-03
BD Series
Cable management

2
P2585JH | 2022-03
Apex Tool Group
Copyright © Apex Tool Group, 2022
No part of this document may be reproduced in any way or in any form, in whole or in part, or in a natural
or machine-readable language, or transmitted on electronic, mechanical, optical, or other media, without
the express permission of the Apex Tool Group.
Disclaimer
Apex Tool Group reserves the right to modify, supplement, or improve this document or the product with-
out prior notice.
Trademark
Cleco Production Tools is a registered trademark of Apex Brands, Inc.
Apex Tool Group
670 Industrial Drive
Lexington, SC 29072
USA
Manufacturer
Apex Tool Group GmbH
Industriestraße 1
73463 Westhausen
Germany

Content
Apex Tool Group
P2585JH | 2022-03
3
EN
Content
1About this document ...........................................................................4
1.1 Other documents ............................................................................................................4
1.2 Symbols in the text .........................................................................................................4
2Measures...............................................................................................5
2.1 General information ........................................................................................................5
2.2 Manually operated tools..................................................................................................6
2.3 Robotics applications......................................................................................................7
2.4 Use of cable ducts ..........................................................................................................8
2.5 Cable routing, transducer cable......................................................................................8
3Cable ...................................................................................................10
4Auxiliaries ...........................................................................................13

About this document
4
P2585JH | 2022-03
Apex Tool Group
1
EN
1 About this document
This document is intended for specialists in cable installation and maintenance (administrators, mainte-
nance staff, service personnel).
It contains information
•on installation
•on configuration and function.
The original language of this document is German.
1.1 Other documents
Number
Document
P2577SB
System manual – BD Series
P2578WA
Maintenance instruction – Fixtured Spindle BD Series
P2579MA
Assembly instructions – Fixtured Spindle BD Series
1.2 Symbols in the text
italic
Menu options (e.g., Diagnostics) input fields, check boxes, radio buttons or dropdown
menus.
>
Indicates selection of a menu option from a menu, e.g., File > Print.
<...>
Specifies switches, pushbuttons or the keys of an external keyboard, e.g., <F5>.
Courier
Indicates Filenames and paths, e.g., setup.exe.
•
Indicates lists, level 1.
-
Indicates lists, level 2.
a)
b)
Indicates options.

Indicates results.
1. (...)
2. (...)
Indicates action steps.
►
Indicates single action steps.

Measures
Apex Tool Group
P2585JH | 2022-03
5
2
EN
2 Measures
Why cable management?
Correct cable management increases service life and prevents failures. Comply with the following points
when routing cables:
2.1 General information
Routing
►Route cables such that there is no risk of tripping.
►Route cables in light loops. Maximum freedom of movement should ensure that the cable is never ten-
sioned.
►Do not use extra-long wires (reserve).
►Route cables such that they are free of torsion.
►Cables should not knock against parts, rub or hang loose.
►Make sure that the length of the cable compensates for torsional loads.
►Obverse the respective allowed bending radii and torsional lengths. The larger the bending radius and
the torsional length, the longer the service life will be.
►Take appropriate measures to limit cable bending radii and torsion.
►All plug connections must be closed. Locks must be tightened firmly.
Strain relief
►There must be no tensile or transverse forces acting on plug connections.
►Fit strain relief elements at start and finish of all sections of an extension cable.
►Only use the specified auxiliaries (see 6.3 Strain relief., Page 20) to relive cables of tensile forces.
►Do not use cable ties. Cable ties stress the cable and reduce the expected service life.
►Keep the number of plug connectors as low as possible.

Measures
6
P2585JH | 2022-03
Apex Tool Group
2
EN
2.2 Manually operated tools
Additional measures see chapter 2.1 General information, page 5
►Use short wire cables to limit the possible travel of the carriages.
►After installing cables, run a number of motion cycles and optimize the routing as necessary.
Fig. 2-1: Example of the use of a manually-operated fixtured spindle
1
Strain relief clamp
2
Tool cable plug connection
3
Strain relief strap
1
23

Measures
Apex Tool Group
P2585JH | 2022-03
7
2
EN
2.3 Robotics applications
Great care must be taken when routing cables and hoses in robotics applications.
Additional measures see chapter 2.1 General information, page 5:
►When routing cables in robotics applications, make sure that the cables do not make contact with any
other parts, and that they do not rub or sag.
►After installing cables, run a number of motion cycles and optimize the routing as necessary.
Fig. 2-2: Example of a robotics application
1
Strain relief strap
2
Strain relief clamp
3
Tool cable plug connection
4
Balancer
5
Plug connection fixing
1
2 3 4
5

Measures
8
P2585JH | 2022-03
Apex Tool Group
2
EN
2.4 Use of cable ducts
Great care must be taken when routing cables and protective hoses in cable ducts.
Additional measures see chapter 2.1 General information, page 5:
►Choose cable ducts with a length that ensures that the routed cables are never subjected to tensile or
compressive strain.
►There must be no plug connections in the area of the cable duct. Secure the plug connections with
clamps
Fig. 2-3: Example of the use of cable ducts
1
Plug connector
2
Plug connection fixing
►All edges in the cable duct must have a radius to protect the cables against rubbing, overstressing and
pinching.
►Route cables such that they are free of torsion. Prior to installation, lay the cables on an even surface
so that they can be inserted while stretched out.
►Cables must be able to follow the radius of curvature without being forced around it.
►Do not cross cables or hoses in the cable duct.
►Do not bundle cables; if possible route them individually in the cable duct, loosely adjacent to each
other. Route a maximum of two cables per partition.
►Separate cables lying adjacent to each other using cut-off bridges whenever possible.
►For vertical routing, allow approx. 20% clearance within the bridge height. The lines hang out down-
ward due to the cable weight, including the chain. This lengthening due to sagging must be monitored
at regular intervals and adjusted if necessary.
►Never lay cables with different diameters (difference > 3 mm) together in the same partition.
►Avoid pinching individual wires or subcomponents. We recommend applying a clamping force around
the entire circumference of the cable.
►After installing cables, run a number of motion cycles and optimize the routing as necessary.
2.5 Cable routing, transducer cable
►With a Velcro strip,see chapter 4 Auxiliaries, page 13 fasten the transducer cable tightly to the fixtured
spindle.
Size
A
Velcro strip length
[cm]
B
Velcro strip length
[cm]
1
20
23
2
23
28
3
32
31
4
32
32
1 2

Measures
Apex Tool Group
P2585JH | 2022-03
9
2
EN
Examples of fastenings:
Fig. 2-4: 1BD-2K-ZB
Fig. 2-5: 1BD-2K-VK
Fig. 2-6: 1BDU-2K-ZB
Fig. 2-7: 1BDU-2K-VK

Cable
10
P2585JH | 2022-03
Apex Tool Group
3
EN
3 Cable
Fig. 3-1: Cable
Size
A
B
C
D
E
Order No.
Lengt
h
[m]
Order No.
Order No.
Order No.
Order No.
1
961561-010
…
961561-250
1
…
25
962343-002
942769PT-002
943290PT-002
943835PT-002
2
961923-010
...
961923-340
1
…
34
962343-002
942769PT-002
943290PT-002
943835PT-002
3
961923-010
...
961923-340
1
…
34
962343-003
942769PT-002
943290PT-002
943835PT-002
4 961923-010
...
961923-340
1
…
34
962343-005
942769PT-002 943290PT-002 943835PT-002
962343-007
(4Z2800G)
Note
Malfunction
The total length of the tool cable must not exceed 50 m.
►Match the length of the tool cable with the extension cable.