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

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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
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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
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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
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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
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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

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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
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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
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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
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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.

Cable
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Tool cable A/Size 1
Order No.
Length
[m]
Weight1
[kg]
961561-010
1
0.43
961561-020
2
0.61
961561-030
3
0.79
961561-035
3.5
0.88
961561-040
4
0.97
961561-050
5
1.15
961561-060
6
1.33
961561-070
7
1.51
961561-080
8
1.69
961561-100
10
2.05
961561-110
11
2.23
961561-150
15
2.95
961561-200
20
3.85
961561-250
25
4.75
Properties
Thermal
Ambient temperature
-20 °C to +90 °C
Flammability
In accordance with UL 1581
Chemical (jacket)
Jacket material
PUR, low adhesion, hydrose
and microbe resistant, UV re-
sistant, abrasion resistant,
tear resistant, cut resistant,
gouge resistant
DIN ISO 4649, DIN EN 5025-
2-21
Oil resistance In accordance with
DIN EN 50363-10-2, IRM902
Resistance to hydrolysis
In accordance with
DIN EN 50363-10-2
Color
Similar to RAL 2004
Mechanical
Diameter [mm]
10.3 ± 0.3
Bending radius R [mm]
Single bends
Multiple bends
25 min.
75 min. Rolling movement
110 min. Alternate bending
Torsion length [mm]
(+180° around its own central axis)
500 min.
Max. acceleration [m/s²]
100 (10 G max.)
1Plug connection 0.25 g/cable 0.18 g/m

Cable
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Tool cable A/Size 2–4
Order No.
Length
[m]
Weight1
[kg]
961923-010
1
0.56
961923-020
2
0.87
961923-030
3
1.18
961923-040
4
1.49
961923-050
5
1.80
961923-060
6
2.11
961923-080
8
2.73
961923-100
10
3.35
961923-150
15
4.90
961923-200
20
6.45
961923-250
25
8.00
961923-280
28
8.93
961923-340
34
10.79
Properties
Thermal
Ambient temperature
-20 °C to +90 °C
Flammability
In accordance with UL 1581
Chemical (jacket)
Jacket material
PUR, low adhesion, hydrose
and microbe resistant, UV re-
sistant, abrasion resistant,
tear resistant, cut resistant,
gouge resistant DIN ISO 4649
Oil resistance
In accordance with
DIN EN 50363-10-2, IRM902
Resistance to hydrolysis
In accordance with
DIN EN 50363-10-2
Color
Similar to RAL 2004
Mechanical
Diameter [mm]
13.9 ± 0.3
Bending radius R [mm]
Single bends
Multiple bends
35 min.
105 min. Rolling movement
140 min. Alternate bending
Torsion length [mm]
(+180° around its own central axis)
500 min.
Max. acceleration [m/s²]
100 (10 G max.)
1Plug connection 0.25 g/cable 0.18 g/m

Auxiliaries
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4 Auxiliaries
Article
Use
Clamp body STAUFF with
elastomer insert
Type 410 PP-R (10 mm)
Order No. –
Type 414 PP-R (14 mm)
Order No. 961509PT
Securing of cable and hose compo-
nents at the beginning and end of
the sections.
Broad, padded clamping area.
Adapts to the corresponding cable
diameter, e.g.,
STAUFF clamp body
Type 428-PP-H (28 mm)
Order No. 917900
Securing of plug-in connections un-
der extreme forces, such as vibra-
tions, shocks or rotary movements.
Velcro strap
e.g., type ONE_WRAP Strap
More cost-effective cable manage-
ment solution for additionally fixing
or bundling cables. Cables are not
clamped too tightly and make the
package flexible, in contrast to ca-
ble ties.
Do not use as strain relief!

POWER TOOLS SALES & SERVICE CENTERS
Please note that all locations may not service all products.
Contact the nearest Cleco® Sales & Service Center for the appropriate facility to handle your service requirements.
Sales Center
Service Center
NORTH AMERICA | SOUTH AMERICA
DETROIT, MICHIGAN
Apex Tool Group
2630 Superior Court
Auburn Hills, MI 48236
Phone: [phone]
-5644
Fax: [phone]
-6295
LEXINGTON,
SOUTH CAROLINA
Apex Tool Group
670 Industrial Drive
Lexington, SC 29072
Phone: [phone]
-5629
Phone: +1
[phone]
Fax: [phone]
-7681
MEXICO
Apex Tool Group
Vialidad El Pueblito #103
Parque Industrial Querétaro
Querétaro, QRO 76220
Mexico
Phone: [phone]
Fax: [phone]
EUROPE | MIDDLE EAST | AFRICA
ENGLAND
Apex Tool Group UK
C/O Spline Gauges
Piccadilly, Tamworth
Staffordshire B78 2ER
United Kingdom
Phone: [phone]
Fax: [phone]
FRANCE
Apex Tool Group SAS
25 Avenue Maurice Chevalier
- ZI
77330 Ozoir
-La-Ferrière
France
Phone: [phone]
00
Fax: [phone]
GERMANY
Apex Tool Group GmbH
Industriestraße 1
73463 Westhausen
Germany
Phone: [phone]
Fax: [phone]
HUNGARY
Apex Tool Group
Hungária Kft.
Platánfa u. 2
9027 GyörHungary
Phone: [phone]
Fax: +
36 96 66 1135
ASIA PACIFIC
AUSTRALIA
Apex Tool Group
519 Nurigong Street, Albury
NSW 2640
Australia
Phone: [phone]
CHINA
Apex Power Tool Trading
(Shanghai) Co., Ltd.
2nd Floor, Area C
177 Bi Bo Road
Pu Dong New Area,
Shanghai
China 201203 P.R.C.
Phone: [phone]
Fax: [phone]
INDIA
Apex Power Tool Trading
Private Limited
Gala No. 1, Plot No. 5
S. No. 234, 235 & 245
Indialand Global
Industrial Park
Taluka
-Mulsi, Phase I
Hinjawadi, Pune 411057
Maharashtra, India
Phone: [phone]
JAPAN
Apex Tool Group Japan
Korin
-Kaikan 5F,
3
-6-23 Shibakoen, Minato-Ku,
Tokyo 105
-0011, JAPAN
Phone: +81
-3-6450-1840
Fax: +81
-3-6450-1841
KOREA
Apex Tool Group Korea
#1503, Hibrand Living Bldg.,
215 Yangja
e-dong,
Seocho
-gu, Seoul 137-924,
Korea
Phone: +82
-2-2155-0250
Fax: +82
-2-2155-0252
0322 | Cleco® is a registered trademark of Apex Brands, Inc. | © 2022
Apex Tool Group, LLC
Phone: [phone]-
5629
Phone: [phone]-
0099
Fax: [phone]-
7681
www.ClecoTools.com
www.ClecoTools.de