Cleco LiveWire Vmax PM48 User manual

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Power Module PM48
Order No. 961350
Instruction Manual
P1963E/EN
2008-06

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Contents
1 Safety 3
1.1 Warnings and notes.............................................................................. 3
1.2 Basic requirements for safe working practices..................................... 4
1.3 Designated use..................................................................................... 4
1.4 Items supplied....................................................................................... 4
1.5 Transport .............................................................................................. 4
1.6 Storage................................................................................................. 4
2 Product description 5
2.1 General description............................................................................... 5
2.2 System overview – optional accessories.............................................. 5
2.3 Dimensions in mm – Drilling plan ......................................................... 6
3 First Operation 6
3.1 Hardware ............................................................................................. 6
3.2 Software ............................................................................................... 7
4 Troubleshooting 8
5 Maintenance 8
6 Service 8
7 Technical data 9
8 Cable and connector 9
8.1 Connector Power module..................................................................... 9
8.2 Adapter cable 961341-... .................................................................... 9
8.3 Extension cable 961342-... ............................................................... 10
8.4 Cable quality ...................................................................................... 10
9 Disposal 11

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Safety 1
Copyright protection
Cleco reserves the right to modify, supplement or improve this document or the product without prior notice.
This document may not be reproduced in whole or in part in any way, shape or form, or copied to another
natural or machine-readable language or to a data carrier, whether electronic, mechanical, optical or other-
wise, without the express permission of Cleco.
1 Safety
1.1 Warnings and notes
Warning notes are identified by a signal word and a pictogram:
• The signal word describes the severity and the probability of the impending danger.
• The pictogram describes the type of danger.
WARNING! Indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION! Indicates a potentially hazardous situation which, if not avoided, may result in minor or moder-
ate injury or property and environmental damage. If this warning is not observed, injuries, prop-
erty or environmental damage may occur.
NOTE General notes
include application tips and useful information but no hazard warnings.

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Safety
1
1.2 Basic requirements for safe working practices
Before using the power module for the first time, ensure that you have carefully read and understood the
operating instructions. Failure to observe the instructions below may result in electric shock, fire and serious
injuries.
1.3 Designated use
• The power module is intended solely for supplying voltage to the CLECO cordless EC tool.
• Do not use it in areas where there is a risk of explosion.
1.4 Items supplied
Check shipment for transit damage and ensure that all items have been supplied:
1 Power module
1 EU power cable
1 NA power cable
1 GB power cable
1 Operating instructions
1.5 Transport
Transport and store the power module in the original packaging. The packaging can be recycled.
1.6 Storage
CAUTION! Electrical safety
➔Do not open the power module.
➔Do not modify the power module structurally.
➔Operate the power module in dry, enclosed rooms only.
➔Protect the power module from moisture and rain.
➔Never operate the power module under unsuitable ambient conditions (e.g. where combusti-
ble gases, solvents, dust, vapors or moisture is present).
➔Do not operate the power module if the housing or power plug are damaged.
➔Do not use damaged cables.
Work area
➔Ensure that there is enough space in the work area.
➔Keep the work area clean and dry.
Storage temperature -20 to +70 °C (-4 to 158 °F)
Relative humidity 0 to 90%

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Safety 1
2 Product description
2.1 General description
The power module supplies the cordless EC tool with voltage via a cable.
• The higher voltage of 48 VDC (compared to a 26 V Li-Ion battery) increases the speed of the cordless
EC tool up to 80%.
• Stable metal housing
• Wide-range input 85 VAC to 276 VAC
• Operating mode display with 2 LEDs
• Short-circuit proof
• Easy to install with 4 keyholes in the housing.
2.2 System overview – optional accessories
63_Overview Corded tool
Pos. Description
1 Power module 961350 (delivery contents)
2 Tool series 17BP…/ 47BA…
3 Adapter cable, see 8.2 Adapter cable 961341-..., page 9
4 Extension cable, see 8.3 Extension cable 961342-..., page 10
5 Power cable EU, NA, GB (delivery contents)
6 2× Fuse, Bussmann, Product Code S506-6.3A, time delay (delivery contents)
12
3
4
5
LED
On / Off
6

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First Operation
3
2.2.1 LED display
2 LEDs behind front plate
2.3 Dimensions in mm – Drilling plan
3 First Operation
3.1 Hardware
LED Operating status Result
DC – OK Green continuous light 48 VDC present
Overload Red continuous light 48 VDC overload or short-circuit
Overload Red flashing light (1 Hz) 48 VDC overload or short-circuit
1. Plug the Adapter cable and/or exten-
sion cable into the power module.
The plug connector on the Adapter
cable is equipped with a slide lock.

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First Operation 3
3. Connect the power module to the power supply.
4. Switch on the power switch.
The green LED DC – OK signals: power supply and 48 VDC output voltage present.
3.2 Software
1. Check the installed servo firmware of the cordless EC tool at the tool LCD:
➔Pushing the right function key: Main menu/Administration/Servo.
See also operating instructions cordless EC tool.
➔Contacting Cleco Service Center for the update of the servo firmware.
2. Check the installed measuring card software of the cordless EC tool.
Either at the tool LCD:
➔Pushing the right function key: Main menu/Administration/Version.
See also operating instructions cordless EC tool.
Or at the controller:
➔See programming manuals TMEC, TMEB-COM, m-Pro-400S(E).
➔Contacting Cleco Service Center for the update of the measuring card software.
➔Updating software over controller (see programming manuals controller).
2. Connect the adapter cable and/or
extension cable with the tool guide until
the catches securely engage.
To remove the adapter cable, press the
catches together and pull the adapter
out of the handle.
NOTE • Operate the system only when the slide lock of the plug is closed.
• Wait approx. 1 minute before reconnecting the Adapter cable. Compensating currents between the
power supply and Adapter cable can damage the contacts.
NOTE The cordless EC tool is only able to work on the power module only with:
Servo Firmware T10C / measurement card software 2.00.05 or higher.
The increased speed (up to 80%) is only reached with the called software stands.
NOTE Remove the cordless EC tool and the Adapter cable only when the power supply is switched off.

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Troubleshooting
4
4 Troubleshooting
5 Maintenance
➔Keep the contacts of the power module and the battery free of contamination. Only in this way is proper
function of the power module guaranteed.
6 Service
NOTE
If repair is required, send the complete power module to Cleco. It may be repaired only by authorized tech-
nicians. Opening the power module will void the warranty.
Error Cause Measure
The green DC OK LED is not
illuminated when the power
supply is connected.
No power supply voltage. ➔Check and restore the power
supply voltage.
Power cable defective. ➔Replace power cable.
Defective fuse in the power supply
module.
➔Replace 6.3 AMT fuse, see
2.2 System overview – optio-
nal accessories, page 5.
Power module defective. ➔Replace power module.
Power module overloaded. ➔Switch off the power supply
and switch it back on after
approx. 30 sec.
The red Overload LED is illu-
minated.
Overload of the 48 VDC output
voltage.
➔Check EC tool and cable for
damage.
Short circuit in the Adapter cable. ➔Replace Adapter cable.
Short-circuit in the EC tool. ➔Replace EC tool.
EC tool requires too much power. ➔Check EC tool for damage
and replace if necessary.
The temperature of the power mod-
ule is too high.
➔Decrease the ambient tem-
perature to <40° C (104° F).
The red >Overload< LED
flashes at a frequency of
approx. 1 Hz.
Continuousoverload ofthe 48 VDC
output voltage.
➔Check EC tool and cable for
damage.
Short circuit in the Adapter cable. ➔Replace Adapter cable.
Short-circuit in the EC tool. ➔Replace EC tool.
EC tool requires too much power. ➔Check EC tool for damage
and replace if necessary.

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Technical data 7
7 Technical data
8 Cable and connector
8.1 Connector Power module
Assignment of the contacts
8.2 Adapter cable 961341-...
Features Data
Supply voltage 85 to 276 VAC
Power supply frequency 47 to 63 Hz
Rated output 200 W
Peak output 750 W
Rated output voltage 47,5 to 48,5 VDC
Output current 10 A
Output current max. 4 s 15 A
Protection category IP54
Weight 3.1 kg (6.8 lbs)
Ambient temperature +5 to +40 °C (+41 to +104 °F)
Relative humidity 0 to 90%
NOTE Total cable length cannot exceed 20 m.
Contact Assignment
A +48 VDC
B +48 VDC
Cnc
D 0 VDC
E 0 VDC
Order no. Length
961341-030 3 m
961341-060 6 m
961341-080 8 m
961341-100 10 m

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Cable and connector
8
Assignment of the contacts
8.3 Extension cable 961342-...
Assignment of the contacts
8.4 Cable quality
Contact on
connector Contact on tool adapter Assignment
A 1 +48 VDC
B 1 +48 VDC
C-nc
D 3 0 VDC
E 3 0 VDC
Order no. Length
961342-030 3 m
961342-060 6 m
961342-080 8 m
961342-100 10 m
Contact on
connector pin Contact on con- nector socket Assignment
A A +48 VDC
B B +48 VDC
CCnc
D D 0 VDC
E E 0 VDC
Thermal properties
Ambient temperature -40…+80 °C (-40 to +176 °F)
Chemical properties of the coating
Coating material PUR, low-adhesion, resistant to hydrolysis and microbes,
UV-resistant, abrasion-resistant, tear-resistant, cut-resis-
tant, notch-resistant
Oil resistance Oil-resistant in accordance with DIN VDE 0472, part 803,
ASTM oil 1 to 3 and HD 505.2.1
Mechanical properties
Diameter approx. 7,2 mm
Minimum bending radius
Single bends
Alternate bendings 30 mm 70 mm
Torsional length
( ±360 ° around separate central axis) 1000 mm min.

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Disposal 9
9 Disposal
CAUTION! Injuries and environmental damage from improper disposal.
Components and auxiliary materials of the power module pose risks to health and the environment.
➔Separate the components of the packing and dispose of them by segregating them clearly.
➔Follow the locally applicable regulations.
➔Hand in the power module at your company collection point or return it to Cleco.

Apex Tool Group, LLC
1000 Lufkin Road
Apex, NC 27539
Phone: [phone]
Fax: [phone]
www.apextoolgroup.com