Cleco LiveWire P1891E User manual

For additional product information visit our website at http://www.apextoolgroup.com
47BA…B…
Cordless EC tool
Instruction Manual
P1891E/EN
2014-02

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Disclaimer:
Apex Tool Group 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, opti-
cal or otherwise, without the express permission of Apex Tool Group.
Notes on this Instruction Manual
This instruction manual is the – Translation of Original Instruction Manual – and is intended for any persons
working with this tool without carrying out programming work.
The instruction manual has the following purposes:
• provides important instructions for safe and effective operation.
• describes the function and operation of the cordless EC tool.
• It serves as a reference work for technical data, service intervals
and spare part orders.
• It points out options.
LiveWire 1: Nomenclature 47BA(…)
47B A……B………
Series Lock device
47 – Pin
B– Ball1)
1) upon request
Energy
B– Battery / PM48 Output drive
AM3 – Square 3/8"
Tool style P4 – Square 1/2" (pin)
A– Angle
Max. torque
Property 1 (Data Transmission) 15 – 15 Nm
– IrDA 21 – 21 Nm
R – RF868 MHz 28 – 28 Nm
X – WLAN: 2.4 GHz 35 – 35 Nm
Y – WLAN: dual band 2.4 GHz, 5 GHz 50 – 50 Nm
Z – RF15.4: IEEE 802.15.4 70 – 70 Nm
90 - 90 Nm
Peripheral equipment
S – Barcode scanner Power supply
P – Platform B– 26–48 V max.
– None

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LiveWire 2: Nomenclature 47BA(…)L
Symbols in the text:
Symbols in graphics:
47 B A … P B … AM3 … L
Series Tool Series
47 L – LiveWire 2
Energy Lock device
B– Battery / PM48 – Pin
B– Ball1)
1) upon request
Tool style
A– Angle Output drive
AM3 – Square 3/8"
Property 1 (Data Transmission)
Y – WLAN: dual band 2.4 GHz, Max. torque
15 – 15 Nm
Peripheral equipment 21 – 21 Nm
P – Platform 28 – 28 Nm
35 – 35 Nm
50 – 50 Nm
Power supply
B– 26–48 V max.
47BA(…) stands for all versions of the cordless EC tool/LiveWire 1 described here.
47BA(...)L stands for all versions of the cordless EC tool/LiveWire 2 described here.
EV stands for all versions of the power supply described here: Battery pack or Power module.
LMC stands for the LiveWire Memory Chip memory module
 identifies instructions to be followed.
• identifies lists.
italics Indicates menu items such as Diagnostics in software descriptions
<…> Identifies elements that have to be selected or deselected, such as push buttons or check
boxes, i.e. <F5>
Courier Indicates the name of paths and files, e.g. setup.exe
\ A backslash between two names indicates the selection of an item from
the menu, e.g. file \ print
identifies movement in one direction.
identifies function and force.

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P1891E-ENU_2014-02_47BA-BIVZ.fm, 25.04.2014 P1891E/EN 2014-02 5
Contents
1 Safety 7
1.1 Warnings and notes.............................................................................. 7
1.2 Basic requirements for safe working practices..................................... 8
1.3 Operator training................................................................................... 8
1.4 Personal protective equipment............................................................. 8
1.5 Designated use..................................................................................... 9
1.6 Norms / Standards................................................................................ 9
1.7 Noise and vibration............................................................................... 9
2 Items supplied, transport and storage 10
2.1 Items supplied..................................................................................... 10
2.2 Transport ............................................................................................ 10
2.3 Storage ............................................................................................... 10
3 Product description 11
3.1 General description............................................................................. 11
3.2 Operation and functional elements..................................................... 12
4 Accessories 17
5 Before initial operation 18
5.1 Use of reaction bar ............................................................................. 18
5.2 Setting up tool holder.......................................................................... 18
5.3 Ambient conditions ............................................................................. 18
5.4 Charge battery pack ........................................................................... 18
5.5 Changing LMC ................................................................................ 19
5.6 Activating scanner/TAG...................................................................... 20
6 Initial operation 20
6.1 Carrying out rundown ......................................................................... 20
6.2 Operating status ................................................................................. 21
7LCDdisplay 23
7.1 Result display ..................................................................................... 23
7.2 Status display...................................................................................... 24
7.3 Operating menu.................................................................................. 27
7.4 System error messages ................................................................... 40

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8 Servicing 43
8.1 Cleaning instructions .......................................................................... 43
8.2 Service schedule ................................................................................ 43
8.3 Lubricants........................................................................................... 44
8.4 Disassembling gear .......................................................................... 45
8.5 Removing angle attachment 935313.................................................. 46
8.6 Installing angle attachment 935313.................................................... 47
9 Troubleshooting 49
9.1 Reset tool............................................................................................ 58
10 Spare parts 59
10.1 Gearing (15 Nm – 50 Nm) + angle attachment................................... 60
10.2 Gearing (70 Nm / 90 Nm) + angle attachment.................................... 62
10.3 Angle attachment 935313 AM3 with pin lock (15 Nm – 28 Nm)
Angle attachment 941568 AM3B with ball lock (15 Nm – 28 Nm)...... 64
10.4 Angle attachment 525943 AM3 with pin lock (35 Nm – 50 Nm)
Angle attachment 541174 AM3B with ball lock (35 Nm – 50 Nm) ...... 66
10.5 Angle attachment 937776PT P4 with pin lock (70 Nm/90 Nm)........... 68
10.6 Angle attachment 937779PT P4B with ball lock (70 Nm/90 Nm) ....... 68
10.7 Use with reaction bar 1/2" hexagonal................................................. 69
10.8 Tool holder.......................................................................................... 70
11 Technical data 73
11.1 LiveWire 1: Dimensions 47BA(…) in mm ........................................... 73
11.2 LiveWire 2: Dimensions 47BAYPB(…)L (mm).................................... 77
11.3 Dimension of tool holder 935290 / 935395 (optional)......................... 78
11.4 Dimension of tool holder 935999 / 935998 (optional)......................... 78
11.5 LiveWire 1: Performance data 47BA(…) ........................................... 79
11.6 LiveWire 2: Performance data 47BAYPB(…)L ................................... 81
11.7 Electrical Data..................................................................................... 81
12 Service 85
12.1 Recalibration....................................................................................... 86
13 Disposal 86

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Safety 1
1Safety
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! Potentially hazardous situation for personal health and safety.
If this warning is not observed, death or serious injury may occur.
CAUTION! Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or
property and environmental damage. If this warning is not observed, injuries, property or environmental
damage may occur.
Class 2 laser product
Class 2 laser scanners use a laser diode that produces a low-power visible light beam that is comparable to
a very bright source of light, such as the sun.
Do not look into the laser beam when the laser is on.
Doing so can cause damage to the eyes.
General notes
include parameter set tips and useful information but no hazard warnings.

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Safety
1
1.2 Basic requirements for safe working practices
You should read all instructions.
Failure to observe the instructions below may result in electric shock, fire and serious injuries.
1.3 Operator training
All operators must be trained and experienced before operating the 47BA.
The 47BA may only be repaired by authorized technicians.
1.4 Personal protective equipment
When working
CAUTION! Workstation
Ensure that there is enough space at the workstation.
Keep the work area clean.
Electrical safety
47BA against moisture. Operate the tool indoors only (IP40).
Follow the safety instructions printed on the accupack and charger.
47BA with Cleco power supply.
Do not open the accupack .
Safety of persons
Ensure a secure standing position. Maintain balance.
Makes sure the power supply is correctly located before commissioning the 47BA.
47BA tightly in the hand – be prepared for high short-term reaction torques.
Always use a reaction bar for applications in restricted space and torques over 68 Nm. This prevents
injuries to the hands.
47BA Only place in the tool holder provided, see 10.8 Tool holder, page 70 – avoid unintentional com-
missioning.
Do not look into the laser beam of tools with built-in barcode scanners.
Follow generally valid and local safety and accident prevention rules.
Safe working with and around fastening tools
Socket inserts sockets for visible damage and cracks.
Replace damaged Socket insertsimmediately.
Disconnect from the power supply before changing the Socket inserts, 47BA.
Only use Socket inserts for machine-controlled fastening tools.
Socket inserts to the screw head at an angle.
Make sure that the Socket inserts are securely inserted.
Danger of injury by being wound up in and caught by machinery
Do not wear gloves.
Wear close-fitting clothing.
Wear a hairnet.
Do not wear jewelry.
Risk of injury due to metal splinters flying around
Wear protective goggles.

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Safety 1
1.5 Designated use
The 47BA is designed exclusively for fastening and releasing threaded fasteners.
The communication with the controller is allowed only over the following interface ports:
Do not use it in areas where there is a risk of explosion.
Do not open it or modify it structurally.
Only use with accessory parts which are approved by the manufacturer
(see 4 Accessories, page 17).
Do not use as a hammer or for re-bending.
1.6 Norms / Standards
It is mandatory that national, state and local codes and standards be followed.
Other type-specific standards, see 11 Technical data, page 73.
1.6.1 FCC conformity
This device complies with Part 15 of the FCC Rules. Operation satisfies the following two prerequisites: (1)
the device does not cause any impermissible failure, and (2) the device accepts failure, including failures
which cause unwanted operation of the device.
Changes or modifications not expressly approved by the party responsible for compliance could void the
user's authority to operate the equipment.
1.6.2 Canada conformity
Operation satisfies the following two prerequisites: (1) the device does not cause any impermissible failure,
and (2) the device accepts failure, including failures which cause unwanted operation of the device.
1.6.3 EMC
Industrial environment EMC limit class A.
The tool complies with the following EMC standards:
DIN EN 61000-6-4 Emitted interference
DIN EN 61000-6-2 Interference immunity
DIN EN 60601-1-2
1.7 Noise and vibration
Emissions sound pressure (i.e. noise) level Lp < 68 dB(A) free running (i.e. without load) complies with
DIN EN ISO 60745:2010-01.
The vibration values < 2.5 m/s² are in accordance with DIN EN ISO 20643:2005-03
Types Communications
All IrDA interface port of the tool holder, order no. 935290
47BAR(…) RF868 MHz
47BAX(…) WLAN standard IEEE 802.11b WEP, WPA/WPA2
47BAY(…) WLAN standard IEEE 802.11a/b/g WEP, WPA(2), LEAP, PEAP
47BAZ(…) WPAN standard IEEE 802.15.4

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Items supplied, transport and storage
2
2 Items supplied, transport and storage
2.1 Items supplied
Check shipment for transit damage and ensure that all items have been supplied:
1 47BA
1 This instruction manual
1 Declaration of Conformity
1 Factory test certificate for transducers
1 Machine Capability Analysis (MCA)
2.2 Transport
47BA in the original packaging. The packing is recyclable.
2.3 Storage
For short-term storage and for protection against damage.
47BA in the tool holder.
For storage longer than 100 hours
Disconnect the battery pack from the 47BA.
The battery pack is discharged by the electronics integrated in the tool.
Object Time period Storage tempera-
ture
47BA without power
supply No guideline -25 °C to +40 °C

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Product description 3
3 Product description
3.1 General description
• Sturdy, brushless motor with resolver.
Shutoff is torque/angle-controlled.
• LCD display with information on status, torque and angle.
• Grüne OK- und rote NOK-LED-Anzeige informiert
über aktuelles Verschraubungsergebnis.
• LED lighting makes it possible to find the screw point quickly.
• Clockwise/counterclockwise rotation
• Low vibration level
• Servo and fastening electronics are integrated in the 47BA.
• Fastening parameters are set with the controller or a PC.
• An exchangeable memory module (LiveWire Memory Chip) allows the quick exchange of identical tools,
without changing the parameters.
• Depending on the type, data is transmitted between the control and the tool via
- Infrared (IrDA)
Parameters and fastening results are transmitted to the control or to a PC by simply placing the
47BA in the tool holder.
-868MHz
-WLAN
- RF15.4 (IEEE 802.15.4)
• Power can be supplied by way of
- Battery pack 26 V / 44 V
- Power module 48 V
• Optionally, the tools are equipped with a 1D Linear barcode scanner.
• Built-in acoustic signal. The signal is activated after barcodes are scanned. It can also be activated after
NOK rundowns for a programmable time.

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Product description
3
3.2 Operation and functional elements
This chapter describes operational and functional elements and their tasks in the order of their respective
item nos.
8
9
7
2
2
2
54
1 <F2>
2
6
3
2
Item Designation
1 Function keys <F1>, <F2>
2 LED display
3 Start button
4 Reverse switch
5 IrDA (infrared interface port)
6 Set torque – stick-on marking foil
7 LED lights for fast location of the fastening position
8 Power supply; battery pack 26 V illustrated
9 LCD display with information on torque, angle and status
10 Barcode scanner
11 Wireless module
12 LiveWire Memory Chip (LMC); 47BAX(…) illustrated
13 Platform; 47BAYP(…) illustrated
12
10
1 <F1>
11
13

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Product description 3
3.2.1 Function keys
Left function key <F1>
• Confirm error message
Press once.
Programmable, depending on how the key is programmed, actions can be carried out by pressing it briefly.
•Exitmenu
Press for two seconds.
Right function key <F1>
• Activate menu
Press until the display shows the Main menu (for additional information, refer to 7.3 Operating menu,
page 27).
• Select functions, if menu is activated
Press for two seconds. Alternatively, the start button can be pressed.
3.2.2 LED display
The LED display shows the respective operating status and the result of the last fastening sequence (see
6.2 Operating status, page 21):
Software update
During Software Update, the actual programming process is indicated by rapid flashing alternating at irregu-
lar intervals between red and green.
LEDs Operating status Result
after screwing cycle
Green continuous light Active OK
Red continuous light Active NOK
Flashing light Green –
low frequency Energy saver mode
Off Sleep
If linking is selected on the control:
Green flashing light –
high frequency Active / Setting step operation Linking OK
Red flashing light Active / Setting step operation Linking NOK
Do not interrupt programming by disconnecting the power supply during this phase.

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Product description
3
3.2.3 Start button
Depending on the setting, the start button has three functions:
• It activates the LED lighting.
Press the start button halfway down and hold it.
• It starts the motor, the LED light goes out.
Press the start button all the way down.
• It activates the barcode scanner—only for types of the series.
Press the start button all the way down.
3.2.4 Reverse switch
The reverse switch changes the rotation direction of the 47BA:
Clockwise rotation – for screwing in screws
Press reverse switch as far as it will go.
When the start button is pressed Active appears on the LCD display.
Counterclockwise rotation – for loosening or screwing out screws
Press reverse switch as far as it will go.
When the start button is pressed Left appears on the LCD display.
3.2.5 IrDA interface port
The 47BA communicates with the control about the tool holder via the IrDA interface port (infrared). For
secure data transmission and for programming the 47BA, place the 47BA in the tool holder with IrDA inter-
face port, order no. 935290/935999 ab. Data transmission is possible in the Active, Energy saver mode and
Standby operating modes, but not possible in Sleep (see 6.2 Operating status, page 21).
3.2.6 Identification – set torque (accessories, optional)
To identify the set torque on the 47BA, glue the corresponding marking foil to the right and the left of the
LCD display.
3.2.7 LED lighting
LED lighting make it possible to quickly find the screw point.
3 different activation methods are possible. Which is used depends on the programming in the control:
• Activation by pressing the start button halfway down (3.2.3 Start button, page 14).
• Time-controlled beginning at start
If data transmission is interrupted, the 47BA reports a Synch Error on the LCD display. Place 47BA in the
tool holder again. The complete data transmission is acknowledged on the display with Rest 512.

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Product description 3
• You also have the option of disabling it.
Die Reichweite der LED-Beleuchtung beträgt 120 mm.
3.2.8 Power supply
See instruction manual for battery pack / instruction manual for power module PM48
3.2.9 LCD display
See 7 LCD display, page 23
3.2.10 Barcode scanner
For tools of the 47BA(…)S series, the fitted barcode scanner is a class 2 laser scanner with a wavelength of
650 nm.
The barcode scanner reads one-dimensional linear barcodes:
Depending on how the control is programmed, there are two different operating modes:
Barcode as release for further rundowns
Press the start button on the tool; this activates the barcode scanner.
The successful scan is acknowledged by an acoustic signal.
Press the start button on the tool again; this starts the rundown.
If is necessary to read another barcode, proceed as follows.
Barcode not necessary as release for further rundowns
From the Scanner tool menu, select Read barcode.
Press the start button on the tool; this activates the barcode scanner.
The successful scan is acknowledged by an acoustic signal.
Press the start button on the tool again; this starts the rundown.
Alternatively: assign the Read barcode function to the left function key <F1> on the tool.
Press the left function key <F1> on the tool once.
Press the start button on the tool again; this activates the barcode scanner.
Programming the barcode scanner is described in the programming manual of the control.
CAUTION! Eye injury from class 2 laser beam
Do not look into the laser beam window when the laser is on.
Repair any damage immediately.
Damage of the optical components can cause laser radiation.
Modifications to the barcode scanner and procedures not outlined in this instruction manual are
strictly prohibited.
Take defective devices out of operation immediately.
Keep window clean.
A dirty window affects the detection rate of the scanner.
Scanning operation Acoustic signal
• Successful 50 ms long
• Faulty
• Not within 3 seconds
•Cancel by releasing the Start button
3 times in rapid succession

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Product description
3
3.2.11 Wireless interface
Depending on the exact type, the tools are also equipped with a wireless interface in addition to the IrDA
interface. The tool uses this wireless interface port for continuous communication with the controller. This
interface port is used to transmit both the parameters and the rundown results. Data transmission is possi-
ble in the Active, Energy saver mode and Standby operating modes, but not possible in Sleep (see 6.2
Operating status, page 21). Programming and setting up the wireless interface port are described in the pro-
gramming manual of the controller.
3.2.12 LiveWire Memory Chip (LMC), only for models of the series 47BAY(…)
To permit simple replacement of tools in production, a replaceable LMC memory module is installed. When
the tool is switched on, the network settings are read from the LMC chip and used to establish the WLAN
connection. When the tools are changed, the LMC has to be installed in the new tool being used. Please
refer to 5.5 Changing LMC, page 19.
The following data are stored on LMC:
The MAC address is defined by Cleco and cannot be changed. The other data can be changed via infrared
connection of the tool to the controller .
3.2.13 Platform, only for models of the 47BAYP(…) series
Tools with a platform are basic tools which can be fitted with different add-on parts. Scanners and tags can
be ordered individually.
Type Communications Required linking terminal
47BAR(…) RF868 MHz Basis station Order no. 961300
47BAX(…) WLAN standard IEEE 802.11b Access point to standard IEEE 802.11b
47BAY(…) WLAN standard IEEE 802.11a/b/g Access point to standard IEEE 802.11a/b/g
47BAZ(…) WPAN standard IEEE 802.15.4 Basis station Order no. 961390 / 961410
After the tool is switched on, it can take up to 35 seconds until the communication is active.
• MAC address • Use of the DHCP server • Country-specific settings
• Network name (SSID) • IP address
• Encryption • Subnet mask
• Network key • Gateway

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Accessories 4
4 Accessories
General
Battery pack, Li ion, 26 V
Order No. 935377 Battery pack, Li ion, 44 V Order no. 936400PT
Battery charger, Li ion 26 V
(110 – 230 VAC)
Order no. 935391 – 1-piece
Order no. 935302 - 4-piece
Battery charger, Li ion 44 V
(85 - 270 VAC)
Order no. 936491 PT - 1-piece
Adapter cable PM48
Order no. 961341-030 – 3 m
Order no. 961341-060 - 6 m
Order no. 961341-080 - 8 m
Order no. 961341-100 - 10 m
Extension cable:
Adapter cable PM48
Order no. 961342-030 - 3 m
Order no. 961342-060 - 6 m
Order no. 961342-080 - 8 m
Order no. 961342-100 - 10 m
with IrDA interface,
RS232 connection cable
Order no. 935290 – to 50 Nm
Order no. 935999 – from 70 Nm
Without IrDA interface
RS232 connection cable
Order no. 935395 – to 450 Nm
Order no. 935998 – from 70 Nm
RS232 extension cable (IrDA)
Best.-Nr. 935154 – 3 m (9.84")
Best.-Nr. 935155 – 6 m (19.7")
Best.-Nr. 935157 – 10 m (32.8")
Power Module PM48
Order No. 961350
Marker film
Order no. 935330: 1.5 – 28 Nm
Order no. 935759: 30 - 49 Nm
Only for LiveWire 1
Protection, scanner
Up to 50 Nm
Order no. 936424PT
Protection, display
Order no. 937210PT
LMC
Order no. 961461PT
Protection, angle attachment AM3
Order no. 936372 – angle attachment up to 28 Nm
Order no. 936373 – angle attachment 35 Nm / 50 Nm

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Before initial operation
5
5 Before initial operation
The 47BA has been pre-configured by Cleco. A setting for your specific screw joint needs must only be
made with the controller or a PC by a qualified person. For more information, refer to the programming man-
ual.
5.1 Use of reaction bar
5.2 Setting up tool holder
Mount the tool holder on a stable base.
For tool holder with IrDA interface port:
Select the location in such a way that no outside light shines onto the tool holder.
This can inhibit data transmission.
Lay the connection cable in such a way that there is no danger that persons can trip.
5.3 Ambient conditions
5.4 Charge battery pack
Battery pack is only partly charged upon delivery.
It must be fully charged before initial use. See battery pack instruction manual.
Only for LiveWire 2
Scanner
Order no. 937240PT Top plate for platform Order no. 937255PT
LMC
Order no. 961462PT
CAUTION! Danger of hands being crushed.
Always use a reaction bar for applications in restricted space and
torques over 68 Nm.
Ambient temperature 0 °C (32 °F) to maximum +40° C (+104° F)
Humidity 0 to 80 %, not with dew
Working height up to 1000 m above sea level

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Before initial operation 5
5.5 Changing LMC
Abb. 5-1: Changing LMC
NOTE Electrostatically sensitive component. Note handling instructions.
The electronic assemblies of the cordless EC tool can be destroyed or damaged by electrostatic discharge
(ESD). This can lead to immediate failure, or to malfunctions at a later date. To avoid damage when chang-
ing the LMC, make sure that there is a potential equalization between the person and the tool.
Possibly set up equipment in an ESD-protected environment. Recom-
mendation for an ESD workplace: Electrically conductive work surfaces,
anti-static straps, appropriate furniture, clothing and footwear, as well as
grounding of all components.
LMC must only be changed with the battery is disconnected.
L – LiveWire 1 L – LiveWire 2
Removing LMC
Remove the battery.
Unscrew the screws (M4,
DIN 912).
Carefully pull the LMC
out of the handle and
replace it.
Inserting LMC
Carefully insert the LMC
as shown in the illustra-
tion.
Tighten the screws (M4,
DIN 912).
Insert the battery.
Graphic: CANES-

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Initial operation
6
5.6 Activating scanner/TAG
Please refer to Assembly Instructions P2171MA for the TAG; P2172MA for the scanner
Activate the LCD display with the start button.
Select Administration > Platf. To do this, select menu items with <F1>/<F2> and confirm with
the start button.
Enter Pin 254. To do this, count up with <F1> and confirm with the start button..
Select Barcod or TAG and confirm with the start button
6 Initial operation
6.1 Carrying out rundown
Make sure the power supply is correctly located before commissioning the 47BA. The 47BA is now ready
for use.
Press and release the start button: rundown is executed, the LCD display shows Ready.
Types with wireless transmission continuously communicate with the controller. The tool automatically
receives the parameters and, when the rundown is complete, automatically sends the rundown results to
the control system. Programming and setting up the wireless interface port are described in the program-
ming manual of the controller.
Types without wireless transmission must be placed in the tool holder when the rundown is complete. The
rundown results are transmitted and shown under the Run screen menu item.
WARNING! Risk of glove being pulled in due to rotating machine parts.
Risk of fingers being crushed or lost.
Do not wear gloves when working with this tool.
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