Cleco BD Series User manual

For additional product information visit out website www.clecoTools.com
Assembly Instructions
P2579MA-EN
2021-10
Series BD
Fixtured Spindle

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Apex Tool Group
Copyright © Apex Tool Group, 2021
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

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EN
Content
1About this document ...........................................................................4
2Safety ....................................................................................................4
2.1 Warnings and Notices.....................................................................................................4
2.2 Symbols on the Product..................................................................................................5
2.3 Intended Use ..................................................................................................................5
2.4 Foreseeable misuse .......................................................................................................5
2.5 Operator Training............................................................................................................5
2.6 Personal Protective Equipment ......................................................................................5
2.7 Safety instructions relevant to the system ......................................................................5
2.7.1 Use/handling of the spindle ............................................................................................7
3Transport / Storage ..............................................................................7
4Assembly ..............................................................................................7
4.1 Drilling templates in the mounting plate..........................................................................8
4.2 Installing on the mounting plate ....................................................................................12
5Cable ...................................................................................................12
6Initial operation...................................................................................12
7Troubleshooting .................................................................................13
7.1 LED Display ..................................................................................................................13
8Maintenance .......................................................................................13
9Ambient conditions............................................................................13
10 Disposal ..............................................................................................13

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1 About this document
This document is intended for specialists in installation
and maintenance (administrators, maintenance staff, ser-
vice personnel, owners/operators).
It contains information on safe and proper installation.
The original language of this document is German.
Other documents
Number
Document
P2381TS
Troubleshooting – EMS Error mes-
sages
P2468TS
Troubleshooting – mPro300GCD
P2552HW
Hardware Description – mPro300GCD-
STO
P2577SB
System manual – BD Series
P2578WA
Maintenance instruction – Fixtured
Spindle BD Series
P2585JH
Installation Instruction – Cable Man-
agement Fixture Spindel BD Series
P3319H
Declaration of incorporation – BD Se-
ries
CE-1026
EU Declaration of Conformity – BD Se-
ries
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.
2 Safety
►Read all safety warnings and instructions. Failure to
follow the directions and safety instructions could re-
sult in an electric shocks, burns and/or serious inju-
ries.
►Read and observe all appropriate, generally applica-
ble and local safety and accident prevention
regulations. We do not claim that these safety notes
are complete.
►Keep this document in a safe place for future refer-
ence!
►These safety instructions must be accessible at all
times to all persons who use the product.
2.1 Warnings and Notices
Warning notes are identified by a signal word and a picto-
gram:
•The signal word describes the severity and probability
of the impending danger.
•The pictogram describes the type of danger.
Danger
A symbol combined with the word Danger in-
dicates a hazard with a high level of risk
which, if not avoided, will result in death or
serious injury.
Warning
A symbol combined with the word Warning
indicates a hazard with a medium level of
risk which, if not avoided, could result in
death or serious injury.
Caution
A symbol combined with the word Caution in-
dicates a hazard with a low level of risk
which, if not avoided, could result in minor or
moderate injury.
Note
A symbol combined with the word Note indi-
cates a potentially harmful situation which, if
not avoided, could result in damage to prop-
erty or the environment.
General instructions include application tips and
useful information, but no warnings against haz-
ards.
Structure Of Warnings
Caution
Type and source of danger.
Possible consequences of non-observance.
►Measures to avoid danger.

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2.2 Symbols on the Product
Electric voltage
Hot surface
Read the operating instructions carefully
CE compliant
The product corresponds to the prescribed
technical requirements in Europe.
Observe and comply with all local disposal
guidelines for all components of this equip-
ment and it’s packaging.
2.3 Intended Use
The user is liable for any damage caused by improper
use. Use the product only under the following conditions:
•Use only in industrial tightening processes.
•Only in conjunction with the components listed in the
EU Declaration of Conformity.
•Under the prescribed ambient conditions.
•Within the power range, which is specified in the tech-
nical data.
•With equipment parameters set up properly.
•In EMC Limit Class A (electromagnetic immunity for
industrial areas). For the currently observed EMC
standards, see the EU Declaration of Conformity.
•The spindle is intended exclusively for stationary op-
eration and for tightening and loosening threaded
connections.
•The spindle must be fully assembled.
•Insert and lock all connecting cables.
•Always replace the spindle completely from a system.
•Repairs are only permitted personnel authorized by
Apex Tool Group. If the tool is opened, the warranty is
voided. In the event of repair, send the complete tool
to your Sales & Service Center.
2.4 Foreseeable misuse
►Only use the spindle with controllers that are listed in
the EU Declaration of Conformity.
►DO NOT use the spindle as a hammer.
►DO NOT use the spindle in potentially explosive ar-
eas.
►DO NOT use the spindle in a damp environment or
outdoors.
►DO NOT disassemble or modify the spindle.
►DO NOT use the spindle as a handheld tool.
►Never lift the spindle or individual components by the
cable.
►DO NOT use the spindle as a climbing aid.
2.5 Operator Training
2.6 Personal Protective Equipment
►Wear safety shoes.
The motor can heat up and cause burns during re-
moval (max. motor temperature 80 °C).
►Wear gloves when touching the motor.
►When working with rotating parts, it is not permitted to
wear gloves.
Recommendation: Freely rotating u-GUARD pro-
tected fastening tools from APEX.
►Wear suitable clothing. Do not wear loose clothing or
jewelry.
►Wear protective goggles if there is a risk of dirt or
parts being ejected.
►Wear a hair net, if necessary.
2.7 Safety instructions relevant to the sys-
tem
It is imperative to observe the national, state and local reg-
ulations and standards.
►Do not make any changes to the controller, protective
devices or accessories without the prior written con-
sent of.Apex Tool Group.
►Do not open the controller or components of the con-
troller either for troubleshooting or other work. Any in-
tervention can cause serious injuries in case of a fail-
ure.
Operating with the controller open can also cause the fol-
lowing:
•Increased interference emission: Other devices can
be disrupted.
•Reduced immunity to interference: The controller can
deliver incorrect results.
•Loss of warranty.
Risk of injury due to electric shock
In the event of a fault, the controller can carry voltage. An
electric shock can lead to cardiovascular arrest, respira-
tory failure, burns and serious injuries or death.

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►Switch off the controller before connecting the power
supply and tool cables, when converting, unplugging
the plug connector, cleaning or decommissioning.
►Do not operate the fastening system if the housing,
cable or spindle is damaged.
►In the event of any malfunctions, never repair the fas-
tening system yourself without knowing how to do so!
Inform the local repair center or the responsible Sales
& Service Center.
During installation
►Use suitable lifting equipment to lift the controller to
the desired installation location.
►Make sure that the controller is firmly installed and se-
cured (see Quick Reference Guide).
►Route cables and lines such that there is no risk of
damage or tripping hazard.
►Comply with the permissible bending radius of the ca-
ble.
►Use an approved power cable with suitable ratings.
►For 115 VAC: Use a cable with a larger cross-sec-
tional area.
Order No. 5416832‑01.
Before commissioning
►Only operate on an earthed network with a neutral
conductor (TN system). Operation without a neutral
conductor (IT network) is not permitted.
►Make sure the PE connection is compliant with stand-
ards.
►A type "A" residual current operated device (RCD) is
recommended to protect the supply line.
►Prior to commissioning, carry out the protective con-
ductor measurement in accordance with the local reg-
ulations (in Germany, DGUV Regulation 3).
►Do not switch the controller on until all connections
have been properly established.
Risk of injury due to dangerous movements
Inadequate emergency stop devices could have potentially
fatal consequences.
►The necessity of an emergency stop and its imple-
mentation are the responsibility of the operator and
subject of his risk analysis!
►Ensure accessible and effective emergency stop de-
vices. Unlocking an emergency stop device must not
cause an uncontrolled restart of the system!
►Before switching the system on, check the function of
the emergency stop devices.
During operation
►Protect the controller against moisture.
►In the event of unusual noises, heating or vibrations,
switch off the controller immediately.
►Pull out the power plug and have the tightening sys-
tem checked by qualified personnel; have it repaired if
necessary.
►Never pull the plug on the cable from the outlet.
►Protect the cables from heat, oil, sharp edges or mov-
ing parts.
►Replace damaged cables immediately.
►Keep the connections between the controller and
spindle clean.
►Keep the workstation tidy to prevent injury or damage
to the fastening components.
►Ensure that there is enough room at the workstation.
Danger due to incorrect torque measurement
An undetected NOK tightening could have life-threatening
consequences.
►It is imperative that the tool is recalibrated (or a capa-
bility analysis performed) after improper use
(dropped, mechanical overload ...).
►For category A rundowns (VDI 2862) which are critical
for safety, activate a redundancy measurement (e.g.,
current redundancy).
►Introduce regular measuring equipment monitoring for
the machines and spindles.
►Only work with a tightening system that is working
correctly. If in doubt, contact a Sales & Service Cen-
ter.
Danger due to an unexpected motor start or an ex-
pected, but not functioning, stop
Despite redundant control components and monitoring
functions, it can happen in very rare cases that the motor
starts unexpectedly.
Possible reasons: Remote control of diagnostic functions,
bit dump in the memory of the controller.
Starting from the spindle, mechanical hazards can result,
such as jerks/jolts due to reaction torque and the risk of in-
jury due to being reeled in and seized.
►Use sufficiently dimensioned reaction devices for the
maximum possible torque.
►After switching the controller on, wait until the boot
process is complete. This takes about 1 minute. Do
not switch on/off until then.
Use of the secondary controller
Up to 15 secondary controllers can be added to a primary
controller. When the secondary controller is switched off or
fails, the TSNet bus communication is interrupted. The
loss of communication to the primary controller affects the
secondary controller:
•No results are reported back to the primary controller.
•No more fastenings are started.
•A running fastening process shows the error message
SA (aborted by removal of the start signal) if the
TSNet connection was interrupted during the fas-
tening process.
•A shutdown signal is no longer received, so shutdown
only takes place:
-by activating the STO safety shutdown
-after reaching the switch-off criterion or
-via a safety shutdown after two seconds.
WARNING!
During remote start operation (multiple fasteners), an in-
terruption in the TSNet bus leads to a delayed stop of the
tool. This delay is 2 seconds.

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During maintenance
►The controller is generally maintenance-free.
►Comply with local regulations regarding servicing and
maintenance for all operating phases of the tightening
system.
During cleaning
►Only clean the outside of the spindle with a dry or
slightly damp cloth.
►Never immerse the controller or spindle in liquids.
►Do not use a high pressure cleaner.
►Disinfection of the surfaces is permitted with alcohol-
based disinfectants.
2.7.1 Use/handling of the spindle
►Do not exceed the total length of the tool cable:
mPro300GCD-STO max. 50 m
►Only use bits or sockets designed for industrial use
with machine-controlled tools.
►Make sure that the bit or socket is securely inserted.
►Do not attach the bit or socket to the screw head at an
angle.
►Inspect the bit or socket for visible damage and
cracks. Replace damaged screw bits immediately.
Danger from ejected parts
Components of the spindle can become loose due to rota-
tion and cause serious injuries.
►Avoid accelerations in all the axes of over 100 m/s²
(10 g).
►Note the tightening torque for the cap nut.
3 Transport / Storage
►Transport or store in the original packaging. The
packaging is recyclable.
►If the packaging is damaged, check the product for
visible damage. Inform the transporter, if necessary,
your Sales & Service Center.
4 Assembly
►Fasten the spindle onto a grounded, electrically con-
ductive mounting plate. The spindle can be installed
in any direction.
•
No heated air may originate from below the
spindle, including from other components.
•
No component may obstruct the air flow
below or above the spindle.
•
The spindle must not be exposed to direct
sunlight.

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4.1 Drilling templates in the mounting
plate
Size 1
(…)1ZB
(…)1VKD
(…)1WKD

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Size 2
(…)2ZB
(…)2VKD
(…)2WKD

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Size 3
(…)3ZB
(…)3VKD
(…)3WKD

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Size 4
(…)4VKD
(…)4WKD
(…)4Z400A
(…)4Z660A
(…)4Z2800A

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(…)4Z1250A
(…)4Z1600A
4.2 Installing on the mounting plate
Size
Tightening torque +10%
<Nm>
E
<mm>
A
B
C
D
1
10
10
6
25
12–15
Material:
steel or
aluminum
2
25
50
10
25
3
25
50
25
50
4
50
50
85
85
5 Cable
Note
Malfunction
The total length of the tool cable must not ex-
ceed 50 m.
►Match the length of the tool cable with
the extension cable.
Size
A
Tool/extension cable
Order No.
Length
[m]
1
961561-010
…
961561-250
1
…
25
2
3
4
961923-010
...
961923-340
1
…
34
For more information, see P2102JH cable management
spindle.
6 Initial operation
1. If necessary, position the components of the spindle
with respect to one another via face gear interfaces.
-Turn size 1 in 15° increments.
-Turn sizes 2–4 in 10 ° steps.
2. Establish protective grounding of moving machine
parts according to EN 60204-1.
Caution
Risk of falling
Loose cables can lead to tripping and falling.
►Route the connected cables securely.
3. Close and lock the plug connection on the spindle.
4. Connect the power cable to the controller.
5. Close the protective devices (i.e., safety grilles).
6. Switch on the machine control unit (PLC/SPS).
7. Switch on the controller. If there is a fault after switch-
ing on, see the chapter entitled "Troubleshooting" in
the system manual.
8. The process programming for the controller must be
carried out by qualified personnel during initial startup,
see programming instructions.

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7 Troubleshooting
For troubleshooting, see the document
P2468TS Troubleshooting
7.1 LED Display
The status LED indicates the status of the fixtured spindle
software and the connected transducers.
Status LED
Color
Explanation
Continuous
white light
Software update is running. Do not inter-
rupt the power supply.
Continuous
yellow light
Initialisation of fixtured spindle.
▬
Flashing yel-
low light
A connected transducer does not yet pro-
vide valid data.
Continuous
red light
A connected transducer does not provide
valid data.
▬
Flashing red
light, slowly
Internal error: transducer.??
Continuous
blue light
The transducer is in read/write mode.
Continuous
green light
Fixtured spindle is ready for use.
Error analysis
Status LED shows error (flashing red) when two trans-
ducer are connected. Procedure for identifying a defective
transducer:
►Disconnect transducer 2.
Status LED continues to flash: Transducer 1 is
defective.
►Disconnect sensor 1 and connect sensor 2.
Status LED continues to flash: Transducer 2 is
defective.
8 Maintenance
Maintenance is only permitted byApex Tool Group author-
ized personnel. Regular maintenance reduces operational
interruptions, repair costs and downtimes. Therefore, im-
plement a safety-related maintenance program that takes
into account the local regulations for repair and mainte-
nance for all the operating phases of the tool.
See document Maintenance instruction
9 Ambient conditions
Features
Data
Operation site
Indoors
Working temperature
0 °C – 45 °C
Storage temperature
-25 °C – 70 °C
Type of cooling
Convection (self-cooling)
Relative humidity
10 % – 90 % no condensa-
tion
Working height Up to 3000 m (9,843 ft)
above sea level
Degree of protection as per
DIN EN60529 (IEC60 529)
IP40
10 Disposal
Components and auxiliary materials of the product pose
risks to the health and the environment. The tool contains
components that can be recycled as well as components
that must be specially disposed of.
►Separate the components of the packing and segre-
gate the different materials before disposing of them.
►Catch auxiliary materials (oils, greases) when drained
and dispose of them properly.
►Separate the components and dispose of them by
segregating them clearly.
►Follow the locally applicable regulations.
Observe generally valid disposal guidelines
such as, in Germany, the Electrical and Elec-
tronic Equipment Act (ElektroG) and the Battery
Act (BattG). Wasted electronic equipment must
be disposed of.
►Return the defective product to your company collec-
tion facility or to Sales & Service Center.
Status LED

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: +1 (248)
391-6295
LEXINGTON,
SOUTH CAROLINA
Apex Tool Group
670 Industrial Drive
Lexington, SC 29072
Phone: [phone]
-5629
Phone: [phone]
-0099
Fax: [phone]
-7681
MEXICO
Apex Tool Group
Vialidad El Pueblito #103
Parque Industrial Querétaro
Querét
aro, 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]
Fax: [phone]
GERMANY
Apex Tool Group GmbH
Industriestraße 1
73463 Westhausen
Germany
Phone: [phone]
81 0
Fax: [phone]
HUNGARY
Apex Tool Group
Hungária Kft.
Platánfa u. 2
9027 GyörHungary
Phone: [phone]
Fax: [phone]
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 Li
mited
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 1
05-0011, JAPAN
Phone: +81
-3-6450-1840
Fax: +81
-3-6450-1841
KOREA
Apex Tool Group Korea
#1503, Hibrand Living Bldg.,
215 Yangjae
-dong,
Seocho
-gu, Seoul 137-924,
Korea
Phone: +82
-2-2155-0250
Fax: +82
-2-2155-0252
1021 | Cleco® is a registered trademark of Apex Brands, Inc. | © 2021
Apex Tool Group, LLC
Phone: [phone]-
5629
Phone: [phone]-
0099
Fax: [phone]-
7681
www.ClecoTools.com
www.ClecoTools.de