Cleco 17BP Instruction Manual

P.O. Box 1410 Lexington, SC 29071-1410 E U R O P E Postfach 30 D-73461 Westhausen, Germany 17BP Cordless EC tool 17 B P XX Q S Series 17 Type B - Battery Tool model P - Pistol Optional S - Depth sensor Attachment Q - Quick change chuck 1/4" Max. torque 13 - 13 Nm 09 - 9 Nm 07 - 7 Nm 05 - 5 Nm Retain for future reference! Instruction Manual

For this Instruction Manual This Instruction Manual is intended for all persons who work with this tool but do not do any pro- gramming work. The Instruction Manual • provides important information for safe and effective use • describes the function and operation of the cordless EC tool (hereinafter only referred to as 17BP) • serves as a reference work for technical data, service intervals and spare part orders • provides information on options More extensive information on the operation of the tool with the control electronic system TMEB-100 is located in the • programming manual controller TMEB-100, no. P1805E • programming manual controller TMEB-COM, no. P1842E Apex Tool Group reserves the right to modify, supplement or improve the documentation or the product without prior notice. This document or any part thereof should not be copied or – electronically, mechanically, opti- cally, or in any other way - be transferred into another natural or machine-readable language in any form without the express authorization of Apex Tool Group. In the text: 17BP represents all models of the cordless EC tools as described here. ➔ refers to required actions. • refers to lists.

P1846E/EN 02/06 3 Contents Page 1 Safety 5 1.1 Presentation of notes............................................................................ 5 1.2 Basic requirements for safe working practices ..................................... 6 1.3 Personnel training................................................................................. 6 1.4 Personal protective equipment ............................................................. 6 1.5 Proper use ............................................................................................ 7 1.6 EMC...................................................................................................... 7 1.7 Noise and vibration............................................................................... 7 2 Scope of supply, transport and storage 8 2.1 Scope of supply .................................................................................... 8 2.2 Transport .............................................................................................. 8 2.3 Storage ................................................................................................. 8 3 Product description 9 3.1 General description............................................................................... 9 3.2 Operation and functional elements..................................................... 10 3.2.1 LED lighting ........................................................................................ 11 3.2.2 IrDA interface port............................................................................... 11 3.2.3 Depth sensor (only with 17BP…S) ..................................................... 11 3.2.4 LED display......................................................................................... 12 3.2.5 Rechargeable Battery......................................................................... 12 3.2.6 Start button ......................................................................................... 12 3.2.7 Reverse switch ................................................................................... 13 3.2.8 Function keys...................................................................................... 13 3.2.9 Identification – set torque.................................................................... 13 3.3 System overview – optional accessories............................................ 14 4 Before initial operation 15 4.1 Erect the tool holder............................................................................ 15 4.2 Environmental conditions.................................................................... 15 4.3 Load battery........................................................................................ 15 4.4 Replacing the battery.......................................................................... 16 4.5 Inserting / replacing screw inserts ...................................................... 16 5 First Operation 17 5.1 Perform the screw operation............................................................... 17 5.2 Operating modes ................................................................................ 17

6 LCD display 19 6.1 Results display.................................................................................... 19 6.2 Status.................................................................................................. 20 6.3 Set position (only allowed with Linking)............................................. 21 6.4 Communications................................................................................. 22 6.5 Diagnostics ......................................................................................... 24 6.6 System fault messages....................................................................... 29 7 Maintenance 33 7.1 Service schedule ................................................................................ 33 7.2 Lubrication Products........................................................................... 33 7.3 Disassembling the gear box ............................................................... 34 8 Spare parts 35 8.1 Gear.................................................................................................... 36 8.2 Tool holder with IrDA interface............................................................ 38 9 Service 41 9.1 Re-Calibration..................................................................................... 41 10 Technical Data 42 10.1 Dimensions cordless EC tool.............................................................. 42 10.1.1 Dimensions tool holder (Optional) ...................................................... 43 10.2 Performance Data............................................................................... 43 10.3 Electrical data ..................................................................................... 44 10.3.1 Battery power supply .......................................................................... 44 10.3.2 Output stage servo electronic............................................................. 44 10.3.3 IrDA interface port............................................................................... 45 10.3.4 Torque transducer............................................................................... 45 11 Disposal 45 12 Glossary 46

P1846E/EN 02/06 5 Safety1 1 Safety 1.1 Presentation of 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! Possible hazardous situation for the health of persons. If this warning is not observed, very serious injury may result. Caution! Possible harmful situation for the health of persons or which can result in property or environmental damage. If this warning is not observed, injuries, property or environmental damages may occur. Note General notes, Contain application tips and particularly useful information, but no warnings on hazards.

Safety 1 1.2 Basic requirements for safe working practices You should read all instructions. Non-observance of the instructions below may result in electrical shock, burns and serious inju- ries. 1.3 Personnel training All operators must be trained and experienced before operating the 17BP. The 17BP must be repaired by authorized technicians from Apex Tool Group only. 1.4 Personal protective equipment When working • Wear the protective goggles to protect against spurting metal splinters. Danger of injury by being wrapped up in and caught by machinery • Wear a hairnet. • Wear close-fitting clothing. • Do not wear jewelry. CAUTION! Work area ➔ Ensure there is enough space in the work area. ➔ Keep the work area clean. Electrical safety ➔ Protect the 17BP from rain and moisture. ➔ Follow the safety instructions printed on the battery and charger. Safety of persons ➔ Ensure a secure standing position. Maintain balance. ➔ Make sure that the battery is securely installed before operating the 17BP. ➔ Hold the 17BP tightly in the hand – be prepared for high short-term reaction torques. ➔ Do not carry the 17BP with the finger on the start button – prevent accidental operation. ➔ Do not open the battery. Contact with acid will cause injury. ➔ Follow generally valid and local safety and accident prevention rules. Safe working with and around fastening tools ➔ Inspect sockets for visible damage and cracks. Replace damaged sockets immediately. ➔ Disconnect the 17BP from the battery before replacing the sockets. ➔ Only use screw inserts for machine-controlled fastening tools. ➔ Make sure that the sockets are securely inserted.

P1846E/EN 02/06 7 Safety1 1.5 Proper use The 17BP is intended to screw in and loosen threaded joints. The model with depth sensor (17BP…S) also allows you to screw in tapping screws. The 17BP should only communicate via the IrDA interface port of the tool holder (Order no. 935144) with the control unit TMEB-100 or a PC. Do not do the following with the 17BP: • Do not use it in areas with an explosion hazard. • Do not open it or modify it structurally. • Only use with accessory parts which are approved by the manufacturer (see 3.3 System overview – optional accessories , page 14). • Do not use as a hammer or for re-bending. 1.6 EMC Industrial environment EMC limit class A. The following EMC standards are complied with. Interference emission DIN EN 61000-6-4 Interference resistance DIN EN 61000-6-2 1.7 Noise and vibration Noise level < 60 dB(A) when idling (without load) according to ISO 3744. Vibration values < 2.5 m/s² according to ISO 5349.

Scope of supply, transport and storage 2 2 Scope of supply, transport and storage 2.1 Scope of supply Check shipment for transport damage and ensure that contents match scope of supply: 1 17BP 1 18 VDC replaceable battery nickel metal hydride (NiMH) 1 Marking foil 1 Instruction Manual 1 Declaration of Conformity 1 Factory test certificate for transducers 2.2 Transport Transport and store 17BP in original packaging. The packaging is recyclable. 2.3 Storage For short-term storage and for protection against damage. ➔ Place the 17BP the tool holder. For storage longer than 100 hours ➔ Disconnect the battery from the 17BP. Battery is discharged by the electronics system integrated into the 17BP. Warning! Danger of explosion from short circuit ➔ Protect the 17BP and battery from moisture. ➔ Do not bring any electrically conducting objects such as paper clips, coins, keys, nails or screws in contact with the battery contacts. ➔ When storing the battery outside of the 17BP or battery charger, cover the battery contacts. Object Time period Storage temperature Supplemental information 17BP without battery No guideline –25 °C to +40 °C Rechargeable Battery Short-term –20 °C to +45 °C Long-term, from 1 year –20 °C to +35 °C recommended: +10 °C to +30 °C 30 % – 50 % store charged. Recharge after 1 year to avoid total discharge.

P1846E/EN 02/06 9 Product description3 3 Product description 3.1 General description The cordless EC tool has the following characteristics: • Sturdy, brushless motor with resolver. Shut-off is torque/angle-controlled. • LCD display with information on torque, angle and status. • Green O.K. and red N.O.K.-LED display provides information on the current screw result. • LED lighting makes it possible to find the screw point quickly. • Clockwise/anticlockwise rotation. • Low vibration level. • Servo and screw electronics system integrated on the 17BP. • Fastening parameters are set via the controller TMEB-100 or a PC. Data transmission from the controller to the tool holder via RS232. • Rundown data is sent to the TMEB-100 controller or a PC by placing the 17BP into the tool holder. Data is transmitted from the tool holder to the 17BP via the IrDA interface port (infrared).

Product description 3 3.2 Operation and functional elements This chapter describes the operating and functional elements and their functions: Fig. 3-1: 1 LED lighting 2 IrDA (infrared interface port) 3 Depth sensor (only with 17BP…S) 4 LED display 5 Rechargeable battery 6 Start button 7 Reverse switch 8 LCD display with information on torque, angle and status 9 Function keys 10 Set torque – stick-on marking foil 4 3 7 6 5 9 4 4 4 8 1 2 10

P1846E/EN 02/06 11 Product description3 3.2.1 LED lighting LED lighting make it possible to quickly find the screw point. To start it, press the start button half way (see 3.2.6 Start button , page 12). 3.2.2 IrDA interface port Via the IrDA interface port (infrared) the 17BP communicates via the tool holder with the controller TMEB-100 or a PC. For data transmission and programming of the 17BP, place the 17BP in the tool holder. A data transmission is possible in the operating modes Active, Energy saving mode and Stand-by, but not possible in Sleep (see 5.2 Operating modes , page 17). 3.2.3 Depth sensor (only with 17BP…S) The depth sensor makes it possible to securely screw in drive screws, their groove torque is generally higher than the shut-off torque. The sensory monitoring of the screw depth makes it possible that the 17BP does not shut off early but only when the head is attached. You must do the following before starting: ➔ Activate Sequence 16 via the controller TMEB-100 (see Programmer manual on this issue). ➔ Use an appropriate screw attachment with a length of 49 mm. With a deviating length, request a special detent from Apex Tool Group. ➔ Measure dimensions X with an inserted metering screw (see Fig. 3-2: ). if necessary turn the detent by the target dimension 3.5 mm: Clockwise – dimension is smaller, counter-clockwise– dimension is larger. A locking function prevents unintentional setting during operation. Setting tip: 3 clicks equal 0.5 mm. Fig. 3-2: Note If the data transmission was interrupted, the 17BP reports the Synch error on the reversed LCD-display. Place the 17BP in the tool holder again. The complete data transmission is acknowledged on the display with Rest 512. Note After each setting, the detent must audibly lock each time. Length screw insert= 49 mm X = 3.5 mm Detent

Product description 3 3.2.4 LED display The LED display shows each operating mode and the result of the last screwing cycle (see 5.2 Operating modes , page 17): Software update During Software Update, the actual programming process is indicated by rapid flashing alternat- ing between red and green at irregular intervals. 3.2.5 Rechargeable Battery For information on the battery see 4.3 Load battery , page 15 4.4 Replacing the battery , page 16 10.3.1 Battery power supply , page 44 3.2.6 Start button The start button has 2 functions (Standard for TMEB-100): • It activates the LED lighting. ➔ Press down the button halfway and hold it. • It starts the motor, the LED lighting goes out. ➔ Hold down the button completely. LEDs Operating status Result after screwing cycle Steady light Green Active OK Steady light Red Active NOK Flashing light Green – low frequency Energy saving mode Flashing light Green Standby None Sleep If Linking at TMEB-100 is selected: Flashing light Green – high frequency Active / Settings: Linking Linking OK Flashing light Red Active / Settings: Linking Linking NOK NOTE Do not interrupt programming by removing the battery during this phase.

P1846E/EN 02/06 13 Product description3 3.2.7 Reverse switch The reverse switch changes the rotation direction of the 17BP: Clockwise rotation – for screwing in screws Press reverse switch to detent. When the start button is pressed Active appears on the LCD display. Counterclockwise rotation – for loosening or screwing out screws Press reverse switch to detent. When the start button is pressed Left appears on the LCD display. 3.2.8 Function keys Left function key • Confirm error message ➔ Press once. • Activate Diagnosis menu e.g. query number of rundowns to complete the service schedule. ➔ Press for three seconds: Test Menue. ➔ Press once. Count. ➔ To exit the menu, press this key for three seconds: Exit Menue. 3.2.9 Identification – set torque To identify the set torqueon the 17BP, glue the corresponding marking foil to the right and the left of the LCD display. Part no. 935078

Product description 3 3.3 System overview – optional accessories Fig. 3-3: System overview – optional accessories Tool holder with IrDA interface port and connection cable Part no.935144 TMEB-100 Controller for electrical screw driver Replacement battery Part no.935129 IrDA-extension cable 3 m Part no.935154 6 m Part no.935155 10 m Part no.935157 4-battery charger Part no. 935143 (230 VAC) Part no. 935152 (115 VAC) 1-battery charger Part no. 935150 (230 VAC) Part no. 935151 (115 VAC) 17BP Cordless EC tool – Communication unit – (Scope of supply) Screw inserts (Recommendation GETA / APEX): Pulling connection according to DIN 3126 shape E 6.3 (hexagon insert bit ¼“) Prescribed length 49 mm at 17BP…S (with depth sensor)

P1846E/EN 02/06 15 Before initial operation4 4 Before initial operation The 17BP has been configured by Apex Tool Group. A setting for your specific screw joint needs must only be made with the controller TMEB-100 or a PC by a qualified person. See the following: • Programming manual TMEB-100 • Programming manual TMEB-COM 4.1 Erect the tool holder ➔ Mount the tool holder onto a stable base. ➔ 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. 4.2 Environmental conditions 4.3 Load battery ➔ Follow the safety instructions printed on the battery and charger. ➔ Fully charge new batteries or those not used for a long time. The full charge is reached after 4 – 5 cycles (Charge / discharge). ➔ Fully charge the battery without interruption. ➔ After approx. 10 charges, do a controlled discharge of the battery. The battery capacity remains. ➔ Do not totally discharge the battery (< 0.8 V). Ambient temperature 0 °C to maximum +40 °C Humidity 0 to 80 %, not with dew Working height Up to 1000 m over NN Warning! Electrical shock, overheating or the leaking of corrosive liquid from the battery can occur when using inappropriate chargers or batteries. Only use original Cleco batteries and chargers. They have been designed for each other (see 3.3 System overview – optional accessories , page 14). Notes With proper use, the battery can be charged at least 500 times. Here the following is important: Battery charge temperature 5 °C to +40 °C recommended: +10 °C to +30 °C

Before initial operation 4 ➔ Protect the battery from impact. ➔ Keep the charger and battery contacts clean and dry. ➔ Clean and dry the exterior surface of the battery before connecting to the charger. ➔ The battery can remain in the charger when not in use. Power is supplied to it via a float charge. ➔ Replace used batteries and recycle them (see 11 Disposal , page 45). 4.4 Replacing the battery Fig. 4-1: Fig. 4-2: 4.5 Inserting / replacing screw inserts Inserting the battery ➔ Insert the battery into the tool guide until the catches securely engage. Removing the battery ➔ Press the catches together and pull the battery forward from the grip. Caution! Danger of injury: ➔ Check the screw inserts for visible damage and breaks. Replace damaged screw inserts immediately. ➔ Before replacing the screw inserts, disconnect the 17BP from the battery . ➔ Only use screw inserts for machine-controlled fastening tools. ➔ Ensure that the tool inserts lock in securely. 1. 2.

P1846E/EN 02/06 17 First Operation5 5 First Operation 5.1 Perform the screw operation Before first operation of the 17BP, ensure that the battery is firmly in place. The 17BP is now ready for use. After you press and release the start button, the LCD display shows the message Ready. When the rundown has been done, place the tool into the tool holder. The results of the screwing cycle are shown under the process display. 5.2 Operating modes The operating modes change in the following order. The following functions are available depending on the display: Operating mode LED display LCD display Function Active Steady light: Red – Rundown Not O.K Green – Rundown O.K. On Screws Data transmission Automatic switch to the following after 1 minute idle time: Energy saving mode Flashing light Green Off Screws Data transmission Automatic switch to the following after 11 minute idle time: Sleep Off Off No data transmission Manual switch from Sleep to Active: Press down start button and hold it down for approx. 1 second.

P1846E/EN 02/06 19 LCD display6 6 LCD display 6.1 Results display Die LCD display consists of a three-line display with 6 characters each to indicate status, torque and angle. First line – Status: Second line – Shut-off torque in Nm: Third line – Shut-off angle in degrees: OK Result is OK NOK Result is not OK OFF Torque transducer offset fault CAL Torque transducer calibration fault ENC Angle encoder fault IP Current overload in output section IIT Requested motor output is too high TMAX Maximum fastening time exceeded RC Rundown terminated by disabled start signal TS Depth sensor signal was active at Start or deactivated during the fastening process (Series 17BP only) Tq< Torque too low Tq> Torque too high A<< Angle too low A> Angle too high Error Error occurred T Shut-off torque A Shut-off angle

LCD display 6 6.2 Status RUN Screen Ready is displayed when no other status message takes precedence and the tool is ready for operation. Standard operating mode Standard mode is selected when Linking is not activated. The application is selected at the Run Screen or via the App. selection inputs. The display shows how many more rundowns can be executed before the fastening results memory unit is full and the rundown data has to be transmitted to the TMEB-100. Linking operating mode Linking mode is selected if linking is activated (see Advanced application builder\Linking). The top line displays the first position to be fastened. The number of positions in displayed in the second line. The third line displays how frequently this position was repeated in the event of a NOK rundown. Emergency function active If Emergency is active during fastening, this is indicated by the status display Emergency active. (2.6.12 Activate Emergency) Ready Remain 512 N.Pos1 of 3 Rpl 0 Emerge Strate

P1846E/EN 02/06 21 LCD display6 6.3 Set position (only allowed with Linking) Activate Set position To activate the Set position menu, you must hold down the right-hand button for three seconds. If diagnosis is not enabled, the message Settings disabled is displayed. After three seconds, the message Linking Menu is displayed and you can release the right-hand button. Then the status for Linking is displayed. Use the right-hand button to increase the position and the left-hand button to reduce it. This allows you to skip or repeat positions. After the last position, the message Linking End in dis- played. This means that the worker wishes to terminate Linking. Hold 3 sec. NOTE Set position can only be enabled if TMEB-100 is activated in the Advanced application builder\System settings\Set tool enable position menu. Settin locked Linkin menu NOTE When Linking is active fastening is not possible. N.Pos1 of 3 Rpl 0 NOTE If the position is changed, the overall result for linking will be evaluated as NOK in this case.

LCD display 6 Deactivate Set position To deactivate the Set position menu, you must hold down the right-hand button for three sec- onds. After three seconds, the message Leave Menu is displayed and you can release the right-hand button. The message Run Screen is then displayed again. After you release the right-hand button you can proceed to the next fastening cycle using the pro- grammed fastening parameters. 6.4 Communications The tool must be synchronized with the TMEB-100 since all fastening sequences have been pro- cessed. The tool must be synchronized with the TMEB-100 since no fastening sequences have been ini- tialized. No fastening sequence parameters have been set. Check the selected application or tightening group at the TMEB-100 to see if tool settings and process programming have been performed. Hold 3 sec. Leave menu Job comple Sync No Job Sync Parame not set

P1846E/EN 02/06 23 LCD display6 No Linking result; Linking was terminated without an overall result. Not all of the positions in the tightening group have been programmed. Check the selected appli- cation or tightening group at the TMEB-100 to see if tool settings and process programming have been performed. Linking result OK Linking result NOK Linking is disabled; the tool must be synchronized with the TMEB-100. Under TMEB-100Advanced application builder\System settings at the TMEB-100, the function NOK interlock is activated; this function locks the tool when the interlock criterion is met. Application is disabled; the tool must be synchronized with the TMEB-100. Under Advanced application builder\System settings at the TMEB-100, the function NOK inter- lock is activated; this function locks the tool when the interlock criterion is met. NOK interlock is active; the tool has been programmed under Advanced application builder\ NOK interlock. Depending on the parameter setting, the tool can be unlocked by the external input NOK release or by Release on Backoff. For unlocking via the external input NOK release, set the external input and synchronize it with the TMEB-100. Linkin No Result Linkin OK Linkin NOK Linkin locked Sync App locked Sync Reject Releas Sync

LCD display 6 Error during last synchronization of data with the TMEB-100; the tool must be synchronized with the TMEB-100 again. Tool has not yet been synchronized with a TMEB-100; the tool must be synchronized with the TMEB-100 for the first time. The Tool enable input is missing. The input Tool Enable must be set and the tool must be syn- chronized with the TMEB-100. This message can appear only if External Tool Enable has been activated in Advanced application builder\System settings. Tool disabled since no valid barcode data has been set. The barcode must be sent to the TMEB-100 and the tool must be synchronized once again. 6.5 Diagnostics Activate diagnosis function To activate the Diagnosis menu via the function keys, you must hold down the left-hand button for three seconds. Sync Error Tool not Init Input Enable Missin Need Part ID Hold 3 sec. NOTE The Diagnosis function can be activated only if Diagnosis has been enabled with the help of the TMEB-100 in the menu Advanced application builder\System settings.

P1846E/EN 02/06 25 LCD display6 If diagnosis is not enabled, the message Diagnosis Disabled is displayed. After three seconds, the message Test Menu is displayed and you can release the left-hand but- ton. The first Test Function (display tool system time) is then shown. Deactivate diagnosis functions To deactivate the Diagnosis menu via the function keys, you must hold down the left-hand button for three seconds. This can be done from any test function. After three seconds, the message Test Menu is displayed and you can release the left-hand but- ton. The message Run Screen is then displayed again. After you release the left-hand button, you can again proceed to use the programmed fastening parameters. Display Tool System Time Displays the tool system time. The system time can be displayed in US or European format. The system time is set with the aid of the TMEB-100 in the Administration\Date/Time menu. Diag locked Test menu NOTE While test functions are active, fastening cannot take place, or only the test function parameters can be used. Hold 3 sec. Leave menu Time 07:47 30.09

LCD display 6 Display Counter Display The tool counter display is incremented after each rundown throughout the service life of the tool. You can also view the counter display on the TMEB-100 under Diagnosis\Tool\Tool Memory. Display calibration test This test function cyclically recalibrates the system with the values used immediately before the start of a rundown. For this, the tool must be in a relaxed state! The first line displays Cal for cal- ibration test and OK for the status: all values are within the tolerance. The values Offset Voltage in volts, line O and Full Scale Voltage in volts, line K for the torque transducer are displayed. If a value lies outside the tolerance range, the calibration fault display appears. Rated values and tolerances: Display TQ Measurement When you actuate the start button after calling this test function, the same calibration is per- formed as directly before the start of a rundown. For this reason, the tool must be in a relaxed state when this function is called. Then the tool starts at speed "0". The torque is continuously measured and displayed until the start button is released again. The current torque is displayed in the second line, and, in the third, the peak value, the highest value since the start button was pressed. Angle Encoder Display When the Start button is pressed the tool is started at 30 % of the maximum speed. After one rev- olution of the output shaft (setpoint angle 360 deg), measured with the resolver, the tool is stopped. During a permanently adjusted dwell time of 200 ms any further angle pulses occurring are traced. The total result is shown as Actual Angle. If the test run is not terminated by a monitoring criterion, the total result equals or is higher than 360 degrees and is evaluated as okay ( OK). Counte 99 999999 Cal OK K 1.11 O 0.00 Value Rated value Tolerance Calibration offset 0 V ±45 mV Calibration voltage: 1.122 V ±32 mV Torque M 5.57 M 8.23 Angle W 360 OK

P1846E/EN 02/06 27 LCD display6 Monitoring criteria are the torque and a monitoring time. If the torque exceeds 15 % of its calibration value (even during the dwell time), or if the monitor- ing time of 4 seconds expires, the test run is terminated with a TQ> or TMAX result. The user must check, if the output shaft has actually turned by the value indicated (e. g. put mark on the spindle). If the angle reached by the output shaft does not agree with the value displayed, either the angle factor or the resolver is defective. Display Voltages Current battery voltage is displayed in the second line. To ensure high utilization potential, this voltage is monitored continuously during fastening operation. If the voltage drops below limit, a warning is issued at the tool. The programmed value is displayed in the third line; it can be altered in the Tool menu with the TMEB-100. Display Speed The start switch starts the tool at maximum speed. The current output shaft speed is displayed. Rotational speed measurement is based on the angle information of the resolver. If you release the start switch, the tool stops. As a safety function the torque is monitored by the tool trans- ducer. If it exceeds 15 % of its calibrated value, the tachometer function is terminated. Display Serial Number The tool serial number is displayed in this menu. The serial number is also displayed via the TMEB-100 in the Tool menu or Diagnosis\Tool\Tool Memory. Display Software Version Displays the installed software version Voltag V19.40 U13.00 Speed Rpm466 M 0.02 S/N 000000 245 Vers. V1.00. 00

LCD display 6 Activate Emergency Emergency function is disabled. If activated in the TMEB-100 in the Advanced application builder\System settings\Enable emer- gency function menu, the emergency function can be enabled and disabled in the Diagno- sis\Emergency function menu with the tool start button. The Emergency function is disabled automatically when the tool links to the TMEB-100. The last fastening parameters used are always applied as parameters. In Linking mode this is the last position and in Standard mode the last parameters used. The data from 512 rundowns are stored in memory. If more rundowns than this are executed while the Emergency function is active, the oldest results are always discarded once 512 rundowns have been recorded. NOTE The emergency function can only be activated if it is activated in the TMEB-100 in the Advanced application builder\System settings\Enable emergency function menu. Emerge Strate locked Emerge Strate OFF Emerge Strate On Emerge Active NOTE If Emergency is active during fastening, this is indicated by the status display Emergency active.

P1846E/EN 02/06 29 LCD display6 6.6 System fault messages Initialization error in tool Servo. Remedy: remove and replace battery. If this does not help, return to tool to the manufacturer for repair. Speed specification from the measuring board on the Servo is faulty. Remedy: remove and replace battery. If this does not help, return to tool to the manufacturer for repair. Too much power is being demanded from the tool. Remedy: Switch the tool off for a time so that it can cool down. Increase the cycle time, reduce the fastening time or the torque. The Servo current sensor is detecting a current offset fault. Remedy: Return tool to manufacturer for repair. Collective Servo fault caused by hardware. Remedy: Return tool to manufacturer for repair. NOTE If a fault is displayed, fastening is disabled until the fault is acknowledged with the left-hand but- ton on the tool. In the event of serious hardware faults, the tool is not enabled again even after the fault is acknowledged, and must be returned to the manufacturer for repair. Servo Error Init Servo Error PWM Servo Error IIT Servo Error IOFF Servo Error Other

LCD display 6 The current setpoint has been exceeded. Remedy: there may be a short-circuit. Return tool to manufacturer for repair. The Servo has overheated. Remedy: Switch the tool off for a time so that it can cool down. Increase the cycle time, reduce the fastening time or the torque. The tool motor has overheated. Remedy: Switch the tool off for a time so the motor can cool down. Increase the cycle time, reduce the fastening time or the torque. Operating voltage is outside the admissible range. Remedy: Replace the battery. If this does not help, return the tool to manufacturer for repair. Current at Servo output stage is too high. Remedy: there may be a short-circuit. Return tool to manufacturer for repair. Servo Error IP Servo Error Temp > Servo Error TempM> Servo Error Voltage Servo Error Curr>

P1846E/EN 02/06 31 LCD display6 Tool angle encoder is sending incorrect signals to the Servo amplifier. Remedy: Return tool to manufacturer for repair. Warns that battery is running low. Remedy: Recharge battery or replace it with one that is already charged. The counter display could not be read or written. Remedy: Return tool to manufacturer for repair. Tool memory could not be read. Remedy: Return tool to manufacturer for repair. Two-stage Start button faulty Remedy: Return tool to manufacturer for repair. Transducer reference voltage fault. Remedy: Return tool to manufacturer for repair. Servo Error Angle Low voltag warnin Tool Error Counte Tool Error Ident Tool Error Start Transd Ref.V. Error

LCD display 6 Transducer calibration voltage fault. Remedy: Tool was not relaxed at time of calibration. Allow tool to relax and try again. If this does not help, return to tool to the manufacturer for repair. Transducer offset voltage fault. Remedy: Tool was not relaxed at time of calibration. Allow tool to relax and try again. If this does not help, return to tool to the manufacturer for repair. General collective fault. Remedy: Return tool to manufacturer for repair. Transd CAL Error Transd OFF Error Unknow Error

P1846E/EN 02/06 33 Maintenance7 7 Maintenance 7.1 Service schedule Regular service is required to prevent operational failures, repair costs and idle times. 7.2 Lubrication Products For smooth function and a long service life, use of the correct grease types according to the table is essential. Grease lubricants according to DIN51502 /ISO3498 Caution! Danger of injury due to unintentional activation – before service – disconnect the 17BP from the battery. After... fastening cycles1) 1) Number of all fastening cycles, see 3.2.8 Function keys, page 13 Actions 100,000 ➔ Check housing components for damage ➔ Check to ensure battery contacts are clean ➔ Check to ensure battery charger is clean ➔ Check tool holder for wear 250,000 or once a year ➔ Check that screw joints are tight 250,000 or 500 loading cycles ➔ Check the capacity of the battery if necessary 1 million or once a year ➔ Clean gear components ➔ Check the gear components for wear and replace if necessary ➔ Relubricate the gear components, see 8.1 Gear, page 36 ➔ Recalibration 17BP. You should implement a service program in keeping with safety measures which takes into account the local regulations for the maintenance and service for all operating phases of the 17BP. Part no. Pack. unit Standard designation [ kg ] DIN / ISO 912554 15 G-POH Aralub FD00 Energrease HTO GA 0 EP Expa 0 Mobilplex 44 Special Gear unit H 933027 1 KP1K Microlube GL 261

Maintenance 7 7.3 Disassembling the gear box Notes If the 17BP is opened, the warranty is voided. The gearbox should only be opened by qualified specialised personnel. a) ➔ Carefully clamp the 17BP on the pistol grip into a vice with plastic jaws. ➔ Remove countersunk screw part no.920788. SW 2.5 (internal hexagon). ➔ After service on the gearbox, fasten the countersunk screw 1.6 – 1.9 Nm. b) ➔ 1 – as shown- fold together Note! Do not fold out beyond the prescribed angle because otherwise the interior, flexible board can be damaged. ➔ 2 Loosen in a counter-clockwise motion. SW 28 Part no. 935081 -17BP… SW 32 Part no.. 935188 - 17BP…S c) ➔ 3 Loosen in a counter-clockwise motion. ø 42.5 Part no.933257 + 933340 ➔ 3 Completely remove. Part no. 920788 max. 45° 2 1 3

P1846E/EN 02/06 35 Spare parts8 8 Spare parts Note Use only original CLECO spare parts. Failure to comply can result in reduced performance and increased service requirements. If spare parts not manufactured by us are installed, the tool manufacturer is entitled to deny any warranty claims. We are happy to prepare a corresponding spare part and wearing part offer for you. Please send the following data to us: • tool model • number of tools • number of rundown /day • set torque Contact person Customer Service Department Tel.: +49(0) 7363 81 125 Fax: +49(0) 7363 81 383

Spare parts 8 8.1 Gear 7.2 Lubrication Products , page 33 17BP… 17BP…S * Typ 85 56 (3×) 58 60 (3×) 62 90 17BP05Q(S) 935101 541894 542230 541894 935093 541899 17BP07Q(S) 935102 542233 541897 934878 17BP09Q(S) 935103 541893 542231 541894 935093 – 17BP13Q(S) 935104 542232 541897 934878

P1846E/EN 02/06 37 Spare parts8 1) Order no. 2) Quantity 3) Dimension Index 1) 2) Benennung Description 3) 52 800116 1 Sicherungsring circlip 25,98X0,94 IR 53 541887 1 Scheibe washer 54 542724 2 O-Ring o-ring 28,24X 0,78 55 542722 1 Zahnkranz toothed ring 56 * 3 Planetenrad idler gear 57 923095 3 Nadelkranz needle rim 3,X5,X 7, 58 * 1 Planetenradträger gear gage 59 541888 3 Zylinderstift cylinder pin 60 * 3 Planetenrad idler gear 61 923095 3 Nadelkranz needle rim 62 * 1 Planetenradträger gear gage 63 934841 1 Getriebegehäuse gear case 64 1019356 1 Scheibe,Ausgleich- equalizing washer 13,49X 18,64X 0,23 65 542089 2 Rillenkugellager ball bearing 66 541775 1 Distanzring spacer ring 67 800135 1 Sicherungsring circlip 10,03X0,64 AR 68 922361 1 Scheibe,Ausgleich- equalizing washer 17,3X23,8X0,25 69 901602 1 Sicherungsring circlip 24,X1,2IR 70 541904 1 Überwurfmutter union nut 71 935029 1 Hülse sleeve 72 540842 1 Druckfeder compression spring 73 934847 1 Hülse sleeve 74 503009 1 Sicherungsring circlip 75 934876 1 Zentrierhülse sleeve 76 S901724 1 Druckfeder compression spring 1,X17,5 X 42, 77 934879 1 Druckhülse compression sleeve 78 1005164 1 Kugel ball 79 935047 1 Schalthülse kpl. actuating sleeve asm. 80 934875 1 Gewindering threaded ring 81 935072 1 Sprengring retaining ring 25X2 AR 82 922904 1 Kugel ball 1,500MM 83 935073 1 Spannstift dowel pin 1,X6, 84 935074 1 Anschlag kpl. stop cpl. 85 * 1 Getriebe gear 86 935011 1 Tiefenkontrolle depth sensor

Spare parts 8 8.2 Tool holder with IrDA interface

P1846E/EN 02/06 39 Spare parts8 1) Order no. 2) Quantity 3) Dimension Index 1) 2) Benennung Description 3) 95 935144 1 Köcher kpl. mit IrDA- Schnittstelle tool holder with IrDA interface 96 935172 1 Köcher, Gummi holster rubber 97 935174 3 Buchse plug 98 935170 1 IrDA-Serial Adapter IrDA-Serial Adapter 57,6KBIT/S 99 935175 1 Halterplatte mounting plate 100 935173 1 Schrauberauflage screwdriver support 101 918688 1 Senkschraube countersunk screw M 6X 12 102 935171 1 Anschraubwinkel screw-on bracket 103 S902967 3 Halbrundschraube half round screw M 8X 25

P1846E/EN 02/06 41 Service9 9 Service Note If you should require repairs, send the complete cordless EC tool to Apex Tool Group! A repair is only permitted by Apex Tool Group authorized personnel. If the tool is opened, the warranty is voided. Contact person for all customer service and repair services: Mr Anton Schmid TS Department Tel.: +49(0) 7363 81 171 Fax: +49(0) 7363 81 252 Mr Reinhold Eichberger TSK Department Tel.: +49(0) 7363 81 254 Fax: +49(0) 7363 81 263 9.1 Re-Calibration The type-specific calibration data is saved on the integrated screw electronic system in the delivery state of the CLECO tool. If service is requires to change the torque transducer, the screw electronic system or if a recalibration is required, please send the CLECO tool to Apex Tool Group. This ensures that any updating of the calibration data, if necessary, is done correctly.

Technical Data 10 10 Technical Data 10.1 Dimensions cordless EC tool Fig. 10-1: Dimensions cordless EC tool (mm) 17BP05Q 17BP07Q 17BP09Q 17BP13Q 17BP05QS 17BP07QS 17BP09QS 17BP13QS

P1846E/EN 02/06 43 Technical Data10 10.1.1 Dimensions tool holder (Optional) Fig. 10-2: Dimensions tool holder (mm) 10.2 Performance Data Type Depth sensor Recommended torque range Idling speed Screw size Weight Calibration data without Rechargeable Battery with Rechargeable Battery Torque (nominal) Angle pulses (Resolver) Nm max. Nm min. ¹/min mm kg Nm ¹ degrees 17BP13Q 17BP13QS without with 13 3 466 M6 1.3 2.0 17.4 1.9091 17BP09Q 17BP09QS without with 9 650 M5 12.4 1.3529 17BP07Q 17BP07QS without with 7 860 M5 12.6 1.0332 17BP05Q 17BP05QS without with 5 1000 M4 6.4 0.7322 194 60 204 60 235 105

Technical Data 10 10.3 Electrical data Tool Protection class III as per DIN EN 61140 (VDE 0140-1) Protection category IP40 as per DIN EN 60529 (IEC 60529 Tool holder Protection class III as per DIN EN 61140 (VDE 0140-1) Protection category IP40 as per DIN EN 60529 (IEC 60529 10.3.1 Battery power supply 10.3.2 Output stage servo electronic Battery type Nickel metal hydride (NiMH) Capacity 1700 mAh Capacity min. 1600 mAh Rated voltage 18 VDC Voltage range in operation 13 V to 21 V Maximum current in motor operation approx. 50 A Nominal voltage of the controller part approx. 130 mA Battery automatic discharge approx. 0.3 mA Nominal current motor phase 8 A peak value sinus Maximum current motor phase 50 A peak value sinus Time for maximum current 2 s (Actual time of the regulator) Output voltage ULL at Nominal voltage of the battery, nominal current and full level control at least 16 V peak value sinus Nominal output capacity (3-phase, Sin.) 120 VA Maximum output capacity (3-phase, Sin.) 400 VA

P1846E/EN 02/06 45 Disposal11 10.3.3 IrDA interface port 10.3.4 Torque transducer Torque measurement is via a reaction transducer with expandable measurement strips. The reaction transducer is positioned between the motor and the gears in the handle housing. 11 Disposal Recovery of raw materials instead of waste disposal In accordance with the Electrical and electrical device law (ElektroG) and the national Battery ordinance (BattV) the tool and the nickel metal hydride battery must be recycled in an environmentally friendly manner. Return the tool and defective/used batteries to your company collection facility or to Apex Tool Group. Do not throw the battery in household refuse or in water. Do not open the battery. Supply voltage 5.0 V (4.8 to 5.5 V) Type Power consumption 0.30 VA Maximum current 11 mA Transmission speed: 57.6 kbit/s Parity Bit none Data Bit 8 bit Stop Bit 1 bit Error check CRC Working temperature 0 °C to +40 °C Nominal calibration see 10.2 Performance Data , page 43 Sensitivity 2 mV/V Bridge ohms 1000 Ohm Precision class 0.5 % of final value Linearity error +0.25 % of final value Measurement range –125 % to +125 % of final value

Glossary 12 12 Glossary Angle Angle that is to be reached at the end of the fastening sequence (also final angle, rated angle, or nominal angle). Angle High Limit [AHL] Maximum admissible angle of rotation for a fastening stage. Application Programmed setting of the tool for a specific fastening sequence of up to 6 stages. End delay time [ms] Delay from the time the tool is switched off until measurement stops. Fastening parameters Parameters that determine the fastening sequence for a rundown. Linking Linking allows the user to automatically change from application to application (max. 255) for a predefined number of steps (rundowns). The automatic changes are available for eight tightening groups. The corresponding tightening groups can be selected with the Run Screen or by external selection. Max. fastening time [mS] Max time for the tool to run during the stage Maximum tool speed Maximum admissible speed of tool. NOK Active if Torque/Angle/Yield Point are outside the programmed limits or some other fault has occurred. NOK interlock Tool stop following a preset number of faulty rundowns. OK Active if Torque/Angle/Yield Point are within the programmed limits. Resolver (angle encoder) Sensor for measure rotation angle. Speed Nominal speed of nutrunner during a stage. Tightening Group (Linking) Group (1-8), which specified how many rundowns are required during the Linking with which parameters (application). The corresponding tightening groups can be selected with the Run Screen or by external selection. Tool Enable Input to enable or disable the tool. Torque High Limit [THL] Maximum torque that may be reached during a cycle. Torque transducer Sensor for measuring torque. Turn off angle Angle at which a tool is shutoff Turn off torque Torque at which a tool is shutoff