Roth ACO202 Crimping Press Machine Instruction Manual

Roth ACO202 Crimping Press Machine Instruction

Product Information

The ACO202/ECO202 is a cordless hydraulic press tool designed for crimping copper and aluminum connectors up to 125mm². It comes with an 18V DC battery and is supplied in a transport case.

Basic Safety Instructions

• Read all safety instructions and operating instructions before using the tool
• Use the tool only for its intended purpose
• Wear appropriate protective equipment (gloves, safety glasses, etc.)
• Do not modify the tool or use it if it is damaged or malfunctioning
• Keep the tool away from children and untrained persons

Technical Specifications

• Battery: 18V DC
• Power: 450W
• Pressing force: 32kN
• Pressing area: up to 125mm²
• Noise level: 87.5 db(A) (plastic), 76.5 db(A) (metal)
• Weight: 2.9kg without battery

Product Usage Instructions

1. Attach the battery to the tool.
2. Select the appropriate crimping die for your connector.
3. Insert the connector into the die and position it in the tool.
4. Press and hold the trigger until the crimping process is complete.
5. Release the trigger and remove the tool from the connector.
6. Repeat the process for each connector.
7. When finished, remove the battery from the tool and store it in a safe place.

Proper use

These press devices are intended exclusively for use with press jaws/adaptor jaws and press collars manufactured by Novopress or approved by Novopress in agreement with the system supplier. For further details, please contact the system supplier or Novopress direct. The devices, press jaws and press collars are to be used exclusively for the purpose of pressfitting pipes and fittings for which the relevant press jaws and press collars have been designed. Any use beyond or different to that described here shall be regarded as improper use. All work with this tool that does not correspond to proper use may lead to damage to the press device, the accessories or the pipes. Leaks and/ or injury may result. Novopress is not liable for damage resulting from

• the use of unsuitable press tools or press tools from other manufacturers, or
• applications that do not conform to proper use.

Proper use also includes compliance with the Operating Manual, adherence to the inspection and maintenance conditions as well as compliance with the latest versions all the relevant safety regulations.

Basic safety information

The following pictograms are used to highlight sections of text. Please follow these instructions and act with special caution in these cases. Pass all health and safety instructions on to other users and technicians.

• WARNING!
  This information indicates a potentially dangerous situation that could result in serious injury or death.

• CAUTION!
  This information indicates a potentially dangerous situation that could result in minor injuries and/or material damage.

• Information!
  This information is directly linked to the description of a function or an operating sequence.

Please read this Operating Manual carefully.
The safety instructions it contains must be observed.

WARNING!
Read all safety information and instructions.
Failure to comply with the safety information and instructions may result in electric shock, fire and/or serious injuries.
Therefore:

• Keep all safety information and instructions for future use and only pass the devices on to others together with the instructions.

WARNING!
Risk of injury from ejected fragments
Incorrect or improper use or the use of worn or damaged press tools and press devices carries a risk of injury from ejected fragments.
Therefore

• Press tools and press devices may only be used by trained personnel.
• Compliance with the specified service work and service intervals is mandatory.
• Check the press tools and press devices for cracks and other signs of wear before each use.
• Discard all press tools and press devices with material cracks or other signs of wear immediately and do not use them any longer.
• Only use press tools and press devices that are in perfect technical condition.
• Following incorrect use, do not use the press tool and press device any longer and have them inspected by an authorised workshop.

CAUTION!
Unskilled use may lead to damaged or malfunctioning press tools and press devices.
Therefore

• Replace worn press tools.
• Use carrying cases for transportation and storage and keep press tools and press devices in a dry room.
• Have damage checked immediately by an authorised workshop.
• Comply with the safety instructions regarding the cleaning and anti-corrosion agents used.

Information!
Consult the documents provided by the system supplier for handling and assembly instructions for fittings and pipes.

Symbols on the device

Scope of supply

The scope of supply for the standard equipment includes:

Optional additional accessories (e.g. press jaws, adaptor jaws, press collars) may also be included. Please contact the system supplier for information on the scope of supply.

Technical data

ACO202/ECO202

1. Measurement uncertainty 3 db(A) 2) Measurement uncertainty 1.5 m/s²
   The stated vibration emission value was measured using a standard test procedure and can be employed for the purpose of comparison with another device.
   The stated vibration emission value can also be used to obtain an initial estimate of interruptions during intermittent operation.

Caution: The vibration emission value may differ from the stated value while the device is actually in use, depending upon the manner in which the device is used. It may be necessary to establish safety measures to protect operating personnel, depending on the actual conditions of use (intermittent operation).

Rechargeable battery (ACO202 only)

Information!
The batteries are not charged at the factory.
Therefore:

• Charge the batteries before using for the first time.

Information
Limited temperature range for charging and storing the batteries.
Therefore

• It is imperative that the operating instructions for the battery charger are complied with.

Battery charger
For information on the function and operation of the battery charger and the rechargeable batteries, please consult the battery charger operating instructions.

Brief description of the press device

Automatic press cycle (Fig. 1) The device features an automatic press cycle. This ensures that the pressing operation is always completed. For safety reasons, the automatic press cycle only switches on when the pressing operation has started, i.e. when the fitting starts to be shaped. After the automatic press cycle has been triggered, the green LED (2) goes out and the pressing operation runs automatically. The pressing operation can then only be stopped by pressing and holding release button (4). After the pressing operation has been completed, the motor automatically switches off and the green LED lights up again. If start button (1) is released before the automatic press cycle begins, the piston in the press device moves back to its starting position. The pressing operation will not have been completed. The pressing operation must be triggered again.

Release button (Fig. 1)
The pressing operation can be stopped at any time by pressing and holding release button (4).
The piston in the press device then returns to its starting position.

Rechargeable battery (ACO202 only)
Removing the battery (Fig. 2) Push in (1) the two release buttons (A) and then remove the battery (2).

Inserting the battery (Fig. 3) Slide the battery onto the device as illustrated until it clicks into place.

Battery charge indicator (Fig. 2) The battery charge is displayed when button (B) is pressed. The number of LEDs lit up denotes the battery charge. One flashing LED indicates a maximum power reserve of 10%. The battery must be charged soon.
If the battery is inserted in the press device while the battery charge is being checked, the last pressing operation must have been completed at least 1 minute prior to this. Otherwise the display will be inaccurate.

ACO202 and battery
information!
The ACO202 press device must only be operated with 18 V lithium-ion rechargeable batteries. The 18 V rechargeable battery must only be used in the appropriate press devices.

Feature of the press device after extended periods out of use or when changing the battery:
If the press device is out of use for approx. 30 minutes or the battery is reinserted, it switches to SLEEP mode. The LED is no longer illuminated. Press the start button briefly to start the press device.

Feature of the press device when the battery is empty:
When a pressing operation begins, a check is made to determine whether the battery charge is sufficient to complete the pressing operation. If this is not the case the device does not start.
The green LED flashes.
If the green LED flashes following a pressing operation, the pressing operation was carried out correctly. The battery must be recharged prior to the next pressing operation.

Commissioning and operation

Preparing the ACO202 / ECO202
CAUTION!
Fingers risk being crushed if the device is operated without a press jaw/adaptor jaw (Fig. 4). If no press jaw/adaptor jaw is fitted, fingers could be placed in the at-risk zone.
Fingers could be crushed when the device is started.
Therefore:

• Do not operate the device without pressing jaws.
• Keep your fingers away from the at-risk zone.

Information!
The device will not start if the retaining pin (5) is incorrectly inserted. The green LED flashes.

Information!
The press device is not suitable for continuous operation. Following 30 minutes of continuous operation, a short break of at least 15 minutes must be taken to allow the device to cool down.

Insert the press jaw/adaptor jaw into the press device as shown in Fig. 5 to 7

Meaning of the LED display

Performing the pressing operation

CAUTION!
Danger of crushing!
There is a risk of crushed fingers and hands.
Therefore:

• Keep body parts and foreign objects away from the press jaws during the pressing operation.
• Do not hold the jaw levers with your hands during the pressing operation.

CAUTION!
Keep fingers away from the at-risk zone if no press jaw/adaptor jaw is fitted (Fig. 4). Fingers may get crushed.
Therefore:

• Do not operate the device without the jaws.
• Keep your fingers away from the at-risk zone.

Information!
The device will not start if the retaining pin (5) is incorrectly inserted. The green LED flashes.

Information!
Comply with the operating instructions for the press tools.

1. Check whether the nominal width of the press fitting matches the nominal width of the press jaw/press collar.

2. Comply with the system manufacturer’s instructions when fitting the press jaw/press collar (Fig. 8). If using a press collar: Fit the adaptor jaw to the press collar as described in the press collar manufacturer’s instructions.
   Information!
   Make sure that the press jaw is fully closed when pressing is complete (Fig. 9). Information!
   Ensure there is no gap between the segments of the press collar when the pressing operation is complete.

3. To start the process, press the start button.

4. When pressing is complete:

   • If using a press collar: First detach the adaptor jaw from the press collar, then
   • Detach the press jaw/press collar from the press fitting (Fig. 10)

Cleaning, maintenance and repair

CAUTION!
Risk of injury during cleaning or repair work from inadvertently pressing the On switch.

Therefore:

• Comply with the safety instructions and always remove the battery or disconnect the mains plug before performing cleaning, maintenance or repair work.

Service addresses
You can find the addresses of authorised specialist workshops on the “Service addresses” sheet provided or at www.novopress.de.

Service intervals
Service and repair work may only be carried out by Novopress or the authorised Novopress specialist workshops.

Information

• The next service deadline is indicated on the press device.
• This service must be performed at least every 2 years.
• If more than 40,000 pressing operations are carried out in 2 years, a service must be performed after these 40,000 operations, at the latest.
• The LED display indicates that a service is due (see Section 7.2 Meaning of the LED display).

Routine inspection (before use, at the start of the working day) and when soiled (Fig. 10) Check for visible damage, material cracks and other signs of wear. If defects are found, do not use the device and have it repaired.

Six-monthly inspection
Have the device inspected by a qualified electrician or a Novopress workshop.

Annual inspection
Have the press device inspected and serviced at Novopress or a Novopress workshop.

Disposal

CAUTION!
Groundwater hazard
The device contains hydraulic fluid.
Hydraulic fluids pose a hazard to groundwater. Uncontrolled draining or improper disposal is punishable by law.
Therefore:

• Dispose of the device in an environmentally responsible manner.

The instructions in the Operating Manual provided with the battery charger must be complied with when disposing of rechargeable batteries and the charger. Novopress recommends that disposal be carried out by authorised specialist companies. This product conforms to the requirements in EU Directive 2002/95/EC RoHS (Restriction of Hazardous Substances). In accordance with EU Directive 2002/96/EC WEEE (Waste Electrical and Electronic Equipment), manufacturers of electrical devices are obliged to take back old devices and to dispose of them in an appropriate manner. The product must not be disposed of as normal household waste. Old devices must be returned directly to Novopress for proper disposal.

Warranty and guarantee

Novopress provides the full statutory warranty of 24 months for its press devices and tools. The warranty period always commences on the date of delivery, which must be proven by means of the sales documentation in case of doubt. Within the warranty period, the warranty covers the repair of any damage or malfunction of these tools that is attributable to material or production faults.
The following are not covered by the warranty:

• Damage caused by improper use or inadequate maintenance.
• Damage caused by the use of products not approved by Novopress for use with its press devices.
• Damage caused by pressing unsuitable pipes or fittings.

For wearing parts, the Novopress warranty lasts only for the intended service life.
Service work and parts provided in response to warranty claims do not have to be paid for.
However, all shipping costs shall be borne by the user.
Claims can only be accepted if the device is delivered to Novopress or a Novopress workshop in an assembled state.
Repair or replacement of the device under warranty does not result in an extension of the warranty period. Repair or replacement can only be performed using as-new components, the function of which corresponds to that of the old components. All parts that are faulty and consequently replaced are the property of the manufacturer.

Extended warranty on expiry of the statutory warranty period
We voluntarily provide the following extended warranties beyond the statutory warranty period.

1-year extended warranty for new press devices, adaptor jaws and press collars
Novopress provides an extended warranty of one year for all new press devices, adaptor jaws and press collars that have been serviced at least every 12 months by Novopress or by an authorised Novopress workshop. There is a charge for this service work. For details of costs, please contact Novopress or an authorised Novopress workshop.

3-year extended warranty for new press jaws
Novopress provides an extended warranty of three years for all new press jaws, interchangeable jaws and press inserts that have been serviced at least every 12 months by Novopress or by an authorised Novopress workshop. There is a charge for this service work. For details of costs, please contact Novopress or an authorised Novopress workshop.

Repair warranty
Novopress provides the following repair and spare parts warranty beyond the warranty period for new products that undergo repair after this period.

• 6-month warranty for replaced spare parts.
• 12-month warranty for replaced assemblies.
• 12-month warranty for replaced press devices.

EU Declaration of Conformity

in accordance with EU Directives 2004/108/EC; 2006/42/EC
We hereby declare that the design, construction and version sold by us of the ACO202 and ECO202 press devices conform to the relevant, fundamental health and safety requirements. If the relevant product is not used in accordance with proper use or in the event of a modification to the product not agreed by us, this declaration shall become null and void. .

Applicable standards:
EN 55014-1; EN 55014-2; EN 60745-1; EN ISO 14121-1; EN ISO 12100-1; EN ISO 12100-2

Novopress GmbH&CoKG
Scharnhorststr. 1
41460 Neuss
Germany

Repairs / Service

Scharnhorststr. 1 Postfach 101163
41460 Neuss 41411 Neuss
Germany
Tel: +49 (2131) 2880
Fax: +49 (2131) 28855
www.novopress.de
E-mail: info@novopress.de

References

• ellerundernovopress.de
• lubpodadresemnovopress.de
• nebonaadresenovopress.de
• Novopress | Presswerkzeuge & Pressmaschinen seit 1969
• oennovopress.de
• ofkuntuvindenopnovopress.de
• oppurepossonoessereconsultatisulsitoInternetnovopress.de
• osacederaositenovopress.de
• oulesiteWebnovopress.de
• sheetprovidedoratnovopress.de

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