Klauke UAP 2 Alu-LaserPlus System Hydraulic Press Machine Instruction Manual

UAP 2 Alu-LaserPlus System Hydraulic Press Machine
Instruction Manual Joh.-Christoph Schütz
HE.4947_O ©8/98
HE4947_O.doc
Anz. der Seiten: 53
Gustav Klauke GmbH Auf dem Knapp 46
D-42855 Remscheid
Telefon ++49 +21 91- 907-0
Telefax ++49 +21 91- 907-141
www.klauke.textron.com

UAP 2 Alu-LaserPlus System Hydraulic Press Machine

Instruction Manual
UAP 2
for the universal battery powered pressing unit Type UAP 2,
Serial-#. ………………………
Symbols

Safety warnings
Please do not disregard these instructions in order to avoid human injuries and environmental damages.
Operational warnings
Please do not disregard them to avoid damaging the unit.

Introduction

Before starting to use the tool please read the instruction manual carefully.
Use this tool exclusively for its determined use respecting the all international and domestic health and safety regulations.
Use this tool exclusively for its determined use.
This instruction manual has to be carried along during the entire life span of that tool.
The operator has
– to guaranty the availability of the instruction manual for the user and
– to make sure, that the user has read and understood the instruction manual.

Labels

The type specification, details of origin and manufacturer’s name can be found on the type plate attached to the housing. On the opposite side of the housing there is a label which provides technical data. The serial number is on the hydraulic cylinder between the housing and the pressing head. On the pressing head there is a warning against the danger of crushing during operation.

Warranty

If correct operation is guaranteed and regular service is provided our warranty is 12 months from the time of delivery or 10.000 pressing cycles.

Description of the universal pressing unit

The universal battery powered unit type UAP 2 is a hand held tool and consists of the following components:
Table 1 (see Picture 1)

emergency
| Pin| bolt to lock the pressing jaws
4| Pressing head| reception for the pressing jaws, respectively press chains
5| Housing| ergonomically formed plastic housing for perfect handling with a detachable lid
6| Light diode display| indicator for tool functions and battery charge control
7| Battery cartridge| rechargeable NiMH battery 3.0 Ah, with side clips
8| –| –
9| Hand guard| guard to protect the operating hand
I0| Pressing jaws| dies to press the fitting on the tubes (will be supplied by the system provider)
11| Battery retract spring| Spring to stop older batteries w/o side clips from falling out

4.2. Brief description of the important features of the unit
– The hydraulic unit incorporates an automatic retraction which returns the drive rolls into its starting position when the maximum operating pressure is reached.
– The unit is equipped with a special brake which stops the forward motion of the drive rolls when the trigger (Pos.-# 1) is released.
– The unit is equipped with a double piston pump which is characterised by a rapid approach of the drive rolls towards the jaws (Pos.-No. 10) and a slow pressing motion.
– The pressing head (Pos.-# 4) can be smoothly turned by 360° around the longitudinal axis in order to gain better access to tight corners and other difficult working areas. (see Picture 3+4)
– The UAP 2 is equipped with a microprocessor which indicated service intervals, internal checks and low battery charges. It also shuts off the motor automatically after the compression is completed.
4.3. The light diode display
This tool is equipped with a special circuit board incorporating several important features to inform the user about the current status of the unit. The diode (Pos.-No. 6) signals in the following cases:

and battery flat

1. Remarks:
   – Does the diode signal periodically at the end of a working cycle for approx. 20 sec the unit must be returned to an authorised Service Center for Service as soon as possible.
   – In case of an error the light diode display also signals periodically at the end of a working cycle. The signal indicates in this case the circuit opening by the electronic fuse. A possible reason for that is that a cycle was performed with an incorrectly low battery. If  the signal occurs even after changing the battery there must be a different error or a service is due. In these cases the tool must be returned to the manufacturer or an authorised service center.

2. The unit switches off when it gets too hot. It switches on automatically after the unit cooled off.

Remarks in respect of the determined use

Before starting the pressing process the charging levels of the battery cartridge (Pos.-#. 7) should be tested. A low charging level can for example be detected by a continued signal of the light diode display (Pos.-#. 6) for 20 sec. at the end of a test pressing cycle. (see chapter 4.3)
5.1. Operation of the units
After having selected the right pressing jaw for the intended application the jaw must be examined in terms of possible damage, dirt in the compression area and ware. When using competitor products the user has to make sure that the jaw complies with our
tool. To insert or change the pressing jaw please follow picture 611.
After mounting the fitting on the tube the pressing jaws will be opened by pushing the rear end of the pressing jaw together while the jaw has to be positioned on the fitting. (Pls. see also picture 5 Pos. E)
A pressing procedure will be initiated by actuating the trigger (Pos.-#. 1, Picture 2 Pos. C). The pressing process is defined by the closing motion of the pressing jaws. The drive rolls on top of the ram close the pressing jaws scissors like.
Attention
The user has to make sure that the lock pin (Pos. 3) is properly engaged
Attention
A necessary condition for a permanently leaking free connection is that the pressing cycle has to be completed which means that the pressing jaws completely closed at the tip as well as the T-link.
Attention
The assembly of gas pipes in gas distribution lines is prohibited unless the system provider gives an explicit permission to use this tool on special gas fittings.
Attention
The pressing procedure can be interrupted at any moment by releasing the trigger.
Attention
The user has to check by optical means whether the pressing jaws are completely closed.
Attention
If a pressing cycle has been interrupted the fitting has to be either dismantled or pressed a second time.
The user needs to make sure that the pressing jaws are completely closed and that there are no foreign objects (e.g. plaster or stone fractions) between the pressing jaws.
In case of error or emergency push retract button (Pos. 2, Picture 2 Pos. B) to return the drive rolls into starting position.
The drive rolls retract automatically and return into the starting position after the maximum operating pressure has been reached enabling the user open the pressing jaw.
Attention
Before changing the pressing jaws remove battery to avoid unintentional operation.
5.2. Explanation of the application range
The UAP 2 is a hand guided pressing tool to mount fittings on multi Layer, copper and stainless steel type plumbing tubes with∅12 to 54 mm, with pressing chain (picture 12c+d) up to 75 mm. The unit is not supposed to be restrained in a vise. It is not allowed to use the tool in a stationary application. Complying certain conditions the unit can be operated stationary with our presentation support EKST. The conditions can be taken from the instruction manual of the EKST.
The tool is not designed for continued pressing operations. After a sequence of approximately 50 completed cycles you have to make a break of 15 minutes to give the unit time to cool down.
Attention
Too intensive use can cause heat damages for the tool
Attention
During the operation of electric motors sparks can occur which might ignite highly inflammable or explosive liquids and materials
Attention
Electric-hydraulic pressing tools must not be operated in pouring rain or under water.
5.3. Mounting instructions
Please reference the assembly manual of the systems supplier before mounting the fittings on the tubes. In order to safeguard a proper pressing and to guaranty a safe and reliable handling the machine must only be operated with pressing jaws/~ chains recommended by the provider of the tube system and/or the tool manufacturer. If the markings on the tool and pressing jaw do not match respectively if there are no assembly instructions the user has to contact the provider of the system to request a compatibility statement.
Attention
Do not use bent or damaged pressing jaws.
For your job on the location we recommend the accessories shown in picture 12.
Remark
As the tool manufacturer we offer perfectly designed pressing jaws for all known systems and tube dimensions. Special designs and customer solutions upon request.
5.4. Service and maintenance instruction
The reliable performance of the tool is dependent on careful treatment and service. This represents an important condition to safeguard a lasting connection. To safeguard this the tool have to be maintained and serviced regularly (see chapter 4.3 for more information).
We would like to draw your attention to the following points:

1. The electric-hydraulic pressing unit have to be cleaned and dried after each use before being put into the transportation case.
2. In order to guaranty a proper function of the machine the pressing tool should be returned to the manufacturer after the light diode display (Pos.-#. 6) indicates Service.
3. The battery as well as the charging unit must be protected against humidity and foreign objects.
4. The bolt joins, the drive rolls and their guides must be oiled regularly in small amounts.
5. Check through test crimps or have the tool manufacturer check the tool and pressing jaws regularly for proper function.
6. Keep pressing jaws clean. Remove dirt with a brush.

In order to avoid possible malfunctions we offer you a manufacturer service consisting of disassembly, cleaning, exchange of possibly worn out parts assembly and final control. Only a clean and properly functioning press system can over the time safeguard a leaking free connection.
Within the determined use of the tool only the pressing jaws (Pos.-#. 10) are permitted to be changed by the customers.
Attention
Do not damage the seals of the tool.
If the seals are damaged the warranty is invalidated.
5.5. Remarks on the use of the battery cartridge and charging unit.
The charging unit is run with a nominal voltage of 230 V and a frequency of 50 Hz. New batteries must be charged prior to use. To charge the battery cartridge (Pos.-#. 7) the power plug of the charging unit has to be plugged into the power supply and the battery cartridge has to be pushed into the charging unit (Picture 14). The charging time is one hour (Picture 15). The charging level of the battery cartridge can be checked by a LED.
green battery cartridge is charged
red Battery cartridge is empty and is just being charged
flashing battery cartridge is not pushed in properly or too hot, a sound signal occurs
Push the battery into the charging unit so that the polarity of the poles of the battery corresponds to those at the charger. Is the battery plugged in correctly the LED changes from green to red and the charging procedure starts. When the charging procedure terminated the LED changes again to green. Simultaneously a signal occurs for 5 seconds.
No other battery cartridges e.g. dry batteries or car batteries etc. permitted to be used neither in the tool nor in the charging unit. As soon as the speed of the machine decreases noticeably the battery must be recharged. Do not recharge a partially empty battery as a precaution (Picture 20).
If charging a battery which has currently been used or which walaying in the sun for a longer period of time the LED might flash red. In this case wait for a while. The charging procedure starts after the battery cooled down.
Does the LED flash red and green and does an audible tone occufor 20 seconds it is not possible to charge that battery. The poles the battery or the charging unit are dirty or the battery is low or damaged. If you want to charge two batteries in a row wait for 15 min before you charge the second battery.
Avoid great fluctuating temperatures under 0°C and above 40°C (Picture 17). Through these fluctuations damages may result for the battery cartridge as well as for the charging unit. The best operation temperature is between 15-25 °C. Do not leave or operate the charging unit in rain or snow (Picture 19). Do not charge the battery near lightly inflammable materials or gases (Picture 18).
Do not use the cord to transport the charging unit or to pull the plug out of a wall socket with force. Do not insert strange parts into the ducts of the charging unit.
Attention
Do not place the battery in your pocket or in your toolbox if there are any conductive materials in it suc as coins, keys, tools or other metallic parts.
The charging of the batteries must only be done with charging units supplied by the manufacturer.
Pull the plug of the charging unit after charging (Picture 16). Do not disassemble the charging unit or battery.
In order to safeguard a safe and proper performance of the charging unit the repair and service of the unit should be made through our Service Centre.
5.6. Storage and transport of the crimping tool
In order to protect the tool against damages it has to be cleaned carefully after every use and be put into the transportation case which has to be closed safely.
Into this case you can put a spare battery cartridge, the charging unit, 3 pressing jaws and the instruction manual.

Troubleshooting

a.) Constant flashing of the light diode display (Pos.-#. 6) at the end of a pressing cycle.
=>Exchange battery. Does the diode continue to flash the tool must be returned to the manufacturer. (Pls. see also chapter 4.3 for more information)
b.) The tool loses oil.
=>Return the unit to the manufacturer. Do not open it and damage the seal of the tool.
c.) The motor doesn’t switch off and no automatic retraction occurs.
=>Stop the pressing process. Press the retract button (Pos.-#. 2) and the operating switch continuously and simultaneously for about 10 sec. Will the malfunction not be eliminated by this operation the tool has to be returned to the manufacturer.

Putting out of operation/waste disposal

This unit is subjected to the scope of the European WEEE (2002/96/EG) and RoHS (2002/95/EEC) directives.
The WEEE directive regulates the collection and the environmental friendly recycling of electro and electronic units. Information about this can be found in our home page www.Klauke.com under ‘WEEE & RoHS’.
The RoHS directive bans new electrical and electronic equipment put on the market which contains more than 0,1 weight percentage lead, mercury, hexavalent chromium, polybrominated biphenyls (PBB) or polybrominated diphenyl ethers (PBDE) and 0,01 weight percentage cadmium per homogeneous material.
Battery cartridges (Pos.-No. 5) must be specially disposed of according to the EEC Battery Guideline.
Attention
Do not dispose of the unit in your residential waste.
Klauke has no legal obligation to take care of their WEEE outside Germany unless the product has been shipped and invoiced from inside your country by Klauke.
Please contact your distributer to find out more how to get your tool recycled environmental friendly.

Technical Data

Note
Additional copies of the of the IM are available upon request with no charge. The part # is HE.4947_O.

GROSSBRITTANIEN
Norwich Instrument Services
Mr. Norman Cockburn
32 Hellesdon Park Road
Drayton High Road
Norwich NR6 5DR (UK)
Tel.: 0044-1603-416900
Fax: 0044-1603-416902
E-Mail: [email protected]

CE `98 – Declaration of conformity. We declare under our sole responsibility that this product is in conformity with the following standards or normative documents:
EN 60745-1; EN 12100 T1+2; EN 294; EN 349; EN 60204-1; EN 28662-1; EN 50081-1; EN 50082-2; EN 60529; prEN 982; prEN 1037 in accordance with the regulations of directives 98/37/EEC, 89/336/EEC

Remscheid, den 30.11.2007

Dipl.-Ing. Joh.-Christoph Schütz, CE-Beauftragter

References

• l.mr
• H.K.ElectricB.V.Mr

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