CEMBRE B500NDE Battery Crimping Tool Instruction Manual

CEMBRE B500NDE Battery Crimping Tool

Product Information

Battery Operated Hydraulic Crimping Tool

• Model Numbers: B500ND, B500NDA, B500NDE, B500NDT
• Application Range: Suitable for installing electrical compression connectors on conductors up to 300 mm2 (600 MCM)
• Rated Crimping Force: 60 kN (US sh. ton)
• Minimum Operating Pressure: 661 bar (9587 psi)
• Dimensions: 396 x 136 x 81 mm (15.6 x 5.3 x 3.2 inches)
• Weight with Battery: 3.15 kg (6.9 lbs)
• Motor Voltage: 18 V
• Operating Temperature: -15 to +50 °C (+5 to +122 °F)
• Recommended Oil: TOTAL DIEKAN 1640 or equivalents
• Operating Speed: Twin speed operation and automatic switching from a rapid advancing speed of the ram to a slower, more powerful crimping speed
• Safety Features: Maximum pressure valve

Rechargeable Battery:

• Type: CB1820L (Li-Ion)
• Voltage: 18 V
• Ah: 2.0
• Wh: 36
• Weight: 0.4 kg (0.9 lbs)

Battery Charger:

• Type: ASC55EU
• Input Voltage (UK): 220 – 240 V / 50 – 60 Hz
• Input Voltage (AUS/NZ): 115 V / 60 Hz
• Power: 85 W

Acoustic Noise:

• LpA: 67.7 dB (A)
• LpCPeak: 89.2 dB (C)
• LWA: 74.2 dB (A)

Vibration:

• m/s2: 0.724

Product Usage Instructions

• WARNING: Do not use the tool for purposes other than those intended by CEMBRE. The operator should concentrate on the work being performed and be careful to maintain a balanced working position.
• Before starting work on electrical equipment, please ensure that either there are no live parts in the immediate working area or that precautions are taken for working near live parts in accordance with EN50110-1.
• Do not use this tool on or near live conductors without proper personal protective equipment. Failure to observe this warning could result in severe injury or death.
• The tool is unsuitable for continuous use and should be allowed to cool down following uninterrupted, successive crimping operations. For example, having exhausted a fully charged battery in one session, delay battery replacement for a few minutes.

WARNING SYMBOLS

Tool

• Before using the tool, carefully read the instructions in this manual.
• When operating the tool, keep hands away from the danger zone.
• Always close the tool head correctly and securely.
• User information (Directives 2011/65/EU and 2012/19/EU),

Battery

• Never throw batteries into fi re or water.
• Always recycle the batteries.
• Do not discard batteries into domestic refuse or waste disposal.

GENERAL CHARACTERISTICS

kN (US sh. ton)

bar (psi) mm (inches)

kg (lbs)

V ____

°C (°F)

| suitable for installing electrical compression connectors on conductors up to 300 mm2 (600 MCM)
Rated crimping force| 60 (6.75)
Minimum operating pressure| 661 (9587)
Dimensions| 396 x 136 x 81 (15.6 x 5.3 x 3.2)
Weight with battery| 3,15 (6.9)
Motor| 18
Operating temperature| -15 to +50 (+5 to +122)
Recommended oil| TOTAL DIEKAN 1640 or equivalents
Operating speed| twin speed operation and automatic switching from a rapid advancing speed of the ram to a slower, more powerful crimping speed
Safety| maximum pressure valve
Rechargeable battery| V / Ah / Wh

**** kg (lbs)

| 18 / 2.0 /  36
Type| CB1820L (Li-Ion)
Weight| 0,4 (0.9)
Battery charger

**** Input

| type

V / Hz

W

| ASC55- EU| ASC30-36- UK| ASC30-36- AUS/NZ| ASC30-36- USA/CA
220 – 240 / 50 – 60| 115 / 60
85
Acoustic noise (1)| ****

dB (A)

dB (C)

dB (A)

|
LpA| 67,7
LpCPeak| 89,2
LWA| 74,2
Vibration (2)| m/s2| ahv  0,724

• Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u
• LpA = weighted continuous acoustic pressure level equivalent.
• LpCPeak = maximum value of the weighted acoustic displacement pressure at the work place.
• LWA = acoustic power level emitted by the machine.
• Directive 2006/42/EC, annexe 1, point 2.2.1.1
• Weighted root mean square in frequency of the acceleration the upper limbs are exposed to for each biodynamic reference axis.
• Tests carried out in compliance with the indications contained in EN ISO 5349-1/2 Standard, and under operating conditions much more severe than those normally found.

WARNING

• Do not use the tool for purposes other than those intended by CEMBRE.
• The operator should concentrate on the work being performed and be careful to maintain a balanced working position.
• Before starting work on electrical equipment, please ensure that either there are no live parts in the immediate working area or that precautions are taken for working near live parts in accordance with EN50110-1.
• Do not use this tool on or near live conductors without proper personal protective equip- ment. Failure to observe this warning could result in severe injury or death.
• The tool is unsuitable for continuous use and should be allowed to cool down following uninterrupted, successive crimping operations. For example, having exhausted a fully charged battery in one session, delay battery replacement for a few minutes.
• Protect the tool from rain and moisture. Water will damage the tool and battery. Electro-hydraulic tools should not be operated in pouring rain.

INSTRUCTIONS FOR USE

• IMPORTANT: In order to avoid damaging the tool, do not operate at maximum pressure, without dies inserted in the head.
• When introducing or changing dies, the battery must fi rst be removed from the tool.

The part reference includes the following:

• Hydraulic crimping tool.
• Li-Ion rechargeable battery (2 pcs).
• Battery charger (model depends on the tool version). Shoulder strap.
• Plastic carrying case.
• USB cable (Ref. to section 5).

Preparation

• The tool can be easily carried using either the main handle (8) or the shoulder strap attached to the two eyelets of the wrist strap (10) (Ref. to FIG. 6).

1. HEAD
2. 4 LED WORKLIGHT
3. OPERATING BUTTON
4. BATTERY
5. DISPLAY
6. PRESSURE RELEASE BUTTON
7. TOUCH BUTTON FOR MENU SELECTION
8. HANDLE
9. BATTERY RELEASE
10. WRIST STRAP

• The tool can be held in one hand while positioning the conductor with the other.
• Before starting any work, check the battery charge (Ref. to section 2.8) and recharge if necessary, following the instructions in the battery charger user manual.
• To replace the battery, remove it by pressing the release button (9) (Ref. to Fig. 1), then insert the new battery, sliding it into the guides until it locks.
• The display shows the operational parameters of the tool; to customise, proceed as described in section 2.7.
• Select the appropriate die set for the connector.
• Open the latch (41) and release the upper die holder (42) (Ref. to Fig. 2).
• Insert one die into the upper die holder (42) until locked by the ball (83) and one die into the lower die support (49) until locked by the spring clips (62) (Ref. to Fig. 2).
• Close the head.
• Insert the conductor into the connector (Ref. to Fig. 3).
• Position the connector between the dies and ensure the correct location of the crimp (Ref. to Fig. 4). NOTE: when more than one compression is required, proceed according to the sequence and direction indicated in the fi gure opposite.
• Ensure that the latch and the upper die holder are fully secured, otherwise damage may occur during tool operation.

Die advancement

• Press operating button (3) (Ref. to Fig. 4) to activate the motor-pump and advance the lower die. To halt the advancement, release operating button (4) and the motor will cut out.
• Make sure the dies are exactly positioned on the desired crimp point otherwise re-open dies following instructions as per section 2.4 and reposition the connector.

Compression

• By keeping the operating button (3) pressed, the motor continues to operate and the ram will gradually move forward until the two dies touch.
• The motor will stop automatically when the set pressure has been reached.
• To perform a full compression, press and hold the operating button (3) until the motor stops automatically.
• NOTE: To display the momentary force or pressure during the work cycle, select the appropriate display from the menu (Ref. to section 4). When the operating button is released before the motor stops automatically, the display will show the peak force (Fp) or the peak pressure (Pp) reached at that point.
• To complete the cycle, press the operating button again until the motor stops automatically; the display will show the maximum force or pressure reached followed by “OK” to confi rm correct operation.
• The display “ERROR”, combined with a beep and the LEDs fl ashing, indicates an incorrect crimping procedure caused by the work cycle being interrupted before the control parameters (force/pressure) of the tool are reached.
• This error appears when the pressure release button has been operated and the tool has already reached a pressure >100 bar. In this case, repeat the compression by pressing and holding the op-erating button until the motor stops automatically.

Release of dies

• Once the motor has stopped automatically, release the operating button (3), the ram will return, allowing access and release of the dies.
• The oil discharge to reservoir can also be performed in manual mode (Refer to § 4.2 for further details).

LED Worklights

• Whilst the tool is in operation, the compression area is illuminated by four high luminosity LED Worklights that switch off automatically at the end of the cycle.
• The LED Worklights can be disabled by following the procedure described in section 4.3.

Head rotation

• For ease of operation, the tool head can rotate through 180°, allowing the operator to work in the most comfortable position.
• Do not attempt to rotate the head when the hydraulic circuit is pressurised.

Capacitive touch button for menu selection

• This button is located under the display and allows selection of various screens (Ref. to section 4); accessible only when the display is on. Wearing gloves or using other objects may inhibit the operation of the button, therefore use a bare fi nger to apply only a light touch.
• Do not apply pressure to or stab at the touch button, a light touch using a bare fi nger is suffi cient. The command pulse is sent when the fi nger releases the button.

Battery status

• The battery is equipped with LED indicators that indicate the remaining battery life at any time by pressing the adjacent button (P) (Ref. to Fig. 5):
• LEDs illuminated: fully charged
• LEDs illuminated: 50 % capacity
• LED flashing: minimum charge, replace the battery max. min. With the battery inserted in the tool, the remaining battery life can also be checked on the display, via touch button BATTERY BATTERY selection (Ref. to section 4).
• The screen shown alongside indicates that the battery Voltage has dropped below a minimum safety threshold; under these conditions the tool will not start, and it is necessary to recharge or replace the battery.
• The approximate time to fully recharge a battery is about 40 minutes.

Using the battery charger

• Carefully follow the instructions in the battery charger user manual.

MAINTENANCE

• The tool is robust, completely sealed, and requires very little daily maintenance. Compliance with the following points, should help to maintain its optimum performance:
• Thorough cleaning
• Dust, sand and dirt are a danger for any hydraulic device.
• Every day, after use, the tool must be wiped with a clean cloth taking care to remove any residue, especially close to pivots and moveable parts.
• Do not use hydrocarbons to clean the rubber parts.

NAVIGATION MENU

The navigation menu is shown on the display (5). By touching the button (7) it is possible to browse the menu via the various screens.

Structure of the “main menu

• To make a selected screen operational and appear at each start up of the tool, operate the touch button for at least 3 seconds; a continuous beep will confi rm the setting.
• The capacitive menu selection button may not work if touched using objects or when wear- ing gloves, therefore always operate the button using a bare fi nger.

Choosing the “release mode”

• The phase of discharging the oil into the tool’s tank can be carried out in two diff erent ways, de-pending on the mode set in the menu:

To change the “release mode”, proceed as follows:

• Select screen 8 from the “main menu” (Ref. to section 4.1).
• Hold finger on the button (7) until a confirmation “beep” is heard. The choice made is shown by cursor position under the pictogram.
• Enabling/disabling the LED Worklights (factory setting is LED ON)
• Select screen 9 from the “main menu” (Ref. to section 4.1). To deactivate or reactivate operation of the LED Worklights, hold the finger on button (7) until a confirmation “beep” is heard.

Return to original factory settings / fi rmware version

• Select screen 10 from the “main menu” (Ref. to section 4.1). To return the tool to its factory settings, hold finger on button (7) until a confirmation “beep” is heard.
• The RESET screen also shows the fi rmware version of the control board.

Alarms/Warnings

• These appear on the display during operation and inform the operator on the state of the tool.
• ERRORS: these appear during operation, combined with a beep and fl ashing LED Worklights, to notify the operator of procedural or operational errors.
• Error screens are displayed for about 30 seconds before being reset, but will display repeat- edly in the event of permanent anomalies.

CONNECTION TO COMPUTER

(Smartool technology)

• The memory card integrated in the tool records operating data for transfer via the USB cable supplied.
• To view and manage this data, go to www.cembre.com and register in the dedicated area, then download the free CEMBRE software CEM_SWBT01.
• Keeping the Firmware of the tool updated, via free of charge down-load from here, will optimise the tool’s performance.
• Following information applies in member states of the European Union:
• USER INFORMATION in accordance with Directives 2011/65/EU and 2012/19/EU.
• The ‘Not in the bin’ symbol above when shown on equipment or packaging means that the equipment must, at the end of its life, be disposed of separately from other waste.
• The separate waste collection of such equipment is organised and managed by the manufacturer.
• Users wishing to dispose of such equipment must contact the manufacturer and follow the prescribed guide-lines for its separate collection. Appropriate waste separation, collection, environmentally compatible treat-ment and disposal is intended to reduce harmful environmental eff ects and promote the reuse and recycling of materials contained in the equipment. Unlawful disposal of such equipment will be subject to the applica-tion of administrative sanctions provided by current legislation.

DECLARATION OF CONFORMITY

• We: CEMBRE S.p.A. Via Serenissima, 9 – 25135 Brescia (Italy)
• Declare under our sole responsibility that the product: B500ND B500NDA B500NDE B500NDT
• To which this declaration relates is in conformity with the following standard(s) or other normative document(s):
• EN ISO 12100 EN ISO 3744 EN ISO 11202 EN ISO 5349-1 EN ISO 5349-2 EN55014-1/A11 EN 55014-2 Following the provisions of the UK Legislation(s):
• S.I. 2008/1597 S.I. 2012/3032 S.I. 2016/1091

RETURN TO CEMBRE FOR OVERHAUL

• In the case of a breakdown contact our Area Agent who will advise you on the problem and give you the necessary instructions on how to dispatch the tool to our nearest service Centre; if possible, attach a copy of the Test Certifi cate supplied by CEMBRE together with the tool or fi ll in and attach the form available in the “ASSISTANCE” section of the CEMBRE website.
• This manual is the property of CEMBRE: any reproduction is forbidden without written permission.
• Thorne & Derrick +44 (0) 191 410 4292 www.powerandcables.com

Documents / Resources

| CEMBRE B500NDE Battery Crimping Tool [pdf] Instruction Manual
B500NDE Battery Crimping Tool, B500NDE, Battery Crimping Tool, Crimping Tool
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References

• Cembre - Making the right connections

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