B1500 B1500A B1500YA
Contents
1. 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 O Cembre 5 2 Storage case Whennotin use the tool should be stored and transported in the metal case to prevent damage Metal case VALB1500 size 565x410x132 mm 22 2x16 1x5 2 in weight 6 7 kg 14 7 lbs 6 CONNECTION TO COMPUTER The memory card integrated in the tool records operating data from 200 000 cycles for transfer via the USB cable supplied Toviewand manage this data gotowww cembre com and registerinthe dedicated area then download the free Cembre software CEM_SWBTO1 Keeping the Firmware of the tool updated via free of charge download from here will optimise the tool s performance 7 RETURN TO Cembre FOR OVERHAUL In the case of a breakdown contact your local 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 Cembre Test Certificate supplied with the tool or if no other references are available indicate the approximate purchase date and the tool serial number sk Cembre FIG BILD 7 NOTE 0 Cembre Tsk 0 Cembre Cembre Ltd Dunton Park Kingsbury Road Curdworth Sutton Coldfield West M2. Cembre Certified Quality Certified Environmental Management System Management System OPERATION AND MAINTENANCE MANUAL Certified Occupational Health amp Safety Management System 14 M177E Die set Uu 2 oa TD Y O LA D lt 15500 series dies semi circular slotted U dies FIG 5 B1500YA O Cembre OPERATING BUTTON PRESSURE RELEASE BUTTON LED WORKLIGHT OPENING HEAD PIN OPENING HEAD HANDLE TOUCH BUTTON FOR MENU SELECTION RING FOR SHOULDER STRAP DISPLAY BATTERY BATTERY RELEASE HANDLE AIR COOLED un AN RN Externe WARNING SYMBOLS Tool Before using the When operating the Do not operate when tool carefully read tool keep hands away dies are not in place the instructions from the danger zone in this manual io information applies in member states of the European Union USER INFORMATION in accordance with Directives 2002 95 EC and 2002 96 EC 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 guidelines for its separate collec
3. be used please proceed as follows 3 1 Use of P dies Ref to Fig 4a gt Press pins 13 and insert half of the P die into the upper seat of the head and the other half into the lower seat of the ram to disassemble them press the pins 13 and slip them from the head 3 2 Use of semi circular slotted dies U dies Ref to Fig 4b gt Insert the 2 parts of the AU150 C adapter following the instructions as 3 1 gt Select the appropriate U die set for the connector to be crimped gt Press pins 14 and lock the parts of the U dies into the upper and lower parts of the AU150 C 3 3 Use of 15500 series dies Ref to Fig 5 B1500YA tool directly accepts the 15500 series dies commonly used in industry gt Select the appropriate 15500 die set for the connector to be crimped gt Press pins 15 and lock one die into the upper seat of the head and the other die into the lower seat of the ram to disassemble them press the pins 15 and slip them from the head 9 EE Cembre 4 DISPLAY The OLED display switches on automatically when the operating or pressure release buttons are pressed and off after 60 seconds of non operation The display shows The main operational parameters of the tool processed by the circuit board such as peak pres sure or force reached Information on the condition of the tool such as the charge level the battery temperature and mainte
4. can be changed by operating the touch button Enabling disabling the LED Worklights factory setting LED ON When the screen is dis played touch the button LED a LED for at least 3 seconds to ON 0 D gt D OFF A deactivate for reactivate op eration of the LED Worklights 3 SEC during tool use ir a CD re a continuous beep will confirm the setting Return to original factory settings firmware version When the RESET screen is displayed return the tool to its factory setting by operating the touch button for at least 3 seconds a beep will confirm the setting RESET The RESET screen also shows the firmware version of the circuit board SW S1 41AH 4 3 WARNINGS these appear during operation and notify the operator of the status of the tool LOW BATTERY replace the battery BATTERY NOTE when the battery Vage falls below a minimum safety threshold the tool will not start although it is still possible to end the work cycle in progress sal BATTERY TEMPERATURE HIGH remove the battery and wait until it cools M down Q 30001 NO OF CYCLES TO MAINTENANCE REACHED NP the tool continues to work however it is recommended that it is sent to Cembre IC for a complete overhaul see 7 NOTE this message together with a beep will reappear when the tool has been idle for 30 seconds OD Cembre 4 4 ERRORS these appear during operation combined with a beep and flashing LED Worklights to
5. 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 type CB1840L Li lon V Ah Wh 18 4 0 72 Weight kg Ibs 0 66 1 45 Bruit a rien sonore dB La 66 9 A Lera 86 9 E L 74 9 A Vibrations m s 0 398 1 Directive 2006 42 EC annexe 1 point 1 7 4 2 letter u L weighted continuous acoustic pressure level equivalent L rea Maximum value of the weighted acoustic displacement pressure at the work place L acoustic power level emitted by the machine 2 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 UNI ENV 25349 and UNI EN 28662 part 1st Standards and under operating conditions much more severe than those normally found B1500A B1500YA Battery charger ASC30 36 type EU 27044000 USA CAN 27046000 Input V Hz W 220 240 50 60 85 115 60 85 Y Cembre 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 work
6. d a pressure 100 bar In this case repeat the compression by pressing and holding the operat ing button until the motor stops automatically 2 4 Release of dies gt By operating the pressure release button 2 the ram will retract and open the dies gt To take the dies off their guide it is sufficient to press the pins and slip them from the head Ref to Fig 4 and 5 2 5 LED Worklights Whilst the tool is in operation the compression area is illumi nated by two 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 4 2 2 6 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 2 7 Capacitive touch button for menu selection This button is located under the display and allows selection of various screens Ref to 4 it only works when the display is on Wearing gloves or using other objects may inhibit the operation of the button therefore use a bare finger to apply only a light touch Do not apply pressure to or stab at the touch button a light touch using a bare finger is sufficient The command pulse is sent when the finger releases the button O Cembre ER 2 8 Battery status The battery is equipped with LED indicators that
7. ds to hold the tool Ref to Fig 3 a Before starting any work check the battery charge Ref to 2 8 and recharge if necessary following the instructions in the battery charger user manual O Cembre f 6 HE gt To replace the battery grip the tool as illustrated in Figure 1 press the release button 11 and push the battery downward unlocking it Insert a charged battery from the bottom by sliding it into the guides until it locks The display shows the operational parameters of the tool to customise them proceed as described in 8 2 7 gt Select the appropriate die set for the connector to be crimped and insert them into the tool head as described in 8 3 When introducing or changing dies the battery must first be removed from the tool Insert the conductor into the connector and position the connector between the die if necessary open the tool head by means the locking pin 4 Ref to Fig 2 gt Ensure the correct location of the crimp NOTE when more compression is required proceed according to the sequence and direction indicated in the figure uniformly spacing the terminal compressions Before carrying out further crimping operations make sure thelocking pin 4 is completely inserted its partial insertion may damage the tool head 2 2 Die advancement gt Press operating button 1 to activate the motor pump and advance the lower die To halt the advancement release operatin
8. g button and the motor will cut out Make sure the dies are exactly positioned on the desired crimp d point otherwise re open dies following instructions as per 2 4 and reposition the connector 2 3 Compression gt By keeping operating button 1 pressed the motor continues to operate the ram will gradually move forward until the two dies touch The motor will stop automatically when the set pressure has been reached 1 To perform proper compression press and hold the operating button 1 until the motor stops automatically 7 E _ Q Cembre NOTE Todisplaythemomentaryforce or pressureduring BK EEN the work cycle select the appropriate display from the Fp 102 3 kN menu Ref to 8 4 When the operating button is released beforethe motor stops automatically the display will show the peak force Fp or the peak pressure Pp reached at that instant Pp 565 bar OK To complete the work press the operating button again until the motor stops automatically the dis play will show the maximum force or pressure reached followed by OK to confirm correct operation 1 The display ERROR combined with a beep and the LEDs flashing Gy indicates an incorrect crimping procedure caused by the work cycle ERROR being interrupted before the control parameters force pressure of the tool AN are reached This error appears when the pressure release button has been operated and the tool has already reache
9. idlands B76 9EB Great Britain Tel 01675 470440 Fax 01675 470220 E mail sales cembre co uk www cembre co uk Cembre Espa a S L Calle Verano 6 y 8 P I Las Monjas 28850 Torrej n de Ardoz Madrid Espa a Tel fono 91 4852580 Telefax 91 4852581 E mail comercial cembre es www cembre es Cembre GmbH Heidemannstrale 166 80939 Munchen Deutschland Telefon 089 3580676 Telefax 089 35806777 E mail sales cembre de www cembre de 0 Cembre ___ Cembre S p A Via Serenissima 9 25135 Brescia ltalia Telefono 030 36921 Telefax 030 3365766 E mail sales cembre com www cembre it Cembre S a r l 22 Avenue Ferdinand de Lesseps 91420 Morangis France T l 01 60 49 11 90 Fax 01 60 49 29 10 B P 37 91421 Morangis C dex E mail info cembre fr www cembre fr Cembre AS Fossnes Senter N 3160 Stokke Norway Phone 47 33361765 Telefax 47 33361766 E mail sales cembre no www cembre no Cembre Inc Raritan Center Business Park 181 Fieldcrest Aenue Edison New Jersey 08837 USA Tel 732 225 7415 Fax 732 225 7414 E mail sales US cembreinc com www cembreinc com This manual is the property of Cembre any reproduction is forbidden without written permission cod 6261390 www cembre com AA
10. ing area or that precautions are taken for working near live parts in accordance with EN50110 1 Do not use this tool on or near energised 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 Ed Ed Ed E down following uninterrupted successive crimping operations for instance having exhausted a fully charged battery in one session delay battery replacement for a few minutes A Protect the tool from rain and moisture Water will damage the tool and ZN battery Electro hydraulic tools should not be operated in pouring rain 2 INSTRUCTIONS FOR USE IMPORTANT Never pressurise the tool without inserting the dies this could cause damage to the head and the ram The part reference includes the following gt Hydraulic crimping tool gt Li lon rechargeable battery 2 pcs gt Battery charger model depends on the tool version Shoulder strap gt Metal carrying case gt USB cable Ref to 8 6 page 13 2 1 Preparation The tool can be easily carried using either the main handle 12 or the shoulder strap attached to the two rings 8 Ref to Fig 6 The main operating positions are horizontal standing on its feet and vertical standing on its bat tery In addition to the main handle 12 the lower handle 6 allows a safer and more balanced grip when using two han
11. nance requirements Any operational or procedural ERRORS Use the touch button 8 to navigate through the menu screens to manage INFORMATION AND SELECTION 4 1 INFORMATION SCREENS display a pre determined parameter which will then appear each time the tool is started and during the entire work cycle Em 134 3 kN Fm Minimum set force expressed in KN Fp 94 5 kN Fp Peak force reached expressed in kN screen as factory setting Fm 15 1 ton Fm Minimum set force expressed in USA sh tons Fp 10 61 ton Fp Peak force reached expressed in USA sh tons EVA TN Pm Minimum set pressure expressed in bar JAY E Pr Peak pressure reached expressed in bar AJ Pm Minimum set pressure expressed in psi Dee kyee ON Pp Peak pressure reached expressed in in psi ET Ep Battery charge level BATTERY a Q 1000 No of cycles performed viii No of cycles before scheduled recommended maintenance d B1500 Cembre logo tool model NR 14A2541 Tool serial no O Cembre 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 confirm the setting Cs 1 The capacitive menu selection button may not work if touched using objects or when wearing gloves therefore always operate it using a bare finger 4 2 SELECTION SCREENS control parameters that cannot be set as automatic upon start up of the tool
12. notify the operator of procedural or operational errors Error description The pressure release button 2 was pressed before the control parameters were reached Force Pressure Abnormal power consumption of the motor for more than 3 seconds The tool stops Output voltage of the pressure transmitter is out of the pre set range Failure to reach the set pressure within 30 seconds of continuous operation of the machine Overcharging of the battery with protection tripping The tool stops the event of permanent anomalies 5 MAINTENANCE Solution Repeat the work cycle and wait for the motor to stop automatically Wait for the display to turn off 60 sec or remove and re insert the battery then re start the tool If the error occurs frequently contact Cembre Repeat the work cycle if the error occurs frequently contact Cembre Repeat the work cycle if the error occurs frequently contact Cembre Wait for the display to turn off 60 sec or remove and re insert the battery then re start the tool If the error occurs frequently contact Cembre Errors are displayed for about 30 seconds before being reset but will display repeatedly in The tool is robust completely sealed and requires very little daily maintenance Compliance with the following points should help to maintain its optimum performance 5 1 Thorough cleaning Dust sand and dirt are a danger for any hydraulic device
13. show the remaining battery life at any time by pressing the adjacent button P TAN 4 LEDs illuminated fully charged P 2 LEDs illuminated 50 capacity 1 LED flashing minimum charge replace the battery gt With the battery inserted into the tool the remaining battery life can also be checked on the display via touch button selection Ref to 8 4 max min CR al LIRE A BATTERY BATTERY 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 80 minutes BATTERY After each working cycle and after the extraction of the battery from the tool an integrated battery cut off device will operate after 70 s approx Then the LED nearest to button P will flash 5 times each 14 s approx The battery will be reactivated when it is reintroduced into the tool and the operating button is pressed 2 9 Using the battery charger Carefully follow the instructions in the battery charger user manual 3 DIE AND ADAPTER ASSEMBLES B1500 and B1500A tools directly accept all P type dies commonly used in industry and when used with adapter AU150 C optional accessory will accept semi circular slotted dies U dies common to most 12 ton tools and 14 6 ton Cembre tools Depending on the dies to
14. tion Appropriate waste sepa ration collection environmentally compatible treatment and disposal is intended to reduce harmful environmental effects and promote the reuse and recycling of materials contained in the equipment Unlawful disposal of such equipment will be subject to the application of administrative sanctions provided by current legisla tion Battery Always recycle Never throw Do not discard batteries the batteries batteries into fire into domestic refuse or or water waste disposal O Cembre 1 GENERAL CHARACTERISTICS B1500 B1500A B1500YA Application range suitable for installing electrical compression connectors for Copper conductors up to 800 mm 1500 MCM and for Aluminum conductors up to 630 mm 1250 MCM Type of accettable dies accepts all P type dies commonly accepts all used in industry and the semi cir 15500 series cular slotted dies U dies common dies commonly to most 12 ton tools and 14 6ton used in industry Cembre tools Rated crimping force kN US sh ton 136 15 3 Minimum crimping force kN US sh ton 134 3 15 1 Minimum operating pressure bar psi 742 10762 Dimensions Fig 7 page 14 mm inches 525 x 251 x102 5 20 6 x 9 9 x 4 Weight with battery kg Ibs 9 7 21 3 Motor V DC 18 Operating temperature UE 15to 50 5 to 122 Recommended oil AGIP ARNICA 32 ou quivalents Operating speed
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