Cembre B1500 User manual

1

BATTERY OPERATED HYDRAULIC CRIMPING TOOLBATTERY OPERATED HYDRAULIC CRIMPING TOOL

B1500 B1500A B1500E B1500YA

OPERATION AND MAINTENANCE MANUAL

(Translation of the original instructions)

ENGLISHENGLISH

22M283E -

6261390

2

FIG. 1

11

Battery

Die set

6

12

FIG. 2

4

FIG. 3

FIG. 5 (B1500YA)

FIG. 4

a)

b)

13

14

semi-circular slotted "U" dies

"P" dies

"15600" series dies

15

AU150-C adapter

3

Die set

FIG. 6

3

8

4

3

11

9

10

2

1

7

8

12

5

6

1

OPERATING BUTTON

2

PRESSURE RELEASE BUTTON

3

LED WORKLIGHT

4

OPENING HEAD PIN

5

OPENING HEAD

6

HANDLE

7

TOUCH BUTTON FOR MENU SELECTION

8

RING FOR SHOULDER STRAP

9

DISPLAY

10

BATTERY

11

BATTERY RELEASE

12

HANDLE

4

Before using the

tool, carefully read

the instructions

in this manual.

WARNING SYMBOLS

TG.0932

Always recycle

the batteries.

















TG.0932

Battery:

Tool:

When operating the

tool, keep hands away

from the danger zone.

Do not operate when

dies are not in place.

Never throw

batteries into re

or water.

Do not discard batteries

into domestic refuse or

waste disposal.

Following 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 collection. Appropriate waste sepa-

ration, collection, environmentally compatible treatment and disposal is intended

to reduce harmful environmental eects 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.

5

B1500 B1500A B1500E B1500YA

Application range suitable for installing electrical compression connectors

for Copper conductors up to 1500 MCM (800 sqmm) and

for Aluminum conductors up to 1250 MCM (625 sqmm).

Type of accettable dies: accepts all“P” type dies commonly used

in industry and the semi-circular slotted

dies (U-dies) common to most 12 ton

tools and 14,6 ton Cembre tools.

accepts all

“15600”series

diescommonly

usedinindustry

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 (lbs) 9,7 (21.3)

Motor V 18

Operating temperature °C (°F) -15 to +50 (+5 to +122)

Recommended oil ENI ARNICA ISO 32 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 type CB1852L Li-Ion

V / Ah (Wh) 18 / 5,2 (93,6)

Weight kg (lbs) 0,66 (1.45)

Acoustic noise (1) dB LpA 66,9 (A) LpCPeak 86,9 (C) LWA 74,9 (A)

Vibrations (2) m/s20,398

(1) 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.

(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 EN ISO 5349-1/2 and Standard, and

under operating conditions much more severe than those normally found.

1. GENERAL CHARACTERISTICS

B1500 B1500E B1500A B1500YA

Battery charger

Input

type ASC55-EU ASC55-UK ASC30-36-USA/CA

V / Hz (W) 220 - 240 / 50 - 60 (85) 115 / 60 (85)

6

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 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

down following uninterrupted, successive crimping operations; for instance,

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.

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:

Hydraulic crimping tool.

Li-Ion rechargeable battery (2 pcs).

Battery charger (model depends on the tool version).

Shoulder strap.

Metal carrying case.

USB cable (Ref. to § 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 hands to hold the tool (Ref. to Fig. 3).

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.

7

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.

Thedisplayshowstheoperationalparameters of thetool;to customisethemproceedas described

in § 2.7.

Select the appropriate die set for the connector to be crimped and insert them into the tool head

as described in § 3.

When introducing or changing dies, the battery must rst 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).

Ensure the correct location of the crimp.

NOTE: when more compression is

required, proceed according to the

sequence and direction indicated

in the gure, uniformly spacing the

compressions.

Beforecarryingoutfurther

crimpingoperationsmake

sure the locking pin (4) is

completely inserted: its partial in-

sertion may damage the tool head.

2.2) Die advancement

Press operating button (1) to activate the motor-pump and

advance the lower die.

To halt the advancement, release operating button and the

motor will cut out.

Makesurethediesareexactlypositionedonthedesiredcrimp

point otherwise re-open dies following instructions as per

§ 2.4 and reposition the connector.

2.3) Compression

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.

To perform proper compression, press and hold the operating button (1) until the motor

stops automatically.

12

21

terminal

connector

conductor

1

8

NOTE: To displaythemomentaryforceor pressureduring

the work cycle, select the appropriate display from the

menu (Ref. to § 4). When the operating button is released

beforethe motor stops automatically,the displaywill show

the peak force (Fp) or the peak pressure (Pp) reached at

that instant.

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 conrm correct operation.

The display ‘ERROR’, combined with a beep and the LEDs ashing, indi-

cates an incorrect crimping procedure caused by the work cycle being

interrupted before the control parameters (force/pressure) of the tool

arereached.Thiserror appearswhen thepressurerelease buttonhasbeenoperatedandthetool has

already reached 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

By operating the pressure release button (2), the ram will retract

and open the dies.

To take the dies o their guide, it is sucient 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 illuminated by

two high luminosity LED Worklights that switch o 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 nger to apply only a light touch.

Do not apply pressure to or stab at the touch button, a light touch using a bare nger is

sucient. The command pulse is sent when the nger releases the button.

B1500

NR 14AZ541

RESET

SW:S1J41AH

LED

OFF

Fm= 134.3 kN

Fp = 94.5 kN

Fm= 15.1 ton

Fp = 10.61 ton

1000

-29000



BATTERY

3 SEC.

ERROR

001

30001



BATTERY 











Fm= 134.3 kN

Fp= 102.3 kN

Fm= 134.3 kN

OK

Pm= 10762 psi

Pp = 7575 psi





002





003





BATTERY





004





LED

ON

LED

OFF

3 SEC. LED

ON

max.

BATTERY BATTERY





min.

Pm= 742 bar

Pp = 522.3 bar

Pm= 742 bar

Pp = 565 bar

Pm= 742 bar

OK

B1500

NR 14AZ541

RESET

SW:S1J41AH

LED

OFF

Fm= 134.3 kN

Fp = 94.5 kN

Fm= 15.1 ton

Fp = 10.61 ton

1000

-29000



BATTERY

3 SEC.

ERROR

001

30001



BATTERY 











Fm= 134.3 kN

Fp= 102.3 kN

Fm= 134.3 kN

OK

Pm= 10762 psi

Pp = 7575 psi





002





003





BATTERY





004





LED

ON

LED

OFF

3 SEC. LED

ON

max.

BATTERY BATTERY





min.

Pm= 742 bar

Pp = 522.3 bar

Pm= 742 bar

Pp = 565 bar

Pm= 742 bar

OK

B1300

NR 14AF035

RESET

SW:S1J41AH

LED

OFF

Fm= 125.2 kN

Fp = 94.5 kN

Fm= 14.07 ton

Fp = 10.61 ton

1000

-12000



BATTERY

3 SEC.

ERROR

001

13001



BATTERY 











Fm= 125.2 kN

Fp= 102.3 kN

Pm= 692 bar

Pp = 565 bar

Fm= 125.2 kN

OK

Pm= 692 bar

OK

Pm= 10037 psi

Pp = 7575 psi





002





003





BATTERY





004





LED

ON

LED

OFF

3 SEC. LED

ON

max.

BATTERY BATTERY





min.

Pm= 692 bar

Pp = 522.3 bar

2

9

B1500

NR 14AZ541

RESET

SW:S1J41AH

LED

OFF

Fm= 134.3 kN

Fp = 94.5 kN

Fm= 15.1 ton

Fp = 10.61 ton

1000

-29000



BATTERY

3 SEC.

ERROR

001

30001



BATTERY 











Fm= 134.3 kN

Fp= 102.3 kN

Fm= 134.3 kN

OK

Pm= 10762 psi

Pp = 7575 psi





002





003





BATTERY





004





LED

ON

LED

OFF

3 SEC. LED

ON

max.

BATTERY BATTERY





min.

Pm= 742 bar

Pp = 522.3 bar

Pm= 742 bar

Pp = 565 bar

Pm= 742 bar

OK

2.8) Battery status

The battery is equipped with LED indicators that show the

remaining battery life at any time by pressing the adjacent

button (P):

4 LEDs illuminated: fully charged

2 LEDs illuminated: 50 % capacity

1 LED flashing: minimum charge, replace the battery.

With the battery inserted into the tool, the remaining

battery life can also be checked on the display, via touch

button selection (Ref. to § 4).

The screen shown alongside indicates that the battery voltage has

dropped below a minimum safety threshold; under these conditions

thetoolwillnotstart,anditisnecessarytorechargeorreplacethebattery.

The approximate time to fully recharge a battery is about 100 minutes.

2.9) Using the battery charger

Carefully follow the instructions in the battery charger user manual.

3. DIE AND ADAPTER ASSEMBLES

B1500, B1500A and B1500E 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 be used,

please proceed as follows:

3.1) Use of “P” dies (Ref. to Fig. 4a)

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)

Insert the 2 parts of the AU150-C adapter following the instructions as § 3.1.

Select the appropriate “U” die set for the connector to be crimped.

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 “15600” series dies (Ref. to Fig. 5)

B1500YA tool directly accepts the “15600” series dies commonly used in industry.

Select the appropriate “15600” die set for the connector to be crimped.

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.

B1500

NR 14AZ541

RESET

SW:S1J41AH

LED

OFF

Fm= 134.3 kN

Fp = 94.5 kN

Fm= 15.1 ton

Fp = 10.61 ton

1000

-29000



BATTERY

3 SEC.

ERROR

001

30001



BATTERY 











Fm= 134.3 kN

Fp= 102.3 kN

Fm= 134.3 kN

OK

Pm= 10762 psi

Pp = 7575 psi





002





003





BATTERY





004





LED

ON

LED

OFF

3 SEC. LED

ON

max.

BATTERY BATTERY





min.

Pm= 742 bar

Pp = 522.3 bar

Pm= 742 bar

Pp = 565 bar

Pm= 742 bar

OK

B1500

NR 14AZ541

RESET

SW:S1J41AH

LED

OFF

Fm= 134.3 kN

Fp = 94.5 kN

Fm= 15.1 ton

Fp = 10.61 ton

1000

-29000



BATTERY

3 SEC.

ERROR

001

30001



BATTERY 











Fm= 134.3 kN

Fp= 102.3 kN

Fm= 134.3 kN

OK

Pm= 10762 psi

Pp = 7575 psi





002





003





BATTERY





004





LED

ON

LED

OFF

3 SEC. LED

ON

max.

BATTERY BATTERY





min.

Pm= 742 bar

Pp = 522.3 bar

Pm= 742 bar

Pp = 565 bar

Pm= 742 bar

OK

P

10

4. DISPLAY

The OLED display switches on automatically when the operating or pressure release buttons are

pressed, and o after 60 seconds of non-operation.

The display shows:

- The main operational parameters of the tool processed by the circuit board, such as peak pressure

or force reached.

- Information on the condition of the tool, such as the charge level, the battery temperature and

maintenance 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.

B1500

NR 14AZ541

RESET

SW:S1J41AH

LED

OFF

Fm= 134.3 kN

Fp = 94.5 kN

Fm= 15.1 ton

Fp = 10.61 ton

1000

-29000



BATTERY

3 SEC.

ERROR

001

30001



BATTERY 











Fm= 134.3 kN

Fp= 102.3 kN

Fm= 134.3 kN

OK

Pm= 10762 psi

Pp = 7575 psi





002





003





BATTERY





004





LED

ON

LED

OFF

3 SEC. LED

ON

max.

BATTERY BATTERY





min.

Pm= 742 bar

Pp = 522.3 bar

Pm= 742 bar

Pp = 565 bar

Pm= 742 bar

OK

Fm: Minimum set force, expressed in kN.

Fp: Peak force reached, expressed in kN,

(screen as factory setting).

Fm: Minimum set force, expressed in USA sh. tons.

Fp: Peak force reached, expressed in USA sh. tons.

Pm: Minimum set pressure, expressed in bar.

Pp: Peak pressure reached, expressed in bar.

Pm: Minimum set pressure, expressed in psi.

Pp: Peak pressure reached, expressed in in psi.

Battery charge level.

No. of cycles performed.

No. of cycles before scheduled recommended maintenance.

Cembre logo, tool model.

Tool serial no

Cembre B1500 User manual

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