BLUCHER CP 700E User manual

Compact hydraulic pump with accumulator
Instruction manual
BLUCP 700E
Drainage and pressure piping solutions
PO Box 107; Corunna Avenue, Melrose Park SA 5039
T: 08 8374 3426 | M: 0425 567 241
[e-mail] | www.blucher.com.au

English
Please read this instruction manual carefully before using our pro-
duct. In case of any open issues or questions, please contact our
service center immediately.
(Find Information on the last cover page)
2 BLUCP700E

English
3 BLUCP700E
Index
1. Technical data 4
2. Definition of components basic unit 4
3. Accessories supplied with the basic unit 6
4. Description of signs and symbols 6
5. General information 7
6. Guarantee 7
7. Field of application and inappropriate application 7
8. Safety instructions when using the equipment 8
9. Storage and transportation 9
10. Start-up of the equipment 10
11. Information for the use of the power pack and battery charger 10
12. Functions 12
12.1 Remote control unit 13
13. Working cycles standard program 13
13.1 „Compression“ working cycle 13
14. Tool variations 14
15. Maintenance instructions 15
16. Technical features and performance 15
17. Rating plate 16
18. Installation instructions of software 16
18.1 System requirements 16
18.2 Software installation through apparatus / CD 17
18.2 Plug & Play 17
19. What to do in case of dysfunction 18
19.1 Error codes 18
19.2 Oil filling 20
19.3 Changing the filter 20
20. Removal from service/disposal 21
21. Guarantee/Repair 22
The entire or partial contents of this document shall not be copied or
made available to third parties in any other way without the prior written
permission of BLUCHER.

English
4 BLUCP700E
1. Technical data
2. Definition of components basic unit
Operating pressure: 700 bar (70 MPa)
Max. Lift: depending on the tool used
Battery voltage: 18 V DC
Drive motor: DC permanent magnet motor
Battery capacity: 3,0 Ah
Time of pressing cycle approx. 4-7 sec. (depending on ND)
Type of battery: Li-Ion (without memory effect)
Charging time: approx. 60 min.
Compression time depending on the tool used
Noise level: 70 dB (A) at a distance of 1 m
Acceleration: < 2,5 m/s² (weighted root mean square acceleration)
Hydraulic oil: 750 ml usable type „Shell-Naturelle HF-E15“
Operating temperature: from -20 °C to +50 °C
Dimensions basic unit: approx. 300 x 195 x 210 mm (incl. power pack)
Mass basic unit: approx. 4,7 kg (incl. power pack)
Class of protection: IP 43
Item Definition Item Definition
[ 1 ] LED operating indicator lights [ 7 ] Hydraulic connection
(max. 700 bar)
[ 2 ] Return - Handwheel [ 8 ] Mechanical emergency return
switch
[ 3 ] Shoulder strap support [ 9 ] USB interface
[ 4 ] Power Pack [ 10 ] Air filter
[ 5 ] Name of model & technical data [ 11 ] Oil filling screw
[ 6 ] Connection for remote control
ACaution: The mechanical return switch allows the operator to restore the tool to
the starting position in emergency cases and thus to remove the pressure from
the tube and operating keys.
The name of the model, the manufacturer´s data, the serial number and technical data
are located on the bottom of the BLUCP700E Compact pump.

English
BLUCP700E 5
1 2
3
5
8
6
7
9
11
4
10

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6 BLUCP700E
4. Description of signs and symbols
LDanger: This indicates a warning; lack of observance may lead to injury or death.
PParagraphs: Product safety information.
ACaution/Important: This indicates a warning; not following this warning may lead to
damage of the equipment or materials.
MOperation and maintenance: Advice and indications in order to maintain the
product´s value.
NInformation: Useful information for the proper application of this product.
3. Accessories supplied with the basic unit
1
4
2
5
3
6
Item Definition Item Definition
[ 1 ] 1.5m pressure hose [ 4 ] USB 2.0 cable with 5 pole mini type
connectors: A plug and B socket
[ 2 ] Remote control unit [ 5 ] CD-ROM
[ 3 ] C 18 C type battery charger
AEG 18 V CC/3Ah type battery [ 6 ] Shoulder strap

English
BLUCP700E 7
7. Field of application and inappropriate application
The BLUCP700E Compact Pump is suitable for the operation of hydraulic tools which are
designed for an operating pressure of at least 700 bar. Only those cutting and compres-
sion tools shall be used that are suitable in terms of operating pressure and capacity. The
pump cannot be connected with hydraulic equipment other than the tools foreseen. It is
strictly prohibited to use the pump on lifting equipment, lifting cylinders and similar de-
vices. The battery powered BLUCP700E pump may be used exclusively in environments
with illumination of at least 400 lux, or in daylight.
Please refer to the provided instruction manuals concerning the respective fields of appli-
cation of hydraulic tools.
5. General information
Wear gogglesRead the in-
struction manual
before usage
LThe manufacturer shall not be liable for any damages or injury resulting from non-
observance of the operating instructions.
This device must be used exclusively for its intended use. This product shall only be
used by personnel who have received training whereas the instruction manual must
be carried along with the device for its entire life period..
The user is required to:
• make the instruction manual available to operators
• ensure that the operator has read and understood the instructions
PFor all legal intents and purposes, the German versions of this instruction manual is
legally binding.
6. Guarantee
Caution!
Danger of squee-
zing
The manufacturer must be notified in writing of any defects in the product latest and
within 8 days after receipt of the same, enclosing the shipment documents and a de-
tailed description of the defect(s). In case of hidden defects, the claim in this regard must
be made within 8 days of its detection and not later than one year after receipt of the
product. BLUCHER shall not be held liable for any defects claimed after the abovementi-
oned period. The guarantee does not cover any damage caused by improper handling,
poor maintenance, by using other than original BLUCHER spare parts, by opening the de-
vices by non-authorized staff. In case of repairs the warranty is extended on the replaced
parts but not on the entire tool.

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8 BLUCP700E
ACaution: In case of non-observance of the safety instructions there is danger to life
and health or it can cause material damage to the machine and the surrounding
environment!
ACaution: Never place fingers or other parts of the body into the working area of the
tool head!
ACaution: Keep other people, particularly unauthorized people, away from the wor-
king area during the operation with the battery-powered tool!
ACaution: Wear appropriate workwear, gloves and safety shoes!
ACaution: Inspect the battery powered tool to make sure it has not been damaged.
Only use the machine if it is free of defects and works failure-freely!
ACaution: If situations of danger for persons or for the machine occur during operati-
on, stop the BLUCP700E Compact pump by pressing the return button on the remote
control.
ACaution: The pressure hose must must be designed for a nominal pressure of 700bar
(70MPa) and must not be damaged, bent or worn.
ACaution: In the event of serial assembly, it is necessary to use the shoulder strap pro-
vided with the machine.
ACaution: The operator must always have the battery pump at hand.
ACaution: Accessing the danger zone of the pressing tool is only permissible when the
tool is completely opened and the battery removed.
ACaution: The battery may only be removed when the pump BLUCP700E has been
shut down safely.
ACaution: During work performed at heights the tool must be adequately protected
from falling.
ACaution: Before using the equipment, it is necessary to perform a visual inspection to
ascertain the condition of the BLUCP700E Compact pump. In case of damage do
not use the device.
ACaution: Reverse movement is activated exclusively with the relative key (on the re-
mote control unit). The mechanical release lever located on the equipment must be
used in emergency situations.
8. Safety instructions when using the equipment

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BLUCP700E 9
9. Storage and transportation
In order to protect the BLUCP700E Compact pump from
possible damage, it is necessary to clean it after every
use and to protect it with the respective protection caps
for the hydraulic connection and remote control connec-
tion. After cleaning stow away the tool in the provided
cotton bag and make sure it is securely closed..
ACaution: Do not open the machine! All terms of the warranty become invalid if the
seal is damaged. The equipment must not be operated without protective cover.
ACaution: If the service warning light flashes up, the device must be sent to the ma-
nufacturer. The customer is not authorized to perform any maintenance as this would
entail the loss of guarantee and can lead to situations of danger.
Caution: The typical A-weighted noise level can exceed 70dB (A) during operation. -
Wear ear protection!
ACaution: The equipment shall only be operated with the original BLUCHER power
packs.
ACaution: The equipment must not be operated in explosive atmospheres.
ACaution: Complete shutdown of the equipment takes place exclusively upon remo-
val of the battery.
ACaution: If oil leaks from the Compact pump, it must be sent to the BLUCHER custo-
mer service department.
ACaution: The BLUCP700E Compact pump must not be operated in case of heavy
rain or underwater.
ACaution: Hydraulic oils pose a risk to the ground water. Uncontrolled discharge or
disposal of hydraulic oils not in conformity with norms may be persecuted under envi-
ronmental protection laws.
ACaution: The applied components must demonstrably withstand the occurring tem-
peratures.

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10 BLUCP700E
10. Start-up of the equipment
11. Information for the use of the power pack and battery charger
The battery charger is designed for 230 V CA 50-60 Hz. The new batteries are provided
partially charged and must be charged before using the machine for the first time. In
order to recharge the battery, the charger plug must be inserted into a wall socket and
the power pack must be placed in the battery charger. A 3.0 Ah power pack can be
recharged in approximately 60 minutes. The status of the charge for the power pack is
indicated by the luminous diode on the battery charger.
Remove the protection caps from remote control and hydraulic connection from the
BLUCP700E Compact pump. Next, connect the pressure tube and remote control unit as
shown in the illustration.
Insert the battery on the rear of the unit (see illustration)
and push until the safety switch clicks.
Attach the shoulder strap as shown in the illustration.
ACaution: The eyelet of the shoulder strap can only be
hooked or unhooked in the position illustrated.

English
BLUCP700E 11
ACaution: When the power pack is not being used keep it away from paper clips,
coins, keys, nails, screws and other small metal objects which could act as contact
bridges. A short circuit between the battery contacts could cause combustion or fires.
ACaution: Do not charge the power pack in the presence of easily inflammable gas
or materials. After charging, remove the battery charger plug from the wall socket.
Do not disassemble the battery charger.
ACaution: In case of longer storage periods the state of charge of the battery must
be checked periodically. The optimum charge is between 50% and 80%. The power
packs should be recharged every 12 months at most to avoid complete discharge
which could cause damage.
ACaution: Discharged power packs should not be stored for periods of more than one
month to avoid depth discharge which could destroy the battery.
ACaution: Only use battery chargers recommended by the manufacturer. There is a
danger of fire when using a battery charger suitable for a specific type of battery for
recharging other batteries.
ACaution: Only use those batteries specified for the tools. The use of other batteries
could cause injury and the danger of fire.

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12 BLUCP700E
ACaution: In case of improper use liquid could leak from the battery. Avoid contact
with the liquid. Leaking battery liquid can cause skin irritations or burns. In case of
contact with the skin, rinse with abundant water. Consult a physician if liquid contacts
eyes.
The charge status can be read by pressing the relative button on the
power pack. In doing so the battery
may remain in the BLUCP700E Com-
pact pump which must be shut off
beforehand, however, and remain
shut off for at least one minute (otherwise, the rea-
ding will be imprecise).
The number of flashing LEDs indicates the charge
status. A flashing LED indicates a maximum power
reserve of 10%. This indicator should only be used
for assessing the power reserve. The real power
consumption depends on the applied working
parameters which are taken into account by the
battery indicator on your Compact BLUCP700E
pump.
For further information please refer to the AEG inst-
ructions for use provided with the battery charger.
The charge status can be read by pressing the relative button on the
12. Functions
In order to turn on the BLUCP700E Compact pump, briefly press the „+“ button on the
remote control unit (the LED ON light will flash briefly).
The machine also shuts down automatically after 3 minutes on standby with no activity.
1LED on indicator light
2Return - Handwheel
Automatic mode (flashes during any
automatic movement)
Battery charge indication
Information about failures (see
chapter 19.1 for flashing codes. See
paragraph „LED Technical Assistance“
for what to do in the event of failures).
2
1

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BLUCP700E 13
12.1 Remote control unit
Operating-LED
ON or FORWARD button
STOP or REVERSE button
Magnetic support
Fastening clip
Description of operating LEDs on the remote control unit:
ORANGE LED - lights up during start up
GREEN LED - lights up when the work cycle is regular
RED LED - flashes when the work cycle is not regular
RED/GREEN LED - blinks when the service interval has expired and
technical assistance is required
13.1 „Compression“ working cycle
In order to perform the working cycle, hold the „+“ button down until the green LED lights
up on the remote control unit (at the same time the green info-service LED lights up as
well), signalling that the working cycle has been successfully concluded. If the „+“ button
is released during forward movement, the tool automatically stops.
Thereupon the tool automatically reverses for the duration of the return time set. However,
you can stop the reverse movement at any time by pressing the „+“ button. If the return
time set is too short, you can reverse manually by holding the „+“ button down. During
reverse movement, the LED indicating the automatic mode lights up.
„Pump ON“
The compression head cuts off
as long as the button is held down
„Interruption“
Compression head opens up
13. Working cycles standard program
00-∞ (100%)

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14 BLUCP700E
14. Tool variations
14.1 Pressing tools
Press head 54-75
Press collar head
Remove the protection caps for the hydraulic connection and connect the high-pressure
hose of your Compact pump CUP 700 with the tool heads by pulling back the locking
snap ring of the quick connector type CEJN series 115, then by sliding the connection on
the plug nipple, releasing the locking snap ring and checking the connection for tight-
ness. Both the connectors must be totally clean. Disconnecting is performed in reverse
order. Connecting and disconnecting is only possible in depressurized state. The pump
must be turned off be-
fore connecting. The
oil return flow must be
initiated. Put the pro-
tection caps back on
the connecting parts
again after discon-
necting for protecting
them against dirt.
ACaution: The complete hydraulic connection must not be damaged, it may lead to
oil leaking under pressure or the connection may break off.
Find more information on grouting with tool heads in their individual instruction manuals.
Press collar head

English
BLUCP700E 15
16. Technical features and performance
• The pump casing as well as all components are made of high resistance materials
and are tested.
• The casing is entirely made of isolating, shock resistant polyamide, reinforced with fiber
glass.
• The equipment has a light, compact and robust structure.
• The range of the operating temperature is between –20°C and +50°C.
• The maximum operating pressure of the pump and power pack is 700 bar (70 MPa).
• The safety valve of the system is adjusted to 800 bar (80 MPa).
• The hydraulic coupling connection to the pump is in conformity with the CEJN S115
norm.
• The remote control unit has a start-up „ON“ and reverse button.
• The system is equipped with an extreme rapid advancement due to a special double
piston technology, characterized by a low-pressure advancement and a slow high-
pressure advancement.
• The capacity of the battery-powered press is 1.15 l/min under low pressure and 0.146
l/min under high pressure.
• Automatic conversion from low to high pressure takes place at approximately 90 bar
(9 MPa).
• The machine has great reverse capacity for quicker working cycles.
• The equipment has a volume recogniton system that permits precise work with or wit-
hout the hydraulic hose (the machine may be connected directly to the pump).
• The return way of the working head is controlled by the software.
• The motor is activated by PWM (soft start to save the transmission, motor and battery).
• Control of the equipment is effected by a micro-controller.
• Pressure control is performed by an electronic pressure sensor.
• The charging state of the power pack is constantly monitored.
15. Maintenance instructions
The BLUCP700E Compact pump must be cleaned after use and stored in a dry place.
Both the power pack and the battery charger must be protected from humidity and for-
eign materials. Technically the equipment does not require maintenance.
After completion of the previously set working cycles, it is necessary to take the BLUC-
P700E Compact pump to the technical assistance service for inspection to guarantee
perfect operation and to increase the long-life cycle of the machine. The customer is not
authorized to perform any maintenance.

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16 BLUCP700E
• Management of technical assistance is performed with an electronic system.
• The traceability of processes is ensured by automatic recording and saving in the ma-
chine memory.
• The data saved can be read and the software can be updated by a mini USB inter-
face.
• Additional LED indicators provide rapid information on the status of the machine.
• The life cycle of the device is approximately 50,000 cycles.
• The first service assistance should be performed after 10,000 cycles, but can be freely
programmed according to the conditions of use.
• Integrated and intelligent electronic module with a large LCD display.
17. Rating plate
Manufacturer: BLUCHER
Item Nr.: BLUCP700E Compact pump
Serial Number: BLUCP700E ................
Year of construction: 20..
W: 200 W
V: 18 V d.c.
bar max.: 700 bar
IP Class: 43
Power pack: 18 V d.c./3 Ah
18. Installation instructions of software
18.1 System requirements
The PC on which the software is installed must fulfill the following requirements:
Operating system: Windows 2000, Windows XP, Windows Vista, Windows 7
CPU: Pentium 4; 1,7 GHz at leas
Random acces
memory: 512 MB or more (we advise at least 1 GB)
Hard disc: 200 MB (1 GB recommended)
Screen resolution: 1024 x 768 or higher, 65.535 colors or more
Miscellaneous: CD-ROM-Reader, USB 2.0

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BLUCP700E 17
18.2 Software installation through apparatus / CD
1 Remove battery
2 Hold down start stop button on the remote control at the same time while plugging
in battery
3 Wait till both LEDs are flahing alternately
4 Push „+“ button on the remote control one time only. Automatically LED will light
green
5 Compact pump is detected
6 run setup.exe
Installation of software by CD (point 6-10)
7 8
9 click „finish“
10 remove and plug in battery again
18.2 Plug & Play
After successful installation of the software provided the battery powered tool BLUCP700E
is automatically recognized by the computer and the programs or data can thus be
updated .

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18 BLUCP700E
19. What to do in case of dysfunction
In case of dysfunction, the BLUCP700E Compact pump is disused. The „service informati-
on LED“ signals the error code by the numbers of the flashing process.
The error code may be cancelled by removing and plugging in battery; this also resets
the system. (The error codes shown below provide information to eliminate the problem).
If the problem persists after resetting the BLUCP700E Compact pump, apply to the BLU-
CHER customer assistance service.
Error message - code 1: Check the oil level
Procedure: Unscrew the oil cap; if you cannot check the oil level, top up the oil to the
brim with „Shell-Naturelle HF-E15 hydraulic oil“. (see 19.2)
Error message - code 7: Check the air filter
Procedure: Check the air filter, which is located above the power pack compartment
and replace it if necessary. (see 19.3)
19.1 Error codes
Indications after inserting the power pack
Assistance
LED
Battery
LED
Error
code
Description
flashing red flashing red Boot loader activated
flashing orange Error during initialization of the SD card
lightning green Regular initializations
lightning red 3 Battery tension low
Indications after inserting the power pack
Assistance
LED
Battery
LED
Error
code
Description
lightning red 1 Operating range not achieved at timeout
lightning red 2 Operating value in red area
lightning red Operating value in yellow area
lightning green Operating value in green area
lightning red 3 Battery tension low
flashing red/green Assistance service interval expired

English
BLUCP700E 19
flashing orange SD card error
lightning red 5 Overload
lightning orange 6 Device too cold (continuous checking)
lightning orange 7 Device too hot (continuous checking)
Other indications
Assistance
LED
Battery
LED
Error
code
Description
lightning red 4 Error during initialization of sensor temperature
lightning red 8 Drop in pressure during compression
lightning red 9 Fan not working
lightning red 10 Control of battery discharge (check battery)
lightning red 11 Low tension of 3.3V
lightning red 12 Pressure sensor error; pressure below calibration value of 0 bar
lightning red 13 I-Fuse error fuse/shunt burnt or motor operating wi- thout control

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20 BLUCP700E
19.2 Oil filling
1Disconnect coupling 2Position the device turning it 3Unscrew
and remote control by 90° (battery on top) with a coin
4Fill to the brim with hydraulic oil 5Tighten screw
„Shell-Naturelle HF-E15“ with a coin
19.3 Changing the filter
1Disconnect coupling 2 Lift the device 3Press down lever
and remote control
4Remove filter 5Insert new filter
Lever snaps into place
Oil
klick