Brady BSP45 User manual

BSP45 Wire/Cable
Sleeve Applicator
User’s Manual
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ENGLISH
2/25/16 i BSP45 User’s Manual
Copyright
This manual is copyrighted with all rights reserved. No portion of this manual may be copied or
reproduced by any means without the prior written consent of BRADY Worldwide, Inc.
While every precaution has been taken in the preparation of this document, BRADY assumes no
liability to any party for any loss or damage caused by errors or omissions or by statements
resulting from negligence, accident, or any other cause. BRADY further assumes no liability
arising out of the application or use of any product or system described, herein; nor any liability for
incidental or consequential damages arising from the use of this document. BRADY disclaims all
warranties or merchantability of fitness for a particular purpose.
Trademarks
BSP45 Sleeve Applicator is a trademark of BRADY Worldwide, Inc.
BRADY reserves the right to make changes without further notice to any product or system
described herein to improve reliability, function, or design.
© 2016 BRADY Worldwide, Inc. All Rights Reserved
Printed April 2016
Software Version 1
Brady Worldwide Inc.
6555 West Good Hope Road
Milwaukee, WI 53223 U.S.A.
Telephone: [phone] USA Domestic
Facsimile: 414-438-6958

ENGLISH
BSP45 User’s Manual ii 2/25/16
BSP45 Agency Compliance and Approvals
UNITED STATES
FCC Notice - US Only
This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and used
in accordance with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at his own expense.
Changes or modifications not expressly approved by the party responsible for compliance could
void the user’s authority to operate the equipment.
INDUSTRY CANADA
Industry Canada ICES-03:
CAN ICES-03(A) NMB-03(A)
EUROPE
Warning - This is a Class A product. In a domestic environment, this product may cause radio
interference in which case the user may be required to take adequate measures.
WasteElectricalandElectronicEquipmentDirective
In accordance with the European WEEE Directive, this device needs to be
recycled in accordance with local regulations.
RoHS Directive 2011/65/EU
This product is CE marked and complies with the European Union's Directive 2011/65/EU OF
THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 8 June 2011 on the restriction of the
use of certain hazardous substances in electrical and electronic equipment.

ENGLISH
2/25/16 iii BSP45 User’s Manual
BRADY Warranty
Our products are sold with the understanding that the buyer will test them in actual use and
determine for him or herself their adaptability to his/her intended uses. BRADY warrants to the
buyer that its products are free from defects in material and workmanship, but limits its obligation
under this warranty to replacement of the product shown to BRADY’s satisfaction to have been
defective at the time BRADY sold it. This warranty does not extend to any persons obtaining the
product from the buyer.
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESSED OR IMPLIED
INCLUDING, BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY OTHER OBLIGATIONS OR LIABILITY
ON BRADY’S PART. UNDER NO CIRCUMSTANCES WILL BRADY BE LIABLE FOR ANY LOSS,
DAMAGE, EXPENSE OR CONSEQUENTIAL DAMAGES OF ANY KIND ARISING IN
CONNECTION WITH THE USE, OR INABILITY TO USE, BRADY’S PRODUCTS.
YOU SHOULD CAREFULLY READ THE FOLLOWING TERMS & CONDITIONS OF THIS
LICENSE AGREEMENT. IF YOU DO NOT AGREE WITH THESE TERMS & CONDITIONS,
PLEASE PROMPTLY RETURN THIS PACKAGE FOR A FULL REFUND.

ENGLISH
BSP45 User’s Manual iv 2/25/16
Safety and Environment
Please read these instructions completely and carefully before operating your BSP45 Sleeve
Applicator machine. Keep this Instruction Manual for future reference.
Intended Use
The BSP45 Wire/Cable Sleeve Applicator is a benchtop machine that assists in the application of
sleeves to wires and cables. If the equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be impaired.
Warnings:
Cautions:
•ALWAYS wear safety glasses during operation of the machine and/or servicing to prevent eye
damage in the case of flying debris from a broken mandrel.
•ALWAYS use E-Stop button in the event of a emergency to disable die module, mandrel &
pneumatic operation.
•ALWAYS use proper instructions for dropped sleeves. Refer to “Recovering from a Dropped
Sleeve" section on page 11.
•ALWAYS use proper instructions for machine error in "Recovering from an Error" section
provided.
•ALWAYS use Brady sleeves/material, when operating the machine.
•NEVER insert more than one wire, or bundle, into machine.
•NEVER insert any object other than the appropriate-sized wire.
•DO NOT place the machine on an unstable surface or stand.
•DO NOT position the machine such that the electric and pneumatic power cannot be readily
disconnected.
•ALWAYS use handles provided at bottom front and back to lift machine.
•DO NOT place anything on machine. Keep clear of obstruction
•DO NOT wear loose clothing that could become caught in the machine.
•ALWAYS use the machine in a well-ventilated area. DO NOT block the slots and opening on
the machine, which are provided for ventilation.
•ALWAYS use the power source indicated on the rating label.
•ALWAYS use only the power cord provided with the machine.
•ALWAYS connect the three-conductor plug to AC outlet. Be sure the outlet is grounded and
easily accessible to the unit.
•ALWAYS use air pressure greater than 40 psi but less than 145 psi.
•DO NOT operate machine in direct sunlight.
•ALWAYS allow machine to acclimate to ambient temperature for an hour before operating.
• Make sure you have easy access to the main plug in case of an emergency. In case of an
emergency, immediately unplug the unit from the wall AC outlet.
DO NOT insert fingers or hands into die module opening; pinch hazard.
DO NOT operate machine with covers open.
DO NOT power up the machine when any of the shrouds are removed (tool required);
electrical hazard. See Maintenance section.
ALWAYS unplug power cord to disable power when servicing.

ENGLISH
2/25/16 v BSP45 User’s Manual
System Specifications
BSP45 Sleeve Applicator
•Voltage: 100 - 240 V, 50/60 Hz, 2A
•Mechanicals:
-Max input air pressure 145 PSI (1.0 MPa ).
-Pneumatic connector, industrial quick coupler plug, 1/4" NPTF, 18 threads per inch.
-Filtered air supply source recommended.
-Supplied air should NOT contain in-line oil in the compressor hose.
•Operating Temperature: 41 to 104°F (5 - 40°C)
•Relative Humidity: 10% to 80% RH
•Weight: 42 lbs (19 kg)
•Altitude of Operation: up to 2000M
Media Specifications
The BSP45 Sleeve Applicator is designed to function only with a specific range of Brady sleeve
parts constructed to allow correct feed, sensing, and auto-application by the machine. Non-Brady
sleeve parts and non-BSP45-specific sleeve parts will not function in the system. Contact Brady
Technical Support or Customer Support for specific media information.
BSP45 Footswitch
30V AC Max, 3A, Class 2 Circuits only, EN 60529 (IP20), UL REC / E83123

ENGLISH
BSP45 User’s Manual vi 2/25/16
Technical Support
Technical Support Numbers/On-line Help
For repair or technical assistance, find your regional Brady Technical Support in the following
table.
Repair and Replacement Parts
Brady Corporation offers repair and replacement services. Contact Brady Technical Support for
repair and replacement information.
Country Website Telephone Email
United
States
www.bradyid.com 1-800-643-8766 [e-mail]
Canada www.bradycanada.ca 1-800-263-6179 [e-mail]
Mexico www.bradylatinamerica.com 1-800-212-8181 [email protected]
Central
America
www.bradylatinamerica.com 1-866-748-4424 [e-mail]
South
America
www.bradylatinamerica.com 1-866-748-4424 [e-mail]
Brazil www.brady.com.br [phone]-
1500 ext 5
[e-mail]
Australia http://www.bradyid.com.au 1800 644 834 [e-mail]
Europe www.bradyeurope.com [phone] [e-mail]
South Asia http://www.bradyid.com.sg 65-64777261 [e-mail]

ENGLISH vii
2/25/16 BSP45 User’s Manual
Contents
Unpack Your Applicator ..............................................1
Register Your Sleeve Applicator ..........................1
External View............................................................... 2
Sleeve Applicator Setup ............................................... 3
Changing Dies/Sleeve Size........................................... 4
Changing Mandrel........................................................ 5
Loading Media ..............................................................6
Selecting a Sleeve .........................................................9
Applying a Sleeve (IN-PEDAL-UP)...........................10
Stopping the Application ............................................11
Recovering from a Dropped Sleeve .....................11
Maintenance ...............................................................12
Cleaning the Applicator ........................................12
Fuse .......................................................................12
Cleaning Dies .......................................................12
Troubleshooting.......................................................... 13
Recovering from Errors ..............................................17
Appendix A - Loading Material on BBP72 Printer ....18
Appendix B - Loading Material on PR300+ Printer ...19
Template Side #1 (first side to print for 1- and
2-sided printing) ............................................19
Template Side #2 (second side for double-sided
printing) ..........................................................20

ENGLISH Unpack Your Applicator 1
2/25/16 BSP45 User’s Manual
Unpack Your Applicator
Carefully remove any transportation protection from between the Die opening and the area in front of
the Poke and Lift Module.
The following items are included in the standard BSP45
Sleeve Applicator package:
• BSP45 Wire/Cable Sleeve Applicator
• User’s Manual (on memory stick)
• Power Cord
• Dies
• Mandrel Assembly
• Foot pedal
Register Your Sleeve Applicator
Register your applicator on-line at www.bradycorp.com/register and receive free product support and
updates.

2External View ENGLISH
BSP45 User’s Manual 2/25/16
External View
1Start/Stop buttons 8Die module release lever
2Function button 9Rear door
3Sleeve size selection buttons 10 On/Off switch
4E-stop button 11 Fuse
5Rear door safety lock 12 Power cord connection
6Die module 13 Pneumatic hose attachment
7Foot pedal jack

ENGLISH Sleeve Applicator Setup 3
2/25/16 BSP45 User’s Manual
Sleeve Applicator Setup
1. Attach free end of the pneumatic hose that is
attached to an air compressor to the male
connector on the BSP45 unit. MAKE SURE
THE PNEUMATIC LINE IS FREE OF OIL.
Note: Air pressure must be greater than
40 psi but less than 145 psi.
2. Plug in the foot pedal.
3. Attach the power cord (included) to the applicator and plug into an electrical outlet, then flip the
electrical switch on the back of the applicator to the ON (I) position.
1
2
3

4Changing Dies/Sleeve Size ENGLISH
BSP45 User’s Manual 2/25/16
Changing Dies/Sleeve Size
In order to apply the desired sleeve, you must install the correct mandrel and dies that correspond to
the chosen sleeve diameter. For instance, for 0.125-inch diameter sleeves, the associated 0.125-
inch mandrel and 0.125-inch dies must be installed. Both the mandrel and the dies are stamped with
the sleeve diameter.
1. Press the Function button on the bezel.
Both dies display.
2. Push the silver die release tab (circled)
toward the back of the machine. While
holding the release tab with one hand, with
the other hand grasp the die and pull
straight up and out.
3. Insert the desired die into the slot and
gently push down until it clicks. The release
tab will flip back into place.
4. On the unit’s front panel, press the sleeve
size selection button corresponding to the
size of the inserted dies.
The dies return back under the housing. The machine is now ready for operation.
See Changing Mandrel (page 5) to complete the material changeover process.
1
2
3
4

ENGLISH Changing Mandrel 5
2/25/16 BSP45 User’s Manual
Changing Mandrel
Install the mandrel that corresponds to the chosen sleeve diameter. The sleeve diameter is stamped
on the side of the mandrel block.
Note: If only changing the mandrel (not the dies), the Function button does
not have to be pressed.
For this procedure, you will need a #1 drive Philips head screw driver.
1. Open the access door to display the mandrel
assembly.
2. Unscrew the mandrel holder with the Philips
head screw driver.
3. Pull out the installed mandrel assembly. 4. Insert another mandrel assembly
(corresponding to the size previously
selected on the bezel and as indicated by
the dies) and secure by tightening the
screws.
1
2
3
4

6Loading Media ENGLISH
BSP45 User’s Manual 2/25/16
Loading Media
1. Ensure that the E-stop (safety switch) is
released. If not, twist the red E-stop knob
clockwise and pull out. Then, gently lift the
rear door. Opening this door releases the
safety lock, which automatically evacuates
the system air and removes electrical power.
2. Press the extended latch on the lower front
of the die module to release it. The die
module automatically opens to a set
position.
3. Lift and flip up the door covering the rear
tractor pin feed.
4. Load the media with the notch on the edge
of the cardstock (marked with the red circle)
facing towards the front of the unit. The blue
lines on the back of the cardstock should
face down. A minimum cardstock length of
6 inches is required
Note: For proper operation, the
minimum length of media that can be
loaded is 6 inches.
1
2
3
4

ENGLISH Loading Media 7
2/25/16 BSP45 User’s Manual
The edge of the cardstock should be flat and in “out of the box” condition. Below are examples of
damaged material, which should be trimmed to remove the damaged portion of the media.
5. Feed the card-stock into the unit, engaging
all tractor pins. If there are sleeves missing,
when started, the machine automatically
advances to the first available sleeve.
To avoid wasting sleeves, ensure that the
mandrel is inserted into the first viable
sleeve. Unused stock rolls have several
blank sleeve windows (as shown in Figure 5
below). The red dotted line in Figure 5
indicates where the cardstock should be
inserted and engaged.
6. Close the door on the rear tractor feed.
Note: If the tractor door is not closed
before closing the die module, it could
stall the motor.
5
6

8Loading Media ENGLISH
BSP45 User’s Manual 2/25/16
WARNINGWARNINGWARNING
DO NOT insert fingers or hands into die module opening - pinch hazard!
DO NOT operate machine with covers open!
7. Press and hold the extended latch on the
die module while pushing the die module
down. When the module is closed, release
the latch.
8. Close the rear door. The safety lock
engages again when the door is shut. The
STOP button is lit, signifying the machine is
ready.
7
8

ENGLISH Selecting a Sleeve 9
2/25/16 BSP45 User’s Manual
Selecting a Sleeve
A new sleeve size must be selected whenever the media is changed.
1. Press the Stop button.
Refer to Changing Dies/Sleeve Size
(page 4) and Changing Mandrel (page 5) to
complete the media changeover.
2. Press the sleeve selector button.
3. After the dies and mandrel are changed, press the Start button to continue applying sleeves.
1
2
3

10 Applying a Sleeve (IN-PEDAL-UP). ENGLISH
BSP45 User’s Manual 2/25/16
Applying a Sleeve (IN-PEDAL-UP).
Applying a sleeve is as simple as 1-2-3. It involves a 3-step procedure called IN-PEDAL-UP. IN-
PEDAL-UP is done rapidly but after a few tries you will develop a rhythm to it and the procedure will
be seamless
1. Press the START button to advance the
media to the first sleeve. The unit
compresses the sleeve from both sides,
creating the opening through which the wire
is passed.
2. Insert a wire into the open sleeve, making
sure the wire passes completely through
the open sleeve. (IN)
3. Tap the foot pedal with your foot. (PEDAL) 4. Quickly lift the wire up and out of the die
module. (UP)
DO NOT insert fingers or hands into die
module opening; pinch hazard.
DO NOT operate machine with covers
open.
1
2
3
4