Cable Lock AS-ECO User manual

The retaining system for high pressure hoses
H) Installation/Positioning of the Cablelock AS retaining system:
Before starting please read and consider the information on the cover page and in the standard A) Functional description:
BGI 5100 carefully! Avoid chafing on adjacent components! The 'AS' retaining system prevents the pressure hose
from uncontrolled whipping into the surrounding area
in case of a tear-out from the crimping ferrule. This is
Basic formula for the radius of tear-out: possible as the Cablelock 'basic' tensioner lock is fixed
X-Y = min. FL+20mm, max. FL+170mm to the hose and the fixing bracket to the fixation point through
'Length of the cable bow minus shortest distance of the fixation points' the cable (the fixation point consists of the crimping ferrule
and the hose fitting). The length of the cable has to be
Position of the tensioner lock 'basic': dimensioned in that way that there is a possibility for the
Z = min. 50mm, max. 100mm hose to slip out of the crimping ferrule (to ensure a pressure
release).
ATTENTION: If the hose is lead in a bend, NEVER install the
tensioner locks 'basic' in the outer region of the bending radius!
Assembly steps:
1) Enlarge the pre-mounted cable sling by hand and place it moveable on the hose.
2) Attach the bracket and screw down the end of the hose tightly (union nut/external thread or flange plate). DN5-8 (AD11-19) 3mm 12,5 x 2,0 CL-AS-E125 DN12-16 (AD19-31) 4mm 8,5 x 4,0 CL-AS-S085
3) Push the hose-sided tensioner lock 'basic' including the cable sling towards the hose. DN5-8 (AD11-19) 3mm 14,5 x 2,0 CL-AS-E145 DN20-25 (AD26-44) 4mm 10,5 x 4,0 CL-AS-S105.1
The hose-sided fixpoint has to be located 50mm to 100mm behind the end of the crimping ferrule. DN5-8 (AD11-19) 3mm 17,0 x 2,0 CL-AS-E170 DN32 (AD43-52) 5mm 10,5 x 4,0 CL-AS-S105.2 DN5 450bar 60mm - 0,40
4) If the hose-sided fixation point is chosen according to 3) attach the Cablelock AS-Tape if desired. DN8-10 (AD14-23) 3mm 18,5 x 2,0 CL-AS-E185 DN20-25 (AD26-44) 4mm 12,5 x 4,0 CL-AS-S125.1 DN6 450bar 75mm 150mm 0,65
Afterwards install the tensioner lock 'basic' according to the enclosed installation manual starting at point D4). DN8-10 (AD14-23) 3mm 20,5 x 2,0 CL-AS-E205 DN32-50 (AD43-74) 5mm 12,5 x 4,0 CL-AS-S125.2 DN8 450bar 85mm - 0,70
5) Please make sure that the brackets of the 'E' series are able to rotate even after final assembly (after union nut DN10-12 (AD17-28) 3mm 22,5 x 2,5 CL-AS-E225 DN25 (AD34-44) 4mm 14,5 x 4,0 CL-AS-S145.1 DN10 450bar 90mm 150mm 0,85
has been tightened firmly). DN10-12 (AD17-28) 3mm 24,5 x 2,5 CL-AS-E245 DN32 (AD43-52) 5mm 14,5 x 4,0 CL-AS-S145.2 DN12 450bar 130mm 200mm 1,15
6) The brackets of the 'S' and 'P' series always have to be installed with the appropriate screws (not too small and DN16-20 (AD23-35) 4mm 27,0 x 2,5 CL-AS-E270 DN32-40 (AD43-61) 5mm 16,5 x 4,0 CL-AS-S165 DN16 420bar 150mm 240mm 1,40
at least 8.8). Furthermore they have to be installed with the torque recommended in the DIN, so that the head DN16-20 (AD23-35) 4mm 30,5 x 3,0 CL-AS-E305 DN40-50 (AD50-74) 5mm 20,5 x 4,0 CL-AS-S205 DN20 420bar 180mm 240mm 1,80
of the screw presses against the bracket with this torque. DN20-25 (AD26-44) 4mm 34,0 x 3,0 CL-AS-E340 DN25 420bar 230mm 300mm 2,30
DN20-25 (AD26-44) 4mm
36,5 x 3,0 CL-AS-E365 DN32 325bar 420mm 460mm 3,35
Machine-sided fixation points for Cablelock AS (see also text above): DN20-25 (AD26-44) 4mm 42,5 x 3,0 CL-AS-E425.1 DN40 290bar 500mm 560mm 3,90
DN32 (AD43-52) 5mm 42,5 x 3,0 CL-AS-E425.2 DN5-12 (AD11-28) 3mm 9,0 x 3,0 CL-AS-P090 DN50 250bar 630mm 660mm 5,30
DN32-40 (AD43-61) 5mm
45,5 x 3,0 CL-AS-E455 DN16-25 (AD23-44) 4mm 11,0 x 4,0 CL-AS-P110
DN40-50 (AD50-74) 5mm
49,0 x 3,0 CL-AS-E490 DN32-50 (AD43-74) 5mm 13,0 x 4,0 CL-AS-P130
DN32-40 (AD43-61) 5mm
52,5 x 3,0 CL-AS-E525
DN40-50 (AD50-74) 5mm
61,0 x 3,0 CL-AS-E610
* When correctly installed for hose types 1 & 2SN, 1 & 2SC, 4SP & 4SH (up to DN25 and also for R13 & R15). ATTENTION: Do
not use any type for hoses with 6 steel inlays; see also the information below. The above hose types meet the standards below.
** The inner diameter specifications may deviate slightly, but they are suitable for the intended DIN EN connections.
The strap thickness “t” is generally suitable for conventional standard fittings without terminals, but always under reservation.
*** Cablelock retention systems are exclusively tested for liquid media. All pressure specifications refer exclusively to applications
using liquid media! In addition to the max. OP (max. operating pressure incl. pressure spikes), the limit values must also always
must also always comply with the right hose data table (values in accordance with the standard or the data of leading hose manufacturers).
Pressure specifications refer to the hose ID, e.g.: type E225-DN10 = r² x p x450 bar, i.e. 5 mm x5 mm x 3.14 x 450 bar.
C) Application/Operating conditions and IMPORTANT safety Instructions:
Cablelock retaining systems are supposed to protect against uncontrolled whipping of hydraulic hose assemblies. The information and
instructions in this operating manual must be followed carefully. Failure to comply can lead to failure of the retaining system an possibly
to further risks due to whipping or flying parts of Cablelock! Cablelock retaining systems have been developed and tested in compliance
with the following standards: DIN 20066, DIN EN 853, DIN EN 854, DIN EN 855, DIN EN 856, DIN EN 857 and ISO 3862 - for more
information concerning the hose types see above. If the maximum operating pressure is exceeded, Cablelock retaining system does not
ensure a sufficient protection. In accordance to the company standards reference retaining systems have been dynamically tested in
quasi-static pressure tests with at least 150% of the maximum operating pressure and have been able to stop the end of the hose reliably.
Protection provided by Cablelock retention systems shall only be guaranteed if the installation requirements in accordance with DIN 20066
are complied with and at least the lowest bend radius in accordance with the above standard is used! The maximum operating
temperature is -40°C up to +150°C. Before installing Cablelock AS it has to be checked that the hose and machine can move safely with
the protection. It has to be assured that no trapping during movement can occur. Keep away from children! A safety distance must be
I) Storage/Maintenance/Care/Warranty/Manufacturer/Conformity/Sample images: adhered to regardless of the attached safety catch (see point F)! The suitability in explosive environments or other special environments
- Cablelock AS retaining system should be stored in a dry and dust free area and they should NOT be dismounted
(Pharma, foods, radiation etc.) should be agreed with the manufacturer in each individual case. The retaining systems neither protect from
completely* (see page 2)
the leaking fluid in case of the tear-out of the crimping ferrule, nor from any other fitting parts or the crimping ferrule tearing off in addition
- Cablelock protection devices of this series are rust-protected, but NOT suitable for use in moist conditions! For more to the hose. Cablelock AS is designed for 4-5 assemblies/disassemblies; more frequent applications might damage components. It
information see: www.cablelock.de - important information - exclusion of liability/corrosion
has to be ensured that the selected machine fixpoint contains enough stability. Residual risks may remain regardless of the safety catch;
- Do not replace individual components. In case of damage or a retaining action (=hose tear-out) completely replace Cablelock. the file “possible residual risks”, which includes important information, is available at www.cablelock.de. Cablelock retaining systems are
- Before reuse (if there was no tear-out) check whether the retaining system (especially the cable) is in a functional condition. not suitable for use in moist conditions, see also point I). Cablelock retaining systems have are not tested for gaseous media - see information
- Limited warranty in case of vibration load, see also the CE label safety catch information sheet at www.cablelock.de
in catalogue. This series must NOT be used for 6-layer hoses (e.g. R13/R15 fromDN32). The increased weight-per-metre of these hose
- Check the retaining system regularly for damage and firm fixation (e.g. during the annual pressure inspection as required in types compared to 4-layer hoses as well as the increased bending stress at the lowest bend radius may result in the safety catch being
DGUV-113-020). In case of excessive vibrations etc. shorten the checking intervals! overloaded! It is also extremely important that the Cablelock locks are always sufficiently secured - see section D). The meanings of the
- If there are signs of corrosion or damage precautionary replace the retaining system! terms used in these operating instructions are to be understood in the context of DIN EN ISO 8330. In the event of the hose being torn off,
- Manufacturer: Hydraulik Schmitz Siegen GmbH - Seelbacher Weg 17 - 57072 Siegen no part of the safety lock must strike any other components (otherwise the cables may become torn, etc.).
- All images show safety catches with 3 mm wire rope diameter (4+5 mm types may differ slightly).
- An EC declaration of conformity is available at www.schmitzsiegen.de.
Page 4 Page 1
machine
sided bracket
IDxt**
min. BR = 'Minimum bend radius': Lowest
permissible hose bend radius
1+2 wire=1&2SN/SC; 4-wire=4SP&4SH
When using this securing series, do not secure
any heavy hoses NOR lay them in a small
bend radius! (Exceptions only permitted after
all individual parameters have been tested and
upon the express written consent of the safety
catch manufacturer).
Ident. No.
S-bracket
max.
kg/m
min. BR
4 wire
min. BR
1+2 wire
max.
BD***
B) Sizes and dimensions of the different types: Compatible for all standard fittings of the corresponding diameter nominal 'DN' according to DIN 20066
Other technical data to be complied with
regarding the hose line to be secured
E bracket for union nuts; S bracket for SAE flanges; P bracket for
a free fastening point. See the illustration below & point F
Size
cable-
Ø
for hydraulic hose
(OD in mm)*
for hydraulic hose
(OD in mm)*
Ident. No.
E-bracket
machine
sided bracket
IDxt**
for hydraulic hose
(OD in mm)*
cable-
Ø
Subject to change without notice - the latest version of the operation manual is available on www.cablelock.de
E-bracket
S-bracket
P-bracket
Subject to change without notice - the latest version of the operation manual is available on www.cablelock.de
cable-
Ø
The last characters of the ID no. are stamped
on the CE label. E.g.: "E224"
machine
sided bracket
IDxt**
Ident. No.
P-bracket
Translation of the original operating
Instructions
(without guarantee for correctness) Version 2021 Translation of the original operating
Instructions
(without guarantee for correctness) Version 2021
Component overview
(example AS3-ECO):
(Example AS3 ECO)
X
FL Z
Y
AS-ECO
AS-ECO
tensioner lock 'basic'
cable bow
fixing
bracket
machine-sided fixation point
crimping
pressure hose
hose protection
'AS-Tape'
hose-sided
cable sling
hose fitting
Bracket forms:
E-bracket
S-bracket
P-bracket
Attention:
only use the shown
fixation options if
the tensioner locks
are positioned in
the inner region of
the bending radius.
Otherwise turn the
tensioner locks
around. Mounting method:
free, sufficiently
stable fastening point
with screw (with
installation lengths as
described in the
above formula on this
page)

D) Installation tensioner lock 'basic' - overall positioning see backside D6) Secure
-After reaching the required strength (see D7), you have to tighten the
safety screw a) and at least one of the safety screws b) or c) (M3
- In the delivery status the clamping ferrule of slightly, i.e. with maximum 0,05 Nm), so that the Cablelock tensioner
AS-ECO' is loosely tightened on the basic screw. lock cannot loosen itself.
Please unscrew it at first (it will be reinstalled later ATTENTION: Don't tighten the safety screw b) or c) if it is located above
on, see D2/D3). the insert slot of the basic screw. In this case either tighten the safety
- Please note the adjacent picture as an screw on the opposite side or turn the clamping ferrule (buffer ferrule)
advanced information: A cable protection disk into another position and then you can tighten the safety screw.
is located under the locking screw. In case of a -The installation of the Cablelock tensioner lock 'basic' is finished.
complete disassembly (not recommended)
insert the cable protection disk as shown in
the picture. Extremely high strengths can be achieved with Cablelock retaining systems. When the clamping ferrule is
used for hose securing, the following tightening torques are correct:
Attention: Before starting the installation we highly AS3: 2Nm AS4: 3Nm AS5: 4Nm
recommend the use of Cablelock AS-Tape as Info: AS3 = 3mm wire cables AS4 = 4mm wire cables AS5 = 5mm wire cables
a protection against pulsation/vibration. The required strength is approximately achieved when the wire cable sling can no longer be moved in the axial
- Push the basic screw including the clamping direction even with relatively high physical effort.
ferrule over the cable (with external hex showing The sling is automatically tightened further if the hose tears off!
in direction of the basic screw, see picture).
-
Place the end of the cable with the limiter ferrule
around the installation point. For disassembling the Cablelock tensioner lock please first loosen the safety screws a), b) and c)*(*see page 2).
Afterwards loosen the locking screw* and open the cable sling by pulling the tensioner lock. Now follow
the steps in the installation manual from D2) to D1) in REVERSE order.
- Push the end of the cable including the limiter ferrule
through the CLAMPING FERRULE AGAIN and fixate A safety distance must be adhered to regardless of the attached retention system! This safety distance must be
it in the insert slot (the cable builds a sling). determined by each user in accordance with the prevailing conditions in their circumstances, and a simple rule of
- Pull the cable so that the cable sling tightens itself and thumb will be provided below. When additional information is required, please refer to our information sheet
the limiter ferrule fits completely into the blind hole of 03) Safety distance table' at www.cablelock.de - important information.
the basic screw.
- Screw the CLAMPING FERRULE COMPLETELY
onto the BASIC SCREW (G1/4" or G3/8")!
-Move the turnbuckle to the desired fastening position (please refer to D7)
and also observe the back page of these operating instructions!).
-Firmly tighten the cable by hand (sling gets smaller) and
prefixate it. Fasten the hand fixated Cablelock with the locking screw
(AS3 with 2,5Nm; AS4 with 3,0Nm; AS5 with 4,5Nm).
AS3=3mm cable; AS4=4mm cable; AS5=5mm cable
Attention: PRECISELY position the Allen key, otherwise there is
the risk of the Allen wrench skidding the grub screw.
-ATTENTION: firmly tightening 'by hand' supports the later tightening with
an open-end wrench. This assembly step could require some exercise. 'Ls' always has to be measured from the middle of the little hole
-The Cablelock tensioner lock has now reached the status 'fastened' for the cable in the bracket to the position of the tensioner lock!
-Tighten the Cablelock tensioner lock with an open-end wrench by
screwing the clamping ferrule (buffer ferrule) in direction of the sling.
-Tighten the clamping sleeve until the required strength has been achieved. MATERIALS:
For information regarding the “required strength”, see point D7). Clamping ferrule: bright brass
Secure the base screw against rotation either by hand or with a wrench. Basic screw: galvanized steel
-Noises and the production of chips during assembly are harmless. Locking screw: galvanized steel
-the maximum clamping distance (the visible length of the external Safety screws: galvanized steel
thread of the basic screw) is 8mm. Limiter ferrule: light metal or bright brass
-If the required strength is not achieved (see D7), loosen the fixing screw*, Cable: galvanized steel
screw the clamping sleeve counter-clockwise and begin again from point D4). Cable protection disk: stainless steel
(The cable protection disk is located hidden
under the locking screw).
Page 2 Page 3
D4) Fastening
D5) Tightening
D7) Required strength of the clamping ferrule for the clamping procedure
Rule of thumb for the safety distance:
minimum safety distance= (LS+LF)x1,2
G) Component overview of the tensioner lock 'basic':
*Never unscrew the safety and locking screws completely, just loosen them! Otherwise the
cable protection disks, located under the locking screws can drop out and damage the
functional reliability!
D1) Advanced information 'Cable protection disk'
F) Safety distance
D3) Preinstallation
D2) Place
E) Disassembly of Cablelock tensioner lock 'basic'
cable
limiter ferrule
insert slot
BASIC SCREW
safety screw b) + c)
locking screw
cable
sling
safety screw a)
CLAMPING
FERRULE
Also useful: Our
assembly video at
www.cablelock.de:
Videos - assembly”
Safety
distance
Ls
Lf
Please order the AS-
Tape separately!