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
13
14
14
semi-circular slotted "U" dies
"P" dies
"15600" series dies
15
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
TG.0932
Always recycle
the batteries.








TG.0932
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
12
21
terminal
connector
conductor
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