Cembre B1500A User manual

1
BATTERY OPERATED HYDRAULIC
CRIMPING TOOL
B1500A B1500NA
ENGLISH OPERATION AND MAINTENANCE MANUAL
17 M 196 U

2
6
12
FIG. 2
4
FIG. 4
FIG. 3
a)
b)
14
14
15
15
semi-circular slotted "U" dies
"P" dies
AU150-C adapter
FIG. 1b
10
Makita battery
B1500NA
FIG. 1a
Metabo battery
B1500A
10

3
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 RELEASE
11
BATTERY
12
BATTERY ADAPTER
13
HANDLE
3
8
4
3
12
9
11
2
1
78
13
5
6
10
B1500A
B1500NA
3
8
4
39
11
2
1
78
13
5
6
10
FIG. 5

4
– Before using the tool, carefully read the instructions in this manual.
– When operating the tool, keep hands away from the danger zone.
– Do not operate when dies are not in place.
WARNING SYMBOLS
– User information applies in member states of the European Union
(Directives 2011/65/EU and 2012/19/EU).
Tool
– Never throw batteries into re or water.
– Always recycle the batteries.
– Do not discard batteries into domestic refuse or waste disposal.
Battery

5
B1500A B1500NA
Application range suitable for installing electrical compression connectors
for Copper conductors up to 800 mm
2
(1500 MCM) and
for Aluminum conductors up to 630 mm
2
(1250 MCM)
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
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. 8 page 14) mm (inches) 525 x 251 x102.5
(20.6 x 9.9 x 4)
543 x 251 x102.5
(21.4 x 9.9 x 4)
Weight with battery kg (lbs) 9,7 (21.3) 9,8 (21.6)
Motor V DC 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 CB1840L MAKITA BL1850B
V / Ah (Wh) 18 / 4.0 / (72) 18 / 5.0 (90)
Weight kg (lbs) 0,66 (1.45) 0,6 (1.3)
Acoustic noise (1) dB L
pA
66,9 (A) L
pCPeak
86,9 (C) L
WA
74,9 (A)
Vibrations
(2)
m/s
2
0,398
Battery charger
Input
type
V / Hz
ASC30-36 MAKITA DC18RC
115 / 60 120 / 50 - 60
(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 Standard and under
operating conditions much more severe than those normally found.
1. GENERAL CHARACTERISTICS

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,successivecrimpingoperations;forinstance,havingexhaustedafullycharged
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 (B1500NA is tted with adapter to use Makita battery).
Li-Ion rechargeable battery (2 pcs) (model depends on the tool version).
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 (13) or the shoulder strap attached to
the two rings (8) (Ref. to Fig. 8).
The main operating positions are: horizontal standing on its feet and vertical standing on its bat-
tery. In addition to the main handle (13) the lower handle (6) allows a safer and more balanced grip
when using two hands to hold the tool (Ref. to Fig. 4).
Beforestartinganywork,checkthebatterycharge(Ref.to§2.8)andrechargeifnecessary.
Refer to the manufacturer's instructions for the correct use of battery and battery charger.

7
To replace the battery, grip the tool as illustrated in the Figures 1a and 1b.
B1500A: grip the tool as illustrated in Fig 1a, press the release button (10) and push the battery
downward unlocking it.
B1500NA: position the tool as illustrated in Fig 1b, press the release button (10) and pull the bat-
tery unlocking it.
Insert a charged battery from the bottom by sliding it into the guides until it locks.
Thedisplayshowsthe operationalparametersofthetool;tocustomisethemproceedasdescribed
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:whenmorecompressionis
required,proceedaccordingtothe
sequence and direction indicated
inthegure,uniformlyspacingthe
compressions.
Beforecarrying out further
crimping operations make
sure the locking pin (4) is
completely inserted: its partial
insertion may damage the tool
head.
2.2) Die advancement
Pressoperatingbutton(1)toactivatethe motor-pumpand advance
the lower die.
To halt the advancement, release operating button and the motor
will cut out.
Make sure the dies are exactly positioned on the desired crimp
pointotherwisere-opendies followinginstructionsasper§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.
Toperformpropercompression,pressandholdthe operatingbutton(1) untilthemotor stops
automatically.
12
12
21
terminal
connector
conductor
conductor
1

8
NOTE:Todisplaythemomentary forceorpressureduring
the work cycle, select the appropriate display from the
menu (Ref. to § 4).When the operating button is released
beforethemotorstopsautomatically,thedisplaywillshow
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.
Thedisplay‘ERROR’,combinedwithabeepandtheLEDsashing,indicates
an incorrect crimping procedure caused by the work cycle being inter-
rupted before the control parameters (force/pressure) of the tool are
reached. This error appears when the pressure release button has been operated and the tool 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.
2.5) LED Worklights
Whilst the tool is in operation, the compression area is illuminated
by two high luminosity LEDWorklights 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.
ERROR
Ï
Ð
Fm= 134.3 kN
Fp= 102.3 kN Fm= 134.3 kN
OK
Pm= 742 bar
Pp = 565 bar Pm= 742 bar
OK
2

9
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 suf-
cient. The command pulse is sent when the nger releases the button.
2.8) Battery status
With the battery inserted into the tool, the remaining bat-
tery 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 the tool will
not start, and it is necessary to recharge or replace the battery.
2.9) Using the battery charger
Carefully follow the instructions in the battery charger user manual.
3. DIE AND ADAPTER ASSEMBLES
B1500A and B1500NA 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) com-
mon 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. 3a)
Press pins (14) 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 (14) and slip them from the head.
3.2) Use of semi-circular slotted dies (“U” dies) (Ref. to Fig. 3b)
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 (15) and lock the parts of the “U” dies into the upper and lower parts of the AU150-C.
BATTERY Ï
Ð
max.
BATTERY BATTERY
Ï
Ð
min.
3 SEC.

10
4. DISPLAY
The OLED display (9) 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 (7) to navigate through the menu screens to man-
age 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
Fm= 134.3 kN
Fp = 94.5 kN
Fm= 15.1 ton
Fp = 10.61 ton
1000
-29000
3
BATTERY
Pm= 10762 psi
Pp = 7575 psi
Pm= 742 bar
Pp = 522.3 bar
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.
97

11
To make a selected screen operational and appear at each start-up of the
tool, operate the touch button for at least 3 seconds; a continuous beep
will conrm the setting.
Thecapacitivemenuselectionbutton maynot workiftouchedusingobjectsorwhenwearing
gloves, therefore always operate it using a bare nger.
4.2) SELECTION SCREENS: control parameters that cannot be set as automatic upon start-up
of the tool, can be changed by operating the touch button:
Enabling/disabling the LED Worklights (factory setting LED ON)
When the screen is displayed,
touchthe buttonforat least 3sec-
onds to deactivate for reactivate
operation of the LED Worklights
during tool use; a continuous
beep will conrm the setting.
Return to original factory settings / rmware version
When the ‘RESET’ screen is displayed, return the tool to its factory setting by operating the touch
button for at least 3 seconds; a beep will conrm the setting.
The RESET screen also shows the rmware version of the circuit board.
4.3) WARNINGS: these appear during operation and notify the operator of the status of the tool:
LOW BATTERY: replace the battery.
NOTE:whenthe batteryVagefallsbelowaminimumsafetythreshold,thetool
will not start; although it is still possible to end the work cycle in progress.
BATTERYTEMPERATUREHIGH:removethebatteryandwaituntilitcoolsdown.
NO. OF CYCLES TO MAINTENANCE REACHED:
the tool continues to work however, it is recommended that it is sent to
Cembre for a complete overhaul (see § 7).
NOTE: this message, together with a beep, will reappear when the tool has
been idle for 30 seconds.
LED
OFF
LED
ON
LED
OFF
3 SEC. LED
ON
30001
3
BATTERY Ï
Ð
Ï
Ð
BATTERY
Ï  Ð
RESET
SW:S1J41AH
3 SEC.

12
4.4) ERRORS: these appear during operation, combined with a beep and ashing LEDWorklights,
to notify the operator of procedural or operational errors.
Message Error description Solution
ERROR
Ï
Ð
The pressure release button (2) was
pressed before the control param-
eterswerereached(Force/Pressure).
Repeat the work cycle and wait for the
motor to stop automatically.
001
Ï
Ð
Abnormal power consumption of
the motor for more than 3 seconds.
The tool stops.
Wait for the display to turn o (60 sec.)
orremoveandre-insertthebattery,then
re-start the tool.
If the error occurs frequently, contact
Cembre.
002
Ï
Ð
Output voltage of the pressure
transmitter is out of the pre-set
range.
Repeat the work cycle; if the error
occurs frequently, contact Cembre.
003
Ï
Ð
Failure to reach the set pressure
within 30 seconds of continuous
operation of the machine.
Repeat the work cycle; if the error
occurs frequently, contact Cembre.
004
Ï
Ð
Overcharging of the battery with
protection tripping.
The tool stops.
Wait for the display to turn o (60 sec.)
orremoveandre-insertthebattery,then
re-start the tool.
If the error occurs frequently, contact
Cembre.
Errors are displayed for about 30 seconds before being reset, but will display repeatedly in
the event of permanent anomalies.
5. MAINTENANCE
The tool is robust, completely sealed, and requires very little daily maintenance. Compliance with
the following points, should help to maintain its optimum performance:
5.1) Thorough cleaning
Dust, sand and dirt are a danger for any hydraulic device.
Every day, after use, the tool must be wiped with a clean cloth taking care to remove any residue,
especially close to pivots and moveable parts.
Do not use hydrocarbons to clean the rubber parts.

13
6. CONNECTION TO COMPUTER
Thememorycardintegratedinthetoolrecordsoperatingdata fortransferviatheUSBcablesupplied.
To view and manage this data, go to www.cembre.com and register in the dedicated area, then
download the free Cembre software CEM_SWBT01.
Keeping the Firmware of the tool updated, via free of charge download from here, will optimise
the tool’s performance.
Screw FIG. 6
B1500NA: To access the mini-USB port (Ref.
to g. 7) and connect the USB cable to the
computer it is necessary to remove CBA-MTMK
battery adapter. Remove the screws (Ref. to g.
6 and 6a) and slide the adapter out.
mini-USB
FIG. 7
CBA-MTMK
FIG. 6a
B1500NA
5.2) Storage case
When not in use, the tool should be stored and
transported in the metal case, to prevent damage.
Metal case: VAL-B1500, size 565x410x132 mm
(22.2x16.1x5.2 in.), weight 6,7 kg (14.7 lbs).
– Following information applies in member states of the European Union:
USER INFORMATION in accordance with“Directives 2011/65/EU and 2012/19/EU.“
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 separation, collection, environmentally compat-
ible 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 sub-
ject to the application of administrative sanctions provided by current legislation.

14
B1500A
543 (21.4)
251 (9.9)
102.5 (4)
B1500NA
mm (inch)
7. RETURN TO Cembre FOR OVERHAUL
In the case of a breakdown contact our Area Agent who will advise you on the problem and give
you the necessary instructions on how to dispatch the tool to our nearest service Centre; if possible,
attach a copy of theTest Certicate supplied by Cembre together with the tool or ll in and attach
the form available in the “ASSISTANCE” section of the Cembre website.
FIG. 8
525 (20.6) 102.5 (4)
251 (9.9)

15

16
cod. 6261410
1
6
cod.
6
2
6
141
0
This manual is the property of Cembre: any reproduction is forbidden without written permission.
www.cembre.com
Cembre Ltd.
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Kingsbury Road, Curdworth - Sutton Coldfield
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Tel.: [phone] - Fax: [phone]
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Telefon: [phone] - 60
Telefax: 7151 20536 - 80
E-mail: [email protected]
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