Cembre B550 User manual

1
BATTERY OPERATED HYDRAULIC
CRIMPING TOOL
B550 B550E B550BA B550CA B550KA
ENGLISH
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DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ
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,ĞĂůƚŚΘ^ĂĨĞƚLJ
DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ
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DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ
OPERATION AND MAINTENANCE MANUAL
15 M 089 E

2
1
LED WORKLIGHT
2
HEAD
3
LED WORKLIGHT
4
OPERATING BUTTON
5
PRESSURE RELEASE BUTTON
6
BATTERY
7
BATTERY RELEASE
8
TOUCH BUTTON FOR MENU SELECTION
9
DISPLAY
10
RING FOR SHOULDER STRAP
FIG. 1
3
10
5
6
7
8
9
2
1
4

3
Before using the
tool, carefully read
the instructions
in this manual.
WARNING SYMBOLS
Always recycle
the batteries.
Battery:
Tool:
When operating the
tool, keep hands away
from the danger zone.
Always wear safety
gloves when operating.
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.

4
(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 UNI ENV 25349 and UNI EN 28662
part 1st Standards, and under operating conditions much more severe than those normally found.
B550 B550E B550BA B550CA
B550KA
Application range suitable for installing electrical compression connectors
on conductors up to 240 mm2(500 MCM).
Rated crimping force
kN (US sh. ton) 57,7 (6.48)
Minimum crimping force
kN (US sh. ton) 54,8 (6.16)
Minimum operating pressure bar (psi) 570 (8,267)
Dimensions (ref. to Fig. 3) mm (inches) 359 x 358 x 83 (14.13 x 14.1 x 3.3)
Weight with battery kg (lbs) 5,3 (11.7)
Motor V DC 18
Operating temperature °C (°F) -15 to +50 (+5 to +122)
Recommended oil AGIP ARNICA 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 V / Ah / Wh 18 / 4.0 / 72
Type CB1840L (Li-Ion)
Weight kg (lbs) 0,66 (1.45)
Battery charger
ASC30-36
Input
type EU
27044000
UK
27045000
USA/CAN
27046000
V / Hz 220 - 240 / 50 - 60 115 / 60
W85
Acoustic noise (1)
LpA dB (A)
73
LpCPeak dB (C) 94.5
LWA dB (A) 79
Vibration (2) m/s20.575 max.
1. GENERAL CHARACTERISTICS

5
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.
Each tool is supplied with relevant adaptors (see table above).
Adaptors can also be supplied separately:
AU55-B
to be used with
“W” dies
(Burndy type).
Usable together
with the AU55-K
adaptor only.
AU55-K
to be used with
“O” dies
(Kearney type).
AU55-50
to be used with
dies common to
50 kN (6 tons)
Cembre tools.
AU55-W
to be used with
“W” dies
(Burndy type).
B550
B550E B550BA B550CA B550KA
AU55-B adaptor √
AU55-K adaptor √ √
AU55-50 adaptor √ √
AU55-W adaptor √

6
2. INSTRUCTIONS FOR USE
IMPORTANT: In order to avoid damaging the tool, do not operate it at maximum pressure
without dies inserted in the head.
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.
Plastic carrying case.
USB cable (Ref. to § 6 page 14).
Adaptor for specic dies (depends on the tool version).
2.1) Preparation
The tool can be easily carried using either the handle or the shoulder strap attached to ring (10)
(Ref. to Fig. 1).
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.
To replace the battery, remove it by pressing the release button (7), then insert the new battery,
sliding it into the guides until it locks.
Insert a charged battery from the bottom by sliding it into the guides until it locks.
Thedisplayshowstheoperationalparametersofthetool;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 dies into the head tool (see paragraph 3).
Insert the conductor into the connector.
Position the connector between the dies and 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. 12
12
21
terminal
connector
conductor
conductor

7
2.2) Die advancement
Press operating button (4) (Ref. to Fig. 1) to activate the motor-pump and advance the
lower die.
To halt the advancement, release operating button (4) and the motor will cut out.
Make sure the dies are exactly positioned on the desired crimp point otherwise re-open
dies following instructions as per § 2.4 and reposition the connector.
2.3) Compression
By keeping operating button (4) 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 (4) until the motor
stops automatically.
NOTE: Todisplaythemomentaryforceorpressureduring
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 completethework, press theoperatingbutton again untilthemotor stopsautomatically; thedis-
playwill showthemaximum force orpressurereachedfollowedby ‘OK’toconrmcorrectoperation.
The display ‘ERROR’, combined with a beep and the LEDs ashing,
indicates an incorrect crimping procedure caused by the work cycle
being interrupted before the control parameters (force/pressure) of the tool are
reached.Thiserrorappearswhenthepressurereleasebuttonhasbeenoperated
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 (5) (Ref. to Fig. 1), the ram will retract and open the dies.
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.
ERROR
Ï
Ð
Fm= 54.8 kN
Fp= 32.5 kN Fm= 54.8 kN
OK
Pm= 570 bar
Pp = 338 bar Pm= 570 bar
OK

8
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.
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
the tool will not start, and it is necessary to recharge or replace the battery.
The approximate time to fully recharge a battery is about 80 minutes.
Aftereachworkingcycle,andaftertheextractionofthebatteryfromthetool,anintegrated
battery cut-o device will operate after 70 s approx.
Then the LED nearest to button (P) will ash 5 times each 14 s approx. The battery will be reactivated
when it is reintroduced into the tool and the operating button is pressed.
2.9) Using the battery charger
Carefully follow the instructions in the battery charger user manual.
BATTERY Ï
Ð
max.
BATTERY BATTERY
Ï
Ð
min.
P
3 SEC.

9
3. DIE AND ADAPTOR ASSEMBLES
Make sure that the ram of the tool is fully retracted.
Depending on the dies to be used, please proceed as follows:
3.1) Use of ”W” dies Burndy type with AU55-B adaptor
– Insert half of the adaptor AU55-B in the upper seat of the head (1) and the second half
into the adaptor AU55-K (2); the two halves of the adaptor will be held by pins (11 and 12).
– Insert the adaptor AU55-K into the seat of the ram (3) (see Fig. 2a).
– Press pins (13 and 14) and insert one “W” die into the upper adaptor AU55-B and the
other into the lower adaptor AU55-B (4) (see Fig. 2b); to disassemble them it will be
sucient to press the pins and to slip them from the head.
3.2) Use of ”W” dies Burndy type with AU55-W adaptor (*)
– Insert the upper adaptor AU55-B in the upper seat of the head (1); it will be held by pin
(11) (see Fig. 2c).
– Insert the lower adaptor AU55-W into the seat of the ram (2) (see Fig. 2c).
– Press pins (13 and 15) and insert one “W” die into the upper adaptor AU55-B and the
other into the lower adaptor AU55-W (3) (see Fig. 2d); to disassemble them it will be
sucient to press the pins and to slip them from the head.
AU55-B adaptor
"W" dies
13
11 14
AU55-K adaptor
AU55-W
lower adaptor
11
12
3
1
2
21
4
FIG. 2a FIG. 2b
FIG. 2c FIG. 2d
(*) The part code AU55-W includes:
1 pc - AU55-W (lower adaptor)
1 pc - AU55-B (upper adaptor)
"W" dies
13 15
AU55-B
upper adaptor
3

10
3.4) Use of dies common to 50 kN (6 tons) Cembre tools
– Insert the AU55-50 adaptor into the seat of the ram (1) (see Fig. 2g).
– Insert one M...-50 type die into the adaptor AU55-50 (2) and one into the upper part of
the head (3); the two dies will be held by pins (11 and 16).
– To disassemble them it will be sucient to slip them from the head (see Fig. 2h).
"M...-50" dies
AU55-50 adaptor
11
"M...-50" dies
16
1
2
3
FIG. 2g FIG. 2h
3.3) Use of ”O”dies Kearney type
– Insert one “O” type die in the upper seat of the head (1) and the other die into the adaptor
AU55-K (2), the two dies will be held by pins (11 and 12) (see Fig. 2e).
– Insert the adaptor AU55-K into the seat of the ram (3).
– To disassemble them it will be sucient to slip them from the head (see Fig. 3f).
"O" dies
AU55-K adaptor
11
"O" dies
12
3
2
1
FIG. 2e FIG. 2f

11
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:
- Themainoperationalparametersof thetool processedbythe circuitboard,suchas 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.
B550
NR 15AZ541
Fm= 54.8 kN
Fp = 32.5 kN
Fm= 6.16 ton
Fp = 3.65 ton
1000
-29000
3
BATTERY
Pm= 8267 psi
Pp = 4902 psi
Pm= 570 bar
Pp = 338 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. ton.
Fp: Peak force reached, expressed in USA sh. ton.
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

12
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.
The capacitive menu selection button may not work if touched using objects or when wear-
ing 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,
touch the button for at least
3 seconds to deactivate or
reactivateoperation oftheLED
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:
LED
OFF
LED
ON
LED
OFF
3 SEC. LED
ON
LOW BATTERY: replace the battery.
NOTE: when the battery Vage falls below a minimum safety threshold, the tool
will not start; although it is still possible to end the work cycle in progress.
BATTERY TEMPERATURE HIGH: remove the battery and wait until it cools down.
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.
30001
3
BATTERY Ï
Ð
Ï
Ð
BATTERY
Ï  Ð
RESET
SW:S1J41406
3 SEC.

13
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 (5)
was pressed before the control
parameters were reached (Force/
Pressure).
Repeat the work cycle and wait for the
motor to stop automatically.
001
Ï
Ð
Abnormal power consumption of
themotorformorethan3seconds.
The tool stops.
Wait for the display to turn o (60 sec.)
or remove and re-insert the battery,
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.)
or remove and re-insert the battery,
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.

14
6. CONNECTION TO COMPUTER
The memory card integrated in the tool records operating data from
200.000 cycles for transfer via the USB cable supplied.
Toview andmanagethisdata,gotowww.cembre.com andregisterinthe
dedicatedarea, thendownloadthefreeCembresoftwareCEM_SWBT01.
Keeping the Firmware of the tool updated, via free of charge download
from here, will optimise the tool's performance.
7. RETURN TO Cembre FOR OVERHAUL
In the case of a breakdown, contact your local 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 the CembreTest Certicate supplied with the tool or, if no other references are available,
indicate the approximate purchase date and the tool serial number.
5.2) Storage case
When not in use, the tool should be stored
and transported in the plastic case, to prevent
damage. The case, type VAL P40, is suitable for
storing the tool and the accessories.
VAL P40: Size 520x432x126 mm (20.5x17.0x5.0
inches). Weight 2,6 kg (5.7 lbs).
358 (14.1)
359 (14.13) 83 (3.3)
FIG. 3

15

16
cod. 6261371
16
c
o
d
. 626137
1
This manual is the property of
Cembre:
any reproduction is forbidden without written permission.
Ltd.
Dunton Park
Kingsbury Road, Curdworth - Sutton Coldeld
West Midlands B76 9EB (Great Britain)
Tel.: [phone] - Fax: [phone]
E-mail: [email protected]
www.cembre.co.uk
Cembre S.p.A.
Via Serenissima, 9
25135 Brescia (Italia)
Telefono: 030 36921
Telefax: 030 3365766
E-mail: [email protected]
www.cembre.it
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Tél.: [phone] - Fax: [phone]
B.P. 37 - 91423 Morangis Cédex
E-mail: [email protected]
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Calle Verano, 6 y 8 - P.I. Las Monjas
28850 Torrejón de Ardoz - Madrid (España)
Teléfono: 91 4852580
Telefax: 91 4852581
E-mail: [email protected]
www.cembre.es
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Fossnes Senter
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Phone: [phone]
Telefax: (47) 33361766
E-mail: [email protected]
www.cembre.no
Cembre GmbH
Heidemannstraße 166
80939 München (Deutschland)
Telefon: [phone]
Telefax: 089/35806777
E-mail: [email protected]
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Cembre Inc.
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181 Fieldcrest Avenue
Edison, New Jersey 08837 (USA)
Tel.: [phone] - Fax: [phone]
E-mail: [email protected]
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Cembre