Elpress CS2500 User manual

CS2500
Instructions for use
GB

2 CS2500 | INSTRUCTIONS FOR USE

3 CS2500 | INSTRUCTIONS FOR USE
CONTENTS PAGE
1. INSPECTION CERTIFICATE...................................................................................4
2. ASSISTANCE......................................................................................................................................4
3. PERSONAL SAFETY..............................................................................................................5
4. GENERAL DESCRIPTION..........................................................................................6
5. CS2500 SYSTEM COMPONENTS...........................................................7
6. USE OF CS2500.........................................................................................................................8
7. DISPLAY MENU...........................................................................................................................9
8. MAINTENANCE................................................................................................................... 10
9. ENVIRONMENTAL ASPECTS...................................................................... 10
10. TECHNICAL SPECIFICATION................................................................. 11
11. DECLARATION OF CONFORMITY................................. 12-13

4 CS2500 | INSTRUCTIONS FOR USE
1. Inspection Certicate
Product description Crimp station
Product designation CS2500
Serial No. (crimp unit) ……….....................…………………….
Serial No. (pump unit) ……….....................…………………….
Elpress AB hereby certify that the product specied above is inspected and approved in accordance
with current routines within Elpress and in correspondence with the relevant requirements in ISO
9001-2000.
Inspection records are led with Elpress and are available upon request.
Inspection date: ……................................…… Inspector: ………………………...............................................………………
2. Assistance
In case of questions regarding this product, please contact your Elpress supplier or Elpress directly
through the customer support dept at the main ofce in Kramfors, Sweden.
Telephone [phone]
Telefax [phone]
E-mail [email protected]
4

5 CS2500 | INSTRUCTIONS FOR USE
IMPORTANT! Read this section before using CS2500
3. Personal safety
• This equipment may only be used by persons with sufcient
knowledge about its application and function.
• The use of other hydraulic tools than from Elpress may bring
about considerable risks for personal injury.
CS2500 is a crimp station with integrated hydraulic pump and foot pedal.
This equipment is designed for crimping of Elpress terminals on to power cables.
The crimp station shall not be operated with more than one person at a time.
The mains unit may only be connected to a 100 - 240 VAC outlet with protective earth.
This Instruction shall always be kept with the equipment.
• The CS2500 creates high hydraulic pressure (max 700 bar) and high press forces
(up to 260 kN). To minimise risks, always use protective glasses when operating.
Always check equipment before use, with special regards to damage on the hose, control cable
and mains cable. If damage is seen or suspected, the unit must not be used and immediate service
actions must be taken.
Note that only authorised service units with access to technical documentation may service the
CS2500. Always use spare parts supplied by Elpress.
Reduce the safety risks and prolong the service time for the CS2500 by handling it with care and by
keeping it clean.
Do not try to use the crimp station for other purpose than crimping terminals.
At all work, observe the movements of crimp dies to avoid nger damages.
CS2500 has a unique fast and with low force, locking/unlocking of terminals.
That secure high personal safety. All movements are quickly stopped
by releasing start switch on foot pedal. Stop switch on pedal retracts all
movements.
At longer stops, switch off the unit and disconnect the mains cord plug.

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4. General description
Elpress crimp station CS2500 is a product designed for harness production.
A foot pedal operated crimp unit connected to a separate electro hydraulic pump give several
opportunities to form individual working stations in most places.
The concept is to combine high productivity with high crimp quality, all the time with high
personal safety and ergonomics.
With use of a fast locking and unlocking screw function the terminal can be xed in the correct
crimp position with a very low force. This avoids risk of accidents.
As the available crimping force is very high, only one crimpcycle. Crimp force is individual
programmable and selfadjusting in two steps, high and low, for optimal durability and energy
saving.
Elpress patented DUAL system is build in for use with Elpress terminals of type KRF/KSF.
All set parameters relevant to the function of the system as well as the pressure build up of each
crimp cycle, are continuously monitored and logged into the electronic control module. Most of
the information can be directly read on the display after each crimp cycle. More information can
be seen using display menu and by pressing menu buttons on membrane keyboard on crimp unit.
For further crimp analysis, crimp data can be transferred to a PC and then studied and saved as
traceable protocols for manufacturing batches, calibration etc.
If the memory is full and crimps are not to be transferred to PC computer memory can be deleted
by use of ”clear logs” function in the main menu.
The special developed PC software is called ELPRESS ANALYZER and can be easy installed by using
ELPRESS ANALYZER Manual. This software gives the user a tool for process control in realtime.
The control system also has a self-diagnostic functionality where fault messages makes the
operator aware of eventual disturbances.
The operator controls the equipment with the foot pedal. Display on crimp unit shows actual
status and relevant information. Both displays shows the same information.

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5. CS2500 System components
Crimp station
CS2500
Pump PS710D
Foot pedal
PC Software for crimp
analysis and quality
process integration
Display
Footpedal
connection
CAN bus
system
Hydraulic
connection
USB

8 CS2500 | INSTRUCTIONS FOR USE
6. Use of CS2500
When crimp unit is to be moved use the lifting hooks which are attached on CS2500. Make sure
that crimp unit is placed on a stable place, preferable with a hard wood board. If a moveable
working place is used make sure that wheels can be locked.
Set main switch to position “0” on top of pump unit.
- Connect hydraulic hose to pump. Do not bend the hose too much. Connect control cable to the
pump and lock it. Than attach separate cable to foot pedal.
- If all internal connections are made, then attach the mains cord plug to 100-240 VAC power
outlet with a protective earth, PE.
- Set the main switch on the pump unit in position “II”. Than press the right switch in the foot
pedal to activate self check of system, a green LED will light above the display to indicate
ready for use state.
Running.
- When the left switch in the foot pedal is pressed the crimp process starts with low force screw
locking of terminal. If the foot pedal switch is kept down the pump starts and hydraulic pressure is
built up. When pressure exceeds 15 bar, the green LED ashes at about 4 Hz and the display shows
“press active”. This is starting point for crimp data logging into pump computer memory. When
preset max pressure is reached, the system is automatically released and both cylinder piston
and locking screw are retracted. This procedure is referred to as one crimp cycle. Display gives
information for each cycle. See Display Information in this manual.
A crimp cycle can be interrupted by releasing foot pedal switch, the left one.
A crimp cycle can be restarted by again pressing foot pedal switch, the left one.
A crimp cycle can be ended by pressing the foot pedal switch, the right one.
If the crimp cycle is interrupted before the pump starts, pressing right switch will retract screw
and make new locking of terminal possible. Between locked terminal and start of pump there is a
security time delay in the control system of 1 second.
The main switch, on pump unit, should be set in position “0” when equipment is out of use.
During longer stops the mains power plug should be disconnected.

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7. Display Menu
When the system is made ready for use, display will show “Date and time” and “Pump-No”
The four switches on the keypad are used for navigation in the control system.
“Main menu” is reached by pushing the “OK” switch. Up and down switches moves
the cursor to desired line, then the switch marked “OK” must be pressed. Return to main menu
by pressing the “esc” switch. In the main menu it is easy to get information about pump status.
- Log info Show used part of computer memory
- Reset counter Reset counter of crimps shown in display
- Clear logs Clear out memory from all crimplogs
- Settings Show set values
- Active faults Show and clear out of error messages
- Admin Time set log in
- Version info Information about software
After a complete crimp cycle, information about relevant parameters is shown in display. By using
the down switch on the keypad thid information is easy reached.
If any of the parameters above, press time, pressure, current, voltage, oil temp or motor temp is
out of preset limits there will be an error message with information about the actual problem.
When a crimp cycle has been started but not completed within 60 sec, a message “Time out” will
be shown in the display. All faulty messages can be cleared in ”Active faults” menu.
Press time Crimp time, when pressure p is over
15 bar
Max pressure Max hydraulic pressure reached
during crimp cycle
Max current Max motor current reached during
crimp cycle
Min battery Min voltage, battery or net power,
during crimp cycle
Crimp complete Crimp cycle has been fullled, max
pressure reached
Log ID Crimp identity saved with crimp
characteristic
Cycle counter Counts every crimp (p > 15 bar),
possible to reset
Total counter A not resetable total press
counter
Oil temp Max hydraulic oil temperature during
crimp cycle
Motor temp Max DC motor temperature during
crimp cycle

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8. Maintenance
The life of the CS2500 is prolonged if the units are kept clean and dry. A daily check at hydraulic
hose and cable is importent.
Daily cleaning of dies and the crimp unit are recommended. Never use air blowing tools when
cleaning crimp unit, especially close to the hydraulic piston.
The automatic driven screw for locking of cable lugs shall be carefully lubricated each 20 000
cycles. A few drops of mineral based hydraulic oil, Hydrex MV22, shall be used. Cleaning of screw
shall never be made. Oil is delivered with the equipment.
Never try to repair this equipment without consulting Elpress. Personal safety may then be put out
of functionality.
9. Environmental aspects
Elpress are continuously working for a better environment and are certied according to ISO14001.
This equipment is designed for low power consumption. When not in use, main switch should be
turned off and mains power plug disconnected.
All material in the CS2500 crimp station equipment full ROHS demands and are recyclable.
Electrical equipment shall not be disposed together with normal waste. In accordance with
European Directive RoHS 2011/65/EU, 2012/19/EU waste of electric and electronic equipment
that reached the lifetime must be collected separately and decommissioned and sent to
appropriate environmentally responsible recycling facility, regional collection centre or nearest
Elpress representative.
The pump contains one litre of mineral oil which never should be thrown into nature.
TROUBLESHOOTING
Display or switches do not Check mains outlet power fuse and than
function cable and connector.
ERROR MESSAGES DISPLAY
Stop button stuck Signal cable not connected or damaged
Motor temp high Improve air ventilation around pump
Log memory full Use “Clear logs” in main menu
High motor current Contact Elpress
Time for service Time for preventive maintenance
No CAN comm Check cable and connector