NovoPress Comfort-Line ACO202XL User manual

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ACO202XL
EN Operating Manual
17795

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ACO202XL
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EN
EN English
Translation of the original Operating Manual
Contents
1Proper use ...............................................................................................................................................15
2Basic safety information...........................................................................................................................16
3Definition of terms....................................................................................................................................17
4Symbols on the device and information on the rating plate.....................................................................18
5Scope of supply .......................................................................................................................................19
6Technical data..........................................................................................................................................19
7Brief description of the press device........................................................................................................20
8Commissioning and operation .................................................................................................................22
9Cleaning, maintenance and repair...........................................................................................................24
10 Disposal ...................................................................................................................................................25
11 Warranty and guarantee ..........................................................................................................................26
12 EU Declaration of Conformity ..................................................................................................................27
1 Proper use
These press devices are intended exclusively for use with press jaws/adaptor jaws and press
collars manufactured by Novopress or approved by Novopress in agreement with the system
supplier. For further details, please contact the system supplier or Novopress direct.
The devices, press jaws and press collars are to be used exclusively for the purpose of press-
fitting pipes and fittings for which the relevant press jaws and press collars have been designed.
Any use beyond or different to that described shall be regarded as improper use.
All work with this tool that does not correspond to proper use may lead to damage to the press
device, the accessories or the pipes. Leaks and/or injury may result.
Novopress is not liable for damage resulting from
•the use of unsuitable press tools or press tools from other manufacturers, or
•applications that do not conform to proper use.
Proper use also includes compliance with the Operating Manual, adherence to the inspection
and maintenance conditions as well as compliance with the latest versions of all relevant safety
regulations.

ACO202XL
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EN 2 Basic safety information
The following pictograms are used to highlight sections of text. Please follow these instructions
and act with particular caution in these cases. Pass all health and safety instructions on to other
users and technicians.
WARNING!
This information indicates a potentially dangerous situation that could
result in serious injury or death.
CAUTION!
This information indicates a potentially dangerous situation that could
result in minor injuries and/or material damage.
Information!
This information is directly linked to the description of a function or an
operating sequence.
Please read this Operating Manual carefully.
The safety instructions it contains must be observed.
Compliance with local safety regulations is essential!
WARNING!
Read and follow all safety information and instructions!
Failure to comply with the safety information and instructions may result in
electric shock, fire and/or serious injuries.
Therefore:
– Keep all safety information and instructions for future use and only pass
the devices on to others together with the instructions.

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WARNING!
Risk of injury from ejected fragments
Incorrect or improper use or the use of worn or damaged press tools and press
devices carries a risk of injury from ejected fragments.
Therefore:
– Press tools and press devices may only be used by trained personnel.
– Compliance with the specified service work and service intervals is mandatory.
– Check the press tools and press devices for cracks and other signs of wear before
each use.
– Separate all press tools and press devices with material cracks or other signs of
wear immediately and do not use them any longer.
– Only use press tools and press devices that are in perfect technical condition.
– Following incorrect use, do not use the press tool and press device any longer and
have them inspected by an authorised workshop.
CAUTION!
Unskilled use may lead to a damaged or malfunctioning press tool and
press device.
Therefore:
– Replace worn press tools immediately and do not use them any longer.
– Use carrying cases for transport and storage and keep press tools and the press
device in a dry room.
– Have damage checked immediately by an authorised workshop.
– Comply with the safety instructions regarding the cleaning and anti-corrosion
agents used.
Information!
Consult the documents provided by the system supplier for handling and assembly
instructions for fittings and pipes.
3 Definition of terms
V volt Ah ampere hour Ø diameter
A ampere db(A) decibel (sound
pressure)
h hour
Hz hertz bar bar min minute
W watt °C degree Celsius s second
kW kilowatt kN kilonewton m/s² metre divided by
square second
(acceleration)
g gram a.c. alternating current
voltage
kg kilogram d.c. direct current voltage
Bj year of
manufacture
F force No. number

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EN 4 Symbols on the device and information on the rating
plate
Symbol Meaning
Warning of ejected fragments
Warning: Danger of crushing
Service sticker; indicates when the next service is
due.
Using the retaining pin
Information on the rating plate
1 Manufacturer logo
incl. address
6 Power consumption
2 Perm. uninterrupted
operating time
7 Country of manufacture
3 Part No. 8 Permissible voltage range in
volt
4 Serial No. 9 Nominal force
5 Year of manufacture
in mm.yy
10 Type designation of device
Explanation of possible pictograms on the rating plate
Legal certification China
CE conformity marking product safety in
Europe
Verification marking Canada
and USA Protection class II (insulated housing)
Verification marking Russia Verification marking Australia
Read Operating Manual
WEEE Directive on environmentally
sound disposal of electrical and electronic
equipment waste

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5 Scope of supply
The scope of supply for the standard equipment includes:
ACO202XL
Press device incl. operating manual Safety information
Battery charger incl. operating manual Service addresses
Battery 18 V DC Carrying case
Optional additional accessories (e.g. press jaws, adaptor jaws, press collars) may also be
included. Please contact the system supplier for information on the scope of supply.
6 Technical data
ACO202XL
Device: ACO202XL
Rated voltage/battery: 18 V DC (lithium-ion)/1.5 Ah/3.0 Ah
Power consumption 450 W
Nominal force: 32 kN
Height: 125 mm
Length: 515 mm with 1.5 Ah battery
535 mm with 3.0 Ah battery
Width: 80 mm
Net weight: 3.85 kg (without battery)
Compression range: Plastic: up to Ø 110 mm
Metal: up to Ø 108 mm / 4‘‘
Max. noise level: 87.5 db(A) 1)
Noise pressure level at user's ear: 76.5 db(A) 1)
Vibration value: <2.5 m/s² 2)
Type of protection: IP20
Temperature range during operation: -10 °C to +50 °C
1) Measurement uncertainty 3 db(A) 2) Measurement uncertainty 1.5 m/s²
The stated vibration emission value was measured using a standard test procedure and can be
employed for the purpose of comparison with another device.
The stated vibration emission value can also be used to obtain an initial estimate of
interruptions during intermittent operation.
Caution: The vibration emission value may differ from the stated value while the device is
actually in use, depending upon the manner in which the device is used. It may be necessary to
establish safety measures to protect operating personnel, depending on the actual conditions of
use (intermittent operation).

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EN Battery charger
For information on the function and operation of the battery charger and the rechargeable
batteries, please consult the battery charger operating instructions.
7 Brief description of the press device
7.1 Automatic press cycle (Fig. 1)
The device features an automatic press cycle. This ensures that the pressing operation is
always completed. For safety reasons, the automatic press cycle only switches on when the
pressing operation has started, i.e. when the fitting starts to be shaped.
After the automatic press cycle has been triggered, the green LED (2) goes out and the
pressing operation runs automatically. The pressing operation can then only be stopped by
pressing and holding the release button (4). After the pressing operation has been completed,
the motor automatically switches off and the green LED lights up again.
If the start button (1) is released before the automatic press cycle begins, the piston in the press
device moves back to its starting position. The pressing operation will not have been completed.
The pressing operation must be triggered again.
7.2 Release button (Fig. 1)
The pressing operation can be stopped at any time by pressing and holding the release button
(4). The piston in the press device then returns to its starting position.
7.3 Slidable finger guard (Fig. 1)
The press device is equipped with a slidable finger guard (6) as the press jaws differ in length.
Slide the finger guard forwards until you hear it click in as soon as you insert shorter press jaws.
7.4 Rotatable head (Fig. 1)
The device is equipped with a rotatable head. The head can be rotated through 180°. It is only
possible to adjust the head before the pressing operation. The head cannot be rotated while the
pressing operation is being performed.
7.5 Stroke limit (Fig. 1)
The press device features a stroke limit. When using shorter press jaws the stroke limit helps
save time.
The stroke limit can be switched on and off using an indexing bolt (7) as follows:
•Press the start button (1) with the stroke limit being actuated. Immediately:
•Pull out the indexing bolt (7) and rotate through 90°.
•Allow the indexing bolt (7) to lock into the groove.
Press the start button (1) with the stroke limit being actuated. The indexing bolt can then be
pulled out.

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7.6 Battery
Information!
The batteries are not charged at the factory.
Therefore:
– Charge the batteries before using for the first time.
Information!
Limited temperature range for charging and storing the batteries.
Therefore:
– It is imperative that the operating instructions for the battery charger are complied
with.
7.6.1 Removing the battery (Fig. 2)
Push in (1) the two release buttons (A) and then remove the battery (2).
7.6.2 Inserting the battery (Fig. 3)
Slide the battery into the device as illustrated until it clicks into place.
7.6.3 Battery charge indicator (Fig. 2)
The battery charge is displayed when button (B) is pressed. The number of LEDs lit up denotes
the battery charge. One flashing LED indicates a maximum power reserve of 10 %. The battery
must be charged soon.
If the battery is inserted in the press device while the battery charge is being checked, the last
pressing operation must have been completed at least 1 minute prior to this. Otherwise the
display will be inaccurate.
7.7 ACO202XL and battery
Information!
The ACO202XL press device must only be operated with 18 V lithium-ion
rechargeable batteries. The 18 V battery must only be used in the
appropriate press devices.
Behaviour of the press device after extended periods out of use or when changing the
battery:
If the press device is out of use for approx. 30 minutes or the battery is reinserted, it switches
off. No LED is lit up any longer. Press the start button (1) briefly to start the press device.
Behaviour of the press device when the battery is empty:
When a pressing operation begins, a check is made to determine whether the battery charge is
sufficient to complete the pressing operation. If this is not the case the device does not start.
The green LED (2) flashes.
If the green LED (2) flashes following a pressing operation, the pressing operation was still
carried out correctly. The battery must be recharged prior to the next pressing operation.

ACO202XL
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EN 8 Commissioning and operation
8.1 Preparing the ACO202XL
CAUTION!
Fingers risk being crushed if the device is operated without a press
jaw/adaptor jaw (Fig. 4)
If no press jaw/adaptor jaw is fitted, fingers could be placed in the at-risk zone.
Fingers could be crushed when the device is started.
Therefore:
– Do not operate the device without the press jaws.
– Keep your fingers away from the at-risk zone.
CAUTION!
Fingers risk being crushed if the device is operated with the finger
guard incorrectly adjusted (Fig. 8)
If the finger guard has not been slid forwards when shorter press jaws are fitted,
fingers could be placed in the at-risk zone. Fingers could be crushed when the device
is started.
Therefore:
– Do not operate the device without having slid the finger guard forwards if shorter
press jaws have been inserted (Fig. 9).
– Keep your fingers away from the at-risk zone.
CAUTION!
Not locking the retaining pin (3) fully can cause damage to the device.
(Fig. 5 to 7)
If the retaining pin is not fully inserted and locked, the cylinder can break during the
pressing operation.
Therefore:
– Press in retaining pin as far as it will go and turn 180° to the rear.
Information!
The press device is not suitable for continuous operation. Following 30
minutes of continuous operation, a short break of at least 15 minutes
must be taken to allow the device to cool down.
•Insert and lock the press jaw/adaptor jaw in the press device as shown in Figs. 5 to 7.

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8.2 Meaning of the LED display
LED display Status/cause Measure
Green LED off. The device is switched
off.
Briefly press the start button (see section
7.7).
Green LED lights up. Ready for operation.
Green LED off
(pressing operation
in progress).
Automatic press cycle is
on, device ends the
pressing operation
automatically.
Green LED flashes. Insufficient battery
charge.
Charge or replace battery.
Red LED (3) flashes. Device not within the
temperature range.
The device only works within a
temperature range from -10 to +50 °C. If
the red LED is flashing, the device must
be moved into a warmer or colder area.
The device can be warmed to operating
temperature by means of dry runs.
Red LED lit up. Device fault Press the start button. If this is
unsuccessful, the press device is
defective.
Send the device to a specialist workshop.
NOTE:
The pressing operation may not have
been completed; please check and repeat
if required.
Red and green LED
flash alternately.
Service interval
reached.
Take the press device to be serviced.
8.3 Performing the pressing operation
CAUTION!
Danger of crushing!
There is a risk that fingers and hands will be crushed.
Therefore:
– Keep body parts and foreign objects away from the press jaws during the pressing
operation.
– Do not hold the jaw levers with your hands during the pressing operation.

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CAUTION!
Keep fingers away from the at-risk zone if no press jaw/adaptor jaw is
fitted (Fig. 4)
Fingers risk being crushed.
Therefore:
– Do not operate the device without the press jaws.
– Keep your fingers away from the at-risk zone.
Information!
Always comply with the operating instructions for the press tools.
1. Check whether the nominal width of the press fitting matches the nominal width of the
press jaw/press collar.
2. Comply with the system manufacturer's instructions when fitting the press jaw/press collar
(Fig. 10)
When using a press collar - Fit the adaptor jaw to the press collar as described in the
press collar manufacturer's instructions.
Information!
Make sure that the press jaw is fully closed when the pressing operation
is complete (Fig. 11)
Information!
Ensure there is no gap between the segments of the press collar when
the pressing operation is complete.
3. To start the process, press the start button (1).
4. When the pressing operation has been completed
•if using a press collar: first detach the adaptor jaw from the press collar, then
•detach the press jaw/press collar from the press fitting (Fig. 12).
9 Cleaning, maintenance and repair
CAUTION!
Risk of injury during cleaning or repair work from inadvertently pressing
the On switch.
Therefore:
– Comply with the safety instructions and always remove the battery before
performing cleaning, maintenance or repair work.

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Service addresses
You can find the addresses of authorised specialist workshops on the “Service addresses”
sheet provided or at www.novopress.de.
Service intervals
Service and repair work may only be carried out by Novopress or the authorised Novopress
specialist workshops.
Information!
The next service deadline is indicated on the press device.
This service must be performed at least every 2 years or at the latest when the LED
display indicates that a service is due (see Section 8.2 Meaning of the LED display).
Routine inspection (before use, at the start of the working day) and when soiled
(Fig. 13 + 14)
Check for visible damage, material cracks and other signs of wear. If defects are found, do not
use the device and have it repaired.
Six-monthly inspection
Have the device inspected by a qualified electrician or a Novopress workshop.
Annual inspection
Have the press device inspected and serviced at Novopress or a Novopress workshop.
10 Disposal
CAUTION!
Groundwater hazard
The device contains hydraulic fluid.
Hydraulic fluids pose a hazard to groundwater. Uncontrolled drainage or improper
disposal is punishable by law.
Therefore:
– Dispose of the device in an environmentally responsible manner.
The instructions in the operating instructions provided with the battery charger must be
complied with when disposing of rechargeable batteries and the charger.
Novopress recommends that disposal be carried out by authorised specialist companies.
This product conforms to the requirements in EU Directive 2002/95/EC RoHS (Restriction of
Hazardous Substances).
In accordance with EU Directive 2002/96/EC WEEE (Waste Electrical and Electronic
Equipment), manufacturers of electrical devices are obliged to take back old devices and to
dispose of them in an appropriate manner.
The product must not be disposed of as normal household waste. Old devices must be returned
directly to Novopress for proper disposal.

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11 Warranty and guarantee
Novopress provides a full legal guarantee of 24 months for its press devices and tools. The
warranty period always commences on the date of delivery, which must be proven by means of
the sales documentation in case of doubt.
Within the warranty period, the warranty covers the repair of any damage or malfunction of
these tools that is attributable to material or production faults.
The following are not covered by the warranty
•Damage caused by improper use or inadequate servicing.
•Damage caused by the use of products not approved by Novopress for use with its
press devices.
•Damage caused by pressing unsuitable pipes or fittings.
For wearing parts, the Novopress warranty lasts only for the intended service life.
Service work and parts provided in response to warranty claims do not have to be paid for.
However, all shipping costs shall be borne by the user.
Claims can only be accepted if the device is delivered to Novopress or a Novopress workshop
in an assembled state.
Repair or replacement of the device under warranty does not result in an extension of the
warranty period. Repair or replacement can only be performed using as-new components, the
function of which corresponds to that of the old components. All parts that are faulty and
consequently replaced are the property of the manufacturer.
Extended warranty on expiry of the statutory warranty period
We voluntarily provide the following extended warranties beyond the statutory warranty period.
1-year extended warranty for new press devices, adaptor jaws and press collars
Novopress provides an extended warranty of one year for all new press devices, adaptor jaws
and press collars that have been serviced at least every 12 months by Novopress or by an
authorised Novopress workshop. There is a charge for this service work. For details of costs,
please contact Novopress or an authorised Novopress workshop.
3-year extended warranty for new press jaws
Novopress provides an extended warranty of three years for all new press jaws,
interchangeable jaws and press inserts that have been serviced at least every 12 months by
Novopress or by an authorised Novopress workshop. There is a charge for this service work.
For details of costs, please contact Novopress or an authorised Novopress workshop.
Repair warranty
Novopress provides the following repair and spare parts warranty beyond the warranty period
for new products that undergo repair after this period:
•6-month warranty for replaced spare parts.
•12-month warranty for replaced assemblies.
•12-month warranty for replaced press devices.

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12 EU Declaration of Conformity
in accordance with EU Directives 2004/108/EC; 2006/42/EC
We hereby declare that the design, construction and version sold by us of the
ACO202XL press devices
conforms to the relevant, fundamental health and safety requirements. If the relevant product is
not used in accordance with proper use or in the event of a modification to the product not
agreed by us, this declaration shall become null and void.
Applicable standards:
EN 55014-1; EN 55014-2; EN 60745-1; EN ISO 14121-1; EN ISO 12100-1; EN ISO 12100-2
Novopress GmbH & Co KG _______________________
Scharnhorststr. 1 Sven Meyer
41460 Neuss Managing Director
Germany 05.06.2012

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Repairs / Service
Scharnhorststr. 1 Postfach 101163
41460 Neuss 41411 Neuss
Germany Germany
Tel.: [phone]
Fax: [phone]
www.novopress.de
E-mail: [email protected]