NovoPress HP 300 User manual

01000\B04eng
0295
Operating Instructions
for
CRIMPING TOOL
HP 300

01000\B04eng
0295
TABLE OF CONTENTS
CE Conformity Attestation
Safety Regulations
Operative Range.........................................................................................1
Technical Specifications..............................................................................1
Operation....................................................................................................1
Use.............................................................................................................2
Crimping.....................................................................................................3
Changing Tools...........................................................................................5
Maintenance ...............................................................................................6
Minimum Quantity of Pressing Operations
to be carried out per Cable Termination ......................................................7

01000\B04eng
0295
1
HYDRAULIC CRIMPING TOOL HP-300, Order No.: 1000
Operative Range
Cable lugs and pressing connectors for copper and aluminium conductors can be pressed with the
HP 300.
Pressing Range for V-pressings:
Copper conductors from 50 to 300 mm2
Aluminium conductors from 35 to 240 mm2
For the minimum quantity of the V-pressings to be carried out per cable termination, see the table on
page 7.
The lower tool is to be changed as follows for aluminium conductors:
from 35 to 50 mm² Lower tool, No. 1018
from 70 to 240 mm² Lower tool, No. 1015
Pressing Range for Hexagon Pressings:
Copper conductors from 35 to 240 mm²
Aluminium conductors from 25 to 185 mm²
For the minimum quantity of the hexagon pressings to be carried out per cable termination, see the
table on page 7.
The HP300 can be operated with the hydraulic unit HA 1-ES, Order No. 31070, or the foot pump
HA 1-FS, Order No. 2900.
Technical specifications
Diameter: 80 mm (3.8")
Length: 430 mm (17")
Weight: 4.55 kg (10 lb)
Operating pressure min.150 bar (2200 psi)
(measured on hydr. unit) max.160 bar (2346 psi)
Power: 98.5 kN (9.85 tonf)
Operation:
Crimping has three phases.
Phase 1 - quick idle stroke and supercharging
Phase 2 - slow crimping stroke
Phase 3 - hydraulic shut off after completion of crimping and the return stroke.
The three phases are carried out automatically.
The piston returns after the hand switch (H) has been released.
WARNING!
THE HP 300 IS A HAND TOOL AND SHOULD NOT BE USED AS A STATIONARY TOOL.

01000\B04eng
0295
2
Use
1. Connect the crimping tool to the HA 1 hydraulic unit by using the rapid-action coupling (S).
2. Rapid-action coupling
Coupling
Hold the coupling sleeve (KM) on to the sliding
sleeve (SH) and slide it on to the coupling plug
(KS).
De-coupling
Hold the coupling sleeve (KM) on to the sliding
sleeve (SH) and pull away from the coupling plug
(KS).
3. Connect the crimping tools to the hydraulic unit HA 1 using the connector (A).
Note!
The HP 300 can only be oprerated with the hand switch (H). The foot switch (F) is used only
for the EMERGENCY STOP function (see operating instructions HA 1 / HA 2).
4. Carry out a few idle strokes to remove air from the system.
The hydraulic unit should be on a higher level than the crimping tool during the operation.
5. The hand switch (H) is a swivelling switch and can be locked into any desired position.
Proceed as follows: - Slacken the set screw in the nut SW 36 (between hand switch (H)
and coupling plug)
- Tighten the nut SW 36.
- Tighten the set screw.
WARNING!
While hydraulic unit is connected, keep fingers out of crimping area (area between upper (12)
and lower tool (13)).
RISK OF INJURY!

01000\B04eng
0295
3
Crimping
Place the end of the cable with the terminal into the crimping head.
Then:
A: If the HA 1-ES
is used, press the hand switch (H) and keep pressed until the control valve shuts the machine
off. Then release the hand switch (H).
NOTE:
The piston must return completely before the next crimp is made.
OTHERWISE THE NEXT PRESSING WILL BE TOO DEEP!
B: If the HA1FS
is used, operate the pressure lever (4) of the pump until the piston stroke stops and the gauge
(1) constantly shows the maximum pressure.
By pressing the release lever (3) oil is released from the cylinder.
NOTE:
Keep the release lever pressed until the gauge shows Zero and the piston has returned to its
original position.
OTHERWISE THE NEXT PRESSING WILL BE TOO DEEP!
NOTE:
Only for V-pressings:
When crimping aluminium conductors, the sleeve may bend. This can be prevented if every other
crimp is made at 180° with respect to the first.
1
4
3

01000\B04eng
0295
4
NOTE!
−Crimping should not be interrupted before the hydraulic valve has automatically shut off.
Otherwise the crimp depth will not be sufficient.
−Only for V-pressings:
If more than one crimp is made in the same place, the cross-section will be too small.
−We can supply test pieces for checking the depth (Order No. 4104).
Pressing of Al conductor
−Roughen oxidized cable ends with abrasive paper before pressing.
−Use cable/pressing connectors filled with quartz containing heat-conductive grease or
lubricate the cable terminations with a suitable grease.
−Select the distance to the next pressing operations such that the tool is fully contacting a
nondeformed area.
Selected distance all right: identical pressing depth
Too close a distance: pressed too deep
6
5
5
6
Key:
5 = Lower tool
6 = Cable lug

01000\B04eng
0295
5
Changing Tools
Loosen the retaining screw (10) and threaded pin (11) until the upper tool (12) can be removed from
the crimping head or the lower tool (13) can be removed from the piston rod (15).
Insert the new tool and tighten the screws firmly.
NOTE:
When mounting a lower tool for hex. press moulding operations, care is to be taken that the side with
the centering bore (14) will ALWAYS point to the threaded pin (11).
F A U L T Y P R E S S M O U L D I N G IN CASE OF ANY NON-COMPLIANCE
WARNING!
UNCOUPLE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS BEFORE CARRYING
OUT MAINTENANCE WORK!

01000\B04eng
0295
6
Maintenance
If dirty: Clean upper and lower tool.
Clean entire crimping cylinder.
Every week: Check upper and lower tool for any damage.
Replace, if necessary.
Every month: Check marked areas for possible leakage and send in
HP300 for repair, if necessary.
Every 3 months: Load crimping head (1) into a vise. Place 30mm wrench
on coupling plug (KS) and fasten cylinder (2).
WARNING!
UNCOUPLE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS BEFORE CARRYING
OUT MAINTENANCE WORK!
1
2
KS

01000\B04eng
0295
7
Pressing Cylinder HP 300
Minimum Quantity of the Pressing Operations to be carried out per Cable
Termination
V-pressings Hexagon Pressings as per
DIN 48083, Part 4
Cross
section
mm²
Cu Al Tool Ident No. Cu Al
< 80
N/mm² > 80 N/mm² Cu Al Cable Lug DIN 46235
Connector
DIN 46267
Part 1
Cable Lug
DIN 46329
Connector
DIN 46267
Part 2
10 ——— 6— — —
16 ——— 8 10 — —
25 ———10 12 —2
35 —2* 2* 12 14 1 3
50 1 2* 2* 14 16 2 3
70 1 3** 2** 16 18 2 3
95 1 3** 2** 18 22 2 4
120 2*** 4** 3** 20 22 2 4
150 2*** 4** 3** 22 25 2 5
185 2 4** 3** 25 28 3 5
240 2 4** 3** 28 32 3 —
300 2 ——————
*Lower tool No. 1018 for an aluminium cross section of 35 to 50 mm²
** Lower tool No. 1015 for an aluminium cross section of 70 to 240 mm²
*** Crimp DIN 46234 cable lugs only once.

Repairs / Service
Scharnhorststraße 1 Postfach 101163
D-41460 Neuss D-41411 Neuss
Telex 8 518 015
Tel. 02131 / 288-0
Telefax 02131 / 28855