NovoPress HSBL Series User manual

Operating Instructions
for the
SYSTEM TOOLS
HSBL
02420\B05eng
0696

Contents
Page
CE Conformity Attestation
Safety regulations
Working cylinder 1
HSBL - Cable cutters, Order No. 1081 3
HSBL - Cutting tool 120, Order No. 2350 4
HSBL - Cutting tool 160, Order No. 7020 7
HSBL - Plying iron with angle indicator, Order No. 1179 10
HSBL - Punching tool 120, Order No. 1118 14
HSBL - Punching tool 160, Order No. 7050 19

1
HSBL SERIES HYDRAULIC SYSTEM TOOLS
HSBL Hydraulic Cylinder, Order No. 2420
Operative Range
This cylinder has been designed to work with a pressure of max. 150 bar (2200 psi) and is used with
HSBL-Series tools.
The cylinder (1) is fastened with a bolt (2) to the tool being used. The bolts (2) are situated at the end of
the cylinder spars.
The cylinder can be driven by the NOVOPRESS hydraulic unit; we recommend the HA 1 hydraulic
system with an electric motor.
Technical specifications
Length 620 mm ( 24.4")
Width 140 mm (5.5")
Height 365 mm (14.4")
Stroke length 120 mm (4.7")
Weight 21 kg (46 lb)
Max. working pressure 150 bar (2200 psi)
Power 150 kN (15 tonf)
Operation
Connect the control conduit (1) of the hydraulic unit to the plug on the device (HSBL cylinder).
Note:
The hydraulic unit can only be operated if the plug is connected.
The cylinder is attached to the HA hydraulic system with a rapid-action coupling (S)

2
Rapid-action coupling
Coupling
Hold the coupling sleeve (KM) at the sliding
sleeve (SH) and slide onto the coupling plug (KS).
Uncoupling
Hold the coupling sleeve (KM) at the sliding
sleeve (SH) and pull off of the coupling plug (KS).
To deaerate the cylinder carry out a few idle strokes. The hydraulic unit must be on a higher level than
the cylinder during this procedure.
ATTENTION ! WHEN ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING
OUT MAINTENANCE WORK, UNCOUPLE THE HYDRAULIC UNIT OR DI-
SCONNECT IT FROM THE MAINS!
Maintenance
ATTENTION !
UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS BEFORE CARRYING
OUT MAINTENANCE WORK.
Every week: – Clean and grease piston rod.
– Clean and grease fixing bolts.
Every month: Check cylinder for leakage. If necessary, send in for repair.

3
HSBL CABLE CUTTERS, Order No. 1081
Operative range
Copper and aluminium cables of up to a diameter of 120 mm (4 3/4") can be cut with these cutters.
Technical specifications:
Width: 140 mm (5.5")
Length with working cylinder 650 mm (25.6")
Height 350 mm (13,8")
Weight 3 kg (6.6 lb)
ATTENTION ! BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR
CARRYING OUT MAINTENANCE WORK, UNCOUPLE THE HYDRAULIC
UNIT OR DISCONNECT IT FROM THE MAINS!
Attaching the Tools:
Place the HSBL cylinder (1) on the stand
(5). Slide the pressure plate (Order No.
1098) (11) on to the piston rod (3) and
tighten the fastening screw.
Slide the cutting edge (Order No. 1097)
(13) between the cylinder spars (4) and
fasten using the bolts (2).
Operation
The mouth can be opened by pulling out a
fixing bolt (2) and by tilting out the edge
(13). This makes it easier to put in longer
cable pieces.
The HA hydraulic unit is switched on and
off by using the foot switch on the unit.
Accessories
A specially ground edge is available for cutting reinforced cables (Order No. 4121)
Maintenance
ATTENTION !
UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS BEFORE CARRYING
OUT MAINTENANCE WORK.
In case of wear or damage: Replace or regrind cutting edge.
Regrinding
The cutting edge can be reground up to a max. of 4 mm. When the edge is reground,
care should be taken that the edge remains parallel to the edge’s back.
The cutting edge and the pressure piece of the cable cutters are subject to wear and
tear. When changing the cutting edge, the pressure piece should also be changed.

4
HSBL - 120 Cutting Tool, Order No. 2350
Operative range
You can cut the following with this tool:
– copper and aluminium rails of up to 120 x 10 mm (4 3/4" x 3/8" ) with a max. strength of 250 N/mm2
(36 250 psi).
– steel rails of up to 120 x 6 mm (4 3/4" x 1/4") with a max. strength of 370 N/mm2(53 650 psi).
Waste consists of a piece as wide as the cutting edge.
Technical specifications
Width: without vice 210 mm ( 8.3")
with vice 340 mm (13.4")
Depth: without vice 200 mm (8")
with vice 225 mm (8.8")
Height with working cylinder 785 mm (31")
Weight: without vice 12,0 kg (26.4 lb)
vice 3,0 kg (6.6 lb)
Operation
There are four holes in the bases of the HSBL cutting tool 120. Use these holes to fasten the tool to a
work bench.
The working cylinder (1), Order No. 2420, should be attached to the cutting tool as follows:
1. Place the protective device with the cutter blade (10) into the stand (13).
2. Pull out the fixing bolts (2) on the cylinder (1) as far as possible.
3. Slide the cylinder (1) with the spars (4) on to the cutting tool’s spars. Align the holes on the cutting
tool with the fixing bolts (2) on the working cylinder (1).
4. Slide the fixing bolts (2) in as far as possible.
5. Push the base plate (11) with the knurled screws (12) onto the piston rod (3).
6. Fix the base plate (11) to the piston rod (3) using the knurled screws (12). The points of the knurled
screws (12) must enter the groove in the piston rod (3).
7. Connect the working cylinder (1) and the HA hydraulic unit using the rapid-action coupling and the plug
(see page 2).
To deaerate the cylinder, carry out a few idle strokes. The hydraulic unit should be on a higher level than
the working cylinder when deaerating.

5
Cutting:
1. Lift the protective device (10).
2. Place the rail into the cutting tool and align.
Note:
The distance between the outer edge of the cutting strip (14) and that of the cutting
edge (15) is 25 mm.
3. Release the protective device (10).
4. Press the foot switch on the hydraulic unit and keep pressed until cutting is completed.
ATTENTION ! BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR
CARRYING OUT MAINTENANCE WORK, UNCOUPLE THE HYDRAULIC
UNIT OR DISCONNECT IT FROM THE MAINS!
Accessories
Vice (100), Order No. 6950
The vice is fastened to the cutting tool with 2 screws.
It is used for holding and aligning the rail at right angles to
the cutting edge.

6
Maintenance
ATTENTION !
BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING OUT MAINTE-
NANCE WORK, UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS !
After every 10 cutting operations: Remove any shreds, chips etc. from the cutting edge (6) and cutting
strips (4).
Every week: Clean complete cutting tool.
Any worn or damaged cutting edges or strips must be replaced immediately.
Changing the cutting edge
1. Pull the cutting edge (6) together with the base
plate (7) and the protection device (8) out of the
stand (1) (see fig. 2).
2. Unscrew the screws (8.9) from the protective device
(8) and remove items 8.2 and 8.3.
3. Pull the base plate out of the protection device (8)
together with the cutting edge.
4. Knock out the clamping sleeve (12) with a mandrel
with a diameter of 5 mm.
5. Change the cutting edge.
6. Assemble the base plate and the new cutting edge.
7. Slip the protective device (8) over the base plate (7)
and onto the cutting edge (6).
8. Use the screws (8.9) to attach items 8.2 and 8.3 to
the protective device.
Changing the cutting strips
1. Dismantle the cutting edge (14) guides.
2. Unscrew the bolts (10); change the cutting strips (4).
14
10 4
1

7
HSBL - 160 Cutting Tool, Order No. 7020
Operative range
You can cut the following with this tool:
– copper and aluminium rails of up to 160 x 12 mm (6" x 1/2" )with a strength of max. 250 N/mm2
(36 250 psi).
– steel rails of up to 160 x 6 mm (6" x 1/4") with a strength of max. 370 N/mm2(53 650 psi).
Waste consists of a piece the width of the cutting edge.
Technical specifications:
Width: without vice 255 mm (10")
with vice 375 mm (14.8")
Depth: without length stop 310 mm (12.2")
with length stop 1440 mm (56.7")
Height with working cylinder 940 mm (37")
Weight without vice
and length stop 21.5 kg (47.3 lb)
vice 3,0 kg (6.6 lb)
length stop 6.0 kg (13.2 lb)
Operation
There are four holes in the bases of the HSBL cutting tool 160. Use these holes to fasten the tool to a
work bench.
The working cylinder (1), Order No. 2420,
should be attached to the cutting tool (10) as
follows:
1. Pull out the fixing bolts (2) on the work-
ing cylinder (1) as far as possible.
2. Slide the working cylinder (1) with the
spars (4) onto the cutting tool (10).
Align the holes on the cutting tool (10)
with the fixing bolts (2) at the working
cylinder (1).
3. Slide the fixing bolts (2) in as far as
possible.
4. Slide the base plate (11) onto the piston
rod (5) of the working cylinder (1). The
tip of the holding screw (12) must be
able to fit into the groove on the piston
rod (5).
5. Tighten the holding screw (12).
6. Connect the working cylinder (1) and
the HA hydraulic unit using the rapid-
action coupling and the plug (see
page 2). To deaerate the cylinder,
carry out a few idle strokes. The
hydraulic unit should be on a higher
level than the working cylinder when
deaerating.

8
Cutting:
1. Place the rail into the cutting tool and align.
2. Press the foot switch on the hydraulic unit and keep pressed until cutting is completed.
Return Stroke Limitation:
The return stroke can be adjusted continuously.
Before setting the return stroke, the cutting edge must
have been lowered.
1.1 Lower the cutting edge and keep the foot
switch depressed.
1.2 Turn in the handwheel (14) of the return stroke
screw (15) against the stop in the direction of
the arrow.
1.3 Release the foot switch.
1.4 Turn out the handwheel (14) until the cutting
edge is in the desired position.
Attention!
The cutting edge must not be forced down
with the return stroke screw (15).
ATTENTION ! BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING
OUT MAINTENANCE WORK, UNCOUPLE THE HYDRAULIC UNIT OR DIS-
CONNECT IT FROM THE MAINS!
Accessories:
1). Vice (16), Order No. 7030
Description on page 5
2). Length stop (17), Order No. 6990
The length stop (17) is fastened to the
cutting tool by two screws.
Any sizes between 20 and 1600 mm
can be set with the slide (18).

9
Maintenance
ATTENTION ! BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYING
OUT MAINTENANCE WORK, UNCOUPLE THE HYDRAULIC UNIT OR DI-
SCONNECT IT FROM THE MAINS !
After every 10 cutting operations: Remove any shreds, chips etc. from the cutting edge (2) and cutting
strips (3).
Every week: Clean complete cutting tool.
Any worn or damaged cutting edges or strips must be replaced immediately.

10
Changing the cutting rails
1. Unscrew the four bolts (21)
2. Remove parts Nos. 5 and 6 also the complete protective device.
3. Remove the cutting edge guides (8).
4. Unscrew the bolts (23) and change the cutting strips (3).
Changing the protective window
1. Unscrew the No. 21 bolts.
2. Remove Nos. 5 and 6 and the complete protective device.
3. Pull the guard plates (14) out of the protective device.
4. Loosen the No. 25 bolts on one side.
5. Change the window.
Changing the cutting edges
1. Remove the working cylinder.
2. Take out the guard plate (14).
3. Pull up the cutting edge holder with the edge
(29 and 2) and tilt out.
4. Unscrew the bolt (24) and change the edge (2).

11

12
HSBL - Plying Iron and Angle Indicator, Order No. 1179
Operative range
This plying iron can bend:
copper and aluminium conductor rails of up to 120 x 10 mm (4 3/4" x 3/8") with a strength of up to 250
N/mm2(36 250 psi). The maximum bending angle is 100°(degrees).
Technical specifications:
Width 210 mm (8.3")
Depth 200 mm (7.8")
Working cylinder length 625 mm (24.6")
Weight 4.4 kg (9.7 lb)
Smallest flange length (inside size) at a rail thickness of 10 mm (3/8):
At a 90° angle 40 mm (1.6")
At U, flange height 80 mm (3.1")
At Z at 90° flange height 80 mm (3.1")
Operation
1. Connect the HSBL cylinder (1) to the hydraulic unit using the rapid-action coupling and the plug
(see page 2).
2. Carry out a few idle strokes to deaerate it. The hydraulic unit should be on a higher level than the
working cylinder when deaerating.
Installing the tool
1. Place the HSBL cylinder (1) on the stand (5). Put the U-shaped bottom tool (11) on to the piston rod
(3) and screw in the 2 holding screws (12) by hand.
2. Place the angle indicator (13) with the fitting piece between the two cylinder spars (4) and slide in
as far as possible.
3. Slide the top tool (14) between the cylinder spars (4) so that the chosen bending radius – 8 or
16 mm – faces towards the bottom tool.
4. Fasten the top tool (14) with the fixing bolts (11).
5. Push the angle indicator (13) back onto the top tool (14) as far as possible and tighten with the
screw (3.3).

13
6. Aligning the bottom tool
A) At right angles to the angle indicator
Align the U-shaped bottom tool (11) at right
angles to the angle indicator (13) with the help
of a back square (20).
Screw the threaded pins (15 and 17) onto the
cylinder spars (4) so that they slide along the
whole length of the cylinder spars (4) without
any play. To test this, let the piston (3) run its
whole length backwards and forwards.
Counter the threaded pins (15 and 17) with the
nut (16).
Tighten the screws (12).

14
B) By running the machine with a piece of con-
ductor rail, sized 120 x 10 (4 3/4" x 3/8)",
placed in it.
1. Turn back the nuts (16) on the threaded
pins (15 and 17) by about 3 revolutions.
2. Unsrew the threaded pins (15 and 17)
so that there is at least 2 mm of play be-
tween the cylinder spars (4) and the
threaded pins.
3. Place a piece of conductor rail (21), e.g
120 x 10 – 200 (4 3/4" x 3/8" – 8") into the
plying iron.
4. Bend until the safety valve in the basic
unit shuts the machine off.
Keep the foot switch pressed down and
tighten the screws (12).
Now switch off and let the piston (3)
return.
5. Tighten the threaded pins (15 and 17) so
that they slide along the whole length of
the cylinder spars (4) without any play.
To test this let the piston (3) run its whole
length forwards and backwards.
Then counter the threaded pins (15 and
17) with the nuts (16).
Bending without the hydraulic stop
1. Place the conductor rail on the angle indicator and hold straight.
2. Activate the foot switch and keep pressed until the required angle has been reached.
Red scale for 8 mm (5/16") radius
Black scale for 16 mm (5/8") radius
3. Release the foot switch and let the piston return.
4. Check the angle on the angle indicator.
If the angle is not sufficient then bend further by tapping the switch lightly.
Note:
The top tool can be tilted out by removing one of the fixing bolts on the cylinder spar. This makes
removing long pieces of rail easier.
ATTENTION ! BEFORE ATTACHING AND REMOVING THE SYSTEM TOOLS OR CARRYIN
OUT MAINTENANCE WORK, UNCOUPLE THE HYDRAULIC UNIT OR DIS-
CONNECT IT FROM THE MAINS!

15
Accessories
HAV-2 Hydraulic Stop, Order No. 1627
Operative range
A hydraulic stop (HAV-2) can be supplied as an accessory to the HSBL plying iron. The HAV-2 hydraulic
stop limits the forward and backward movements of the HSBL cylinder. The HAV-2 is of great use in
mass production. Once the angle has been set, it can be used over and over again.
Mounting the hydraulic stop
1. The cylinder must be upright with the coupling plug facing upwards. Screw the coupling plug out of
the HSBL cylinder (2) (see page 1).
2. Fix the valve’s body (20) to the cylinder with the banjo bolt (21).
3. Screw the coupling plug (22) into the valve’s body (20).
4. Remove a nut (16) from the threaded pin (17) (of the bottom tool).
Place the fastening square (24) onto the threaded pin (17) and replace the nut (16) and tighten.
5. Loosen the banjo bolt (21) a little. Then align the valve’s body (20) so that the holes for the sliding
selector rod (25) in the fastening square (24) are in a line with those of the valve’s body (20).
Then tighten the banjo bolt (21) again.
Setting the forward movement limit
1. Place the conductor rail on the angle indicator and hold straight.
2. Screw the adjusting nut (23) to a distance of approximately 20 mm (3/4") from the shut-off valve.
Press the foot switch and keep pressed until the HAV-2 shuts off.
3. Turn the adjusting nut (23) back a little and then activate the foot switch again. Keep pressed until
the HAV-2 shuts off. Then measure the angle on the bent rail. Repeat this procedure until the re-
quired angle has been achieved.
After this, counter the adjusting nut (23) with the star grip. (26)
Setting the backward movement limit
The backward movement is set by moving and tightening the control cam (27).
The movement should be set so that it is easy to remove the angled piece of material.

16
Maintenance
ATTENTION !
UNCOUPLE THE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS BEFORE
CARRYING OUT MAINTENANCE WORK.
After each use: Remove any dirt, chips etc. from the HSBL plying iron and the HA2-V.
Every week: Clean HSBL plying iron.
HA2-V
After every 3 months: Grease thread of the HA2-V.

17
HSBL - 120 Punch, Order No. 1118
Operative range
Holes can be punched into the following with this puncher:
– copper and aluminium rails of up to 120 x 13 mm (43/4" x 1/2") with a strength of up to 250 N/mm2
(36 250 psi). The largest hole diameter is 18 mm (at a 10 mm rail thickness 21 mm).
– steel rails of up to 120 x 6 mm (4 3/4" x 1/4") with a strength of up to 370 N/mm2(53 650 psi).
The largest hole size is 21 mm diameter.
The punch can be operated with all NOVOPRESS hydraulic units (except with the HA 2). We recom-
mend that the HA 1 hydraulic unit equipped with an electric motor be used.
Technical specifications
Width 260 mm (10.2")
Depth: 200 mm (7.8")
Working cylinder height: 860 mm (33.8")
Weight: 15 kg (33 lb)
Clear width of the stand: 200 mm (7.8")
Operation:
There are four holes in the bases of the HSBL punching tool 120. Use these holes to fasten the tool to a
work bench.
Slide the working cylinder (1), Order No.
2420, with the cylinder spars (4) onto the
punch’s press plate (10) and fasten with the
fixing bolts (2). Connect the cylinder to the
hydraulic unit using the rapid-action coupling
and the plug (see page 2).
To deaerate carry out a few idle runs. The
hydraulic unit should be on a higher level
than the working cylinder when deaerating.
ATTENTION !
BEFORE ATTACHING AND REMOVING
THE SYSTEM TOOLS OR CARRYING
OUT MAINTENANCE WORK, UNCOUPLE
THE HYDRAULIC UNIT OR DISCON-
NECT IT FROM THE MAINS!

18
Application rules for tools
–The diameter of the hole to be punched must not be less than the thickness of the material.
If this rule is not followed, the tool will be damaged.
–It is not permitted to increase the size of a hole by consequential punching, since this results in
damage of the tool. Furthermore, the minimum distance from one hole to the next and the distan-
ce from a hole to the edge of the bar must be at least the diameter of the tool.
–Exchange the tools at due time.
Excessive wear of the tool might result in the upper tool getting stuck in the rail. Sepration of the
tools from the rail by excessive force can lead to tools damage.
– When not in use, clean and oil the tools. The tools’ life is increased if they are lightly oiled from
time to time.
Tool storage: Do not place the upper tool into the lower tool. The cutting edges can be damaged.
Top tool
1. Place the top tool (15) with the shaft into the
hole in the column. The counter-sunk hole in
the tool’s shaft should be facing the locking
screw (16).
2. Screw in the locking screw (16) by hand and
test whether the point of the locking screw
(16) is in the counter-sunk hole of the shaft by
turning the top cool (15).
3. Tighten the locking screw (16).
The top tool has a fixed back center and
cannot be eground.
Bottom tool
1. Mounting
Note:
The receptacle for the lower tool must be free
from dirt, chips etc.
Place the bottom tool (17) into the hole on the
press plate (10) and fasten with the locking screw (18).
2. Dismantling
a) Unscrew the screw (18) from the bottom tool
b) Push out the bottom tool (17) with the ejector
The bottom tool can be reground by
approximately 2 mm.
Warning: When mounting tools with a profile, the top (15) and bottom tools (17) are not to be staggered.