OP BC 800/W ES SP User manual

OP S.r.l. 25131 BRESCIA - Via Serpente, 97 - Tel. [phone] - Fax [phone]
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USE AND MAINTENANCE MANUAL
BC 800/W ES SP

OP S.r.l. 25131 BRESCIA - Via Serpente, 97 - Tel. [phone] - Fax [phone]
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Copyright © 2016, OP
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Richieste di autorizzazioni, ulteriori copie di questo manuale o di informazioni tecniche sullo stesso,
devono essere indirizzate a:
OP s.r.l.
Via del Serpente, 97
25131 Brescia (BS)
Italia
[email protected]
www.op-srl.it
[phone]
Copyright © 2016, OP
All rights reserved.
Any unauthorised distribution, modification, translation or reproduction of this document or part of it is
forbidden unless receiving a written authorization from OP, with the exception of the following actions:
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OP reserves the right to make any modification or improvement to this document at any time, without
any previous notice.
Any authorization requests, further copies of this manual or relative technical information must be sent
to:
OP s.r.l.
Via del Serpente, 97
25131 Brescia (BS)
Italia
[email protected]
www.op-srl.it
[phone]

OP S.r.l. 25131 BRESCIA - Via Serpente, 97 - Tel. [phone] - Fax [phone]
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CONTENTS
•Declaration of conformity .............................................................................pag.5
•Safety regulations ........................................................................................pag.7
•Use of manual .............................................................................................pag.9
•Characteristics of the bench..........................................................................pag.10
•Handling and transport.................................................................................pag.12
•Lighting.......................................................................................................pag.12
•Plates and warning signs ..............................................................................pag.13
•Preventive maintenance ...............................................................................pag.13
•Routine Maintenance....................................................................................pag.14
•Spare parts..................................................................................................pag.14
•Control panel (pict. 1) ..................................................................................pag.15
•Preliminary checks and start-up ....................................................................pag.17
•Instructions for use (testing cycle) ................................................................pag.18
•Manifolds diagram (pict. 2)...........................................................................pag.19
•Connection diagram (pict. 3) ........................................................................pag.20
•Starting procedure .......................................................................................pag.21
•Cycle setting screen (pict.4)……………..…………………………………………..…..........pag.22
•Setting prescriptions (pict.5)………….……………………………….……………………..…..pag.29
•Storing the name of a pipe with all its respective test parameters………............pag.30
•Alarms (pict.6)…..…………………………………………….……………………..……............pag.32
•Settings (pict.7)…..……………………………………………………………….……...........….pag.34
•Print out of test report (pict.8) ………..………..………….………………….………........pag.38
•Switching off procedure ………...…………………………………………….……….............pag.39
•Troubleshooting...........................................................................................pag.40
•Air-hydraulic system.....................................................................................pag.41
•Electric system diagrams ..............................................................................pag.43
•Characteristics and safety data sheet of CUT-MAX H 05 .................................pag.66
•Polycarbonate data sheet .............................................................................pag.79

OP S.r.l. 25131 BRESCIA - Via Serpente, 97 - Tel. [phone] - Fax [phone]
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OP S.r.l. 25131 BRESCIA - Via Serpente, 97 - Tel. [phone] - Fax [phone]
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DICHIARAZIONE DI CONFORMITA’
DECLARATION OF CONFORMITY
2006/42/CE Nuova direttiva per la marcatura CE
( Abrogazione della direttiva 98/37/CE ex 89/392/CEE )
2006/42/CE New machinery directive for the CE
( Abrogation of Directives 98/37/CE ex 89/392/CEE )
NOI –WE OP S.r.l.
( Nome del fabbricante o del suo mandatario stabilito nella comunità - Supplier’s name)
Via del Serpente, 97 - 25131 BRESCIA
( Indirizzo completo - Address)
DICHIARIAMO SOTTO LA NOSTRA ESCLUSIVA RESPONSABILITA’ CHE IL PRODOTTO :
DECLARE UNDER OUR SOLE RESPONSIBILITY THAT THE PRODUCT :
BC800/WES
( nome - name, tipo - type, modello - model / n° di serie - serial number )
• La macchina non rientra nell’elenco contenuto nell’All. IV della Direttiva Macchine 2006/42/CE
The machine is not part of the list included in Ann. IV Machinery Directive 2006/42/CE.
• La macchina rispetta i requisiti essenziali di sicurezza indicati sulla Direttiva Macchine e successive modifiche:
The machine follows the safety requirements included in the Machinery Directive and its following modifications:
2006/42/CE DIRETTIVA MACCHINE
2006/42/EC MACHINE DIRECTIVE
2014/35/EU DIRETTIVA BASSA TENSIONE
2014/35/UE LOW VOLTAGE DIRECTIVE (LVD)
2014/30/EU DIRETTIVA COMPATIBILITA’ ELETTROMAGNETICA
2014/30/UE ELECTROMAGNETIC COMPATIBILITY (EMC)
• La macchina è provvista di marcatura CE
The machine is provided with EC mark
• Norme di riferimento applicate:
Applied references normative:
UNI EN ISO 12100:2010 CEI EN 60204-1
UNI EN ISO 12100:2010 CEI EN 60204-1
IL LEGALE RAPPRESENTANTE
THE LEGAL REPRESENTATIVE
Brescia, lì DANIELE PIANTONI
(nome e firma o timbratura della persona autorizzata)
(name and signature or equivalent marking of authorized person)
Dichiariamo che il Fascicolo Tecnico è costituito presso OP s.r.l Via del Serpente 97, 25131 BRESCIA
We declare that the technical documentation is established c/o OP s.r.l. Via del serpente 97, 25131 BRESCIA
La persona responsabile del fascicolo tecnico è il Sig. Massimo Ziliani Resp. Uffi cio Tecnico.
Our technical manager, Mr. Massimo Ziliani, is responsible for the technical dossier

OP S.r.l. 25131 BRESCIA - Via Serpente, 97 - Tel. [phone] - Fax [phone]
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OP S.r.l. 25131 BRESCIA - Via Serpente, 97 - Tel. [phone] - Fax [phone]
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SAFETY REGULATIONS
1. Always make sure that the machine is placed on a stable, safe surface and that it is not
causing vibrations that, in addition to being bothersome and useless, may cause
malfunctions.
2. Leave enough room in the work area.
3. The manufacturer is not liable for any damage caused by negligence.
4. Never use the equipment before reading the user manual and
understanding its contents
5. Caution! If improperly used, the equipment may be dangerous and may
cause injury to parts of the body, which must never come within the range
of moving parts.
6. Test operations are safe provided the regulations given below are complied
with.
7. Caution! It is absolutely essential that all work is carried out by one operator only
8. Never attempt to use the machine above the permitted working pressures; this might
cause serious danger to the operator .
9. This manual must be given to the operator and kept. The proprietor of the equipment is
responsible for it. Ensure that the operator is aware of his responsibilities.
10. Never remove or tamper with guards.
11. Before connecting to the power supply, make sure that there is adequate protection
upstream of the connection against overloads and short circuits (it is advisable to have
protection against excessive undervoltage as well).
12. Check that the supply voltage and frequency correspond to the rating on the machine's
rating plate.
13. Use only cables, plugs and extension cables that comply with CEI standards; keep the
power cable far from the work zone.
14. Make sure that hoses are always tested in safety conditions
15. Always remove the plug from the socket , before performing any work on the machine.
Operations of maintenance, as well as repairs, should be performed by specialised
personnel.

OP S.r.l. 25131 BRESCIA - Via Serpente, 97 - Tel. [phone] - Fax [phone]
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16. Use adequate personal protection (gloves, appropriate clothing,
etc.).
17. Keep the supply cable far from the work zone.
18. Always turn off the machine while maintaining it
19. Use of the Crimping machine is permitted only to skilled adult staff (a training course is
recommended for those who have never used the equipment).
20. During work, always follow all instructions given by the labels on the machine
21. Our equipment is designed with the technical safety features required; customers are
advised to strictly comply with the instructions given in this manual.
22. Original spare parts must be used in order to maintain the original characteristics and
the validity of the certification.
23. Once you have finished maintenance operations always re-mount the eventually
removed protections before turning on the machine.
24. Use limit:
•The machine cannot be used in explosive settings.
•The machine cannot be used in outdoor settings.
•Do not leave the machinery exposed to environmental agents which do not meet into
protection level (IP55) of the installed components.
25. The machine presents residual risks derived from incorrect use: strictly follow the
directions defined in the use and maintenance manual.
26. Do not insert animals or body parts in the operating area or in moving parts.
27. Do not insert plastic, glass or other kinds of objects in the operating area or in moving
parts.
28. Do not make repairs yourself; contact the manufacturer.

OP S.r.l. 25131 BRESCIA - Via Serpente, 97 - Tel. [phone] - Fax [phone]
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READ INSTRUCTIONS FOR USE AND MAINTENANCE
USE OF THE MANUAL:
It is important to keep this manual near the machine where it can be consulted. The manual is
provided to give the user a general knowledge of the machine and instructions for its use and
maintenance as needed for satisfactory operation.
The manual, as required by the regulations in effect, is an integral part of the machine and
must accompany it for its entire lifetime. The instructions and warnings must be read with care
for safety reasons prior to installation and use. Do not make any changes in the manual, for
any reason, without the prior written authorisation of the manufacturer or authorised
distributor.
CAUTION:
The operator is personally responsible for respect, not only by himself but also by any others
who may be exposed to the hazards presented by the machine, of all safety rules.
Before performing any operation with the machine, therefore, read this manual carefully.
It describes the procedures for safe use. Keep the manual for future consultation.
The machine is constructed in a workmanlike manner. Its duration and reliability will be all the
more effective if the machine is used correctly and given regular maintenance.
The testing fluid “CUT-MAX H 05”, supplied by O+P, wholly respect the community norms on
the chemical products safety;
The disposal of the materials must be carried out in compliance with the laws in force.

OP S.r.l. 25131 BRESCIA - Via Serpente, 97 - Tel. [phone] - Fax [phone]
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CHARACTERISTICS OF THE BC 800/W ES TEST BENCH
MACHINE WITH NO HYDRAULIC FLUID OR SOLVENT
•Add hydraulic fluid with this characteristics:
- viscosity at 40°C : 40 mm²/s
- suggested contamination class : ISO 4406 20/18/15
- fluid quantity : as shown in table below
•For the characteristics of the solvent see the attached document
(CHARACTERISTICS AND SAFETY DATA SHEET OF CUT-MAX H
05)
This test bench has been designed to perform high-pressure tests on hydraulic hoses.
It is equipped with user-friendly control panel, and can be ordered customised with special
instruments. Special care has been dedicated to the safety devices; tests can only be carried
out with the testing chamber closed, and it cannot be accessed as long as there are
pressurised components in the circuit.
Filling stage: a low pressure pump fills the hydraulis hose so as to eliminate all the air, after
which the outlet is blocked and the pressure in the circuit begins to rise until it reaches the set
value, holding the circuit at that pressure with minimum consumption.
The test bench is designed and produced in respect of the essential health and safety rules set
forth by the machine directive. In particular, since the operator comes directly into contact with
the machine we have done our best to:
•Eliminate sharp edges and points.
•See that the controls, though ensuring prompt, safe and univocal action, do not involve any
additional hazards: actions can only occur by voluntary use of the controls.
SAFETY DEVICES: The test bench mounts some safety device to prevent the entrance in the
chamber during the test operations.
Furthermore there is an emergency stop system to halt immediately the test, if necessary.
Besides a pressure regulator on the pneumatic circuit maintains the multiplier action into the
desired pressure range.