Operating Instructions for CRIMPING TOOL HP 95

Operating Instructions for CRIMPING TOOL HP 95
Operating Instructions
for
CRIMPING TOOL
16518
HP 95
03000\B05eng
0695
TABLE OF CONTENTS
CE Conformity Attestation
Safety Regulations
Operative Range ............................................................................................ 1
Technical Specifications................................................................................. 1
Operation........................................................................................................ 1
Use ................................................................................................................. 2
Crimping ......................................................................................................... 3
Maintenance ................................................................................................... 5
03000\B05eng
0695
CE - KONFORMITÄTSERKLÄRUNG
entsprechend EG-Richtlinie
98/37/EG
Novopress GmbH & Co KG
Scharnhorststr. 1
D-41460 Neuss
Verpresszylinder
HP 95
Ser-nr:
1.
..............................................
EN 294, EN 349, EN ISO 12100-1, EN ISO 12100-2
Hiermit erklären wir, daß die nachfolgend bezeichnete
Maschine aufgrund Ihrer Konzipierung und Bauart sowie
der von uns in Verkehr gebrachten Ausführung den
einschlägigen grundlegenden Sicherheits- und
Gesundheitsanforderungen entspricht.
Bei einer nicht bestimmungsgemäßen Anwendung der
Maschine oder bei einer nicht mit uns abgestimmten
Änderung der Maschine verliert diese Erklärung ihre
Gültigkeit.
We hereby declare that with respect to its design and
construction the machine stated below and the
model thereof which we have brought into circulation
conform with the applicable basic requirements on
health and safety.
Any use of the machine other than that for which it is
intended and any modification made thereto without
our consent shall render this declaration null and
void.
Die Konformitätserklärung ist nur gültig, wenn die
Maschine mit dem Hydraulikaggregat HA1ES oder HA3
betrieben wird.
This declaration of conformity shall only be valid if
the machine is operated with hydraulic unit HA1ES
or HA3.
Angewandte harmonisierte Normen, insbesondere:
Applied harmonized standards, in particular:
siehe Punkt 1
see Item 1 above
Nous déclarons par la présente que par sa conception
et son type ainsi que par l'exécution que nous avons
mise sur le marché, la machine désignée ci-après
répond aux exigences de sécurité et de prévention de la
santé applicables.
La présente déclaration perd sa validité si la machine
n'est pas utilisée conformément aux instructions ou
dans le cas d'une modification de la machine à laquelle
nous n'avons pas donné notre accord.
Hiermede verklaren wij, dat de hierna genoemde
machine op grond van haar constructie en type
alsmede de door ons in de handel gebrachte
uitvoering aan de desbetreffende fundamentele
eisen ten aanzien van de veiligheid en de
gezondheid voldoet.
Wordt de machine niet overeenkomstig haar
bestemming gebruikt of worden hieraan niet met ons
overeengekomen wijzigingen aangebracht, dan
verliest deze verklaring haar geldigheid.
La déclaration de conformité n'est valable que si la
machine est utilisée avec le groupe hydraulique HA1ES
ou HA3.
De conformiteitsverklaring is slechts geldig, indien
de machine met het hydraulische aggregaat HA1ES
of HA3 wordt aangedreven.
Normes harmonisées utilisées, en particulier :
Toegepaste geharmoniseerde normen, in het
bijzonder:
voir point 1
zie punt 1
Datum / Herstellerunterschrift:
Angaben zum Unterzeichner:
Formular-Nr: Norm\001NP037.doc
01.08.05
Geschäftsführer
s:\03000\ce\03000c05.doc
Con la presente declaramos que la máquina
denominada a continuación, por su concepto y por su
construcción, cumple con los requisitos
fundamentales de seguridad y sanidad en vigor. Lo
dicho aplica exclusivamente a la máquina en su
versión original, tal y cual ha sido fabricada por
nosotros.
El empleo inapropiado de la misma, así como
cualquier modificación ejecutada sin nuestra
intervención hace que esta declaración pierda su
validez.
Para que esta declaración de conformidad tenga
validez, la máquina se habrá de operar
categóricamente con un grupo hidráulico tipo HA1ES
o tipo HA3.
Si dichiara che la macchina appresso descritta
soddisfa, per concetto, tipo e modello messo in
commercio, le esigenze di base di sicurezza e sanità
relative a tali apparecchiature.
In caso di uso non appropriato della macchina o in
caso di una sua modifica eseguita senza il nostro
accordo, questa dichiarazione non ha più effetto.
La dichiarazione di conformità è valida solo se la
macchina è messa in funzione con il gruppo idraulico
HA1ES o HA3.
Norme armonizzate applicate, in particolare
vedi punto 1
Normas armonizadas aplicadas, en particular:
véase bajo el punto 1
Härmed försäkrar vi att nedan nämnd maskin
motsvarar de tillämpliga och principiella säkerhetsoch hälsoföreskrifterna både gällande koncipieringen
och konstruktionen samt gällande den av oss sålda
modellen.
Används denna maskin inte enligt anvisningarna eller
förändras maskinen på ett sätt som vi inte har
godkänt, gäller denna försäkran ej.
Täten vakuutamme, että seuraavassa nimetty kone
vastaa suunnittelunsa, rakenteensa sekä meidän
taholtamme liikenteeseen päästetyn mallinsa puolesta
asiaankuuluvia perustavaa laatua olevia turvallisuus- ja
terveysmääräyksiä.
Jos konetta ei käytetä määräysten mukaisesti tai jos
koneeseen tehdään muutos ilman meidän
suostumustamme ei tämä selvitys enää päde.
Konformitetsförsäkran gäller endast om maskinen
drivs med hydraulikaggregat HA1ES eller HA3.
Standardinmukaisuusselvitys on vain silloin voimassa,
kun konetta käytetään hydraulisen yksikön HA1ES tai
HA3 kanssa.
Tillämpade harmoniserade normer, i synnerhet:
Käytetyt harmonisoidut standardit, varsinkin:
se punkt 1
katso Kohta 1
Herved erklærer vi at den i det følgende betegnede
maskinen på grunn av dens konsipering og
konstruksjon samt utførelsen som vi har brakt på
markedet tilsvarer de respektive grunnleggende krav
til sikkerhet og helse.
Ved en bruk av maskinen som ikke er formålstjenlig
eller ved en endring av maskinen som ikke er avstemt
med oss mister denne erklæringen sin gyldighet.
Konformitetserklæringen er bare gyldig hvis maskinen
drives med hydraulikkaggregatet HA1ES eller HA3.
Benyttede harmoniserte standarder, særlig:
se punkt 1
Declaramos pelo presente, que a máquina a seguir
designada, na sua planificação e construção, assim
como no modelo por nós comercializado, obedece às
respectivas exigências fundamentais de segurança e
de saúde.
A presente declaração perde a validade em caso de
uso impróprio da máquina ou em caso de modificações
na máquina, que não tenham sido acordadas
antecipadamente connosco.
A declaração de conformidade é válida somente
quando a máquina é accionada com o agregado
hidráulico HA1ES ou HA3.
Normas harmonizadas aplicadas, especialmente:
vide parágrafo 1
Formular-Nr: Norm\001NP037.doc
s:\03000\ce\03000c05.doc
GENERAL SAFETY REGULATIONS
Read all safety regulations and instructions!
1.
Keep the place of work clean.
Disorderly work-places and work-benches invite accidents.
Ensure that lighting is good.
2.
Keep children away.
Do not allow unauthorised persons to touch the device or the cable.
Keep unauthorised persons away from your place of work.
3.
Wear suitable working clothing.
Do not wear any wide clothes nor jewellery - they may get caught up in moving parts.
When working in the open it is recommended that you wear rubber gloves and non-slip
footwear. Wear a hair- net if you have long hair.
4.
Always be alert.
Only use a device after having been instructed in its operation.
Concentrate on your work. Proceed sensibly.
Do not use the device when you are distracted.
5.
Do not lean too far forward. Avoid abnormal stance.
Make sure that you have a secure standing position, and maintain balance at all times.
6.
Leave safety devices where they belong.
7.
Hand tools may not be installed as fixtures.
8.
Repair and maintenance.
Have repairs and maintenance work carried out in an authorised NOVOPRESS specialist
workshop.
Only use original and identical NOVOPRESS spare parts.
We reject all responsibility and liability for work carried out by third- party personnel.
009NP004.DOC
SAFETY INSTRUCTIONS FOR HYDRAULIC EQUIPMENT
1.
Please read the operating instructions.
Acquaint yourself with the hydraulic equipment.
2.
Provide the equipment with the necessary care.
Always keep the equipment in operational condition.
Cleanness is an essential requirement for good and safe working.
3.
Switch off the electric power supply to the hydraulic equipment,
• when the equipment is not in use
• when maintenance work is to be carried out.
4.
Avoid unintentional switching - on.
Keep hands and feet away from the switch when the equipment is not being used.
5.
Do not use the equipment in a manner in contravention of the instructions.
Never carry the equipment by the pipe or pull on the pipe.
Protect the piping from heat, oil, sharp edges and high levels of weight strain.
6.
Use only piping, fittings and accessories wich have been designed for the operating pressure of
the hydraulic unit.
BURSTING PRESSURE OR TEST PRESSURE IS NOT OPERATING PRESSURE!
Avoid squashing or bending of the piping.
Piping must not be painted over.
7.
Replace the hydraulic piping
• when cracks, squashed or bent points are to be seen
• when blistering is established
• when hydraulic fluid escapes
• when pipe fittings are damaged
• when discolouration is established on the outer layer,
e.g. due to the influence of solvents.
8.
The hydraulic fluid used in the system is kerosene-based.
This requires particular care and attention.
• Avoid continuous contact with the skin
• ensure that the hydraulic fluid does not get into the eyes or mouth.
Hydraulic pipes have to be replaced after 5 years of usage, despite of the circumstance that no
damages should be remarkable.
9.
The equipment must not be operated, if it has leaks and there is a danger of hydraulic fluid
coming into contact with persons, open fire, heating equipment, electric cabling, ground water,
foods and other substances which are intended for human consumption.
10. Hydraulic units with petrol engines
• must not be operated in closed rooms, due to the
DANGER OF INTOXICATION!
• do not pour in petrol while the motor is running or in the vicinity of open fire.
DANGER OF EXPLOSION!
009NP006.DOC
1
HYDRAULIC CRIMPING TOOL HP 95, Order No.: 3000
Operative Range
WARNING!
THE HP 95 IS A HAND TOOL AND SHOULD NOT BE USED AS A STATIONARY TOOL.
The HP 95 can crimp cable lugs and connectors for copper conductors with a cross-section ranging in
size from 10 to 95 mm2 (8 AWG to 4/0.)
Minimum Quantity of the Pressing Operations:
Cross Section
mm²
10
16
25
35
50
70
95
Min.Qty. of
Pressings
1
1
1
1
1
1
1
The HP95 can be operated with the hydraulic unit HA 1-ES, Order No. 31070, or the foot pump HA 1FS, Order No. 2900.
Technical specifications
Diameter:
Length:
Weight:
Operating pressure
(measured on hydr. unit)
Power:
65
350
3.0
min. 150
max. 160
59.5
mm
(2.6")
mm
(13.8")
kg
(6.6 lb)
bar (2200 psi)
bar (2346 psi)
kN
(5.95 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.
03000\B05eng
0695
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).
WARNING!
While hydraulic unit is connected, keep fingers out of crimping area (area between upper (10)
and lower tool (11)).
RISK OF INJURY!
3.
Connect the crimping tools to the hydraulic unit HA 1 using the connector (A).
Note!
The HP 95 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 this 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.
03000\B05eng
0695
3
Crimping
Place the end of the cable with the terminal into the crimping head.
Then:
A:
HA1ES
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!
1
4
3
B:
HA1FS
Operate the pressure lever (4) 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 crimping 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!
03000\B05eng
0695
4
NOTE!
− Crimping should not be interrupted before the hydraulic valve has automatically shut off.
Otherwise the crimp depth will not be sufficient.
− 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. 4103).
− 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
5
6
Too close a distance:
pressed too deep
5
6
03000\B05eng
0695
Key:
5 = Lower tool
6 = Cable plug
5
Maintenance
WARNING!
UNCOUPLE HYDRAULIC UNIT OR DISCONNECT IT FROM THE MAINS
BEFORE CARRYING OUT MAINTENANCE WORK!
If dirty:
Every week:
Every month:
Every 3 months:
Clean upper and lower tool.
Clean entire crimping cylinder.
Check upper and lower tool for any damage. Replace, if
necessary.
Check marked areas for possible leakage and send in
HP 95 for repair, if necessary.
Load crimping head (1) into a vise. Place 30mm wrench
on coupling plug (KS) and fasten cylinder (2).
KS
2
1
03000\B05eng
0695
Repairs / Service
Scharnhorststraße 1
D-41460 Neuss
Postfach
101163
D-41411 Neuss
Tel.
02131 / 288-0
Telefax 02131 / 28855
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