Panduit CT-2500 Installation Manual

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PA25346A01

BATTERY OPERATED CRIMPING TOOL

OPERATION MANUAL

CT-2500 TOOL SHOWN WITH CT-2525CH CRIMPING HEAD

• CT-2500 and CT-2500/E Battery Operated Crimping Tools, to be used with optional Crimp Heads: CT-2525CH, CT-2550CH, CT-2570CH and CT-2500CH (sold separately).

CT-2500 and CT-2500/E

Rev. 04 4-2014

techsupport@panduit.com

www.panduit.com/emea

emeatoolservicecenter

information in this manual prior to operating or servicing this tool.

Email:

EU Website:

EU Email:

@panduit.com

WARNING

Read and understand all of the instructions and safety

Retain this manual for future reference.

Technical Support

1-888-506-5400, Ext. 83255

www.panduit.com

Panduit Europe • EMEA Service Center

Almelo, Netherlands

Tel: +31 546 580 452 • Fax: +31 546 580 441

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Purpose of this Manual

OPERATION MANUAL CT-2500 and CT-2500/E

TABLE OF CONTENTS

INTRODUCTION ................................................................................................................................ 2

TOOL SPECIFICATIONS ................................................................................................................... 2

OPTIONAL ACCESSORIES ............................................................................................................... 3

CT-2500 and CT-2500/E TOOLS ....................................................................................................... 3

PRECAUTIONS AND GENERAL GUIDELINES ................................................................................ 3

IMPORTANT FEATURES OF THE CT-2500 and CT-2500/E

BATTERY OPERATED CRIMPING TOOLS....................................................................................... 6

INSTALLATION

Crimping Head Installation ............................................................................................................... 7

TOOL OPERATION ............................................................................................................................ 7

MAINTENANCE ................................................................................................................................. 8

Storage and Transport ........................................................................................................................ 8

USE OF THE BATTERY CARTRIDGE AND CHARGI NG UNIT ......................................................... 9

Terminations per Battery Charge ...................................................................................................... 10

Battery Charger ................................................................................................................................. 10

TROUBLESHOOTING ...................................................................................................................... 10

DISCONTINUATION OF USE / DISPOSAL...................................................................................... 10

• This manual is intended to familiarize the user with the safe operation and maintenance procedures for this tool.

• Use this tool exclusively for its determined use.

• This instruction manual should be available during the entire life span of the tool.

• The operator has to ensure the availability of this instruction manual to the

end user; and to make sure, that the user has read and understood this instruction manual.

• Mounting and assembly of connecting material with the help of this tool must only be performed by specially trained personnel.

• Replacement manuals ar e avai l abl e upo n req uest .

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CT-2500 or CT-2500/E

CT-2500BC

CT-2500CHR

CT-2500CHR/E

This manual will guide you step-by-step in the set-up, operation, and maintenance of your

OPERATION MANUAL CT-2500 and CT-2500/E

INTRODUCTION

The CT-2500 and CT-2500/E Battery Operated Crimping Tools can crimp #10 AWG thru #22 AWG Panduit terminals, disconnects and splices. The Battery Operated Crimping Tool develops up to 1.7 tons (15kN) of compressive force.

The information contained in this literature is based on our experience to date and is believed to be reliable. It is intended as a guide for use by persons having technical skill at their own discretion and risk. We do not guarantee favorable results or assume any liability in connection with its use. Dimensions contained herein are for reference purposes only. For specific dimensional requirements consult the factory. This publication is not to be taken as a license to operate under, or a recommendation to infringe any existing patents. This supersedes and voids all previous literature, etc.

Safety

Safety is essential in the use and maintenance of Panduit tools and equipment. This manual and any markings on the tool provide information for avoiding hazards and unsafe practices related to the use or service of this tool. Observe all of the safety information provided.

CT-2500 or CT-2500/E Tool. Proper maintenance is vital to the continued trouble-free

operation of the tool. If you have a problem not covered in the manual, call:

1-(888) 506-5400, Ext. 83255

Ask for one of our Tool Service Technicians

TOOL SPECIFICATIONS

Battery Operated Crimping Tools

Battery Cartridge

Battery Charger

Battery Charger for EU

Weight (including battery) 3.3 lbs. (1,5 kg) Dimensions: Crimping Time 2 seconds

Crimping Force 1.7 tons (15 kN) Stroke .35 (9 mm) Sound Level: 75 dB (A) at 39.3” (1 meter) Ambient Temperature -4° F to +104° F (-20°C to +40°C) Battery Type: Nickel Cadmium (Ni-Cd) Output: 9.6 V Capacity: 1.3 Ah

Charging time:

Output: 7.2 V - 14.4 Volt DC Input: 120 Volt AC, 50~60Hz Output: 7,2 V – 14,4 Volt DC Input: 230 Volt AC, 50~60Hz

11-3/4” L x 2-3/8” H x 3-1/8” W – with battery [298 L x 60 H x 80 W] mm

Approx. 40 minutes (15 min. with fast charger)

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CT-2525CH or

Crimping head or die insert for installing the following Panduit products: CT-2550CH or

Crimping head or die insert for installing the following Panduit products:

CT-2570CH or

Crimping head or die insert for installing most of the following Panduit CT-2500CH

Crimping head (frame only); to be used with crimping die inserts CD-525, Replacement Batteries and Battery Chargers are sold separately.

CT-2500BC

Replacement Battery Cartridge

CT-2500CHR

Replacement Battery Charger

CT-2500CHR/E

Replacement Battery Charger for Europe

This symbol is used to call your attention to hazards or unsafe practices which could result in an

DANGER

OPTIONAL ACCESSORIES

OPERATION MANUAL CT-2500 and CT-2500/E

CD-525

CD-550

CD-570

#26 – #22 AWG insulated terminals and splices, #22 – #10 AWG fully insulated disconnects, insulated parallel splices; and specific #22 – #14 AWG barrel insulated disconnects.

#22 – #10 AWG insulated terminals and splices; and specific insulated disconnects.

products: #22 – #10 AWG and 0,5 – 6,0 mm2 non-insulated terminals, disconnects; and specific non-insulated splices.

CD-550 or CD-570.

CT-2500 and CT-2500/E TOOLS

The CT-2500 and CT-2500/E Tools include:

• 1 – Battery Operated Crimping Tool (with battery cartridge)

• 1 – Spare Battery Cartridge

• 1 – Battery Charger

• 1 – Tool Case

PRECAUTIONS AND GENERAL GUIDELIN ES

IMPORTANT SAFETY INFORMATION

SAFETY ALERT SYMBOL

injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard.

Immediate hazards which, if not avoided, WILL result in severe injury or death.

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Read and understand all of the instructions and safety inf ormation in this manual

The operator has to ensure the

Electric Shock Hazard:

Wear eye protection when operating or servicing this tool.

• Do not use solvents or flammable liquids to clean the crimping tool. Solvents or flammable liquids could ignite and cause serious injury or property

Keep hands away from the crimping tool head when crimping.

OPERATION MANUAL CT-2500 and CT-2500/E

WARNING

Hazards which, if not avoided, COULD result in severe injury or death.

CAUTION

Hazards or unsafe practices which, if not avoided, MAY result in injury or property damage.

WARNING

before operating or servicing this tool. availability of this instruction manual to the end user; and t o make sure, that the user has read and understood this instruction manual.

Failure to observe this warning can result in severe injury or death.

WARNING

This tool is not insulated. When using t his unit on or near energized electrical lines, use proper personal protective equipment.

Failure to observe this warning can result in severe injury or death.

WARNING

Failure to wear eye protection can result in serious eye injury from flying debris.

WARNING

damage.

• During the operation of electric motors, sparks can occur which might ignite highly flammable or explosive liquids and materials.

• Do not use tool in or near a highly flammable or explosive atmosphere and/or materials.

WARNING

Failure to observe this warning can result in severe injury or death.

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Do not dispose of batteries in a fire. They will vent fumes and may explode.

Inspect tool before use. A worn or damaged tool may result in breakage striking the operator or

• Do not place the tool in a vise. The crimping tool is designed for hand-held operation.

Do not allow anything to contact the battery terminals.

• Do not store the battery at more than 140°F (60°C). Damage to the battery can result. Do not perform any service or maintenance other than as described in this manual. Injury or damage

OPERATION MANUAL CT-2500 and CT-2500/E

WARNING

Failure to observe this warning can result in severe injury from harmful fumes or burns from flying debris.

WARNING

nearby personnel. Failure to observe this warning can result in severe injury, death or property damage.

CAUTION

• Protect the crimping tool from rain and moisture. Water will damage the crimping tool and battery. Crimping tools should not be operated in pouring rain or under water.

• Use this tool for the manufacturer’s intended purpose only. Failure to observe these precautions can result in injury or property damage.

CAUTION

• Do not immerse the batteries in liquid. Liquid may create a short circuit and damage the battery. If batteries are immersed, contact your service center for proper handling.

• Do not place the battery into a pocket, tool pouch, or tool box with conductive objects. Conductive objects may create a short circuit and damage the battery.

• Do not place a battery on moist ground or grass. Moisture may create a short circuit and damage the battery.

Failure to observe these precautions can result in injury or property damage.

CAUTION

• Do not use another manufacturer’s charger. Other manufacturers’ chargers may overcharge and damage the battery.

• Do not attempt to open the battery. It contains no user-serviceable parts.

Failure to observe these precautions can result in injury or property damage.

CAUTION

to the tool may result. Failure to observe this precaution can result in injury and property damage.

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Adapter for interchangeable crimping heads. Crimping head secured by locating pins.

Figure 1

RETRACT

LOW BATTERY

BATTERY

UNLOCKING DEVICE

TRIGGER

LOCATING PINS (2)

PISTON

CRIMPING HEAD

OPERATION MANUAL CT-2500 and CT-2500/E

IMPORTANT FEATURES OF THE CT-2500 and CT-2500/E BATTERY OPERATED CRIMPING TOOLS

• The hydraulic unit incorporates an automatic retraction which returns the piston into its starting position when the maximum force is reached.

• The unit is equipped with a special brake which stops the forward motion of the piston/dies when the trigger is released.

• To simplify operation and gain better access to tight corners and other difficult working areas, the crimping head may be rotated, by hand, 360° relative to the tool body.

• The tool is very lightweight and provides good handling through an ergonomic design.

CT-2500 TOOL

ADAPTER

SLIDE

INDICATOR

Description Function

Piston Advances dies during crimping cycle Crimping Head Adapter Retract Slide Bar to open the crimping dies in case of an error or emergency

Unlocking Device Switch for unlocking the battery Battery Rechargeable Ni-Cd batt er y, 9.6 V Low Battery Indicator LED flashes to indicate low battery Trigger Actuator to start the crimping cycle Locating Pins Pins to secure crimping head to crimping head adapter

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1. Rotate crimping head adapter fully -clockwise (see Figure 2).

2. Press retract slide to lower piston completely.

3. Pull out the pins for mounting a different change the crimping dies.

4. Before installing different crimping head,

Crimping using the CT-2525CH, CT-2550CH and CT-2500CH (equipped with Locator):

1. The Locator shall be used to assist in positioning the product

2. Position the product in the proper die position by matching the

3. Press the trigger until the crimping head jaws just touch the

4. Insert the wire.

5. Pull and hold the trigger until the tool has completed the

6. Remove the finished crimped product and wire combination.

OPERATION MANUAL CT-2500 and CT-2500/E

INSTALLATION

CRIMPING HEAD REMOVAL / INSTALLATION

crimping head on the adapter, or to

slide the crimping dies to the full open position. Lock the head with the locating pins (see Figure 3), paying attention that the pins are locked securely before starting.

ATTENTION:

The product to be crimped must be the type specified for the crimping head and die combination. See specific crimping head information on Page 3.

TOOL OPERATION

to be crimped (see Figure 3 above).

product color and the die position color code (see Figure 4).

terminal, holding the product securely.

operating cycle of crimping. The jaws will open automatically.

Crimping using the CT-2570CH:

1. Position the product in the proper die position by matching the size (wire gage).

2. Press the trigger until the crimping head jaws just touch the terminal, holding the product securely.

3. Insert the wire.

4. Pull and hold the trigger until the tool has completed the operating cycle of crimping. The jaws will open automatically.

5. Remove the finished crimped product and wire combination.

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Skin Injection Hazard:

death. If injured, seek medical help immediately to remove oil.

• Do not use solvents or flammable liquids to clean the crimping tool. Solvents

Monthly Maintenance

STORAGE AND TRANSPORT

1. Thoroughly clean all surfaces.

Always store the tool in its clean, dry carrying

dust.

2. Oil the locating pins.

Annually or After 10,000 Crimps

Return tool to Panduit Tool Division

ATTENTION:

The crimping process can be interrupted at any time by releasing the trigger. After having terminated the crimping process and prior to changing the heads,

remove battery to avoid unintended starts.

NOTE:

• By sliding the retract slide in the direction of the battery, the dies can be retracted in case of an error or emergency.

• The terminal can first be pre-clamped. This allows the operator to adjust the position of the terminal during the crimping cycle. To use this feature, push the trigger until the die contacts the terminal and then release the trigger. The terminal can now be re-positioned or even the wire can still be inserted into the terminal.

• The crimping cycle is terminated when the dies are completely closed and the maximum crimping force is reached, which is indicated by the auto retraction of the piston.

OPERATION MANUAL CT-2500 and CT-2500/E

MAINTENANCE

Daily Maintenance

Befor e Use:

1. Inspect dies for wear or damage such as cracks, gouges, or chips.

2. Inspect the tool for damage or leaks. If damage is detected, contact PANDUIT Tool Division.

WARNING

• Do not use hands to check for leaks.

• High pressure oil easily punctures skin causing serious injury, gangrene, or

After Use:

1. Wipe all tool surfaces clean with a damp cloth and mild detergent.

WARNING

2. Place the tool in the carrying case. Store in a cool, dry place.

3. Charge the battery.

or flammable liquids could ignite and cause serious injury or property damage.

case when not in use, and during transport. The battery cartridge and the battery charging unit should be protected against humidity and

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Indicator Color

OPERATION MANUAL CT-2500 and CT-2500/E

USE OF THE BATTERY CARTRIDGE (CT-2500BC) AND CHARGING UNIT (CT-2500CHR AND CT-2500CHR/E

The charging unit is run with a nominal voltage of 120 V (CT-2500CHR), or (230 V for CT-2500CHR/E) and a frequency of 50-60 Hz. New batteries must be charged prior to use. To remove the battery, actuate the battery lock and pull it out of the tool. To charge the battery, connect the power plug of the charging unit with the power supply and slide the battery into the charging unit. The charging time is 40 minutes. The charging level of the battery cartridge can be checked by the right LED (multi-color) of the charging unit.

Left LED (Red) Right LED (Multi-color)

Red Charg ing unit rea d y to operate Battery defective

Charging unit out of order.

Red Flashing

Green – Charging cycle starts

Green Flashing –

Yellow

New or unused batteries whose nominal capacity is not sufficient.

–

Battery too hot or too cold. Remove battery. Safety components possibly defective.

Battery fully charged. Charging unit switches automatically into a maintaining mode. Battery can stay in charger for indefinite time w/o being damaged.

Battery at least 90% charged. Charging cycle can be terminated.

If the right LED does not light up, the circuit of the battery is disconnected or the battery is incorrectly polarized.

• If the nominal capacity of the battery is not achieved, e.g. at first charge, the battery is not necessarily faulty. Full capacity can be achieved after (3) charging/discharging cycles.

• When the speed of the tool decreases noticeably, the battery must be recharged.

ATTENTION:

Do Not recharge a partially discharged battery as a precaution.

• Charge the battery at room temperature between 50°F and 104°F (10°C and 40°C).

• If charging a battery which has recently been used, or which has been exposed to sun for a

long period of time (T>149°F / T>65°C), the right LED may flash red. In this case, remove battery out of charger. The charging procedure can be re-started after the battery has cooled down.

• Charging batteries at low temperatures – under 41°F ( 5°C) is not recommended. Increase battery temperature before starting the charging cycle.

• Do Not expose the charging unit to rain or snow.

• Do Not charge a battery in the vicinity of explosive materials and gases.

• No other batteries (e.g. dry batteries or car batter ies, etc.) are t o be used in the tool or in the

charging unit.

• Do Not use the cord to transport the charging unit, or to pull the plug out of a wall socket with force.

• Do Not insert foreign objects into the ducts of the charging unit. Pull the plug of the charging unit after charging. Do Not disassemble the charging unit or battery.

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Pull trigger and hold retract button approximately 10 seconds.

OPERATION MANUAL CT-2500 and CT-2500/E

ATTENTION:

Do Not place the battery in your pocket or in your toolbox if there are any conductive materials in it such as coins, keys, tools or other metallic parts.

TERMINATIONS PER BATTERY CHARGE

The estimated number of terminations before the battery will need to be recharged is dependent on variables such as the terminal size and type being terminated, ambient temperature, and time lapsed between termination cycles as well as other variables.

BATTERY CHARGER

Read the instructions supplied with the battery charger.

TROUBLESHOOTING

Before You Begin:

1. Make sure that the battery is charged. Recheck the battery after several minutes to make sure the battery is holding its charge.

2. Use a nonflammable contact cleaner or pencil eraser to clean the electrical contacts on the battery and crimping tool.

3. Reinstall the battery and check the tool again.

Problem Probable Cause Probable Remedy

Dirt, contaminants, etc., in ram area of tool.

Tool is inoperative.

Dies stop during operation.

Tool loses oil. Damaged internal seal.

Crimping tool battery contacts damager.

Tool components worn or damaged.

Oil level is low.

Air in hydraulic system.

Clean tool.

Reform contacts.

Return tool to

simultaneously. Hold for

Return tool to

Panduit Tool Division.

DISCONTINUATION OF USE / DISPOSAL

• The battery cartridge must be specially disposed of according environmental Battery Guidelines.

• For the disposal of the remaining parts, please reference environmental guidelines.

• Because of possible environmental damage, we recommend disposal of the tool by

professional companies.

ATTENTION: Do not dispose of the unit in your residential or commercial

waste, as it would be hazardous to the environment.

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