Restek 22358, 22359, 22360, 22362 Operation Manual

1

Electronic Cri m pin g To o l s

Models 22358

22359

22360
22362

Operation Guide

Notices

© Restek Corporation
Revision B

Printed in USA
Aug-2011

Restek Corporation
Bellafonte, PA
USA

Recycling

For recycling contact Restek or
your local Restek distributor.

Safety Notices

A CAUTION notice warns of a hazard. It calls
attention to an operating procedure, practice,
or the like that, if not correctly performed or
adhered to, could result in damage to the
product or loss of important data. Do not
proceed beyond a CAUTION notice until the
indicated conditions are fully understood and
met.

WARNING

A WARNING notice warns of a hazard. It
calls attention to an operating procedure,
practice, or the like that, if not correctly
performed or adhered to, could result in
personal injury or death. Do not proce ed
beyond a WARNING notice until the
indicated conditions are fully u n d erstood
and met.

Sound Pressure

Sound pressure L

pA = 70.1 dB(A)

2 Restek Corporation

Electronic Crimping Tools
Operations Guide

Contents

Warnings, Intended Use, Limits 4
Description and Setup 5
Operation 5
Storage and Shipping 9
Fault Conditions 9
Maintenance/Repair 10

This operation manual applies to the following products:

Model Number

11mm Electronic Crimper 22358
20mm Electronic Crimper 22359
11mm Electronic Decapper 22360
20mm Electronic Decapper 22361

Related Parts Item Number

6.4 Volt Lithium Ion Battery 22362

Electronic Crimping Tools 3

Warnings

Wear safety glasses when crimping or decapping!
The crimper or decapper jaws can pinch severely.
Never insert fingers into the crimper or decapper.
Use only the 7.5v DC Power Supply supplied with the crimper for battery charging.
Use only the specified 6.4 volt replacement battery pack, part number 22362
Use of other batteries may cause fire during charging or use

Special Battery Warnings:

Risk of burns; battery may explode or catch fire if mishandled.
Do not disassemble or dispose of in fire.
U se only the manufacturer-supplied 7.5 volt DC power supply and charge the

battery only in the crimping tool.
Do not heat above 60⁰C or short circuit.
Do not crush or modify.

Disposal of Battery

Do not throw battery away. Recycle in accordance with local regulations.

Intended Use

Electronic Crimpers and Decappers are intended for use in a laboratory environment.

Prohibited Use

All other uses are prohibited.

Limits

Temperature 15ºC to 35ºC
Humidity not more than 75%
Pressure 0.75 to 1 bar

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Battery LED

Description

The Electronic Crimping Tools can be used to crimp and decap standard crimp caps on
laboratory sample vials. A variety of jaw sets are offered to accommodate the most popular sizes.

Crimping Tool Setup

Please read through this entire manual to familiarize yourself with the operation of the instrument
before proceeding. Use the same degree of care as you would with any precision instrument.

Remove the instrument, power supply and cable from the shipping container.
Inspect the crimper or decapper. If there is any visible damage contact your supplier immediately.

Operation

Charging the Battery

The battery must be charged before the crimper or decapper can be used.
The 7.5 volt DC power supply comes with a set of clips to fit power outlets for most countries.

Slide the correct clip into the back of the power supply, and plug the supply into the power main.
Plug the power jack from the DC supply into the crimping tool. After a pause the Battery LED on

the front of the tool will begin blinking green, showing that the charging has started. After 1 to 2
hours the LED will display a steady green light, indicating that the charge is complete.

Disconnect the crimper from the charging supply.

Selecting Compatible Vials, Caps and Seals

Restek electronic crimping tools may not be used with all-steel caps. Aluminum caps or
two-part caps with aluminum sides and seals of standard size and thickness are
appropriate.

Electronic Crimping Tools 5

Adjusting Electronic Crimpers for Use

The electronic crimpers must be adjusted for the vials, caps and seals that will be used. The +
and - adjustment buttons on the top of the crimping tool set a stop position for the motor that drives
the tool.

The adjustment of the crimping tool is effectively a height adjustment. The setting determines the
amount of compression of the cap and is very accurate. There may be some drifting over time due
to stretching or wearing-in of components of the new crimper, but generally the reproducibility of
the crimp is as good as the consistency of the vials and seals.

Select 5 or so vials, caps, and seals for the purpose of setting the crimp. Place the seal and cap
on the vial and rest the crimper on top of the cap.

Squeeze the trigger switch lightly to engage the motor. This switch must be held down until the
crimp is complete. If the switch is released early the crimper will retract.

If the Status LED blinks amber after the cycle is complete a fault was detected. Two yello w blinks
means that the trigger button was released early. Three yellow blinks means that the crimper
stalled – it was not able to deliver enough power to reach the position requested in the setting.

Check the crimped vial for satisfactory form and tightness. If the cap spins easily, press the +
button two or three times. Try the new setting with a new vial and cap.

Crimping the same vial two times will not generally give the same results and sometimes will result
in vial breakage. See the section on “Troubleshooting” for more information.

Special considerations for 20mm Headspace vials. It is common practice to use the “twist test” to
check headspace vials for satisfactory crimps. In fact many sealing systems hold pressure
perfectly well so long as the seal is well compressed.

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Adjusting Electronic Decappers for Use

The adjustment is not very important when decapping. As shipped from the factory the decapper
should remove a cap satisfactorily.

The 11mm decappers wo r k by closing the jaws around the neck of the vial and stripping the cap
off. For the 11mm decapper to work the glass vial must be strong enough to resist the force
applied by the decapper. In the case of inferior or soft glass or if a vial is reused the lip of the vial
may break during decapping.

To adjust the 11mm decapper make sure that the stroke is long enough to remove the cap.
The 20mm decapper works by pinching the sides of the cap with the decapper jaws and pushing

out the glass. The pinching action starts to pull the cap off, and the force of the decapper does
the rest of the work.

To adjust the 20mm decapper, just make sure that the stroke is long enough to remove the cap.

When to Recharge the Battery

The 6.4 volt battery pack for the electronic crimper uses lithium ion cells. After receiving a full
battery charge the electronic crimper or decapper will normally crimp several hundred vials,
depending on the age of the battery and the requirements of the seal and cap chosen.

Unless the crimper is used for a large number of vials each day it is not necessary to recharge
the battery every night. The lithium ion pack will retain its charge for many weeks without losing
its charge.

The Battery LED will blink amber during the crimp stroke if the battery needs charging.
The lithium ion battery pack is expected to last at least 1500 charges. The pack should not be

removed from the crimping tool unless it is due for replacement.
See the instructions on page 5, “Recharging the Battery” for further instructions.

Electronic Crimping Tools 7

Battery Status LED

Reset

Reset

To press the reset button use the end of a small tool to access the recessed button.
Single Reset: Pressing the reset button one time causes the position sensor to be set to zero

and resets the processor.
Factory Reset: This requires pressing the reset button while both the + and – buttons are also

down. The green LED will blink one time and the crimping tool is returned to the factory setting.
This is useful to find a consistent starting point for adjusting the crimping tool if it is far out of
adjustment.

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crimp

high.

Stall Condition –

Recharge battery.

Status

2 Amber

Early trigger release –

cycle.

Try again, making sure to

home position.

Status

3 Amber

Motor drive failure

See Maintenance / Repair

Battery

Continuous

Charge Circuit Failure

See Maintenance / Repair

Battery

Amber blink

Battery needs to be

Charge battery

Battery

One blink after

Battery is too low for

Charge battery

Storage and Shipping
Place protective cap over the jaws to prevent accidental cycling when storing or

shipping the tool.
Fault Conditions

Major and minor faults are identified by LED signals, normally after a crimp cycle.

LED Fault Code Possible Cause Recommendation

Status

3 Amber
Blinks after

Blinks after
tool cycles

Blinks – but
tool does not
cycle.

amber blink
when charger
is plugged in

during crimp
cycle

Stall Condition –
Crimp Setting is too

Battery does not have
sufficient charge.

the tool retracted
before completing

charged

Adjust crimper to a lower
crimp setting.

hold the button down until
the tool is returning to the

section for contact
information for warranty
and repair service
information

section for contact
information for warranty
and repair service
information

Electronic Crimping Tools 9

Go button is
pressed (no
cycle occurs)

crimper cycle.

1) Remove screw holding

4) Push down on

3) Pull battery out of case,

5) Connect new battery to board, making sure the latch is

2) Remove battery cover

Troubleshooting, Maintenance, and Repair

General Maintenance

The electronic crimper tools do not contain user serviceable parts except for the battery pack.

When cleaning or replacing the battery make sure to keep fingers away from the jaws!

Cleaning

The crimping tool may not be immersed in water or solvent. The outside of the case may be
cleaned with an ordinary detergent and wiped off with a damp rag. Care should be taken not to
get the electronics, the battery, or the battery connections wet.

Avoid permitting metal parts of the crimping tool come into contact with corrosive material
during use. If they do, try to wipe them clean with a suitable mild neutralizing solution.

Battery Replacement

Use only the specified 6.4 volt replacement battery pack, part number 22362. Use of
other batteries may cause fire during char g ing or use

the battery cover in place,

leaving wire connected.

connector latch and
pull battery loose
from the board.

secure. Push battery into case, bending the wires if
necessary.

6) Slide the cover back into the case and replace the
retaining screw.

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Cap spins easily.

Crimp setting is too

Adjust crimper to a higher setting by
Cannot find a good

The crimper is far

Return crimper to factory setting. See

Electronic failure in
crimper.

Visit www.restek.com
for support information.

11mm decapper leaves

Decapper

Adjust the decapper to a higher setting

for support information.

Motor does not come

Drive circuit failure.

Visit www.restek.com

Battery Charging is too

Early termination

Leave crimping tool on charger overnight.
Battery is worn out

Replace battery. Battery is rated to
charges.

Troubleshooting

Condition Possible Cause Recommendation

Side of cap is indented.
Seal is deformed in
hole.

crimp setting.
Crimping is

inconsistent. Some
vials are good and
some are not.

caps hanging on vials

on or moves in one
direction only.

Crimp setting is too
high. The crimp is
too tight.

low. The crimp is
too loose

out of adjustment.
Vials, caps or seals

are inconsistent.

adjustment is too
low.

Jaws are worn or
broken

Adjust crimper to a lower crimp setting.

pressing the plus button.

“Reset” above.
Check crimper by using some standard,

approved, vials caps and seals.

by pressing the plus button.

The decapper will have to be replaced or
repaired. Visit

for support information.

www.restek.com

short; battery does not
get a full charge

Support and Repair

If the crimping tool is still in the warranty period, contact your dealer for support. If the warranty
period has expired, please visit
service.

Electronic Crimping Tools 11

by charging circuit.

www.restek.com for information about the crimper repair

Allow trickle current to bring battery to full
charge.

deliver 60% of capacity after 1500