BAC 273 199 5660 Operation And Maintenance Manual Download Page 32

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PART NUMBERS FOR EASYBOND MKII PARTS

Description

Part #

Weight

Easybond MKII System Complete

273 199 5660

31.9 kg

1. Easybond MKII power control unit *

273 199 5610

21.0 kg

2. Standard gun *

273 199 0780

3.5 kg

3. Earth device *

273 199 1360

1.1 kg

4. BAC Pin brazing battery charger *

273 199 5020

3.0 kg

5. AttachécCase *

273 190 4680

3.3 kg

6. Tool kit *

273 190 0610

0.3 kg

7. Manuals on CD *

278 900 1900

Easybond MKII Power Control Unit

273 199 5610

21.0 kg

Battery kit (3 x battery and web) **

273 199 5630

15.3 kg

Pin brazing enclosure **

273 199 5690

5.7 kg

Re-chargable battery pack

273 199 5640

15.8 kg

Battery kit (3 x battery and web) ***

273 199 5630

15.3 kg

Charge adaptor ***

273 199 5620

0.5 kg

Optional accessories

Grinder with 18V battery

273 199 0685

5.8 kg

Grinding burr

273 190 1370

0.04 kg

In car battery charger VEPAC

273 199 5040

1.5 kg

Extension cable 2.5m

273 190 1460

1.3 kg

Portable trolley

273 100 4825

6.5 kg

* Included when purchasing part number 273 199 5660.

** Included when purchasing part number 273 199 5610.

*** Included when purchasing part number 273 199 5640.

PACKING DIMENSIONS

Power control unit: 380mm x 320mm x 420mm

Attaché case: 540mm x 320mm x 160mm

Battery charger: 230mm x 200mm x 120mm

18V grinder case: 470mm x 310mm x 170mm

BAC Pin Brazing equipment and consumables are manufacture within the EU

(excluding batteries)

BAC Corrosion Control Limted.

Stafford Park 11, Telford, Shropshire, TF3 3AY

Tel: +44 (0) 1952 290321

Fax: +44 (0) 1952 290325

Email: [email protected]

www.bacgroup.com

Summary of Contents for 273 199 5660

Page 1: ... 5660 03 28 08 2013 LG SJ SFG For Issue 02 13 11 2012 LG SJ SFG For Issue 01 28 09 2011 SFG GL APG For Issue 00 27 05 2008 GS GS APG For Issue Rev Date Prepared By Checked By Approved By Status Remark BAC Corrosion Control Ltd Stafford Park 11 Telford Shropshire TF3 3AY Tel 44 0 1952 290321 Fax 44 0 1952 290325 Email sales bacgroup com ...

Page 2: ...E EASYBOND 9 5 2 CONNECTION OF BATTERY PACK 10 5 3 ENERGY BRAZE CHARGE MONITOR 10 6 PIN BRAZING CONSUMABLES 11 7 OPERATION OF EASYBOND PIN BRAZING UNIT 13 7 1 PREPARATION OF THE SURFACE 13 7 2 LOADING THE PIN INTO THE BRAZING GUN 13 7 3 ADJUSTMENT OF BRAZING GUN 14 7 4 LOCATION OF CONNECTIONS 15 7 5 PIN BRAZING 15 7 6 TESTING A COMPLETED BOND 17 8 FAULT DIAGNOSIS OF UNSATISFACTORY PIN BRAZE CONNEC...

Page 3: ... Document Number Easybond MKII Manual V03 28 08 13 Page 3 of 32 13 WEEE 29 14 INSPECTION AND ACCEPTANCE OF PIN BRAZING EQUIPMENT GOODS 29 15 WARRANTY 29 15 1 WARRANTY FOR PIN BRAZING BATTERIES 30 NOTES 31 ...

Page 4: ...iable rugged and easily maintained machine to make electrical connections onto metallic structures It is important that you carefully read and understand this manual and take time to watch the training video supplied with your equipment prior to operating the Easybond MKII equipment 2 SAFETY 2 1 SYMBOLS USED Read all manuals before using equipment Wear overalls during operation Wear safety boots d...

Page 5: ...ever operate the AC battery charger outside and in wet conditions Keep bystanders away whilst operating the equipment Do not abuse the cables and connectors and never use the cables for carrying or pulling the equipment Always use the optional extension cables when required 2 4 OPERATOR COMPETENCY It is highly recommended that operatives undertaking pin brazing for any form of attachment should ha...

Page 6: ...s comprised of components detailed in figure 1 When you receive your Easybond MKII unit check that you have the following Figure 1 1 Power control unit with battery pack Part 273 199 5610 6 Tool kit Part 273 190 0610 2 Brazing gun Part 273 199 0780 4 BAC battery charger Part 273 199 5020 3 Earth device Part 273 190 1360 5 Attaché case Part 273 190 4680 7 Manuals on CD Part 278 900 1900 ...

Page 7: ...3 kg Pin brazing enclosure 273 199 5690 5 7 kg Re chargable battery pack with charge adaptor 273 199 5640 15 8 kg Battery kit web and 3 x batteries 273 199 5630 15 3 kg Charge adaptor 273 199 5620 0 5 kg Optional accessories Grinder with 2 x 18V batteries 273 199 0685 5 8 kg Grinding burr 273 190 1370 0 04 kg In car battery charger VEPAC 273 199 5040 1 5 kg Extension cable 2 5m 273 190 1460 1 3 kg...

Page 8: ...However heavy rain may cause the pin fuse wire to burn out prematurely resulting in no bond being made 4 3 COLD WEATHER USE It is possible to undertake pin brazing attachments to metals at sub zero temperatures However the efficiency of the batteries will be reduced in colder weather Therefore where practicable shield the battery pack from extreme cold 4 4 PIN BRAZING CONSUMABLES Brazing Pins Cera...

Page 9: ...stem Charge LED red low battery warning 4 DC socket for 42V grinder or battery charger 5 Energy monitor system Braze LED blue OK to braze indicator 6 Socket for earth device 7 Brazing gun Part 273 199 0780 8 Earth device Part 273 190 1360 9 Power control unit with battery pack Part 273 199 5610 10 42V Grinder Part 273 199 0680 no longer in production 11 BAC battery charger mains Part 273 199 5020 ...

Page 10: ...y condition and is able to assess whether there is sufficient power available for optimum braze results and safe use of the equipment Recovery mode The red LED flashes when the voltage drops below 36 30V This occurs during brazing and whilst the batteries are recovering Re charge mode The red LED will permanently illuminate when the unit has remained below 36 30V for a period indicating that batte...

Page 11: ... to ensure adequate contact CERAMIC FERRULES A new ferrule must always be employed in pin brazing the ferrule must be changed after each brazing operation The purpose of the ferrule is to prevent splattering of the molten solder to prevent oxidation of the molten solder and to protect the operator against radiation from the arc The ferrule must be kept dry stored in delivery tins and care must be ...

Page 12: ...aded brazing pin 12 x 34 mm 40 includes nuts and washer 4 270 077 3680 Ceramic ferrule for threaded pin 12 mm 50 5 278 100 7360 M2 Cable lug 10 mm2 cable 6 x 9 mm 100 5 278 100 9000 M2 Cable lug 16 mm2 cable 6 x 9 mm 100 6 270 088 7800 M2 Cable lug 25 mm2 cable 8 x 12 mm 50 6 278 100 7810 M2 Cable lug 35 mm2 cable 9 x 13 mm 50 6 270 088 7790 M2 Cable lug 50 mm2 cable 11 x 14 mm 50 8 278 100 8012 S...

Page 13: ...strated in STEP ONE figure 4 The metal surface must then be prepared to a bright clean finish to ensure a sound electrical connection between the earth device and the substrate Never continuously work the metal such that any wall thickness is reduced An area sufficient to accommodate the brazing pin and cable lug must be correctly located and cleaned to a bright metal finish To prevent the cleaned...

Page 14: ...JUSTMENT OF BRAZING GUN Before connecting the earth device to the steel adjust the brazing pin Lift Height as follows Hold the cable lug or stinger flat on the steel surface for direct pin connection Insert a loaded brazing pin into the hole in the lug and press the gun ferrule against the surface of the lug evenly overcoming the internal spring Turn the ferrule holder until the white adjustment i...

Page 15: ...7 5 PIN BRAZING STEP FOUR Figure 7 1 The magnetic earth device must be applied to the cleaned surface to ensure a sound electrical circuit 2 The brazing gun must be correctly adjusted with the correct pin and ferrule fitted 3 Locate the brazing pin so that the pin is in the centre of the hole in the cable lug For vertical surfaces the pin must be at the upper part of the hole in the cable lug 4 Ap...

Page 16: ...he work keeping the trigger depressed 9 After the fuse has ruptured the gun must be held in place for a further 3 seconds to allow the braze to set 10 Remove the gun by pulling straight off the pipe or substrate in line with the brazed pin then break out the ferrule if this is remaining in the ferrule holder This can be achieved by levering against a suitable edge Beware it may be hot 11 Hold the ...

Page 17: ... time is usually the result of excessive current being drawn due to the gun lift height being incorrect This short time can also be caused by a poor earth connection If the surface of the broken pin is below the surface of the lug this is an indication that the brazing time was too long figure 9 C The reason for a long braze time is the result of insufficient current being drawn Insufficient curre...

Page 18: ...at Charge replace batteries Arc time too short Figure 9 B Excessive current drawn Poor earth connection Check gun adjustment Reset earth connection Arc time too long Figure 9 C Insufficient current drawn Check gun adjustment Recharge batteries Bond falls off when tested Too short brazing time Base metal not clean enough See above Thoroughly clean the area to be brazed Fuse wire stuck in contact ni...

Page 19: ... also be allocated to the general servicing of equipment on a routine basis Refer to the maintenance manual in section 12 for more information If the servicing procedures set out in this instruction manual have been correctly carried out and a problem still exists contact the sales department at BAC Corrosion Control for advice on 44 0 1952 290 321 or sales bacgroup com If it is necessary to retur...

Page 20: ...ly do not expose to rain or moisture Disconnect the AC mains supply before connecting or disconnecting the charger from the battery If the AC power lead is damaged this appliance should not be used If the plug supplied with this appliance is cut from the power supply cord so that another plug can be fitted it must be disposed of safely If such a plug is inserted in a 13A socket outlet the cut end ...

Page 21: ...ed There are no user serviceable parts in this charger 10 2 INSTRUCTIONS FOR USE 1 Ensure that the voltage input selector switch is correctly set to the mains supply 2 Connect the output lead to the battery pack 3 Connect the charger power cable plug to the AC power outlet and switch on The LEDs will cycle through a self diagnostic check The light sequencing is referenced below 4 Allow 24 hours of...

Page 22: ...twice per second charger will not start to charge 4 Stage four Deeply Discharged Battery Recovery Mode Battery in recovery mode soft start Red Charge Yellow flash alternate 5 Stage five Main Bulk Charge Battery in bulk charge Solid yellow 6 Stage six Proportional Timing Optimisation Charge Battery in last bulk charge 80 charged Yellow flash 7 Stage seven Fully Charged Float Maintenance Battery ful...

Page 23: ... leads to the charger for any damage Switch the charger back off connect the charger to the battery switch back on the lights should now flash in sequence again The yellow charging light should now illuminate Is there any voltage in the battery If yes it needs to be 18V to make the charger work Make sure voltage is measured across all three batteries in series Has the battery unit been left on and...

Page 24: ...r are tight Loose terminals could result in defective and or swollen batteries 11 1 QUICKCHANGE RE CHARGEABLE BATTERY PACK The battery pack is accessible by undoing the safety latch on the side of the enclosure and opening the lid on top of the power control unit Unplug the connector by grasping the red plugs at either end and pulling directly apart do not grasp the cables to pull the connector ap...

Page 25: ...3 Item No Part No Description Item No Part No Description 273 199 0780 Standard brazing gun BB1 Easybond MKII 7 273 190 0570 Contact nipple and washer 5 pack 1 270 074 8150 Ferrule holder for 8mm direct brazing pins 10 273 074 8220 Centre piece complete 273 100 0560 Ferrule holder for M8 threaded brazing pins 12 273 190 0580 Ejector rod complete 273 100 1240 Ferrule holder for M10 M12 threaded bra...

Page 26: ... Open the gun handle plate using the provided allen key 31 to remove screws 1 Unscrew the flat contact with the spanner 30 and remove the gun cable 27 ensure the spring washer is removed 2 Unscrew the domed contact and remove from the contact arm 25 ensure the spring washer is removed Re assembly 1 Screw the domed contact into the spring bracket 23 Ensure that the spring washer is located correctl...

Page 27: ...n place the centre piece to allow removal of the pin holder 5 3 Unscrew by the pin holder 5 4 Remove plastic spark shield 6 5 Remove ceramic washer 8 6 Using the peg spanner 29 remove and replace the new contact nipple 9 The nipple should be a tight fit and screwed down fully The nipple should be flush or no more than 0 2mm below the front face Replace the ceramic washer at the same time 8 When re...

Page 28: ...ed leaf spring Replace contact arm 25 2 Defective trigger spring 22 Replace spring Contacts remain closed after pressure is released from centrepiece 1 Misaligned contact arm 25 Check position of tufnol strip relative to slot in upper part of handle 2 Check contact arm is engaged correctly with moving plastic part in gun barrel 3 Top contact arm retaining screw too long Check and replace ...

Page 29: ...be deemed to have accepted the Goods and that they conform with the Contract 15 WARRANTY 1 The following warranty will apply to the pin brazing equipment Goods The pin brazing equipment excluding pin brazing batteries will correspond with their specification and description and sample if any at the time of delivery and if within twelve 12 calendar months of the Goods being delivered by the Company...

Page 30: ...e United Kingdom or in the case of exports FOB UK port or airport at the cost and discretion of BAC Corrosion Control Ltd BAC Corrosion Control Ltd will reimburse the Customer the reasonable carriage costs incurred by it in returning by road from the customer s premises in Great Britain or by other agreed mode of transport Goods which are repaired or replaced under the warranty or whose purchase p...

Page 31: ...BAC Document Number Easybond MKII Manual V03 28 08 13 Page 31 of 32 NOTES ...

Page 32: ...g Charge adaptor 273 199 5620 0 5 kg Optional accessories Grinder with 18V battery 273 199 0685 5 8 kg Grinding burr 273 190 1370 0 04 kg In car battery charger VEPAC 273 199 5040 1 5 kg Extension cable 2 5m 273 190 1460 1 3 kg Portable trolley 273 100 4825 6 5 kg Included when purchasing part number 273 199 5660 Included when purchasing part number 273 199 5610 Included when purchasing part numbe...

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