Table of Contents
Advertisement
Quick Links
O
PERATION AND MAINTENANCE MANUAL
03
28/08/2013
02
13/11/2012
01
28/09/2011
00
27/05/2008
Rev.
Date
BAC Document Number: Easybond MK2 Manual V03
P
IN BRAZING UNIT
PART NUMBER
LG
SJ
LG
SJ
SFG
GL
GS
GS
Prepared By
Checked By
273 199 5660
SFG
SFG
APG
APG
Approved By
Stafford Park 11, Telford, Shropshire, TF3 3AY
28/08/13
For Issue
For Issue
For Issue
For Issue
Status
Remark
BAC Corrosion Control Ltd
Tel: +44 (0) 1952 290321
Fax: +44 (0) 1952 290325
Email: sales@bacgroup.com
Page 1 of 32
Advertisement
Table of Contents
Troubleshooting
Related Manuals for BAC EASYBOND MK2
Summary of Contents for BAC EASYBOND MK2
- Page 1 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 1 of 32 BAC Document Number: Easybond MK2 Manual V03 28/08/13...
-
Page 2: Table Of Contents
12.2 ROUTINE MAINTENANCE....................... 26 12.2.1 SERVICE SCHEDULE ......................... 26 12.2.2 REPLACEMENT OF THE CONTACT SET .................... 26 12.2.3 REPLACEMENT OF CONTACT NIPPLE AND CERAMIC WASHER ............27 12.3 TROUBLESHOOTING ......................28 BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 2 of 32... - Page 3 WEEE ..........................29 INSPECTION AND ACCEPTANCE OF PIN BRAZING EQUIPMENT (GOODS) ... 29 WARRANTY ......................... 29 15.1 WARRANTY FOR PIN BRAZING BATTERIES ................ 30 NOTES ............................31 BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 3 of 32...
-
Page 4: Introduction
Observe the instructions in the text or graphic opposite Worn out electrical products that should be sorted for recycling Possible dangerous situation that could cause severe or fatal injury BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 4 of 32... -
Page 5: Safety Regulations
OPERATOR COMPETENCY It is highly recommended that operatives undertaking pin brazing for any form of attachment should have attended a BAC approved training course in the pin brazing technique and hold a current certificate of competency. PERSONAL PROTECTIVE EQUIPMENT (PPE) -
Page 6: General
Part # 273 190 0610 Part # 273 199 5020 3. Earth device Part # 273 190 1360 5. Attaché case Part # 273 190 4680 Figure 1 BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 6 of 32... -
Page 7: Part Numbers For Easybond Mkii Parts
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. Attaché case * 273 190 4680 3.3 kg 6. Tool kit * 273 190 0610 0.3 kg... -
Page 8: Pin Brazing
PIN BRAZING CONSUMABLES (Brazing Pins, Ceramic Ferrules and Cable Lugs) The Easybond MKII Pin Brazing unit uses BAC fused pins to make the electrical connections. Each brazing pin is tipped with low temperature brazing alloy and the correct amount of flux, and has attached a copper fuse wire at the other end, which acts as a timed circuit breaker to control the duration of the braze. -
Page 9: Instructions For The Preparation Of The Easybond For Operation
Power control unit with battery pack (Part # 273 199 5610) 42V Grinder Part # 273 199 0680 (no longer in production) BAC battery charger (mains) (Part # 273 199 5020) or In car battery charger VEPAC (Part # 273 199 5040) -
Page 10: Connection Of Battery Pack
Whilst on charge the battery status must ONLY be monitored via the LED’s on the battery charger unit. See section 10, Battery charger. Do not attempt to braze when the unit is in standby, recovery or re-charge mode. BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 10 of 32... -
Page 11: Pin Brazing Consumables
CABLE LUGS BAC cable lugs are specially manufactured in the intended material for pin brazing. The lugs are made in three different types. M1 is pin brazed to the cable. M2 is crimped to the cable and the “stinger” is pin brazed with the cable. The “stinger” permanently connects anode wires with a small diameter to pipes utilising the unique silver alloy BAC pin brazing method, without the use of cable lugs, crimping or old exothermic reactions. - Page 12 Stinger #10AWG kit (includes stinger , brazing pin (278 100 8042) (278 190 3250) & ferrule (270 065 7230) Failure to store consumables correctly can result in defective bonding work. BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 12 of 32...
-
Page 13: Operation Of Easybond Pin Brazing Unit
Load the gun with a brazing pin and ceramic ferrule individually by hand. Ensure that they are both back fully inserted and tight with the palm of your hand, as illustrated in STEP TWO – figure 5. BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 13 of 32... -
Page 14: Adjustment Of Brazing Gun
When using threaded brazing pins, i.e. M8 brazing pin, the ceramic ferrule must be flat against the steel surface when checking the white adjustment indicator tube. STEP THREE Figure 6 BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 14 of 32... -
Page 15: Location Of Connections
The operator’s stance should be stable to enable this movement to be made without altering the critical positioning of the gun. 6. Hold the gun firmly and close the circuit by squeezing the trigger. BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 15 of 32... - Page 16 11. Hold the gun in a vertical position then depress the ejector button to expel the remaining fuse wire. Catch the wire in your hand to ensure it has been ejected, as illustrated below in figure 7(a). Figure 7(a) BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 16 of 32...
-
Page 17: Testing A Completed Bond
* When using cable lugs part number #278 100 9000 /#278 100 7360 this result (figure 9 [B]) is acceptable due to thickness of copper material at braze area. Height of remaining brass shank should not exceed 2mm. BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 17 of 32... -
Page 18: Fault Diagnosis Of Unsatisfactory Pin Braze Connection
Replace ferrule holder Figure 9 BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 18 of 32... -
Page 19: Equipment Check
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. -
Page 20: Battery Charger
The BAC pin brazing battery charger is a 36V 2A, eight-step charge microprocessor controlled charger, designed to quickly and effectively restore discharged 36V sealed valve regulated lead acid battery packs. The charger is specially optimised to be used with all BAC pin brazing units. Light # (figure 10) Colour Condition 1. -
Page 21: Instructions For Use
Stage two: Power Interruption Protection Battery voltage goes straight to full voltage in less than two minutes, it goes straight to solid green (Status as Stage 6) Stage 3: Excessive Discharged Battery BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 21 of 32... - Page 22 16-24 hours on float will cause premature failure and reduce the life of the batteries. BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 22 of 32...
-
Page 23: Battery Charger Troubleshooting
Check the fuse adjacent to power lead socket – spare fuse provided. Please contact us on +44 (0) 1952 290 321 if you need to return the battery charger unit. BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 23 of 32... -
Page 24: Pin Brazing Batteries
(273 199 5620). Or alternatively it can be re-inserted into the Easybond MkII enclosure for re-charging. NO SPARKS, SMOKING OR NAKED FLAMES NEAR THE BATTERIES AS EXPLOSIVE GASES MAY BE EMITTED. BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 24 of 32... -
Page 25: Standard Pin Brazing Gun Maintenance Manual
Servicing, maintenance and repair should always be carried out by fully trained personnel in conjunction with this manual. Should difficulties persist then the complete unit should be sent directly back to BAC Corrosion Control Limited for examination and/or repair. 12.1 PARTS Parts that are damaged or defective in any way should be replaced. -
Page 26: Routine Maintenance
Use the screwdriver between both contacts to assist with tightening. Do not over tighten the contacts. Replace gun handle plate and screws. Figure 14 BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 26 of 32... -
Page 27: Replacement Of Contact Nipple And Ceramic Washer
Reassemble using reverse procedure and removing allen key before replacing the ferrule holder by hand, lightly grease the thread on the to avoid cross threading. . Figure 15 BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 27 of 32... -
Page 28: Troubleshooting
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. BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 28 of 32... -
Page 29: Weee
Control Ltd and any carrier of any claim regarding the quantity or condition of Goods delivered or any damage to them within 5 days of delivery and (b) BAC Corrosion Control Ltd of any claim regarding any defect which should be apparent on reasonable inspection within 15 days of delivery, time being of the essence. -
Page 30: Warranty For Pin Brazing Batteries
Control Ltd.’s agents or sub-contractors involved in the supply of the Goods) or any fault in any other goods. (b) BAC Corrosion Control Ltd will not be liable for any defect in the Goods arising from any document information or materials supplied by or for the Customer. -
Page 31: Notes
NOTES BAC Document Number: Easybond MKII Manual V03 28/08/13 Page 31 of 32... - Page 32 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: sales@bacgroup.com...