BAC EASYBOND MK2 User manual

BAC Document Number: Easybond MK2 Manual V03 28/08/13
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P IN BRAZING UNIT
O PERATION AND MAINTENANCE MANUAL
PART NUMBER 273 199 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: [phone]
Fax: [phone]
Email: [e-mail]

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CONTENTS
1. INTRODUCTION .............................................................................................................4
2. SAFETY ..........................................................................................................................4
2.1 SYMBOLS USED........................................................................................................................ 4
2.2 SAFETY REGULATIONS ........................................................................................................... 5
2.3 GENERAL SAFETY WARNINGS ............................................................................................... 5
2.4 OPERATOR COMPETENCY ..................................................................................................... 5
2.5 PERSONAL PROTECTIVE EQUIPMENT (PPE)........................................................................ 5
3. GENERAL.......................................................................................................................6
3.1 THE EASYBOND MKII PIN BRAZING KIT P ART # 273 199 5660 ............................................... 6
3.2 PART NUMBERS FOR EASYBOND MKII PARTS..................................................................... 7
3.3 PACKING DIMENSIONS............................................................................................................ 7
4. PIN BRAZING .................................................................................................................8
4.1 THE PIN BRAZING PROCESS .................................................................................................. 8
4.2 WET WEATHER USE................................................................................................................. 8
4.3 COLD WEATHER USE............................................................................................................... 8
4.4 PIN BRAZING CONSUMABLES (B RAZING P INS , C ERAMIC F ERRULES AND C ABLE L UGS )............. 8
4.5 STORAGE OF UNIT ................................................................................................................... 8
4.6 TRANSPORT TO/FROM SITE ................................................................................................... 8
5. INSTRUCTIONS FOR THE PREPARATION OF THE EASYBOND FOR OPERATION...9
5.1 CONNECTION OF THE EASYBOND......................................................................................... 9
5.2 CONNECTION OF BATTERY PACK........................................................................................ 10
5.3 ENERGY (B RAZE /C HARGE ) 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 CONNECTION...................18
9. EQUIPMENT CHECK....................................................................................................19
10. BATTERY CHARGER...................................................................................................20
10.1 SAFETY .................................................................................................................................... 20
10.2 INSTRUCTIONS FOR USE ...................................................................................................... 21
10.3 LIGHT SEQUENCE INFORMATION: ......................................................................................... 21
10.4 BATTERY CHARGER TROUBLESHOOTING ......................................................................... 23
11. PIN BRAZING BATTERIES...........................................................................................24
11.1 QUICKCHANGE RE-CHARGEABLE BATTERY PACK............................................................. 24
12. STANDARD PIN BRAZING GUN MAINTENANCE MANUAL .......................................25
12.1 PARTS ...................................................................................................................................... 25
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

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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

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EASYBOND MKII PIN BRAZING UNIT
1. INTRODUCTION
Thank you for choosing the Easybond MKII Pin Brazing Unit, if operated and maintained as
recommended your Easybond MKII should give you many years of reliable use.
Pin brazing is an easy, metallurgically safe method of making electrical connections to steel and
ductile iron pipelines, as well as other metallic substrate that are to be cathodically protected,
electrically earthed or electrically bonded.
The Easybond MKII is designed for the onsite user who needs a portable, simple to use,
reliable, 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 during operation
An exposed surface is very hot and therefore dangerous
Wear safety gloves during operation
Wear eye protection during operation
Wear dust mask during operation
Wear ear defenders during operation
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

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2.2 SAFETY REGULATIONS
The safety of staff must be of prime consideration every time that pin brazing work is
carried out on the site and a full and comprehensive risk assessment must be
completed prior to any pin brazing being undertaken. Pin brazing operators must
comply with all current safety legislation and the specific safety requirements
procedures of the site and plant owners.
2.3 GENERAL SAFETY WARNINGS
Under no circumstances should the pin brazing equipment and its accessories be operated in
explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. The
equipment will create sparks that may ignite dust or fumes.
Always ensure that the equipment is well maintained and never make any modifications to the
equipment or use spare parts and consumables not manufactured or recommended by BAC.
Never operate the equipment when tired, after drinking alcohol, taking drugs, or taking
medication that may make you drowsy.
Never 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 have attended a BAC approved training course in the pin brazing technique and hold a
current certificate of competency.
2.5 PERSONAL PROTECTIVE EQUIPMENT (PPE)
The following personal protective equipment is recommended whilst using the Easybond
equipment:
Overalls – conforming to EN ISO 11612:2008 or equivalent.
Safety Footwear – conforming to EN ISO 20345: 2011 S3 or equivalent.
Protective Gloves - conforming to EN12477:2001/A1:2005 Type B or equivalent.
Eye Protection - conforming to EN175:1997/166:1995/169:1992 or equivalent.
Dust/Fume respirator – conforming to FFP3 to EN149:2001 or equivalent.
Note: that when using the optional 18V grinder (part #273 199 0685) you must carefully read
the specific instruction manuals for this equipment. The manuals detail the safe operation of the
equipment and the PPE required during their use.

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3. GENERAL
3.1 THE EASYBOND MKII PIN BRAZING KIT Part # 273 199 5660
The standard Easybond MKII system part # 273 199 5660 is 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

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3.2 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. Attaché case * 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 (web and 3 x batteries) ** 273 199 5630 15.3 kg
Pin brazing enclosure ** 273 199 5690 5.7 kg
Re
-
c
hargable
b
attery
p
ack
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
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.
3.3 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

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4. PIN BRAZING
4.1 THE PIN BRAZING PROCESS
The Easybond MKII is powered by a 36V battery pack capable of delivering 240A (ampere) for
use with BAC fused brazing pins, ceramic ferrules and cable lugs.
The pin brazing process is initiated by depressing a trigger on the pin brazing gun. The circuit is
completed via the magnet attachment to the substrate through which a DC current is passed.
The brazing pin tip is the point of highest resistance at which point an arc is drawn, melting the
solder whilst simultaneously heating the cable lug material and the surface of the structure to
the required soldering temperature.
After approximately 1.5 seconds the circuit is mechanically broken as the fuse wire breaks, the
solenoid is de-energised and the brazing pin is held into the molten pool of brazing alloy. The
brazing pin tip, alloy, flux and cable lug (if used) rapidly cool into a homogenous unit achieving a
very strong connection onto the substrate.
4.2 WET WEATHER USE
Pin brazing attachments can be successfully made to wet metal and in mildly inclement
weather, i.e. light rain, drizzle or snow.
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, 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. Refer to section 6.
4.5 STORAGE OF UNIT
The unit is to be stored in any dry room or cabinet where a constant power supply to the battery
charger can be made available.
There must be adequate ventilation at all times to prevent possible build up of gas evolved from
the batteries during charging.
It is recommended that the batteries be stored at an ambient temperature of 25°C (77°F)
4.6 TRANSPORT TO/FROM SITE
The unit can be transported safely in the rear of a vehicle when secured to prevent movement.
The unit can also be supplied with an optional trolley that can be used to transport the pin
brazing unit around site.

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5. INSTRUCTIONS FOR THE PREPARATION OF THE EASYBOND FOR OPERATION
5.1 CONNECTION OF THE EASYBOND
The various components of the Easybond MKII are connected as detailed in figure 2.
Figure 2
Item
Description
1
Fuse
15
A
(Part # 010 011 0782)
2
Brazing
g
un plug socket
3
Energy
m
onitor
s
ystem
-
Charge
LED
r
ed (
l
ow battery warning)
4
DC
s
ocket for 42V grinder
or
battery charger
5
Energy
m
onitor
s
ystem
-
Braze LED blue (
OK to
b
raze indicator)
6
Socket for
e
arth
device
7
Brazing
g
un
(Part # 273 199 0780)
8
Earth
device
(Part # 273 190 1360)
9
Power
c
ontrol
u
nit with
b
attery
p
ack
(Part # 273 199 5610)
10
*
42V
Grinder
Part # 273 199 0680 (no longer in production)
1
1
BAC b
attery
c
harger
(mains)
(Part # 273 199 5020)
or
In
c
ar
b
attery
charger VEPAC (Part # 273 199 5040)
* This item has been replaced with a standalone 18V battery operated die
grinder (Part #273 199 0685)

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5.2 CONNECTION OF BATTERY PACK
On receipt of your Easybond MKII you will need to fully recharge the battery pack.
Due to possible lengthy shipping times and unavoidable temperature shifts during
transportation, the power control unit will arrive with the battery pack disconnected. Before using
the equipment for the first time the battery connector must be connected and the power control
unit put on charge until the battery pack is fully charged.
To reconnect the battery pack open the lid of the power control unit (figure 2 -9), accessible by
undoing the safety latch, and connect the red male and female plugs that are located on the
power control unit lid.
The battery pack should then be fully charged using only the recommended battery chargers.
The unit should then remain on trickle charge for at least 24 hours before normal use can
commence. Refer to section 10.2 battery charger
WHEN BATTERIES ARE ON CHARGE ALWAYS LEAVE THE POWER
UNIT BOX LID IN THE OPEN POSITION.
NO SMOKING OR NAKED FLAMES AS EXPLOSIVE GASES MAY BE EVOLVED.
5.3 ENERGY (Braze/Charge) MONITOR
The Energy Monitor System constantly checks the battery 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 battery recovery time (approximately 10 seconds) has been
insufficient and requires fully re-charging.
System ready - The blue LED signals the system is safe to be used (36.40V+).
System standby - Represented when both red and blue LED’s are off, this indicates that the
voltage is below that which is required for safe use of the equipment but battery recovery is
imminent (36.30-36.39V). Once recovered the blue LED will illuminate. If a brazing operation is
attempted whilst the unit is in Standby then the red LED will permanently illuminate to indicate
the system must be fully re-charged.
Once the battery charger is attached directly to the Easybond MKII it is possible that the
blue LED will immediately illuminate. This however does not indicate that the system is
now ready for safe use. 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.