BAC 273 199 0240 User manual

BAC Document Number:
Generator Brazing Gun
Operation Manual
15
/10
/2014
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Operation Manual
Welding Generator/Invertor Compatible
Pin Brazing Guns
Standard Pin Brazing Gun Part # 273 199 0240
Extended Pin Brazing Gun Part # 273 199 5230
BAC Corrosion Control Ltd
Stafford Park 11, Telford, Shropshire, TF3 3AY
Tel: [phone]
Fax: [phone]
Email: sales@bacgroup .com

BAC Document Number:
273 199 5230 Welding
Generator Extended Brazing Gun Service Manual
28/08/2012
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BAC Document Number:
273 199 5230 Welding
Generator Extended Brazing Gun Service Manual
28/08/2012
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CONTENTS
1.0 INTRODUCTION........................................................................................................4
2.0 SAFETY......................................................................................................................4
3.0 PARTS.......................................................................................................................6
3.1 SPARE PARTS ........................................................................................................6
4.0 PINBRAZING USING A WELDING GENERATOR AS A POWER SOURCE ...........7
4.1 SETTING UP THE WELDING GENERATOR............................................................7
5.0 PREPARATION OF THE SURFACE.........................................................................7
5.1 LOADING THE PIN INTO THE BRAZING GUN........................................................9
5.2 ADJUSTING THE BRAZING GUN ............................................................................9
5.3 LOCATION OF CONNECTIONS .............................................................................10
5.4 MAKING A PIN BRAZE..........................................................................................11
6.0 TESTING A COMPLETED BRAZE .........................................................................13
6.1 ACCEPTANCE CRITERIA OF COMPLETED PIN BRAZE.....................................14
7.0 EQUIPMENT CHECK.............................................................................................15
8.2 REPLACEMENT OF THE CONTACT SET .............................................................16
8.3 REPLACEMENT OF CONTACT NIPPLE AND CERAMIC WASHER ...................17
9.0 FAULT DIAGNOSIS OF UNSATISFACTORY BRAZE PIN CONNECTION ...........18
10.0. LIST OF PARTS ....................................................................................................19
11.0 WEEE .....................................................................................................................20
NOTES ............................................................................................................................21

BAC Document Number:
273 199 5230 Welding
Generator Extended Brazing Gun Service Manual
28/08/2012
Page
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1.0 INTRODUCTION
Thank you for choosing the Easybond Generator (Inverter) Pin Brazing Gun, if
operated and maintained as recommended your equipment should give you many
years of reliable use.
Pin brazing is an easy, metallurgical 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 Generator (Inverter) Pin Brazing Gun is designed to run off a Welding
Generator Invertor and is ideal for attaching bracelet anode cables to steel inserts
and pipelines at pipe coating terminals, lay barges and workshops where a large
number of brazes are required in a short period of time at a static location.
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 your equipment.
2.0 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

BAC Document Number:
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Generator Extended Brazing Gun Service Manual
28/08/2012
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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.
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.

BAC Document Number:
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Generator Extended Brazing Gun Service Manual
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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.
3.0 PARTS
Parts that are damaged or defective in any way should be replaced. Experience
has shown that it is uneconomical to replace single parts. The package system is
designed to replace complete sets of parts to ensure effective repair and reliable
operation.
3.1 SPARE PARTS
A full set of spare parts for pin brazing equipment is available off the shelf for
immediate despatch.
We offer a fast and efficient equipment refurbishment / repair service using
genuine spare parts fitted by expert technicians. Most repairs can be completed
within a few days, keeping expensive downtime to a minimum.
If you are offered any pin brazing consumables or parts from sources other than from
BAC directly or a local BAC appointed Distributor/Agent then we strongly advise that
you do not use those consumables with BAC pin brazing equipment to avoid any
serious risk to people, pipelines and BAC pin brazing equipment. If in doubt contact
BAC.
All BAC products are manufactured to the highest standards under our ISO
9001:2008 procedures. If the use of non BAC pin brazing products and
consumables is evident then warranties will be void. All BAC pin brazing
supplies now carry the following notice:

BAC Document Number:
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Generator Extended Brazing Gun Service Manual
28/08/2012
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4.0 PINBRAZING USING A WELDING GENERATOR AS A POWER SOURCE
When a welding generator is to be used in place of the battery pack it must be
"calibrated" to the pin brazing gun and must conform to the following specification:
•Power output 300 amps DC minimum
•Negative earth
•Output voltage adjustable (max 45v)
•Capable of fine adjustment
4.1 SETTING UP THE WELDING GENERATOR
The current and voltage of the welding generator will require adjusting in order to
achieve the optimum braze as indicated in section 6.0 Fig 7.
In order for the brazing gun to operate satisfactorily the minimum required welding
generator output is 240A 36V DC, however due to variables such as cable lengths
and other factors that may introduce a resistance it will be necessary to make some
trial brazes and adjust the welding generator output until the set output is achieving
an acceptable pin braze. A note of the settings should be made for future reference.
•Initially adjust the current output to 240A DC negative earth*.
•Adjust the output voltage to 40V DC*.
•Load the brazing gun as detailed in section 5.1 Fig 2.
•Adjust the brazing gun as detailed in section 5.2.
•Make a series of test brazes and adjustments as necessary until and
acceptable braze as detailed in section 6.0.
•Make a note of the Generator (Inverter) settings.
*Or as close as is practical.
5.0 PREPARATION OF THE SURFACE
It is crucial in order to achieve a successful pin braze, the area of connection onto the
pipeline (or other metal substrate) has a clean bright metal finish. In order to achieve
this some degree of surface preparation will be required.
Pipeline and plant owners often have their own procedures for surface preparation
and you should fully familiarise yourself with these procedures prior to any surface
preparation works.

BAC Document Number:
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STEP ONE
Figure 1
If necessary, the surface encompassing the pin braze area and adjacent earth
connection shall be degreased with a suitable solvent before any grinding operation.
Scrape and clean the steel and clean an area for the earth device as near as
possible to the braze area as illustrated in STEP ONE - figure 1
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. If in doubt use an Ultrasonic
wall thickness measurement instrument to type test and validate the pipe cleaning
procedure.
An area sufficient to accommodate the brazing pin and cable lug must be correctly
located and cleaned to a bright metal finish.
There are many stone and coated abrasive disks available that are suited to pipe
surface preparation and that also minimise metal loss.
To prevent the cleaned metal surface re-oxidising, we recommend that pin brazing
must take place as soon as possible after surface preparation, i.e. not more than 15
minutes delay.
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.
IMPORTANT:
When using the Pin Brazing cable lug never grind, file or abrade the pipe side if the
lug as there is stand off nipple that allows the molten braze material to seep under
the lug. Removing this may compromise the bond quality.

BAC Document Number:
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Generator Extended Brazing Gun Service Manual
28/08/2012
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5.1 LOADING THE PIN INTO THE BRAZING GUN
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 2.
STEP TWO
Figure 2
DO NOT STRAIGHTEN THE KINKED END OF THE PIN FUSE WIRE.
The legs of the pin holder must be adjusted as necessary to ensure a firm grip of the
pin while maintaining concentricity with the ferrule holder.
Important:
Under no circumstances should a brazing pin which has been inserted and
then removed from the gun be re-inserted and used for brazing without
checking the kinked end profile and fuse wire connection to pin.
5.2 ADJUSTING THE BRAZING GUN
Before connecting the earth clamp to the steel, adjust the brazing pin "lift height"
as follows:
Hold the copper cable lug flat on the steel surface. Insert a loaded brazing pin into
the hole in the cable lug and press the gun/ferrule against the surface of the lug
evenly overcoming the internal spring. Rotate the ferrule holder until the white
adjustment indicator tube is flush with the gun's rear face. The brazing gun should
now be correctly set.
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.

BAC Document Number:
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See figure 3 below.
STEP THREE
Fig. 3
Note: Pin, ferrule and cable lug must be in position during adjustment!
5.3 LOCATION OF CONNECTIONS
The desired position of the required pin braze area should be accurately marked on
the steel. Do not use any oil based marker e.g. spray paint, as this will contaminate
the grinding burr.
When pin brazing onto a coated pipeline then sufficient coating needs to be removed
in order to accommodate both the earth device and area of the pin braze, this would
be a minimum of 14 cm x 4 cm using the standard earth device. If the earth device is
placed on a separate earth point on the pipe then the area required at the pin braze
point will be a minimum of 4 cm x 4 cm.

BAC Document Number:
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Generator Extended Brazing Gun Service Manual
28/08/2012
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5.4 MAKING A PIN BRAZE
STEP FOUR
Fig 4
•The earth lead attachment must be applied to the cleaned surface to ensure
a sound electrical circuit.
•The brazing gun must be correctly adjusted with the correct pin and ferrule
fitted.
•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.
•Apply sufficient pressure on the brazing gun so that you are overcoming
and fully compressing the internal spring and that full contact is made
between the ferrule, the brazing pin and cable lug onto the substrate. For
threaded pins it will be the ferrule and the brazing pin.
•When the operator is ready to braze he should look well to one side to
protect his eyes from glare. The operator's stance should be stable enough
to enable this movement to be made without altering the critical positioning
of the gun. The operator should advise any other nearby personnel that he
is about to braze.
•Hold the gun firmly and close the circuit by squeezing the trigger.

BAC Document Number:
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Generator Extended Brazing Gun Service Manual
28/08/2012
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KEEP THE TRIGGER DEPRESSED UNTIL THE BRAZE IS COMPLETED.
•After about 1½ to 2 seconds the fuse wire should rupture, disconnecting the
circuit. The arc will extinguish and the pin will be shot forward into the
molten braze filler.
•In the event of a fuse not rupturing after the normal time, the gun must be
withdrawn completely from the work keeping the trigger depressed.
•After the fuse has ruptured, the gun must be held in place for at least a
further 3 seconds to allow the braze to set.
•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.
•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 in Fig 5
Fig 5

BAC Document Number:
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Generator Extended Brazing Gun Service Manual
28/08/2012
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6.0 TESTING A COMPLETED BRAZE
Fig 6
The shank of the 8mm brazing pin must be carefully broken off with a hammer,
taking care not to damage the lug Refer to Fig 6. This must be done before
another pin braze is made to the bond. Compare the completed braze with the
figures 7, 8 & 9.
Figure 7. is the correct power setting for the generator.
Figure 8. indicates that too much current is being drawn. Therefore, adjust the
generator output down in 10 amp increments and make test brazes until the result
is as figure 3. However, if the acceptance criteria is achieved as detailed is 6.1
then the connection may be acceptable, provided it is not continually repeated.
Figure 9. indicates that too little current is being drawn. Therefore, adjust the
generator output up in 10 amp increments and make test brazes until the result is
as figure 3. However, if the acceptance criteria is achieved as detailed is 6.1 then
the connection may be acceptable, provided it is not continually repeated.
Fig. 7 Fig. 8
Fig. 9

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For threaded pins the brazing time is the only guideline and this should be set as
close to one and a half second as is reasonably practical. An even fillet of solder
around the base of the pin indicates correct conditions.
When the correct result has been achieved note the position of the power dial on
the generator for future use. This may not necessarily be near the original 40V
240A setting.
Regularly check the gun lift height as detailed in section 5.2, as repeated use can
gradually cause the gun to go out of adjustment.
If the ferrule is not held evenly against the copper lug and is in partial contact then
the arc can escape out of the gap and this will result in the side of the copper lug
burning away.
6.1 ACCEPTANCE CRITERIA OF COMPLETED PIN BRAZE
6.1.1 8mm direct brazing pin and cable lug
•Mechanical Strength
When the pin braze is completed it should be tested by firmly hitting the
connection twice with a 1KG hammer (do not hit the shank of the cable lug where
the cable is crimped). If there is no movement of the cable lug at the connection
point then the mechanical integrity can be deemed acceptable. Should there be
any movement whatsoever then the connection should be rejected.
•Electrical Integrity
Using an Ohm meter with a 4 digit resolution, measure the resistance of the pin
braze connection from the cable lug to the pipe. The acceptance criterion is
≤0.010 Ω. Note that the test lead resistance should be measured first and
deducted from the absolute resistance measurement.
6.1.2 M8, M10 & M12 threaded brazing pin
•Mechanical Strength
Threaded pin attachments should be tested by a torque device. For an M8 pin the
torque device should be set to 10 Nm. The threads will fail at 25 Nm, so do not use
excessive force. If there is any movement of the pin up to 10 Nm then the
connection should be rejected.

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Generator Extended Brazing Gun Service Manual
28/08/2012
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•Electrical Integrity
Using an Ohm meter with a 4 digit resolution measure the resistance of the pin
braze connection from the threaded stud to the pipe. The acceptance criterion is
≤0.010 Ω. Note that the test lead resistance should be measured first and
deducted from the absolute resistance measurement.
Warning: Repeated pin braze attempts must not be made at the same position as
this may cause structural/metallurgical damage to the base steel.
7.0 EQUIPMENT CHECK
When the equipment is in use, time must be allowed during a working period to
carry out the necessary checks and servicing required. Carrying out these
procedures will prevent time wasted on site, when work is aborted due to faulty
equipment.
Time and personnel must also be allocated to the general servicing of equipment
on a routine basis.
If the servicing procedures have been correctly carried out and a problem still
exists contact the Technical Service Engineer. If it is necessary to return the
equipment for repair, ensure that the complete pin brazing set, including all
ancillary equipment, is despatched to permit full functional testing.
8.0 ROUTINE MAINTENANCE
8.1 SERVICE SCHEDULE
(numbers in brackets are from Figure 13)
Daily
1. Check that the pin and ferrule holders are undamaged and hold the brazing pin and
ferrule centrally and securely.
Weekly
1. Check and clean the contacts (26) using emery cloth.

BAC Document Number:
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28/08/2012
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8.2 REPLACEMENT OF THE CONTACT SET
Figure 10 Sequence (numbers in brackets are from Figure 12)
8.2.1 Dismantling the contact set (26) – 1 & 2 Figure 10
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.
8.2.2 Re-assembly
1. Screw the domed contact into the spring bracket (23). Ensure that the spring washer
is located correctly in the groove in the contact before tightening.
Do not over tighten the contacts.
2. Place the flat contact through the hole in the gun cable lug (27) and offer both up to
the location. Use the screwdriver between both contacts to assist with tightening.
Do not over tighten the contacts. Replace gun handle plate and screws.
Figure 10

BAC Document Number:
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28/08/2012
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8.3 REPLACEMENT OF CONTACT NIPPLE AND CERAMIC WASHER (7)
This section can also be used for the removal/replacement of ferrule holder (1), pin
holder (5) and plastic spark shield (6)
Figure 11 Sequence (numbers in brackets are from Figure 13):
1. Unscrew by hand the ferrule holder (1).
2. Place allen key (31) in the hole of the front piece silver locking ring (2) and the hole
in the front centre piece (10) (turn pin holder if necessary). This will lock in 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-installing the plastic spark shield (6) ensure that the three indentations are
correctly seated onto the three legs of the pin holder (5).
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 11

BAC Document Number:
273 199 5230 Welding
Generator Extended Brazing Gun Service Manual
28/08/2012
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9.0 FAULT DIAGNOSIS OF UNSATISFACTORY BRAZE PIN CONNECTION
Some common problems can be experienced by operators when first using the
equipment. Listed below are a series of faults together with the most likely cause
and effective solutions. In the event of persistent problems or faults, contact the
Service Engineer for advice or repair.
PROBLEM
CAUSE
REMEDY
No arc Circuit not complete
Generator switched off
Worn Contacts
Trigger malfunction
•
Check fuse wire on pin is
engaged
•Check earth lead is
connected
•Switch on generator
•Replace Contacts
•Check and repair or
replace trigger assembly
Arc time too
short (fig.4)
Excessive current
drawn
Poor earth connection
•
Adjust generator power
down
•Check setting of gun
•Improve earth
connection
Arc time too
long
(fig.5)
Insufficient current
drawn
•
Adjust generator power
up
•Check setting of gun
Bond falls off
when tested
Too short brazing time
Base metal not clean
enough
•
See above
•Clean area to be brazed
properly
Fuse wire
stuck in
contact nipple
Pin loose in holder
Failure to eject previous
fuse wire
•
Tighten fit of pin
•Replace contact nipple
(see manual)

BAC Document Number:
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Generator Extended Brazing Gun Service Manual
28/08/2012
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10.0. LIST OF PARTS
Fig. 12
Item
No
Part No Description Item
No
Part No Description
273 199 5230
Extended Brazing Gun BB1/
Easybond
7
273 190 0570
Contact Nipple and
Washer
(5 pack)
1
270 088 7580
Ferrule Holder for 8mm
direct brazing pins
10
273 074 8220
Centre Piece Complete
(For Standard Gun)
273 100 1900
Ferrule Holder for M8
threaded brazing pins
10
270 088 7590
Extended Centre Piece
Complete
(For Extended Gun)
273 088 7730
Ferrule Holder for M10/M12
threaded brazing pins
12
273 190 0580
Ejector Rod Complete
(For Standard Gun)
2
273 190 0560
Front Piece complete with
locking ring
12
273 190 4580
Extended Ejector Rod
Complete
(For Extended Gun)
4
270 074 8160
Locking Ring
16
270 071 5340
Remanence Washer
5
270 071 5600
Pin Holder for 8mm direct
brazing pins
17
273 190 0590
Conductor Ring and
Insulating Ring
273 100 0550
Pin Holder for M8 threaded
brazing pins
20
273 190 0600
Trigger Assembly
273 100 3870
Pin Holder for M10
threaded brazing pins
25
270 071 5700
Contact Arm
273 100 1230
Pin
Holder for M12
threaded brazing pins
26
273 190 0110
Contact Set Complete
6
270 071 5610
Spark Shield
27
273 190 4599
Cable 35mm sq. 2.7m
long
273 190 4801
Magnetic Earth Device
with
Generator Plug
28
273 190 0610
Tool Kit

BAC Document Number:
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Generator Extended Brazing Gun Service Manual
28/08/2012
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11.0 WEEE
This product is marked according to the European Directive (2002/96/EC)
on Waste Electrical and Electronic Equipment (WEEE)
This symbol appearing on the product, on the product accessories or on
the product packaging means that the product must not be disposed of as
household waste. When the product / batteries durability is over, please,
deliver the product or batteries to the respective collection point, where
the electrical appliance or batteries will be recycled. The places, where the
used electrical appliances are collected, exist in the European Union and
in other European countries as well. By proper disposal of the product
you can prevent possible negative impact on the environment and human
health, which might otherwise occur as a consequence of improper
manipulation with the product or batteries. Recycling of materials
contributes to the protection of natural resources.
For further information contact
BAC Corrosion Control Ltd Sales department
Tel [phone]
BAC Corrosion Control Ltd. EEE producer registration number WEE/DC203WX