SAFETRACK S30 XC User manual

IN-012-03
Safetrack Baavhammar AB
Möllebergavägen 339-24, 245 93 Staffanstorp, Sweden
Phone. [phone]
[email protected] www.safetrack.se
USER MANUAL
Safety, Operation and Maintenance
Safely connecting the world ...
AFETRACK
AFETRACK
www.safetrack.se
®
S
S
S30 XC
Electronic
PinBrazing unit

Warranty:
Units 12 months, batteries 6 months.
Valid only when using original parts, batteries and
chargers supplied or approved by Safetrack®.
The warranty will expire if the equipment was used or has been used with non-original
spare parts, consumables or not used in accordance with the instructions.
Website: www.safetrack.se
E-Mail: [email protected]
2
Read the instructions carefully
before using the pinbrazing unit.
1. Check that all parts are received.
SAFE 9307 Delivered with:
Gun S4, automatic SAFE 9102
Electronic unit S30X/C SAFE 9327
Ground device SAFE 80730
Batteries, sealed, High power 16 Ah, 3pcs SAFE 8093
Cordless Grinding Machine SAFE 593070
Tool case SAFE 95240
Carrying harness SAFE 9523
Goggles SAFE 40210300
S4 tool set SAFE 91250
Grinding pin/stone SAFE 8025
Technical specication
Voltage 36V DC
No. of brazings/charge 40-60
Unit weight incl.batteries 13Ah/16Ah 21/26 Kg
Dimensions LxWxH (mm) 280x230x390
SAFETRACK®
S30 XC
Electronic Pin brazing unit
TECHNICAL SPECIFICATION
IMPORTANT

TECHNICAL SPECIFICATION 2
TABLE OF CONTENTS 3
SAFETY SYMBOLS 4
SAFETY PRECAUTIONS 5
OPERATION 6-11
BATTERY CHARGING 7
CONNECTIONS 8
GRINDING 8
PINBRAZING 9-10
TROUBLESHOOTING 11
MAINTENACE 12-15
ACCESSORIES AND SPAREPARTS 16-17
3
SERIOUS INJURY OR DEATH COULD RESULT FROM
THE IMPROPER REPAIR OR SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE
BY AN AUTHORIZED AND CERTIFIED DEALER.
SERVICING: This manual contains safety, operation, and routine maintenance
instructions. Safetrack recommends that servicing of the unit, other than routine
maintenance, must be performed by an authorized and certied dealer.
Please read the following warning.
TABLE OF CONTENTS
WARNING

4
Safety symbols and signal words, as shown below, are used to emphasize all operator,
maintenance and repair actions which, if not strictly followed, could result in a
life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death.
This safety alert and signal word indicate an imminently
hazardous situation which, if not avoided, will result in death
or serious injury.
This safety alert and signal word indicate a potentially
hazardous situation which, if not avoided, could result in
death or serious injury.
This safety alert and signal word indicate a potentially
hazardous situation which, if not avoided, could result in
death or serious injury.
This signal word indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
This signal word indicates a situation which, if not avoided,
will result in damage to the equipment.
This signal word indicates a situation which, if not avoided,
may result in damage to the equipment.
Always observe safety symbols.
They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the
operator and maintenance personnel.
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________
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SAFETY SYMBOLS
DANGER
WARNING
CAUTION
CAUTION
NOTICE
IMPORTANT

5
Tool operators and maintenance personnel must
always comply with the safety precautions given in
this manual and on the stickers and tags attached to
the tool and hose.
These safety precautions are given for your safety.
Review them carefully before operating the tool and
before performing general
maintenance or repairs.
Supervising personnel should develop additional
precautions relating to the specic work area and
local safety regulations. If so, place the added
precautions in the space provided in this manual.
This tool will provide safe and dependable service if
operated in accordance with the instructions given
in this manual. Read and understand this manual
and any stickers and tags attached to the tool before
operation.Failure to do so could result in personal
injury or equipment damage.
• Do not operate a damaged, improperly
adjusted, or incompletely assembled tools.
• To avoid personal injury or equipment
damage, all tool repair, maintenance and
service must only be performed by authorized and
properly trained personnel.
• Do not exceed the rated limits of the tool or use
the tool for applications beyond its design capacity.
• Always keep critical tool markings, such as labels
and warning stickers legible.
• Always replace parts with replacement parts
recommended by Safetrack.
• Operator must start in a work area without
bystanders. The operator must be familiar with all
prohibited work areas such as excessive slopes,
dangerous terrain conditions, and rail trafc.
• Establish a training program for all operators to
ensure safe operation.
• Do not operate the tool unless thoroughly trained
or under the supervision of an instructor.
• Always wear safety equipment such as goggles,
ear, head protection, and respiratory protection at all
times when operating the tool.
• Do not inspect or clean the tool while the battery
power source is connected. Accidental arcing can
cause serious injury.
• Do not load brazing pins or ceramic rings while the
battery power source is connected. Accidental arcing
can cause serious injury.
• Do not use the tool while it is connected to a
battery charger.
• Ensure battery charging is only done in a dry
environment. Charging batteries in the rain or near
standing water presents an electrocution hazard.
Read the safety and operation instructions provided
with the battery charger before using the battery
charger.
SAFETY PRECAUTIONS

6
OPERATION
GENERAL PROTECTION
Use only recommended repair and replacement parts and materials specied in the spareparts
list section of this manual.
Use only recommended accessories also specied in the spareparts list section of this manual.
Do not use the Electronic Pin Brazers for applications it was not designed for.
Use the carrying handle to transport the unit from location to location.
CLEANING
Establish a routine to keep the unit as free from dirt as possible – daily, or at each shift change,
for example.
Pin Brazers exposed to rain, sand, or grit-laden air should be cleaned prior to each use.
Keep tool labels and stickers legible.
PREOPERATION PROCEDURES
Before putting a new Pin Brazer into initial service, or after an extended period of being unused,
perform a visual inspection for bent, broken, cracked, missing or worn
components.
STORAGE OF UNIT AND BATTERIES
Store the Electronic Pin Brazing Unit in a place where it is protected from the elements,
abrasive dust, and damage.
The batteries must be stored in a clean and dry location, and preferably in a
temperature-controlled environment. Although these batteries are shipped fully charged
and may be stored for up to 1 years at 25ºC (77ºF).
Periodic checks of their open circuit voltages are recommended.
The warmer the storage environment the more frequent the voltage checks should be.
The batteries must be given a freshening charge once every year or when the OCV drops to
36V (3x12V), whichever occurs earlier.
Failure to observe these conditions may result in greatly reduced capacity and service life.

OPERATION
Failure to follow the instructions in the battery charger operation manual can result in
battery explosion and serious bodily injury. To reduce the risk of battery explosion, read and
understand the safety and operation instructions in the battery charger operation manual, the
instructions published by the battery manufacturer, and the instructions in this manual before
attempting to charge the batteries.
Make sure battery charging is only accomplished in a well ventilated room. DO NOT PLACE
THE CONTROL BOX ON TOP OF THE BATTERIES. REMOVE THE BATTERY BOX
COVER. Battery charging produces explosive gases. A battery explosion can cause serious
injuries. Avoid battery explosions by keeping cigarettes, sparks, and ames away from bat-
teries being charged. Always wear safety glasses when working with batteries.
BATTERY CHARGING
1. The three batteries furnished are sealed, maintenance free batteries.
Sealed, maintenance free batteries do not contain cell caps and are already lled with battery
acid. They will require charging before use. Batteries need 3-6 work cycles to reach full capacity.
Use only battery charger specially made for pin brazing units (36V dc) approved by Safetrack.
2. Open the unit and connect the batteries to the unit, check that all cables are securely fastened.
3. Connect the battery charger to the grinder outlet on the unit, then to the mains.
When removing the charger remove the main rst, the remove the plug from the unit.
4. Charging is nished in approximately 3-5 hours. Follow the instructions in the battery charger
manual to complete the charging process.
7
WARNING
WARNING
NOTICE

OPERATION
CONNECTIONS
1. Connect the brazing gun, power and trigger cables to the unit.
2. Connect the ground cable .
3. Connect the grinder. If unit was supplied with battery power grinder, make sure that the bat-
teries are charged. Se manufactures instruction for the grinder on charging the grinder batteries.
GRINDING
Before brazing, the braze area must be cleaned of rust, corrosion, paint, pits, or other
contamination at the points where the brazing is going to be done and on an area close to the
brazing for placement of the grounding cable.
Cleaning is accomplished with a grinder to ensure clean, bare metal.
Always use eye protection when grinding and brazing.
Note, use only Safetrack’s grinding wheel specially made for brazing, other type of wheels will
leave a surface not suitable for brazings.
Keep the grinding wheel clean and free from oil etc.
1. Grind the brazing and ground area until you have
an even and clean surface.
2. Attach the ground magnet on the same work piece
where the pinbrazing should be done. Try to attach
the magnet within 0,5m from brazing area.
3. Move the grinder all time when grinding to get an
even surface.
8
CAUTION
Brazing
Ground
Brazing

9
PINBRAZING
OPERATION
1. When nished grinding for placement of the grounding cable, place the grounding cable on
the cleaned surface.
2. Select brazing pins and ceramic rings to match the specications of the bonding cable you
selected.
3. Check that the pin holder and ring holder on the gun are the correct sizes for the brazing pins
and ceramic rings you selected. If the sizes are incorrect, the pin holder and ring holder can be
changed, se periodically maintenance of S4 gun on page 12.
4. Insert the brazing pin into the pin
holder. The rounded tip should be
facing away from the gun.
5. Insert the ceramic ring into the ring
holder. The serrated edge should be
facing away from the gun.
The S4 automatically adjusts the correct distance
of the brazing pin to the surface to be brazed.
NOTE: The S4 may be adjusted manually if necessary
using the dial located on the back of the gun.
The settings are as follows:
+ = 2.5 mm distance
0 = 2.0 mm distance (normal position)
- = 1.5 mm distance
Se periodically maintenance of S4 gun on page 12.
6. Turn on the unit by setting the PIN TYPE switch on the control box for the appropriate pin
type being used.
Brazing Pin Setting
8 mm Std. P1
8 mm Extra,M8, M10 and M12. P2
9.5 mm. P3
6. Position the terminal lug of the bonding cable against the
cleaned surface.
Position the gun against the cable lug so that the brazing pin is
at the top edge of the cable lug hole when brazing to a vertical
surface and in the center of the cable lug hole when brazing on
a horizontal surface.

7. Hold the gun rmly with both hands as shown and pull the
trigger just once. The electronic will by itself nish the brazing
process.
8. Hold the gun in place for 3-4 sec after the brazing while the
brazing cools down.
9. Remove the gun straight backwards without pulling the trig-
ger!
10. After the braze has cooled, knock the shank off the brazing
pin using a hammer.
11. Use a new ceramic ring for each new pin braze.
The brazing is completed.
PINBRAZING (Continued)
OPERATION
10
A red light indicates low batteries on the unit.
Charge as soon as possible.
IMPORTANT

TROUBLESHOOTING
11
PROBLEM CAUSE SOLUTION
Brazing pin does not ignite
or does not ignite long
enough.
Batteries not charged or are
defective.
Test batteries for proper charge.
Replace and/or
charge as necessary.
Blown fuse. Check fuses.
Magnetic ground faulty. Check that surface magnetic
ground is applied to is ground
clean. Check magnetic ground ca-
ble and plug for damage.
Faulty cables. Check gun cables and plugs for
damage.
Bonding surface
contaminated.
Check that the brazing surface is
ground clean.
Braze is faulty. Batteries not charged or are
defective.
Test batteries for proper charge.
Replace and/or charge as neces-
sary.
Incorrect PIN TYPE
setting.
Check PIN TYPE setting on the
control box.
Magnetic ground faulty. Check that surface magnetic
ground is applied to is ground
clean.
Check magnetic ground cable and
plug for damage.
Bonding surface
contaminated.
Check that the brazing surface is
ground clean.
Incorrect grinding wheel is
used.
Use only Tyrolit grinding wheels or
carbide burr.
Ceramic ring was not
positioned square to the
lug.
Ensure ring is positioned
correctly.
Brazing pin not positioned
correctly in lug hole.
Ensure pin is positioned
correctly.

Part No. Mark For brazing pin With Ring Holder
9211 A 8-9,5 mm 9202 Ringholder for 8-9,5mm
9213 B M8 threaded 9204 Ringholder for M8,M10 and M12
9215 C M10 threaded
9217 D M12 threaded
12
Periodical maintenance of S4 automatic gun
1. Check that all cables and lugs are without damages
and properly tightened in gun and unit.
2. Check that the correct pinholder is tted in the gun.
MAINTENANCE

The ring holder is a “push t” to the gun.
To remove it from the gun, simply pull it away from the gun.
To change the pin holder use spanners as the gure shows.
While holding the nut in place, unscrew the pin holder
counter clockwise.
Use one 8mm spanner and one 10mm for
8-9,5 mm and M8 pinholders.
Two 10mm spanner for M10 and M12 pinholders.
Make sure that pinholder is tightened to the gun,
otherwise a spark can destroy the axle and the pin holder.
The pin holder must have a tight grip on the brazing pin, otherwise you can have a contact fault
or a spark can arise and destroy the pin holder.
To get a tighter t, push together the pin holder ares with your ngers.
3. Check that the ringholder is the right type.
You can dismount it by hand otherwise adjust with
the small screw on the side of the gun.
4. Load the gun with a 8mm pin and ferrule.
Check that the axle move easily with the pin and ferrule
tted when moving back and forward.
If not, change either pinholder or ringholder.
If it still doesn´t move easily the axle is damaged and
must be sent for repair.
13
MAINTENANCE
Make sure, never twist the axle when mounting the pinholder!
IMPORTANT

14
MAINTENANCE
Lift level tool: SAFE 91245
1. Connect the cables for the gun to the pinbrazing
unit and turn on the unit and select P1. Set the dial
on the back of the gun to “0”.
2. Insert the brass part of the tool in the pin holder
and t the plastic part in to the ring holder.
3. Press the trigger on the gun and watch the
brass rod.
Important!
Press the tool completely against the gun when
triggering the gun.
Otherwise the gun may be damaged!
Important!
Hold the gun so the tool is horizontal.
4. The lift level is calibrated when the brass rod
is in same level as the outer plastic sleeve.
Tolerance ±0,2 mm.
If the brass rod stick out more than 0,2 mm, then
the gun needs to be calibrated, see point 6 on the
next page.
If the brass rod goes in more than 0,2 mm, then
the gun needs to be calibrated, see point 7 on the
next page.
If the gun is not calibrated see seperate instruction
for adjusting of the gun.
The normal liftheight is 2mm. This is very important for the arc and energy amount.
Too high liftheight increase the risk of a “coldbrazing”, too low liftheight reduce the
time and increase misres.
IMPORTANT
Advanced maintenance work, Adjusting the liftlevel.

5. Take off the plastic plug with the needle in the upper
small hole in the front of the gun.
IMPORTANT, never adjust in the
hole where the big plug is!
6. When liftheight is too low, use the 3mm hexagon
spanner and adjust the screw in the small hole
counter-clockwise about 1/4 of a turn then recheck
with the lift level tool.
7. When liftheight is too high, use the 3mm hexagon
spanner and adjust the screw in the small hole
clockwise about 1/4 of a turn then recheck with the lift
level tool.
If all is ok, t the plug in the hole again.
If not ok, send for repair.
15
• Check that the pin holder is not burnt or not holding the pin tightly. If not, remove the
ring holder, clean all the parts and squeeze the ngers of the pin holder together.
• Check the cables on the gun from time to time for damage. Replace as required.
• Check that the lift level is correct with lift the level tool.
• Always store the tool in a clean dry space, safe from damage or pilferage.
• Always keep critical equipment markings, such as warning stickers and tags legible.
• Equipment repair should be performed by experienced personnel only.
• Do not use the equipment for applications for which it was not intended.
In addition to the Safetrack Precautions in this manual,
observe the following for equipment protection and care.
MAINTENANCE
NOTICE
Advanced maintenance work, Adjusting the liftlevel.

16
Part Part nummber
S4-Brazing gun SAFE 9102
S4-Angel brazing gun SAFE 91035
Pin holder A 8-9,5mm SAFE 9211
Pin holder B M8 SAFE 9213
Pin holder C M10 SAFE 9215
Pin holder D M12 SAFE 9217
Ring holder 8-9,5mm SAFE 9202
Ring holder M8/M10/M12 SAFE 9204
Extended Pin/Ring holder set, 8-9,5mm SAFE 9227
Extended Pin/Ring holder set, M8 SAFE 9229
Gun cable 2,7M SAFE 9230
Gun cable 4,5M SAFE 9236
Gun cable extension 5m SAFE 9235
S4 tool set SAFE 91250
High Power batteries, sealed 13 Ah SAFE 8092
High Power batteries, sealed 16 Ah SAFE 8093
Extra box for 13Ah batteries with lid (excl. batteries) SAFE 9321
Extra box for 16Ah batteries with lid (excl. batteries) SAFE 9320
Battery adapter for charging SAFE 9318
Battery charger, stationary use, 36V 7A SAFE 8049
Battery charger, car use 12V/36V 2A SAFE 8055
Battery cables kit SAFE 93251
Ground Switchable magnet 2,7M SAFE 80730
Switchable magnet (no cable) SAFE 9035
Ground super magnet 2,7M SAFE 8069
Ground grip 2,7 SAFE 8071
Cordless Grinding machine SAFE 593070
Grinding Pin/Stone SAFE 8025
Carbide burr, Type C SAFE 8014
Carbide burr, Type C Extended SAFE 8014XL
ACCESSORIES AND SPAREPARTS

Safetrack Baavhammar AB
Möllebergavägen 339-24, 245 93 Staffanstorp, Sweden
Phone. [phone]
[email protected] www.safetrack.se
17
ACCESSORIES AND SPAREPARTS
Part Part nummber
Pin type knob SAFE 91301
Grinder/Charger outlet 4 Pols SAFE 91077
Gun outlet 3 Pols SAFE 91075
Gun power outlet SAFE 91093
Ground outlet SAFE 91096
Fuse holder SAFE 91197
Fuse 200mAT (on circuit board) SAFE 91180
Fuse 1AT SAFE 91182
Fuse 15AT SAFE 91181
Gun plug 3pin SAFE 91081
Charger/Grinder plug 4pin SAFE 91085
Gun power plug SAFE 91080
Ground plug SAFE 91091
Tool case SAFE 95240
Carrying harness SAFE 9523
Handy2, rail trolly SAFE 9361
Goggles SAFE 8043
AFETRACK
AFETRACK
www.safetrack.se
®
S
S