Stanley Ep30200 Electronic Pin Brazing Unit User Manual

STANLEY EP30200 Electronic Pin Brazing Unit User Manual

Important

To fill out a product warranty validation form, and for information on your warranty, visit www.stanleyinfrastructure.com and select the Company tab > Warranty.
Note: The warranty validation record must be submitted to validate the warranty

SERVICING: This manual contains safety, operation and routine maintenance instructions. STANLEY Infrastructure recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized and certified dealer. Please read the following warning.

Warning

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.

SAFETY SYMBOLS

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.

Danger: 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.

Warning :This safety alert and signal word indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Caution: This safety alert and signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Caution  This safety alert and signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Notice This signal word indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Important  This signal word indicates a situation which, if not avoided, will 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.

SAFETY PRECAUTIONS

• 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 specific 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.
  
• 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 traffic.
• 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.
• 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 STANLEY.

EP30200 OPERATION

GENERAL PROTECTION

Store the Electronic Pin Brazing Unit in a place where it is protected from the elements, abrasive dust and damage.
Use only recommended replacement parts and materials specified in the Parts List section of this manual.
Use only recommended accessories specified in the Parts 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.

CLEANING

Establish a routine to keep the unit as free from dirt as possible – daily, or at each shift change.
Pin Brazers exposed to rain, sand or grit-laden air should be cleaned prior to each use.
Keep tool labels and stickers legible.

PREPARATION 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.

INITIAL SETUP AND BATTERY CHARGING

Warning 

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.

Warning  

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 flames away from batteries during charging. Always wear safety glasses when working with batteries.

1. The three batteries furnished are sealed, maintenance free batteries.
   Sealed, maintenance free batteries do not contain cell caps and are already filled with battery acid. They will require charging before use.
   Notice
   Use only battery charger specially made for pin brazing units (36V DC) approved by STANLEY.
   
2. Locate the four battery cables and connect them to the terminals on the batteries and the battery box as shown in Figure 1. Do not replace the lid on the battery box at this time.
   Figure 1: Battery cable and terminals
   
3. Insert the enclosed foam-rubber spacers between each battery and at both ends between the battery and the unit.
4. Connect the battery charger to the grinder outlet on the unit, then to the mains. When removing the charger remove the main first, then remove the plug from the unit.
5. Batteries will fully charge in approximately 3-5 hours.
   Follow the instructions in the battery charger manual to complete the charging process.
6. Plug the two cable leads from the adapter box into the battery box.
7. Insert the plug from the battery charger into the grinder outlet on the adapter box.
8. Plug the battery charger into a standard 110 Volt AC outlet.
9. Follow the instructions in the battery charger manual to complete the charging process.

CONNECTIONS

Figure 2: EP30 Connections

1. Connect the brazing gun, power and trigger cables to the unit.
2. Connect the ground cable.
3. Connect the grinder

OPERATION

Prepare the rail surface 

Select the type and length of bonding cable to use for the bond. Use it as a guide to determine where brazing points on the rail will be required.

 Caution

Always use eye protection when grinding and brazing.

1. Grind the surface of the rail where brazing is going to be done, until the surface shows shiny metal, free of rust, corrosion, pits or other contamination. When grinding, use the edge of the grinding wheel – not the face of the wheel.
   Note: Use only grinding wheels furnished by STANLEY. Other wheels have shown to leave residues which cause faulty brazing.
2. Grind the surface of the rail where the grounding cable will be placed to ensure a good ground. The grounding cable should be placed in close proximity to the brazing area.

PLACING THE GROUNDING CABLE 

1. When finished grinding the rail, place the grounding cable on the cleaned surface and then insert the other end into the twist lock receptacle, in the control box marked “GROUND” or “EARTHING”. Twist to lock.

SELECT PINS AND RINGS 

1. Select brazing pins and ceramic rings to match the specifications of the bonding cable you selected.

CHANGING PIN AND RING HOLDER 

1. 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 as follows:
   • The ring holder is “push fit” onto the gun. To remove it from the gun, simply pull it away.
   • The pin holder is threaded onto a threaded shaft in the gun and locked in place with a nut. Place an open
     end wrench over the nut and an open end wrench over the flats on the pin holder. While holding the nut in place, unscrew the pin holder counter clockwise.

EP30200 OPERATION

Figure 3. Pin and Ring Holder

Important
Make sure the correct ferrule and brazing pin are used. The pin braze must be made in the top of the hole when brazing to a vertical surface.

1. Hold the gun firmly with both hands and pull the trigger once. The electronics will finish the braze automatically.
2. Hold the gun in place for 3-4 seconds after the brazing is complete to allow for cooling. Then remove the gun straight backwards, without pulling trigger.
3. After the braze has cooled, knock the shank off the brazing pin using a hammer.
4. Use a new ceramic ring for each new pin braze.

Note: A red light indicates low batteries on the unit. Charge as soon as possible.

TROUBLESHOOTING

EQUIPMENT MAINTENANCE & CARE

Notice
In addition to the Safety Precautions in this manual, observe the following for equipment protection and care.

• Check that the pin holder is not burnt or not holding the pin tightly. Remove the ring holder, clean all the parts and squeeze the fingers of the pin holder together.
• Check the cables on the gun for damage. Replace as required.
• Check that the lift level is correct with the lift 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.

SPECIFICATIONS

EP30200

• Voltage: 36V DC
• Approximate Number of Brazings per Battery Charge : 40-60
• Weight: 44 lbs / 20 kg
• Overall Length: 12.5 in. / 315 mm
• Overall Width: 8.75 in. / 220 mm
• Overall Height: 16 in. / 400 mm

ACCESSORIES

CERAMIC RINGS

Item No.	Part No.	Qty	Description
7	35832	1	8mm
8	35833	1	9.5mm
9	35834	1	12mm

PIN & RING HOLDERS

CABLE LUGS 

Item No	Part No.	Qty	Description	Brazing Pin Required
17	47523	1	Braze Lug for 25 mm Cable	35836
18	47524	1	Braze Lug for 35 mm Cable	35836
19	47525	1	Braze Lug for 50 mm Cable	35836
20	39241	1	Cable Shoe #6	35836 x2
21	35847	1	Cable Shoe 10 mm	35835
22	35855	1	Cable Shoe D=8 mm	35836
23	47526	1	Cable Lug for 16 mm Cable	35835
24	47527	1	Cable Lug for 25 mm Cable	35836
25	47528	1	Cable Lug for 35 mm Cable	35836
26	47529	1	Cable Lug for 50 mm Cable	35836
27	47522	1	Cable Lug 5/8” ground rod to #2 cable	35836 x2
28	47521	1	Braze Sleeve #6 to #6	35836
29	41625	1	Multi-Wire Track Connection	35836 x2
30	67122	1	Brazing Clip (Secures Wire to Rail)	35835

BONDING CABLE WITH LUGS (for pin brazing)

Item No.	Part No.	Qty	Description	Brazing Pin Required
31	35845	1	Contact Bond / 50 mm², 185 mm long, copper	35837	35844 Pictured
32	35844	1	Contact Bond / 25 mm², 145 mm long, copper	35835
33	39243	1	3/16 Bond, 300 mm long	35835
34	39244	1	Bond 25 mm², 200 mm long	35835
35	37944	1	Rail Bond 50 mm², 185 mm long	35836
36	39705	1	Bond Wire 16” OAL x 25 mm	35835	39242 Pictured
37	39706	1	Bond Wire 24” OAL x 25 mm	35835
38	39707	1	Bond Wire 36” OAL x 25 mm	35835
39	39242	1	3/16 Bond Crimp-able Sleeve	35835
40	40366	1	Signal Extension Bond 3/16” (170 mm)	35835	40366 Pictured
41	40091	1	Signal Extension Bond 150 mm L=430	35837
42	40090	1	Signal Extension Bond 2 x 35 mm – 2 x L=170	35836
43	41635	1	3/16 Signal Bond Wire W/Eye & Crimp-able sleeve, 24” long.	35835	41635 Pictured
44	41815	1	3/16 Bond 12’ Long Eyelet one end, AL block for T.I.G. Weld Other End	35835
45	43686	1	Extension Bond CU, 25 mm², x 330 mm Long	35835
46	43519	1	3/16 Extension Bond 12”	35835
47	41225	1	Bond Wire 34” Long C/L-C/L W/9 mm eyelets on both ends	35835
48	41226	1	Bond Wire 46” Long C/L-C/L W/9 mm eyelets on both ends	35835
49	66579	1	25mm2 x 500mm Extension Bond	35835
50	66580	1	25mm2 x 900mm Extension Bond	35835
51	66269	1	Signal Bond 3/16” x 6’ Braze Lug Both Ends	35835
52	67634	1	Railbond 300 mcm L=330 mm Uninsulated (4) 9.5 Pins Required	35837	67634 Pictured
53	73652	1	Railbond 300 mcm L=430 mm Use with 4X Pins
54	73016	1	Railbond 300 MCM
55	72988	1	Railbond 3/16, 4 in. Reversed (50 pack)
56	72989	1	Railbond 3/16, 6 in. Reversed (50 pack)
57	67635	1	Extension Bond 300 mcm x 200 mm crimp, 2) 9.5 Pins Required	35837	67635 Pictured
58	47530	1	Bungalow Grounding Bond 3/16”	35836
59	80784	1	Railbond 95mm², L=155mm, bare copper	35837
60	81167	1	Railbond 95mm², L=155mm 60°, bare copper	35837
61	80785	1	Railbond 95mm², L=255mm, bare copper	35837
62	81168	1	Railbond 95mm², L=255mm 60°, bare copper	35837
63	80786	1	Railbond 95mm², L=355mm, bare copper	35837
64	81169	1	Railbond 95mm², L=355mm 60°, bare copper	35837

“T” CONNECTIONS (for pin brazing)

GRINDER ABRASIVES

GRINDER

COLD WEATHER ACCESSORIES

REPLACEMENT PARTS

FUSES, CHARGERS & BATTERIES

CABLES

GUNS

EP30 PARTS ILLUSTRATION

INTERNAL ELECTRONIC CONTROL BOX

EP30 PARTS LIST

References

• Stanley Infrastructure - World’s Largest Handheld Hydraulic Tool Manufacturer