EP30
ELECTRONIC
PIN BRAZING UNIT
EP30200
EP30250
Safety, OperatiOn and Maintenance
USer ManUaL
© 2013 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
69924 6-2014 Ver-7
Weisbeck, Andy
Directive/Standards
No.
Approved body
SS-EN
60974-10
Self
DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
ÜBEREINSTIMMUNGS-ERKLARUNG
DECLARATION DE CONFORMITE CEE
DECLARACION DE CONFORMIDAD
DICHIARAZIONE DI CONFORMITA
______________________________________________________________________
I, the undersigned:
Ich, der Unterzeichnende:
Je soussigné:
El abajo firmante:
lo sottoscritto:
hereby declare that the equipment specified hereunder:
bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät:
déclare que l’équipement visé ci-dessous:
Por la presente declaro que el equipo se especifica a continuación:
Dichiaro che le apparecchiature specificate di seguito:
Surname and First names/Familiennname und Vornamen/Nom et prénom/ Nom bre y apellido/Cognome e nome
Hydraulic Tools
1. Category:
Kategorie:
Catégorie:
Categoria:
Categoria:
2. Make/Marke/Marque/Marca/Marca
3. Type/Typ/Type/Tipo/Tipo: EP30 / EP60
4. Serial number of equipment:
Seriennummer des Geräts:
Numéro de série de l’équipement:
Numero de serie del equipo:
Matricola dell´attrezzatura:
Has been manufactured in conformity with
Wurde hergestellt in Übereinstimmung mit
Est fabriqué conformément
Ha sido fabricado de acuerdo con
E’ stata costruita in conformitá con
Richtlinie/Standards
Directives/Normes
Directriz/Los Normas
Direttiva/Norme
EMC Directive
5. Special Provisions: None
Spezielle Bestimmungen:
Dispositions particulières:
Provisiones especiales:
Disposizioni speciali:
6. Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France.
Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione
Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA
Signature/Unterschrift/Signature/Firma/Firma
Position/Position/Fonction/Cargo/Posizione Engineering Manager
Nr
Numéro
No
n.
2004/108/EC
Pin Braze / Safebond Unit (Product Group-Railroad)
Stanley Hydraulic Tools
All
Prüfung durch
Organisme agréé
Aprobado
Collaudato
Self
Date/Datum/le/Fecha/Data 1-10-11
2 ► EP30200 / EP30250 User Manual
TABLE OF CONTENTS
DECLARATION OF CONFORMITY ................................................................................................................................... 2
WARRANTY .......................................................................................................................................................................3
SAFETY SYMBOLS ...........................................................................................................................................................4
SAFETY PRECAUTIONS ................................................................................................................................................... 5
OPERATION EP30200 ......................................................................................................................................... 6 THRU 9
OPERATION EP30250 ..................................................................................................................................... 10 THRU 13
TROUBLESHOOTING .....................................................................................................................................................14
EQUIPMENT MAINTENANCE & CARE ........................................................................................................................... 15
SPECIFICATIONS ............................................................................................................................................................ 16
ACCESSORIES.................................................................................................................................................16 THRU 21
EP30200 PARTS ILLUSTRATION....................................................................................................................................22
EP30200 PARTS LIST......................................................................................................................................................23
IMPORTANT
To ll out a Product Warranty Validation form, and for information on your warranty,
visit Stanleyhydraulics.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 Hydraulic Tools
recommends that servicing of the unit, other than routine maintenance, must be performed by an authorized and
certied 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.
For the nearest authorized and certied dealer, call Stanley Hydraulic Tools at the number listed on the back of this
manual and ask for a Customer Service Representative.
EP30200 / EP30250 User Manual ◄ 3
DANGER
WARNING
CAUTION
NOTICE
IMPORTANT
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.
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.
CAUTION
Always observe safety symbols. They are included for your safety and for the protection of the tool.
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.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
4 ► EP30200 / EP30250User Manual
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 pre-
cautions relating to the specic 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 Stanley Hydraulic Tools.
• 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 con-
ditions, and rail trafc.
• 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.
EP30200 / EP30250 User Manual ◄ 5
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 repair and replacement parts and
materials specied in the Parts List section of this manual.
Use only recommended accessories also specied in the
Parts List section of this manual.
Do not use the Electronic Pin Brazers for applications it was
not designed for.
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 ames away from batteries being charged.
Always wear safety glasses when working with
batteries.
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.
INITIAL SETUP AND BATTERY CHARGING
WARNING
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.
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
gure 1. Do not replace the lid on the battery box at this time.
+Pos.
-Neg.
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.
6 ► EP30200 / EP30250 User Manual
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 rst, the remove the plug from the unit.
EP30200 OPERATION
5. Charging is ready 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
Grinder Receptacle
Pin Size Switch
Control Cable
Female Socket
Gun Power Supply
Receptacle
OPERATION
PREPARE THE RAIL SURFACE
Select the type and length of bonding cable to use for the
bond and use it as a guide to determine where brazing points
on the rail will be required.
Before brazing, the rail 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.
NOTE:
Use only grinding wheels furnished by Stanley. Other
wheels have shown to leave residues which cause faulty
brazing.
CAUTION
Always use eye protection when grinding and brazing.
1 A Fuse
15 A Fuse
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.
Ground Receptacle
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.
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
3. When nished grinding the rail for placement of the grounding cable, 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" and
twist to lock.
SELECT PINS AND RINGS
4. Select brazing pins and ceramic rings to match the speci-
cations of the bonding cable you selected.
CHANGING PIN AND RING HOLDER
5. 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:
EP30200 / EP30250 User Manual ◄ 7
EP30200 OPERATION
a. The ring holder is a "push t" to the gun. To remove it from
the gun, simply pull it away from the gun.
b. 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 ats on the
pin holder. While holding the nut in place, unscrew the pin
holder counter clockwise.
Pin Holder
Figure 3. Pin and Ring Holder
c. Install the correct pin holder and tighten it securely against
the nut.
Ring Holder
IMPORTANT
Make sure, never twist the axle when mounting the
pin holder.
The BG10100 automatically adjusts the correct distance of
the brazing pin to the surface to be brazed.
NOTE:
The BG10100 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
Dial
Figure 2. Gun Adjustment Dial
8. Plug the two gun cable into the appropriate outlets on the
control box.
SET CONTROL FOR PIN SIZE
d. Install the correct ring holder by placing it over the pin holder
and into the circular groove in the gun, and nally, pushing
on it to seat it in place.
LOADING PIN AND RING
6. Insert the brazing pin into the pin holder. The rounded tip
should be facing away from the gun.
7. Insert the ceramic ring into the ring holder. The serrated
edge should be facing away from the gun. See gure 4.
Figure 4. Loading pin and ring
ADJUSTING BRAZING PIN DISTANCE TO
BRAZE SURFACE
9. Set the PIN TYPE switch on the control box for the
appropriate pin type being used. See Figure 3 below.
Brazing Pin Setting
8 mm Std P1
8 mm Extra P2
9.5 mm P3
SWITCH
Figure 3. Pin Type Control Switch
10. Turn the POWER switch to 1.
8 ► EP30200 / EP30250 User Manual
EP30200 OPERATION
NOTE:
The EP30 does not have a power switch.
11. Position the terminal lug of the bonding cable against the
cleaned surface of the rail. Position the gun against the cable
lug so that the brazing pin is at the top edge of the cable lug
hole. See Figure 4 below.
Figure 4. Gun position
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.
12. Hold the gun rmly with both hands and pull the trigger
once. The electronics will nish the braze automatically.
13. 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.
14. After the braze has cooled, knock the shank off the brazing pin using a hammer.
15. 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.
EP30200 / EP30250 User Manual ◄ 9
CAUTION
EP30250 OPERATION
The S300 requires a welding machine capable to deliver
250-300 Amp, open circuit voltage of max. 80V.
(Not supplied by Stanley)
1. Check that all parts were received.
EP300 Unit Delivered with:
Gun S15, incl 2,7 m SAFE 91015
Ground device 2,7 m SAFE 8089
1 - Power cord
2 - Power cable 3 m
2. Connect
Connect power cords to mains and power
cables to an welding machine.
(Welding machine not supplied by Stanley).
Make sure positive and negative is correct.
Set welding current on welding
machine to 250 Amp.
(Max 280 Amp)
Open circuit voltage of max. 80V.
Connect brazing gun, power cable and
control cable, to units gun outlets.
Connect ground magnet to ground outlet.
10 ► EP30200 / EP30250 User Manual
WARNING
IMPORTANT
EP30250 OPERATION
3. Brazing instruction.
Warning! Always use eye protectors when grinding and brazing!
Note, use only STANLEY´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.
- Grind the brazing and grounding area until you have an even and clean surface
Move the grinder up and down until you have an
even surface for both the pinbraze and ground
magnet.
- Attach the earth magnet on the same rail/work piece where the pinbrazing should be done. Try to attach the
magnet within 0,5m from brazing area.
- Set pintype:
Pin Setting
8 mm std 1
8 mm Extra 2
9,5 mm 3
- Load the gun with brazing pin and ferrule.
EP30200 / EP30250 User Manual ◄ 11
EP30250 OPERATION
- Press carefully the gun with the cable shoe, the ferrule and the
brazing pin to the work piece.
- Note that you always must use a railbond together with the brazing pin and the ferrule to do a pin brazing, except
when brazing a special threaded brazing pin then only a ferrule and M8, M10 or M12 brazing pin is to be used.
- Make sure to braze in the top of the hole
when brazing to a vertical surface.
Brazing.
- Hold the gun rmly with both hands as shown and
pull the trigger just once.
The electronic will by it self nish the brazing process.
- Hold the gun in place for 3-4 sec after the brazing
while the braze freezes.
- Remove the gun straight backwards without
pulling the trigger!
Knock off the shank of the brazing pin.
The brazing is completed.
ACCESSORIES EP300
SEE PAGE 17
Pin holder 8-9,5 mm (A)
Pin holder M8 (B)
Pin holder M10 (C)
Pin holder M12 (D)
Ring holder 8-9,5 mm
Ring holder M8/M10/M12
12 ► EP30200 / EP30250 User Manual
WARNING
EP30250 MAINTENANCE
PIN HOLDERS
Squeeze the ngers on the pin holder together each time you feel that the brazing pin goes in too easy when
mounting them into the pin holder. This is important since all the current goes thru the pin holder to the
brazing pin. If the ngers are too loose the pin holder will be damaged and must be replaced.
CHANGE PIN HOLDER
-Separate the ring holder from the gun with your hands.
-Hold the nut closest to the pin holder with a 10mm key.
-Screw the pin holder off.
-When replacing the new pinholder, hold the nut, closest to the pinholder even now.
WARNING! Never rotate the shaft! The internal cables may be damaged!
EQUIPMENT
-Check the cables from time to time, to make sure they are not damaged.
-Check the contact surface on the ground magnet from time to time and use a le to even or clean the surface.
BRAZING PINS AND FERRULES
-Keep them dry.
RAILBONDS AND CABLE LUGS
-Keep them free from oxidation.
-Keep them free from contamination like: Grease, oil, dirt, paint, glue etc.
-Make sure that they are not damaged.
EP30200 / EP30250 User Manual ◄ 13
TROUBLESHOOTING
EP30250
In order to perform this trouble shooting you will need: voltmeter, 8 mm and 10 mm spanners, hexagon spanner
3 mm, 4mm and 5 mm, control instrument to check lift height for S15 pistol.
Working material Are the bonds in good condition - no breaks, clean ?
Are the pins of the correct type ?
Grinding wheeel Is the grinding wheel the approved type ?
The Tyrolit is a silicon free wheel.
You can use a steel carbide wheel.
No other wheels are allowed.
Brazing gun
S 15 Check cables, plugs.
Does axle move easily with pin and ring installed ?
Are the pin and ring holders bent ?
Unscrew the front of the gun and open carefully. Smell if there is burning, otherwise
clean and replace.
Check the lifting height with the control instrument.
Ground magnet Is the magnet broken ( between the plates) ?
Is the plug well screwed in ?
Make sure the contact surfaces are even.
Electronic units Check cables and connections for play.
Are the contact on the cables damaged ?
Are the knobs loose ?
Are the fuses whole ?
Open the panel, check for a burnt smell, ( the breaker can have burnt out )
Check that cables are attached correctly.
Make a full optical control.
EP30200
PROBLEM CAUSE SOLUTION
Brazing pin does not ignite
or does not ignite long
enough.
Braze is faulty. Batteries not charged or are defective.
Batteries not charged or are defective.
Blown fuse. Check fuses.
Magnetic ground faulty.
Faulty cables. Check gun cables and plugs for damage.
Bonding surface contaminated. Check that the brazing surface is ground clean.
Incorrect PIN TYPE setting. Check PIN TYPE setting on the control box.
Magnetic ground faulty.
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.
Brazing pin not positioned correctly in
lug hole.
Test batteries for proper charge. Replace and/or
charge as necessary.
Check that surface magnetic ground is applied to
is ground clean. Check magnetic ground cable
and plug for damage.
Test batteries for proper charge. Replace and/or
charge as necessary.
Check that surface magnetic ground is applied to
is ground clean. Check magnetic ground cable
and plug for damage.
Ensure ring is positioned correctly.
Ensure pin is positioned correctly.
14 ► EP30200 / EP30250 User Manual
NOTICE
EQUIPMENT MAINTENANCE & CARE
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. 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 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.
EP30200 / EP30250 User Manual ◄ 15
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
EP30250 ............................................................................................................................................................................... - This unit
does not have on-board batteries but is powered by an external welding machine (not included) capable of 250-300 amps at 80
volts. Otherwise this has the same functionality and uses the same accessories as our other EP30 units.
ACCESSORIES
35812...............................................................................................................................................................Carrying Case
58867.................................................................................................................................Transport Wagon, EPX 31, EP30
EP30010 (Includes Items Below)..................................................................................................... Pin Brazing Kit 110VAC
35866..............................................................................................................................................Battery Charger
40409.....................................................................................................................Battery, Genesis 16amp 12V (3)
72776..............................................................................................................................Nonspillable Battery Label
73358..........................................................................................................................................Carbide Burr SF-5
EP30200..........................................................................................................Medium Duty Elec. Pin Brazing Unit
BG10100.........................................................................................................................................Pin Brazing Gun
HGE12151......................Grinder, Elec. Cordless Kit (Includes: Grinder, Charger 120V & Battery Lithium-Ion 18V
EP30020 (Includes Items Blelow)..............................................................................................Pin Brazing Kit 110V/12VDC
73358...........................................................................................................................Carbide Burr (1/4 in. Shank)
35812.................................................................................................................................................Carrying Case
35818.........................................................................................................................Extension Cable for S4 Pistol
35819........................................................................................................................Extension Cable for Earth 5m
35866..............................................................................................................................................Battery Charger
40409................................................................................................................... Battery, Genesis 16amp 12V (3)
47320.............................................................................................................................Inverter 12VDC to 110VAC
72776............................................................................................................................. Nonspillable Battery Label
EP30200..........................................................................................................Medium Duty Elec. Pin Brazing Unit
BG10100.........................................................................................................................................Pin Brazing Gun
HGE12151......................Grinder, Elec. Cordless Kit (Includes: Grinder, Charger 120V & Battery Lithium-Ion 18V
16 ► EP30200 / EP30250 User Manual
ACCESSORIES
BRAZING PINS & CERAMIC RINGS
STANDARD BRAZING PINS
Part No. Description Ceramic Ring Reqd
35835 8 mm 35832
35836 8 mm w/ extra silver 35832
35837 9.5 mm 35833
35840 M8/12 Threaded 35834
35841 M10 Threaded 35834
35839 M12 Threaded 35834
CERAMIC RINGS
Part No. Description
35832 8 mm
35833 9.5 mm
35834 12 mm
PIN & RING HOLDERS
Part No. Description
Brazing Pins are for
use on Rail Only
35826 Pin Holder for Pinbrazing, 8-9,5 mm brazing pins.
35827 Pin Holder for Pinbrazing, M8 Threaded pins.
35828 Pin Holder for Pinbrazing, M10 Threaded pins.
35829 Pin Holder for Pinbrazing, M12 Threaded pins.
35825 Extended pin and ring holder set for 8-9,5 mm brazing pins.
37945 Ring Holder, 8 mm pin & ringholder Set
35830 Ring Holder, 8-9,5 mm ceramic rings.
35831 Ring Holder, M8/M10/M12 mm ceramic rings.
35827 Pictured
35831 Pictured
CABLE LUGS (for Pin Brazing to rail)
Part No. Description Brazing Pin Reqd
47523 Braze Lug for 25 mm Cable 35836
47524 Braze Lug for 35 mm Cable 35836
47525 Braze Lug for 50 mm Cable 35836
39241 Cable Shoe #6 2 x 35836
35847 Cable Shoe 10 mm 35835
35855 Cable Shoe D=8 mm 35836
47526 Cable Lug for 16 mm Cable 35835
47527 Cable Lug for 25 mm Cable 35836
47528 Cable Lug for 35 mm Cable 35836
47529 Cable Lug for 50 mm Cable 35836
47522 Cable Lug 5/8" ground rod to #2 cable 2 x 35836
47521 Braze Sleeve #6 to #6 35836
41625 Multi-Wire Track Connection 2 x 35836
47523 Pictured
39241 Pictured
47527 Pictured
47521 Pictured
41625 Pictured
35865 Clip for 18x5mm 35835
67122 Brazing Clip 35835
(Secures Wire to Rail)
67122 Pictured
EP30200 / EP30250 User Manual ◄ 17
ACCESSORIES
BONDING CABLE WITH LUGS (for Pin Brazing)
Part No. Description Brazing Pin Reqd
35845 1 AWG / 50 mm², 185 mm long, copper 35837
35844 4 AWG / 25 mm², 145 mm long, copper 35835
39243 3/16 Bond, 300 mm long 35835
39244 25 mm², 200 mm long 35835
37944 50 mm², 185 mm long 35836
39705 Bond Wire 16" OAL x 25 mm 35835
39706 Bond Wire 24" OAL x 25 mm 35835
39707 Bond Wire 36" OAL x 25 mm 35835
39242 3/16 Bond Crimpable Sleev 35835
40366 Signal Extension Bond 3/16" (170 mm) 35835
40091 Signal Extension Bond 150 mm L=430 35837
40090 Signal Extension Bond 2 x 35 mm - 2 x L=170 35836
41635 3/16 Signal Bond Wire W/Eye & Crimpable sleeve 35835
24 inch long
58563 3/16 x 7”/180 mm Long with Electrode & Ferrule
41815 3/16 Bond 12’ Long Eyelet one end, AL block for 35835
Tig Weld Other End
43686 Extension Bond CU, 25 mm², x 330 mm Long 35835
43519 3/16 Extension Bond 12" 35835
41225 Bond Wire 34" Long C/L-C/L W/9 mm eyelets on 35835
both ends
41226 Bond Wire 46" Long C/L-C/L W/9 mm eyelets on 35835
both ends.
66579 25mm2 x 500mm Extension Bond 35835
66580 25mm2 x 900mm Extension Bond 35835
66269 Signal Bond 3/16" x 6' Braze Lug Both Ends 35835
35844 Pictured
39242 Pictured
40366 Pictured
41635 Pictured
67634 Railbond 300 mcm L=330 mm Uninsulated 35837
(4) 9.5 Pins Required
73652 Railbond 300 mcm L=430 mm Use with 4X Pins
73016 Railbond 300 MCM
72988 Railbond 3/16, 4 in. Reversed (50 pack)
72989 Railbond 3/16, 6 in. Reversed (50 pack)
73016 300MCM Rail Bond
67635 Extension Bond 300 mcm x 200 mm crimp sleeve 35837
(2) 9.5 Pins Required
47530 Bungalow Grounding Bond 3/16" 35836
67634 Pictured
67635 Pictured
"T" CONNECTORS
(for Pin Brazing)
TYPE C
Part No. Description Brazing Pin Reqd
35857 Copper Plate with M8 x 18 Brass Threaded Stud 35835 x 2
TYPE D
Part No. Description Brazing Pin Reqd
35860 Copper Plate with M16 x 26 Staniless Steel Threaded Stud 35837 x 4
35861 Copper Plate with M16 x 32 Stainless Steel Threaded Stud 35837 x 4
35857 Pictured
35860 Pictured
18 ► EP30200 / EP30250 User Manual
ACCESSORIES
Grinder Abrasives
Part No. Description
73358 Carbide Burr (1/4 in. Shank)
35810 Grinding Wheel “Note, Not for SAFEBONDING!”
73052 Bull Nose Stone 2 inch (1/4 inch Shank)
Fuses, Chargers, & Batteries
Part No. Description
56557 Fuse, PCB EP30/60
56558 Fuse, Grinder Outlet EP30
56559 Fuse, Control Cable EP30
56560 Auto Fuse, 5A EP60
56561 Auto Fuse, 15A EP60
56562 Auto Fuse, 30A EP60
35866 Charger 36 VDC 7 AMP EP30/60 W/ Special DC plug.
47320 Inverter 12V DC-110VAC
41769 Battery Charger for EP60 20A 36V DC PLG Continuous Use
40409 Battery 16 AH 12 Volt EP30
39434 Battery 30 AH EP60
56557 Pictured
56561 Pictured
40409 Pictured
EP30200 / EP30250 User Manual ◄ 19
ACCESSORIES
CABLES
Part No. Description
35809 Ground Cable_____________________________________
35806 Carrying Harness__________________________________
35820 Extension Cable for Grinding_________________________
35819 Extension Cable for Ground__________________________
41768 Adapter, Charging__________________________________
62214 Pigtail Charge Adapter_______________________________
66266 Ground Clamp Assembly (Vise Grip Style)________________________
72999 Econect Ground Magnet (Magnetic ground for econect kit) (Not Pictured)
35818 Extension Cable for S4 Brazing Gun (Not Pictured)
35816 Standard Cable for S4 Pistol 2.7m/8.8ft (Not Pictured)
35817 Long Cable for S4, 4.5m/14.75ft (Not Pictured)
GRINDER
Part No. Qty Description
HGE12141 Grinder Only (NO Battaery or Charger)
HGE12151 Includes: Grinder, Battery and Charger.
HGE12161 Includes: Grinder, Battery, Charger and Bull Nose Stone
HGE12161B Includes: Grinder, Battery, Charger and Bull Nose Stone & BNSF Stone.
73399 Battery 18V and Charger 120V
73400 Battery Lithium 18V LI-ION
20 ► EP30200 / EP30250 User Manual
ACCESSORIES
GUNS
Part No. Description
BG10100 Pin Brazing Gun____________________________________
BG10101 Angle Head Gun____________________________________
Plugs
Part No. Description
35823 Plug Male Grinder 4-Pin______________
65831 Plug Male Controller Gun 3-Pin______________
66696 Plug Male Power Supply Gun Cable__________________
66697 Plug Male Ground Cable_________________________________
56556 Carger/Generator Plug___________________________________________
Tools
Part No. Description
37946 Hole Punch Tool 9.5mm
35824 Hole Punch Tool 8.0mm
62394 Lift Height Tool BG10100 Pin Braze Gun
EP30200 / EP30250 User Manual ◄ 21
Electronic box for EP30 XC
EP30 PARTS ILLUSTRATION
INTERNAL ELECTRONIC CONTROL BOX
25
26
25
26
A
07
26
25
26
06
25
25
05
31
31
2526
27
25
28
03
20
04
25
28
29
30
33
29
34. Resistor & Circuit Board Unit
Assembled and precalibrated
22
21
16
15
30
23
19
24
14
30
A
29
30
29
24
01
11
02
09
23
16
13
11
32
10
08
12
32
15
18
14
17
22 ► EP30200 / EP30250 User Manual
EP30 PARTS LIST
Item Part No. Qty Description
01 66838 1 FRAME EP30
02 66846 1 LABEL EP30
03 66839 1 CIRCUIT BOARD
04 66018 1 RELAY
05 66840 1
06 66841 1 RESISTOR MOUNTING PLATE
07 66698 1 RESISTOR ASSY W/CABLE
08 66843 1 YELLOW LED LENS
09 66844 1 RED LED LENS
10 66694 1 KNOB FOR ROTARY SWITCH
11 66695 1 ROTARY SWITCH
12 66691 1 GRINDER RECEPTACLE
13 65830 1 GUN CONTROL RECEPTACLE
14 66847 2 FUSE BRACKET 5x20
15 66692 1
16 66693 1 GROUND RECEPTACLE
17 56558 1 FUSE FOR GRINDER 15A
18 56559 1 FUSE 1A
19 2 STRAIN RELIEF BUSHINGS
20 1 SPACER
21 2 NUT M6
22 2 SHAKEPROOF WASHER M6
23 2 SCREW M6x10
24 3 SCREW M4x8
25 10 NUT M4
26 12 WASHER M4
27 4 SCREW M4x30
28 4 SPACER
29 8 WASHER M3
30 8 NUT M3
31 4 SCREW M3x6
32 4 SCREW M3x10
33 56557 1 GLASS FUSE FOR PCB
34 66845 1
66131 1
CIRCUIT BOARD MOUNTING
PLATE
GUN POWER SUPPLY
RECEPTACLE
RESISTOR & CIRCUIT BOARD
UNIT (As shown on previous page
outlined by black line).
EP30 ELECTRONIC BOX
Complete unit as shown on previous page.
35801 1 Battery Box
EP30200 / EP30250 User Manual ◄ 23
Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, Oregon 97267-5698 USA
(503) 659-5660 / Fax (503) 652-1780
www.stanleyhydraulics.com
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