Stanley EP30200 User Manual
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.
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