BAC Document Number: Easybond MKII Manual V03
28/08/13
Page
8
of
32
4. PIN BRAZING
4.1 THE PIN BRAZING PROCESS
The Easybond MKII is powered by a 36V battery pack capable of delivering 240A (ampere) for
use with BAC fused brazing pins, ceramic ferrules and cable lugs.
The pin brazing process is initiated by depressing a trigger on the pin brazing gun. The circuit is
completed via the magnet attachment to the substrate through which a DC current is passed.
The brazing pin tip is the point of highest resistance at which point an arc is drawn, melting the
solder whilst simultaneously heating the cable lug material and the surface of the structure to
the required soldering temperature.
After approximately 1.5 seconds the circuit is mechanically broken as the fuse wire breaks, the
solenoid is de-energised and the brazing pin is held into the molten pool of brazing alloy. The
brazing pin tip, alloy, flux and cable lug (if used) rapidly cool into a homogenous unit achieving a
very strong connection onto the substrate.
4.2 WET WEATHER USE
Pin brazing attachments can be successfully made to wet metal and in mildly inclement
weather, i.e. light rain, drizzle or snow.
However, heavy rain may cause the pin fuse wire to burn out prematurely resulting in no bond
being made.
4.3 COLD WEATHER USE
It is possible to undertake pin brazing attachments to metals at sub-zero temperatures.
However, the efficiency of the batteries will be reduced in colder weather. Therefore, where
practicable, shield the battery pack from extreme cold.
4.4 PIN BRAZING CONSUMABLES (Brazing Pins, Ceramic Ferrules and Cable Lugs)
The Easybond MKII Pin Brazing unit uses BAC fused pins to make the electrical connections.
Each brazing pin is tipped with low temperature brazing alloy and the correct amount of flux,
and has attached a copper fuse wire at the other end, which acts as a timed circuit breaker to
control the duration of the braze. Refer to
section 6
.
4.5 STORAGE OF UNIT
The unit is to be stored in any dry room or cabinet where a constant power supply to the battery
charger can be made available.
There must be adequate ventilation at all times to prevent possible build up of gas evolved from
the batteries during charging.
It is recommended that the batteries be stored at an ambient temperature of 25°C (77°F)
4.6 TRANSPORT TO/FROM SITE
The unit can be transported safely in the rear of a vehicle when secured to prevent movement.
The unit can also be supplied with an optional trolley that can be used to transport the pin
brazing unit around site.
