Stanley EP30200, User Manual

Page 1: ... 2017 STANLEY Black Decker Inc New Britain CT 06053 U S A 69924 1 2019 Ver 15 USER MANUAL Safety Operation and Maintenance EP30200 ELECTRONIC PIN BRAZING UNIT ...

Page 2: ...30 EP60 4 Serial number of equipment Seriennummer des Geräts Numéro de série de l équipement Numero de serie del equipo Matricola dell attrezzatura All 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 Directive Standards Richtlinie Standards Directives Normes Directriz Lo...

Page 3: ...frastructure com and select the Company tab Warranty Note The warranty validation record must be submitted to validate the warranty 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 certified dealer call STANLEY Infrastructure at 503 659 5660 and ask for a...

Page 4: ...y messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicates an imminently hazardous situation which if not avoided will result in death or serious injury This safety alert and signal word indicates a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicates a potentia...

Page 5: ... 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 p...

Page 6: ...peration 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 Makesurebatterychargingisonlyaccomplishedina wellventilatedroom DONOTPLACETHECONTROL BOX ON TOP OF THE BATTERIES REMOVE THE BATTERY BOX COVER Battery charging produces explosive gases A battery explosion c...

Page 7: ...n 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 PL...

Page 8: ...00 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 cables into the appropriate outlets on the control box SET ...

Page 9: ...ger 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 braz ing 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 Cha...

Page 10: ...s ground clean Braze is faulty Batteries not charged or are defective Test batteries for proper charge Replace and or charge as necessary Incorrect PIN TYPE setting Check PIN TYPE setting on the control box Magnetic ground faulty Ensure the grounding surface is clean Check magnetic ground cable and plug for damage Bonding surface contaminated Check that the brazing surface is ground clean Incorrec...

Page 11: ...vel 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 In addition to the Safety Precautions in this manual observe the f...

Page 12: ...6 4 Non spillable Battery Label 6 73358 1 Carbide Burr SF 5 7 EP30200 1 Medium Duty Elec Pin Brazing Unit No Gun 8 BG10100 1 Pin Brazing Gun 10 EP30K12110 1 Pin Brazing Kit 110V 12VDC Kit Includes BG10100 Pin brazing gun EP30200 pin brazing unit DCG426M2 DeWalt grinder kit extension cables battery charger 3 batteries 800 Watt inverter carrying case 73358 carbide burr 11 73358 1 Carbide Burr 1 4 in...

Page 13: ...ing M12 Threaded pins 14 35825 1 Extended pin and ring holder set for 8 9 5 mm brazing pins 15 35830 1 Ring Holder 8 9 5 mm ceramic rings 16 35831 1 Ring Holder M8 M10 M12 mm ceramic rings 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 S...

Page 14: ...6 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 ...

Page 15: ...35 x2 66 35861 1 Type D Copper Plate with M16 x 32 Stainless Steel Threaded Stud T Bolt 35837 x4 GRINDER ABRASIVES Item No Part No Qty Description 67 73358 1 Carbide Burr 1 4 Shank 68 35810 1 Grinding Wheel NOT for SafeBonding 69 73052 1 Bull Nose Stone 2 1 4 Shank GRINDER Item No Part No Qty Description 70 DCG426M2 1 Cordless Grinder Kit Includes 2 Battery 1 Charger ACCESSORIES ...

Page 16: ...net Magnetic ground for econnect kit 87 35818 1 Extension Cable for S4 Brazing Gun 88 35816 1 Standard Cable for S4 Pistol 2 7m 8 8ft 89 35817 1 Long Cable for S4 4 5m 14 75ft ACCESSORIES FUSES CHARGERS BATTERIES Item No Part No Qty Description 75 56557 1 Fuse PCB EP30 60 76 56558 1 Fuse Grinder Outlet EP30 77 56559 1 Fuse Control Cable EP30 78 35866 1 Charger 36 VDC 7 AMP EP30 60 W Special DC plu...

Page 17: ... Description 92 35823 1 Plug Male Grinder 4 Pin 93 65831 1 Plug Male Controller Gun 3 Pin 94 66696 1 Plug Male Power Supply Gun Cable 95 66697 1 Plug Male Ground Cable 96 56556 1 Charger Generator Plug TOOLS Item No Part No Qty Description 97 37946 1 Hole Punch Tool 9 5mm 98 35824 1 Hole Punch Tool 8 0mm 99 62394 1 Lift Height Tool BG10100 Pin Braze Gun ...

Page 18: ... 11 11 23 23 20 30 29 27 28 28 22 21 24 25 25 25 26 26 25 26 25 31 26 25 25 26 29 30 25 31 30 30 29 29 32 32 33 Electronic box for EP30 XC 34 Resistor Circuit Board Unit Assembled and precalibrated INTERNAL ELECTRONIC CONTROL BOX EP30 PARTS ILLUSTRATION 35 Includes all components on this page ...

Page 19: ...OTARY SWITCH 11 66695 2 ROTARY SWITCH 12 66691 1 GRINDER RECEPTACLE 13 65830 1 GUN CONTROL RECEPTACLE 14 66847 1 FUSE BRACKET 5x20 15 66692 1 GUN POWER SUPPLY RECEPTACLE 16 66693 1 GROUND RECEPTACLE 17 56558 1 FUSE FOR GRINDER 15A 18 56559 1 FUSE 1A 33 56557 1 GLASS FUSE FOR PCB 34 66845 1 RESISTOR CIRCUIT BOARD UNIT As shown on previous page outlined by black line 35 66131 1 EP30 ELECTRONIC BOX C...

Page 20: ...STANLEY Infrastructure 6430 SE Lake Road Portland Oregon 97222 USA 503 659 5660 Fax 503 652 1780 www stanleyinfrastructure com ...