In reliable operation for more than 10 years, this product and its technology is now available to the U.S cathodic protection market.
At the heart of the Electrobraze system is the ZE7000 pin braze gun. This tool is adaptable to all pin brazing needs, including down-hole applications (with the optional extension lance). With a simplified system and ergonomic design, the Electrobraze Cathodic Protection Pin Braze System provides reliable pin braze connections and reduces operating costs.
Several battery pack sizes are available for various levels of field usage. Smaller jobs can be made more convenient with the light-weight battery pack, while more extensive applications may call for one of the larger battery packs.
Pin Brazing Gun
ZE7000 Pin Brazing gun is Long Reach as Standard, both Welding Generator and Pin Brazing Battery Pack Compatible comes complete with Custom Fitted Peli-Storm case Enclosure, Toolkit, Pin and Ferrule Collets of your choice and has a range of Bolt-on Accessories.
- Lightweight and well balanced – Only 2.0kg (4.4Lbs)
- Marine Grade Stainless Steel Construction
- Precision Bearing Technology
- Fine Braze Adjustment System
- Fail-Safe, Auto Reset Trigger Mechanism
- Ergonomic Design
- Operating Temperature Range -40o C (-40o F) to 80o C (176o F)
- Compatible with Fuse wire controlled Direct and Threaded Brazing Pins
- Designed for both Welding Generator and Battery Pack power supply.
- Unique Adjustment Mechanism allows for a safer and easier set-up.
- Precision Bearing Solenoid Control
- Adjustable Braze Timing Control to combat URHD
- Adjustable grip size, Quick-release Ergonomic Pistol grip
- Extremely Durable all-weather HPXTM Water Proof Resin Enclosure
- Toolkit and Spares Compartment
- Heavy-Duty Utility Upgrade, consisting – SurefireTM LED Mounted Flashlight for Low Visibility conditions or Confined Space Works, Bungee Sling and Mountings
- Integral Magnetic Earth/Return system
- Extension-Lance for Vacuum Excavation Urban Retrofitting
General Safety Precautions
- Minimum distance for bystanders must be at least 3 meters from the operator and all Grinding preparation and bonding processes
- Operator must be familiar and have carried out an appropriate Risk Assessment of the environment before the commencement of all Pin Brazing and associated operations.
- Operator under the supervision of a qualified instructor or be certified by Electrobraze Limited (or an Electrobraze Limited approved agent) and have carried out training during a period of no longer than 12 months prior to commencement of Pin Brazing Operations.
- Always wear safety equipment such as goggles, ear, eye protection, safety shoes and suitable overalls or safety clothes for grinding and welding work.
- Do not inspect or clean the tool whilst the battery power source is connected, accidental arcing can cause serious injury.
- Ensure battery charging in only done in a dry environment, attaching the battery charger in the rain or near standing water presents an electric shock hazard. Read the safety and operation manual provided with the battery charger before use.
- Do not exceed the rated limits of the equipment or use the tool for applications for which have not been designed.
- Always utilize genuine Electrobraze Limited components when servicing the equipment or replacing parts
- Operators must ensure that all prequalification testing has been thoroughly carried out and approved by the specifying authority before the commencement of the use of this equipment and its associated equipment or consumables.
|Model Code||Farwest Item Number||Production Description|
|ZE3608||13-26205||Pin Braze Kit: Includes ZE7000 gun, 8-amp "light" battery pack, grinder, 8mm direct pin & ferrule holder, tool kit, Pelican case, ground device & cables.|
|ZE3613||13-26200||Pin Braze Kit: Includes ZE7000 gun, 13-amp heavy-duty battery pack, grinder, 8mm direct pin & ferrule holder, tool kit, Pelican case, ground device & cables.|
|ZE7000||13-26212||Pin Braze Gun: Includes tool kit, Pelican case, extra Pin and ferrule holder.|
|EXL7000||13-26215||Extension Lance for down-hole connections. Used with ZE7000 pin braze gun. (Heavy-duty battery pack recommended.)|
|PCH7000M8||13-26200||Pin holder for M8 threaded pins.|
|PCH7000M10||13-26222||Pin holder for MlO threaded pins.|
|FCH70008MM||13-26231||Ferrule holder for threaded pins.|
|Model Code||Farwest Item Number||Production Description|
|BPFD8SF620||13-26240||Direct Braze Pin, 8mm (100 per package)|
|BPFM8SF620||13-26250||Threaded Braze Pin, M8 (SO per package)|
|BPFM10SF620||13-26251||Threaded Braze Pin, MlO (40 per package)|
|CF0800||13-26260||Ceramic Ferrule, 8mm Direct Pins (200 per package)|
|CF12||13-26262||Ceramic Ferrule, Threaded Pins (100 per package)|
|DCLAWG8||13-26272||Crimp terminal/cable lug, #8 AWG cable (100 per package)|
|DCLAWG6||13-26270||Crimp terminal/cable lug, #6 AWG cable (100 per package)|
|DCLAWG4||13-26274||Crimp terminal/cable lug, #4 AWG cable (100 per package)|
- Ensure that all screws and fixings are tight and in-place, missing fasteners must e replaced.
- Ensure that all bolt-on items including Handle Butt, Folding Fore-grip (optional), LED Torch and Mount(optional), Integral Earth Return System (optional), Sling and sling Mounting (optional) are all properly secured
- Carefully Depress the Ejector pin (Fig 1) to ensure that the Solenoid core is free from obstruction (do not force the ejector button as damage may occur to the ejector pin assembly inside the electromagnet)
- If the ejector button will not compress fully, remove and replace the copper Contact Nozzle at the front of the gun - See Pin Brazing Gun Maintenance - Section No2.
- Depress the trigger switch (Fig 2) to ensure this moves freely into the closed position. This should automatically spring open once released.
- Attach the required Pin Holder Collet (Allen Key Provided). This is achieved first removing the Ferrule Holder and loosening the single screw inside the 5mm aperture detailed in fig 3
- Attach the required Ferrule Collet (Fig 5) and secure into the housing using the 3 Socket Set Screws detailed in Fig 6 (Allen Key provided) DO NOT OVERTIGHTEN SCREWS as this may damage the internal threads.
- Select the required Brazing Pin, ensure the Fuse Wire is not damaged or bent and the kinked end of the fuse is intact – Insert the Pin fully into the Pin Collet (Fig 7)(Ferrule holder removed for clarity of image only), ensuring the Fuse wire is threaded through the fuse wire guide bush located within the Pin Collet Housing. Note: The Pin Should be a very tight fit. If this is not the case then the Pin Collet must be removed and adjusted accordingly by evenly compressing the jaws closer together or alternatively prizing them further apart.
- Insert the compatible Ceramic Ferrule into the Ferrule Holder. Note: The Ferrule Should be a very tight fit (Fig 8). If this is not the case then the Ferrule Holder must be removed and the Collet adjusted accordingly by evenly compressing the jaws closer together or alternatively prizing them further apart.
- Press the Pin against the prepared Bright Metallic substrate surface (if making a cable attachment, insert the pin through the eye of the pre-selected Cable Lug or Tab, and then against the substrate surface) and fully depress the Pin Brazing Gun Solenoid until the Ceramic Ferrule is pressed against the Substrate (or the predetermined attachment Lug or Tab). Hold Steady and make sure the Pin Brazing gun and Ferrule are sitting flush against the substrate (Fig 10) or Lug (Fig 9).
- Check the Adjustment Level at the rear of the Pin Brazing Gun – Without Releasing the Solenoid - rotate the Adjustment Bezel (fig 11) at the rear of the gun accordingly until when depressed the Copper Marker tube at the base of the spring is aligned with the rear brass bush (Fig 12) .
- Once set, the brazing gun is now ready for normal pin brazing operation, but depending on any varying braze characteristics (usually due to environmental temperature extremes) can be adjusted or fine-tuned as required by rotating the Adjustment Bezel (up to one-third of a rotation either side of the above setting) Anti-clockwise for a longer braze time or alternatively clockwise for a shorter time. Note that the bezel can also be rotated beyond any notable resistance when turning in order to counter the presence of any Ferrule “hang-up”.
- Welding Generator / Inverter Power Supply
WARNING – Eye protection must be worn before commencing any grinding operation
- Attach the Earth Device Cable to the NEGATIVE (-) pole on the Pin Brazing Battery Pack – push and twist tight.
- Attach the Earth Device Magnet to the Cable – Push and twist tight.
- Making sure the Earth Device magnet plates are clean and free from pitting or damage – Firmly attach the Magnet to the Pre-prepared Bright Metallic Surface on the same substrate which requires Brazing.
- Attach the Pin Brazing Gun cable to POSITIVE (+) pole on the Pin Brazing Battery Pack – Push and Twist Tight.
- Attach the Pin Brazing Gun cable (free end) to the POSITIVE (+) connector on the rear of the Pin Brazing Gun – Push and twist tight.
- Press the Pin against the prepared Bright Metallic substrate surface once more (if making a cable attachment, insert the pin through the eye of the pre-selected Cable Lug or Tab, and then against the substrate surface) and Fully depress the Pin Brazing Gun Solenoid until the Ceramic Ferrule is pressed against the Substrate (or the predetermined attachment Lug or Tab).
- Hold Steady and make sure the Pin Brazing gun and Ferrule are sitting flush against the substrate or Lug.
- Check your Adjustment Bezel is aligned with the Copper marker tube at the rear of the gun.
- Hold steady and click the trigger into the closed position when ready – ALWAYS MAINTAIN PRESSURE ON THE TRIGGER – The Pin Brazing Process is automatically timed and should last approximately 2 seconds.
- Once the process is complete - release the trigger, which should automatically click into the open position and hold steady for 3 seconds before pulling the Pin Brazing Gun vertically (straight up) away from the attached Brazing Pin.
- Push the Ejector Button and eject the remaining section of fuse wire material from inside the Brazing Pin Collet Housing – REMEMBER don’t force the button.
- Scrape away and dispose of the Ceramic Ferrule.
- Direct Pin Brazing Test - Take a 1lb hammer and test the connection by tapping the disposable shank away – The shank should freely break away leaving Tab/Lug attached securely
- Threaded Stud Test – Take a 1lb Nylon/soft hammer and tap the base of the stud 3 times taking care not to damage the threads.
- Remove securing 3no Socket Cap Screws (Allen Key Provided) at the rear of the Trigger Switch Housing – Lower Barrel of the Pin Brazing Gun.
- Pull out the DINSE Socket and housing bush.
- Inspect and clean the Flat Contact using Emery cloth or a flat-file - Remove from the housing if necessary (14mm Box Spanner provided turning anti-clockwise to loosen) fig 14.
- Once Cleaned this can be re-installed and fully tightened into the DINSE Socket Mount.
- Flat Contact should be set so that the circuit is complete when the trigger is 50% closed.
- Using the 14mm Box Spanner provided – Remove the Domed Contact located within the lower gun barrel (turning anti-clockwise to loosen) – Clean or replace as instructed above, avoid distorting the convex form of the Domed Contact through excessive cleaning
- Should the contact Tip (Fig 15) become damaged or blocked by rogue spatter or wear it must be replaced Note: Never attempt to repair the damaged nozzle.
- Expose the nozzle by first removing the entire front Cylinder section of the Pin Brazing Gun (Fig 16), remove the heat shield and Pin Holder complete (Fig 18) by loosening the 3No screws (Allen key provided) at the base of the heat shield.
- Remove the Copper Contact Nozzle Using the 6mm Open Ended Spanner Provided (turning anticlockwise to loosen) (Fig 17)
- Inspect the Heat Shield and Pin Holder (Fig 18) for damage and replace if necessary.
- Screw a new Contact Tip into position and tighten fully against the main shaft (Spanner Provided) ensuring no gap or threads are visible between the two components. Reassemble Heat Shield and depress fully against the steel Return Spring Compression bush, before tightening 3 No screws and reattaching Brazing gun Front Cylinder.
- Magnetic Earth Devices can be cleaned and de-pitted using a flat hand file only.
- Magnetic Plates may need securing screws tightening periodically
Pin Brazing Battery Pack Compatible Micro-Grinder
Due to increasing concern over the potential negative effects of excessive grinding during Pin Brazing Surface preparation, the unique SMG50 Pin Brazing Battery Pack compatible device utilizes a Carbide Burr for speed of installation, but when compared to existing devices can dramatically reduce Substrate disruption whilst providing the ideal surface conditions for Pin Brazing.
- Keyless Chuck
- Detachable 2.5 Metre Cable
- Electrobraze Pin Brazing Battery Pack Compatible
- Low Voltage
|Speed, no load||20,000 RPM|
|Cable with plug||3M|
|Weight according to EPTA||0.25 kg|
|Max Collet Ø||3.2 mm|
- Temperature compensation for extreme environments
- Switchable 110V / 240V input
- Pro-Duty rugged construction
- 4 stage charge cycle
- Proportional timing
- Overrun protection
- Short circuit protection
- Soft start current control
- 3 lamp LED indication
|Dimensions (L x W x H)||170 x 140 x 95 mm|
|Part No||Cable Size||Description||Pin type||Pack Quantity|
Fused Brazing Pin
|Part No||Size||Description||Alloy||Pack Qty||Ceramic|
|BPF8DSF620||8mm||8mm Direct Brazing Pin with Fuse Wire||SF620||100||CF0800|
|BPFM6SF620||M6||M6 Threaded Brazing Pin with Fuse Wire||SF620||50||CF12|
|BPFM8SF620||M8||M8 Threaded Brazing Pin with Fuse Wire||SF620||50||CF12|
|BPFM10SF620||M10||M10 Threaded Brazing Pin with Fuse Wire||SF620||40||CF12|
|BPFM12SF620||M12||M12 Threaded Brazing Pin with Fuse Wire||SF620||20||CF12|