Electrobraze Pin Braze System by Farwest Corrosion

Innovative Pin Brazing Equipment for C.P. Cable Connections
The Farwest Electrobraze Cathodic Protection Pin Braze System is designed to simplify cathodic protection {CP) cable connections to a variety of steel structures. The Electrobraze gun and accessories are ideal for CP connections such as negative cables, test station connections, sacrificial anodes, and similar cable connections.

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 Pin Braze System provides reliable 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.

  IMPORTANT:  In order to make a proper pin braze connection, the surface of the structure you will pin braze to MUST BE BRIGHT AND SHINY METAL.  This is also true for the ground connection from the battery to the structure.  Otherwise, the pin braze process will not work properly.

Pin Brazing Gun Details

The ZE7000 Pin Braze Gun is compatible with Pin Braze Battery Packs or a welder/generator.  The gun can be puchased by itself or in a complete kit, which includes the gun, a custom fitted Pelican enclosure, standard toolkit, required cables, a direct pin holder, direct ferrule holder and complete operating instructions.

Gun Specifications

  • Lightweight and Balanced.  Weighs Only 4.4 Pounds.
  • 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

Features

  • 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

Options

  • Integral Magnetic Ground/Return System
  • Extension-Lance for Down-Hole Vacuum Excavation
 
Common Kits and Equipment Options
 
Model Number Farwest Part 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 Only: 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 M10 threaded pins. 
 FCH70008MM 13-26231  Ferrule holder for threaded pins.  
 
IMPORTANT:  In order to make a proper pin braze connection, the surface of the structure you will pin braze to MUST BE BRIGHT AND SHINY METAL.  This is also true for the ground connection from the battery to the structure.  Otherwise, the pin braze process will not work properly.
 

General Safety Precautions

  • Minimum distance for bystanders must be at least 10 feet (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 proper PPE include safety goggles or face shield, hearing protection, safety shoes and suitable clothing for grinding and welding work.
  • Do not inspect or clean the tool while the battery power source is connected as 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. 

IMPORTANT:  In order to make a proper pin braze connection, the surface of the structure you will pin braze to MUST BE BRIGHT AND SHINY METAL.  This is also true for the ground connection from the battery to the structure.  Otherwise, the pin braze process will not work properly.


Integral Earth (Ground) Device for Gun

The Electrobraze model IED7000 Integral Earh Device easily connectes to the model ZE7000 Pin Braze Gun.  This accessroy eliminates the need for a separate pipeline earth or ground connection.  
 

Picture

Picture

The earth/ground extention cable attaches to the rear of this device for connection to a suitable battery pack.  Easily connects and disocnnects to the Brazing gun using the quick-release connectors and "dovetail" rail.


Extension Lance

The model EXL7000 Extension Lance connects directly to your ZE7000 Pin Brazing Gun to allow the gun to be used for down-hole cable connections.  The lance system features four independently connecting, 1 meter long (39”) sections and an independent remote trigger device. The lance system is provided with a military grade Pelican case.

The Extension Lance is designed for use with vacuum excavated holes allowing you to achieve remote pin braze connections from 3 to 13 feet (1 to 4 meters) in depth.

 

Specifications and Features:

  • Lightweight – Weights only 22 lbs. (10 Kg) including case
  • Optional Integral Earth Device (IED7000) bolts directly to the body of your existing ZE7000 Pin Brazing Gun.
  • Marine grade stainless steel construction
  • Remote trigger mechanism
  • Ergonomic design
  • Operating temperature range -40oC (-40oF) to 80oC (176oF)
  • Compatible with fuse wire controlled Direct and Threaded Brazing Pins
  • Designed for Battery Pack power supply or welding generator

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.

Features

  • Keyless Chuck
  • Detachable 2.5 Metre Cable
  • Electrobraze Pin Brazing Battery Pack Compatible
  • Lightweight
  • Low Voltage
Specifications
 
Output 40 W
Speed, no load 20,000 RPM
Cable with plug 3M
Weight according to EPTA 0.25 kg
Chuck -
Max Collet Ø 3.2 mm
 
  

Battery Charger 
 
The Elite series Electrobraze Pin Brazing Battery Pack charger is designed using Pro-Duty, transformer-based technology. Based around a Toroidal design giving low profile compact size and maximum durability, this charger is fully automatic and self-test startup is included each time the charger is turned on. Highly accurate - Mains '0' crossing - voltage measurement is incorporated in the design.
 
Features
  • 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
 
Specifications
 
Output                      36V 2A     
Bulk 44.4V
Float 41.4V
Connector Neutrik Multi-Pin  
Weight (Kg) 3.5
Dimensions (L x W x H)    170 x 140 x 95 mm  

Electrobraze “consumables” are the brazing pins, ceramic ferrules and crimp cable terminals used to make cable connections to pipelines or other structures.


IMPORTANT:  In order to make a proper pin braze connection, the surface of the structure you will pin braze to MUST BE BRIGHT AND SHINY METAL.  This is also true for the ground connection from the battery to the structure.  Otherwise, the pin braze process will not work properly.

Electrobraze Brazing Pins

All Electrobraze brazing pins include a fuse wire and contains SF620 “Silver Flow” alloy for most pipeline applications.  The “direct pins” are designed to attach the Electrobraze “crimp cable terminals” directly to the pipeline or other structure.  No other hardware is required for this connection.  The “threaded pins” include a nut and washer and allow a mechanical cable connection with any appropriate commercial crimp cable lugs. 

Note:  As with any cable connection to a pipeline or other buried structure, it is important to provide a protective coating or weld cap over the connection for corrosion protection.

 

Fused Brazing Pin Usage Chart

Farwest Part No. Pin Model Number Description Ferrule Required Package Qty.
13-26241 BPFD8SF620 8mm Direct Pin CF0800 100 per can
13-26242 BPFD8SF620 Kit, 8mm Direct Pin with CF0800 Ferrule Included 50 per kit
13-26049 N/A Kit, 8mm Extra Solder Direct Pin with CF0800 Ferrule (for ductile iron pipe connections) Included 25 per kit
13-26253 BPFM8SF620 M8 Threaded Pin CF12 50 per can
13-26256 FPFM8SF620 Kit, M8 Threaded Pin with CF12 Ferrule Included 25 per kit
13-26254 BPFM10SF620 M10 Threaded Pin CF12 40 per kit
13-26257 BPFM10SF620 Kit, M10 Threaded Pin with CF12 Ferrule Included 20 per kit
13-26252 BPFM12SF620 M12 Threaded Pin CF12 25 per can
13-26258 BPFM12SF620 Kit, M12 Threaded Pin with CF12 Ferrule Included 25 per kit

 

Threaded Pin with Fuse Wire

Important Note:  Normal direct braze pins may not work well with certain types of ductile iron pipe.  A test weld should be conducted to determine if the materials are compatible and if not, other brazing options may be advisable. 


 

Electrobraze Cermic Ferrules

Ceramic Ferrules are used in conjunction with all direct and threaded brazing pins and are critical to the pin braze process. The ferrule fits into the Ferrule Holder of the Pin Braze Gun and are a one-time use item.

 

Ferrule Usage Chart

Farwest Part No. Ferrule Model Number Description For Pin Models Package Qty.
13-26221 CF0800 8mm Ceramic Ferrule 8mm Direct 200 per can
13-26263 CF12 12mm Ceramic Ferrule M8, M10 & M12 Threaded 100 per can
 
 
Ceramic Ferrule for Direct or Threaded Pins

 
 
Crimp Cable Terminals
 
Electrobraze heavy-duty “crimp cable terminals” are precision manufactured to ensure optimum capillary gap for joint strength and integrity, while also allowing excess heat created during initiation of the Pin Brazing arc to flow freely away from the substrate material and reduce the risk of any unnecessary damage.  These terminals are required for any direct braze application and highly recommended for threaded pin connections.
 
 
Crimp Cable Terminal Usage Chart
 
Farwest Part No. Terminal Model Number Description Pin Type Package Qty.
13-26273 DCLAWG8 #8 AWG Crimp Terminal  Direct 100 per can
13-26278 DCLAWG8 #8 AWG Crimp Terminal Direct 50 per can
13-26271 DCLAWG6 #6 AWG Crimp Terminal Direct 100 per can
13-26277 DCLAWG6 #6 AWG Crimp Terminal Direct 50 per can
13-26274 DCLAWG4 #4 AWG Crimp Terminal Direct 50 per can
13-26276 DCLAWG2 #2 AWG Crimp Terminal Direct 50 per can
 
Note:  Crimp terminals do not require additional reducing sleeves or cable inserts.
 
 
Crimp Cable Terminals

Extension Lance Introduction 

 
 
 

Copper Core 

 
 

Ejector Rod 

 

Basic Operation 

 
 

Electrobraze Pin Brazing Systems.