PIN BRAZING PROCEDURE

PB001

Rev. Date. Issue Type. Prepared by: Checked by: Approved by:
1 28/08/2013 Issued LG SJ SFG

OPERATION OF EASYBOND PIN BRAZING UNIT

It is crucial that to achieve a successful pin braze, the area of connection onto the pipeline
(or other metal substrate) has a clean bright metal finish. In order to achieve this some
degree of surface preparation will be required.

Pipeline and plant owners often have their own procedures for surface preparation and you
should fully familiarise yourself with these procedures prior to any surface preparation
works.
STEP ONE

Figure 4

If necessary, the surface encompassing the pin braze area and adjacent earth connection shall be
degreased before any grinding operation.

Scrape and clean the steel and clean an area for the earth device as near as possible to the braze
area as illustrated in STEP ONE - figure 4.

The metal surface must then be prepared to a bright clean finish to ensure a sound electrical
connection between the earth device and the substrate. Never continuously work the metal such
that any wall thickness is reduced.
An area sufficient to accommodate the brazing pin and cable lug must be correctly located and
cleaned to a bright metal finish.
To prevent the cleaned metal surface re-oxidising, we recommend that pin brazing must take place
as soon as possible after surface preparation, i.e. not more than 5 minutes delay.

Note that when using the optional 18V grinder (part #273 199 0685) you must carefully
read the specific instruction manuals for this equipment. The manuals detail the safe
operation of the equipment and the PPE required during their use.

REF: QAP 004/4 (T) ISSUE: 3 DATE: 28/04/2015 PAGE 1 OF 6

2 LOADING THE PIN INTO THE BRAZING GUN

Load the gun with a brazing pin and ceramic ferrule individually by hand. Ensure that they are both
back fully inserted and tight with the palm of your hand, as illustrated in STEP TWO – figure 5.

STEP TWO

Figure 5
DO NOT STRAIGHTEN THE KINKED END OF THE PIN FUSE WIRE.
The legs of the pin holder must be adjusted as necessary to ensure a firm grip of the pin while
maintaining concentricity with the ferrule holder.
Important:
Under no circumstances should a brazing pin which has been inserted and then removed
from the gun be re-inserted and used for brazing without checking the kinked end profile
and fuse wire connection to pin.

3 ADJUSTMENT OF BRAZING GUN

Before connecting the earth device to the steel, adjust the brazing pin "Lift Height" as
follows:

Hold the cable lug or stinger flat on the steel surface (for direct pin connection). Insert a loaded
brazing pin into the hole in the lug and press the gun/ferrule against the surface of the lug evenly
overcoming the internal spring. Turn the ferrule holder until the white adjustment indicator tube is
flush with the gun's rear face. The brazing gun should now be correctly set, as illustrated in STEP
THREE – figure 6.
When using threaded brazing pins, i.e. M8 brazing pin, the ceramic ferrule must be flat against the
steel surface when checking the white adjustment indicator tube.
STEP THREE

Figure 6
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4 LOCATION OF CONNECTIONS

The desired position of the required pin braze area should be accurately marked on the steel. Do not
use any oil based marker e.g. spray paint, as this will contaminate the grinding burr.

When pin brazing onto a coated pipeline then sufficient coating needs to be removed in order to
accommodate both the earth device and area of the pin braze, this would be a minimum of 14 cm x
4 cm using the standard earth device. If the earth device is placed on a separate earth point on the
pipe then the area required at the pin braze point will be a minimum of 4 cm x 4 cm.

5 PIN BRAZING

STEP FOUR

Figure 7

1. The magnetic earth device must be applied to the cleaned surface to ensure a sound electrical
circuit.

2. The brazing gun must be correctly adjusted with the correct pin and ferrule fitted.

3. Locate the brazing pin so that the pin is in the centre of the hole in the cable lug. For vertical
surfaces, the pin must be at the upper part of the hole in the cable lug.

4. Apply sustained pressure on the brazing gun so that full contact is made between the ferrule and
the bond attachment (or the steel surface when using threaded pins).

5. When the operator is ready to braze, he should look well to one side to protect his eyes from
glare. The operator’s stance should be stable to enable this movement to be made without
altering the critical positioning of the gun.

6. Hold the gun firmly and close the circuit by squeezing the trigger.

KEEP THE TRIGGER DEPRESSED UNTIL THE BRAZE IS COMPLETE

7. After about 2 seconds the fuse wire should rupture, disconnecting the circuit. The arc will
extinguish and the pin or stud will be shot forward into the molten filler.
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8. In the event of a fuse not rupturing after the normal time, the gun must be withdrawn completely
from the work, keeping the trigger depressed.

9. After the fuse has ruptured, the gun must be held in place for a further 3 seconds to allow the
braze to set

10. Remove the gun by pulling straight off the pipe or substrate in line with the brazed pin, then
break out the ferrule if this is remaining in the ferrule holder. This can be achieved by levering
against a suitable edge. Beware, it may be hot.

11. Hold the gun in a vertical position then depress the ejector button to expel the remaining fuse
wire. Catch the wire in your hand to ensure it has been ejected, as illustrated below in figure
7(a).

Figure 7(a)

6 TESTING A COMPLETED BOND

Threaded pin attachments should be tested by a torque device. For an M8 pin the torque device
should be set to 10 Nm. The threads will fail at 25 Nm so do not use excessive force.
Direct braze pin attachments must be tested as per STEP FIVE – figure 8 as follows:
The shank of the plain pin must be carefully broken off with a hammer taking care not to damage the
lug. This must be done before another pin braze is made to the bond. After breaking off the shank
the broken surface should be level or thereabouts with the outer surface of the lug (figure 9 [A]). The
lug shall be complete in all aspects.
STEP FIVE

Figure 8
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If the surface of the broken pin is proud of the surface of the lug this is an indication that the brazing
time was too short * (figure 9 [B]). The reason for a short braze time is usually the result of
excessive current being drawn due to the gun "lift height" being incorrect. This short time can also
be caused by a poor earth connection.
If the surface of the broken pin is below the surface of the lug, this is an indication that the brazing
time was too long (figure 9 [C]). The reason for a long braze time is the result of insufficient current
being drawn. Insufficient current is usually the result of a poor battery condition.
If it is known that the battery is good then the cause may be incorrect setting of the gun "lift height".
If the ferrule is not held against the copper lug and is in partial contact then the arc can escape out
of the gap and this will result in the side of the copper lug burning away.

Warning: Repeated bond attempts must not be made at the same position as this may cause
structural/metallurgical damage to the base steel.

* When using cable lugs part number #278 100 9000 /#278 100 7360 this result (figure 9 [B]) is
acceptable due to thickness of copper material at braze area. Height of remaining brass
shank should not exceed 2mm.

REF: QAP 004/4 (T) ISSUE: 3 DATE: 28/04/2015 PAGE 5 OF 6

FAULT DIAGNOSIS OF UNSATISFACTORY PIN BRAZE CONNECTION

Some common problems can be experienced by operators when first using the equipment. Listed
below are a series of faults together with the most likely cause and remedy solutions. In the event of
persistent problems or faults, contact the service engineer for advice or repair.

PROBLEM POSSIBLE CAUSE REMEDY

No arc or there is a short Circuit not complete or Check fuse wire on pin is
“pop” of the pin highly resistive engaged
Check earth device is connected
Batteries flat Charge/replace batteries
Arc time too short Excessive current drawn Check gun adjustment
Figure 9 (B) Poor earth connection Reset earth connection
Arc time too long Insufficient current drawn Check gun adjustment
Figure 9 (C) Recharge batteries
Bond falls off when Too short brazing time See above
tested Base metal not clean Thoroughly clean the area to be
enough brazed
Fuse wire stuck in Pin loose in holder Tighten fit of pin holder jaws
contact nipple Failure to eject previous
fuse wire Replace contact nipple

Brazing pin fails to push Pin is out of line from the Take care not to bend ferrule
into molten braze ferrule due to off centre holder jaws when removing
material ferrule holder jaws spent ferrule
caused by heavy removal
of spent ferrule Replace ferrule holder

A. B. C.
  

Figure 9

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