Abicor Binzel ALPHA Series Bedienungsanleitung

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ABICOR ALPHA SERIES

Instruction Manual

CONTENTS

Page

Neckliner lengths and installation ..............................................................4, 5

Installing gun (cable) liners........................................................................ 5-7

Installing connector kit for direct mount models: internal gas..........................8

Installing connector kit for direct mount models: external gas .........................9

Consumable chart ALPHA 1.......................................................................10

Consumable charts ALPHA 2...................................................................11, 12

Consumable charts ALPHA 3...................................................................13, 14

Consumable charts ALPHA 4...................................................................15, 16

Trouble-shooting: Porosity ..........................................................................17

Trouble-shooting: General guide.............................................................. 18-20

Swanneck dimensions: ALPHA 1 ................................................................20

Swanneck dimensions: ALPHA 2 ................................................................21

Swanneck dimensions: ALPHA 3 ................................................................21

Swanneck dimensions: ALPHA 4 ................................................................22

If installing a neckliner into a new swanneck or swanneck without old

neckliner for measuring length:

1. Fit the consumables (diffuser/insulator, tip-holder, contact tip, nozzle) onto the swan-

neck.

2. Insert the neckliner into the swanneck as far as it will go.

3. Measure the length of liner sticking out from the back of the swanneck and subtract

1 mm. (When cut and installed correctly, the neckliner should stick out approximately

1 mm. without tension.)

4. Remove the liner and measure the length from step 3 back from the inserted end and

mark carefully. With a pair of sharp cutters, cut off the excess liner.

5. Check to ensure that there are no burrs or obstructions to the inner

diameter of the liner.

6. Insert the liner into the swanneck, ﬁt the swanneck on the gun body in the desired

position and tighten the swanneck locking ring.

If replacing an existing neckliner:

1. Unscrew the swanneck, remove the old neckliner and measure its length.

2. Carefully cut the new neckliner to the same length as the old liner with a pair of sharp

cutters.

3. Check to ensure that there are no burrs or obstructions to the inner diameter of

the liner.

4. Insert the cut liner into the

swanneck. When cut and

installed correctly, the neck-

liner should stick out

approximately 1 mm

without being held in.

6. Replace the swanneck

on the gun body in the

preferred position and

tighten the swanneck

locking ring.

Installation of neckliners in slip-on

and threaded nozzle swannecks

Liner collet stick-out:

1 mm

NECKLINERS: CUT MEASUREMENTS

ALPHA SWANNECKS

ALPHA 1: 180 Amp

A1-22 5-29/32” (150mm)

A1-45 5-29/32” (150mm)

A1-60 5-29/32” (150mm)

ALPHA 2: 250 Amp

A2T-22 6-57/64” (175mm)

A2T-45 6-57/64” (175mm)

A2T-60 6-57/64” (175mm)

A2T-60S 6-57/64” (175mm)

A2-60 Slip-On 6-57/64” (175mm)

Please note: Swanneck machining tolerances result in small variances in length; consequently the

measurements given below are intended for reference only (for example, to help identify loose cut

neckliners).

ALPHA SWANNECKS

ALPHA 3: 350 Amp

A3T-22 7-29/32” (201mm)

A3T-45 7-29/32” (201mm)

A3T-60 7-29/32” (201mm)

A3T-60S 7-29/32” (201mm)

A3-60 Slip-On 7-29/32” (201mm)

ALPHA 4: 450 Amp

A4T-22 8-1/32” (204mm)

A4T-45 8-1/32” (204mm)

A4T-60 8-1/32” (204mm)

A4T-60S 8-1/32” (204mm)

A4T-60-HD 8-1/32” (204mm)

A4T-45-HD 8-1/32” (204mm)

A4T-22-HD 8-1/32” (204mm)

Installation of insulated steel liners in Euro

or direct mount guns

Note: When using sizes .078” to .094”, run the cable liner to the contact tip.

1. Lay the torch out straight and remove the swanneck.

2. Remove the liner retaining nut at the wire feed end of the torch and remove the old

liner if ﬁtted.

3. Check that the new liner has no kinks in it.

4. Gently feed the liner through the cable assembly from the machine end of the torch,

taking care not to kink it in the process.

5. With the liner collet now fully seated in the rear connection, replace the liner

retaining nut.

6. At the front end of the torch, the liner will now protrude from the handle

7. Measure 2 mm from the end of the brass swanneck-mounting block, and cut the liner

with a pair of sharp cutters (see above).

8. Check to ensure that there are no burrs or obstructions to the inner

diameter of the liner.

9. Reseat the swanneck on the torch body, adjust to the preferred position and tighten

the locking ring.

*10. The torch is now ready to be ﬁtted to the wire feed unit.

*NOTE: If using pass through style liners, trim excess liner as close to the drive rolls as possible

without making contact.

Installation of plastic liners for aluminum/

stainless steel in direct mount guns

1. Lay the torch out straight and remove the liner retaining nut at the wire feed end of

the torch cable. Remove the existing gun liner if ﬁtted. If switching from a steel liner,

remove the swanneck and ﬁt the appropriate brass neckliner for aluminum – stock

number B2440 for wires .024” to .040” (.6mm-1.0mm) or B4052 for wires .040” to

.052” (1.0mm-1.4mm) – as per instructions on pages 2 and 3. Replace the swanneck

with brass neckliner ﬁtted.

2. Gently feed the plastic liner through the cable assembly until the liner bottoms out in

the neckliner collet. If unsure whether the liner is in the neckliner collet as far as it can

go, remove the swanneck, feed the liner through so that it protrudes 7-8 mm from the

body, taking care not to kink the liner. Replace the swanneck, inserting the protruding

end of the liner into the neckliner collet, and tighten down the swanneck locking ring.

Push the liner again to make sure it has bottomed in the neckliner collet.

3. At the machine end of the torch, slide the brass collet, and O-ring over the liner until

they are seated in the rear connection.

4. Install the plastic liner nut, which is supplied in the connector kit. This is the nut with

the large hole for the liner to exit through. Do not overtighten the nut as this can result

in wire feed problems. DO NOT CUT THE EXCESS LINER YET!

5. With the plastic liner still protruding from the rear of the torch, feed the torch into

the feeder mounting block. Lift the feed rollers of the wire feeder to enable the excess

liner material to pass through. Using a sharp tool, cut the liner so that it butts up to

the feed rollers. This will provide the needed wire support to the soft wire immediately

after it exits the drive rolls. If the liner is trimmed correctly, and the wire hub tension is

set properly, “bird-nesting” in the event of a wire jam will be eliminated.

6. Secure the torch rear end into the feeders mounting block by the method used by the

feeder manufacturer (normally a set screw).

7. Reduce the feeder’s wire hub tension by backing off the nut in the center of the hub

until the friction is only enough to stop the wire spool from spinning free. After

conﬁrming that the feed rolls are the correct size and type for the wire being used,

and that the wire is fed into the liner correctly, back off the wire feed roll pressure

until the feed rolls no longer feed the wire, then retighten slightly. Be cautious, as too

much pressure will deform soft wires such as aluminum and cause the wire to jam in

the contact tip. To help prevent wire deformation, a U-groove feed roll is better than a

V-groove feed roll for soft wires.

9. Aluminum wire requires a contact tip with a greater clearance than that used for

steel. (See individual torch parts lists and consumable charts on pages 9-10.)

Installation of Teﬂon®liners for aluminum/

stainless steel in Euro quick-connect guns

1. Lay the torch out straight and remove the liner retaining nut at the wire feed end of

the torch cable. Remove the existing gun liner if ﬁtted. If switching from a steel liner,

remove the swanneck and ﬁt the appropriate brass neckliner for aluminum – stock

number B2440 for wires .024” to .040” (.6mm-1.0mm) or B4052 for wires .040” to

.052” (1.0mm-1.4mm) – as per instructions on pages 2 and 3. Replace the swanneck

with brass neckliner ﬁtted.

2. Gently feed the plastic liner through the cable assembly until the liner bottoms out in

the neckliner collet. If unsure whether the liner is in the neckliner collet as far as it can

go, remove the swanneck, feed the liner through so that it protrudes 7-8 mm from the

body, taking care not to kink the liner. Replace the swanneck, inserting the protruding

end of the liner into the neckliner collet, and tighten down the swanneck locking ring.

Push the liner again to make sure it has bottomed in the neckliner collet.

3. Refer to the diagram below: At the adaptor block end of the torch cable, slide the

brass collet and O-ring over the liner until they are located in the recess in the adap-

tor block; replace the liner retaining nut. DO NOT CUT THE LINER YET!

4. If the wire feed unit was previously set up for steel wire, it may be necessary to take

a pair of long-nosed pliers and remove the steel inlet guide from the central adaptor

installed in the front face of the wire feed unit.

5. With the plastic liner still protruding from the adaptor plug, feed the liner through the

inlet of the central adaptor until the adaptor plug on the torch is butted against the

central adaptor. Fasten into position with the plastic adaptor nut. Lift the feed rollers

of the wire feeder to enable the excess liner to pass through. Cut the liner, using a

sharp knife, so that it butts up to the feed rollers, thereby supplying support to the soft

wire immediately after it exits the drive rolls. If this is done correctly, “bird-nesting” in

the event of a wire jam will be prevented.

6. Remove the welding gun from the machine and ensure that the brass guide tube is 3

mm shorter than the protruding plastic liner (if not, cut accordingly). Slide the guide

tube over the liner and feed the liner (with the guide tube ﬁtted) into the inlet in the

central adaptor; continue to feed through until the adaptor plug is butted against the

central adaptor, then tighten the plastic adaptor nut.

Note: Plastic liners with a diameter of 4.7 mm do not require a guide tube. (See

diagram below for correct location of parts.)

7. Reduce the wire hub tension by backing off the nut in the center of the hub until the

friction is only enough to stop the wire spool from spinning freely.

8. After conﬁrming that the feed rolls are the correct size and type for the wire being

used, and that the wire is fed into the liner correctly, back off the wire feed roll pres-

sure until the feed rolls no longer feed the wire, then retighten slightly. Be cautious, as

too much pressure will deform soft wires such as aluminum and cause the wire to jam

in the contact tip.

Brass Guide Tube

Liner Retaining

Nut

Collet

Adaptor Plug O-ring

(Prevents gas loss)

Liner

Wire Feed Roll

Allen key

Direct Plug

Torch Rear End

Connector Kit

Internal Gas

Connector plug

Set screw

1. Thread the connector plug into the rear of the torch (the connector plug may differ

from the one shown).

2. Tighten down the set screw with the Allen key provided.

3. Connect the appropriate end of the trigger lead jumper supplied in the kit to the con-

nector exiting the torch (the trigger lead may also differ from the one shown).

4. Install the gun liner supplied with the torch as per the liner installation instructions on

pages 4-5.

5. The torch is now ready to install into the feeder. Finally, hook up the trigger connector

on the feeder side.

Trigger lead jumper

Assembly instructions for direct plug

connector kits: internal gas

Assembly instructions for direct plug

connector kits: external gas (Lincoln std. shown)

1. Slide the insulating sleeve over the connector plug (wide end facing the torch) and

screw the plug into the torch rear end.

2. Tighten down the set screw with the Allen key provided.

3. Remove the gas seal and save for possible future use (e.g. for converting the torch to

internal gas). Install the gas nipple in place of the gas seal (removable sealant can be

applied to the threads if so desired, but use care to avoid sealant getting inside the

block).

4. Slide the gas hose over the gas nipple and clamp with the clamps supplied.

5. Connect the appropriate end of the trigger lead jumper supplied in the kit to the con-

nector from the torch rear end.

6. Install the liner supplied with the torch as per installation instructions on pages 4-5.

7. The torch is now ready to install into the feeder. Finally, hook up the gas and trigger

connectors on the feeder side.

Gas seal

Gas

nipple

Set screw

Insulating

sleeve Connector plug

Allen key

Connector Kit

Lincoln

Standard

Direct Plug

Torch Rear End

Trigger lead jumper

Gas hose

ALPHA 1 SLIP-ON NOZZLE: CONSUMABLE COMBINATIONS

Note: The ALPHA 1 is available with a slip-on nozzle only

ALPHA 1 Wire Size Contact Tip Tip Holder Diffuser Nozzle Neckliner Cable Liner

Slip-On Type Part # Part # Part # Part # Part # Part #

.024 Steel 140.0005 N/A N/A 145.0075 S2435 SI-2435-17PT

.030 Steel 140.0051 N/A N/A 145.0075 S2435 SI-2435-17PT

Factory Set-up .035 Steel 140.0169 N/A N/A 145.0075 S2435 SI-2435-17PT

.030 Aluminum 141.0001 N/A N/A 145.0075 B2440 127.9009

.035 Aluminum 141.0004 N/A N/A 145.0075 B2440 127.9003

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