Abicor Binzel AB20 Bedienungsanleitung

T E C H N O L O G Y F O R T H E W E L D E R ´ S W O R L D .

www.binzel-abicor.com

Operating instructions

AB Series MIG/MAG Welding Torches

EN - 2

AB Series Torches

EN English Translation of the original operating instructions

and amendments to these operation Instructions which may become necessary due to misprints,

inaccuracies or improvements to the product. Such changes will however be incorporated into

subsequent editions of the Instructions. All trademarks mentioned in the operating instructions are

the property of their respective owners.

All brand names and trademarks that appear in this manual are the property of their respective

owners/manufacturers.

Our latest product documents as well as all contact details for the ABICOR BINZEL national

subsidiaries and partners worldwide can be found on our website at www.binzel-abicor.com

1DesignatedUse EN-3

1.1 Marking EN-3

1.2 Technical Data EN-3

2SafetyInstructions EN-5

2.1 Classification EN-5

2.2 Emergency information EN-5

3 Putting into operation EN-6

3.1 Equipping the torch EN-6

3.1.1 Equipping spare parts onto the

torch neck EN-6

3.1.2 Changing the torch neck or

adjusting the torch neck´s direction EN-6

3.2 Mounting the wire guide liner EN-7

3.3 Connecting the torch to machine EN-7

3.4 Setting the shielding gas quantity EN-7

3.5 Feed in wire EN-7

4 Operating elements EN-8

5 Removal from service EN-8

6 Maintenance and cleaning EN-9

EN - 3

AB Series Torches 1 Designated Use

1DesignatedUse

The AB series manual welding torches are used for safety welding of carbon

steel and alloy steel materials. They consist of the torch neck with equipment

parts and wearing parts, handle and cable assembly with Panasonic connector

(or OTC/Euro connector). They correspond to the directive EN 60 974-7 and

are not considered to be devices having their own functions. Arc welding can

only be carried out in connection with a welding power supply.

1.1 Marking

This product fulfills the requirements that apply to the market to which it has

been introduced. A corresponding marking has been affixed to the product, if

required.

1.2 Technical Data

Transport and storage - 25 °C to + 55°C

During welding -10°C to +40°C

Relative humidity up to 90 % at 20 °C

Tab. 1 Ambient temperature

Type of voltage DC

Polarity of the electrode Usually positive

Shielding gas (DIN EN ISO 14175) CO2 and mixed gas M21

Wire types commercially available round wires

Guide type Manual

Voltage rating 113 V peak value

Protection type of the machine side

connections (EN 60 529)

IP3X

Tab. 2 General torch data (EN 60 974-7)

EN - 4

1 Designated Use AB Series Torches

Type Type of

cooling

Type of

BIKOX

cable

CO2M21 Wire Flow

rate

duty cycle Load Duty cycle Load

AB Series

Torches

% A % A mm l/min

20.1 air V186 60 200 55 200 0.6 - 1.0 10 - 20

20.2 air R4 55 200 50 200 0.6 - 1.0 10 - 20

35.1 air V407 60 350 55 350 1.0 - 1.6 10 - 20

35.2 air V357 50 350 45 350 1.0 - 1.6 10 - 20

50.0 air R9A 60/35 500/600 50/25 500/600 1.2 - 1.6 15 - 20

50.1 air V657 60 450 50 450 1.2 - 1.6 15 - 20

50.2 air V557 50 450 40 450 1.2 - 1.6 15 - 20

Tab. 3 Product-specific torch data (EN 60 974-7)

Standard length L 3.00 m, 4.50 m, 6.00 m

Control lead 2-wire

Tab. 4 Cable assembly data

Torch

type

AB20 AB35 AB50

Torch

length

3m 4.5 m 6 m 3 m 4.5 m 6 m 3 m 4.5 m 6 m

Standard For wire 0.8-1.0 For wire 1.2-1.4 For wire 1.2-1.4

Wire

liner

394.D004 394.D005 394.D006 394.D007 394.D008 394.D009 394.D007 394.D008 394.D009

Optional For wire 1.6 For wire 1.6

Liner 394.D010 394.D011 394.D012 394.D010 394.D011 394.D012

Gaz

nozzel

145.D371 145.D373 145.D374

Nozzle

holder

768.D321 768.D322

Tip

holder

768.D585.0 768.D132 768.D133

Gas

diffusor

768.D326 768.D327

Torch

neck

768.D576.0 768.D578.0 768.D580.0

Tab. 5 Spare parts´ list

EN - 5

AB Series Torches 2 Safety Instructions

2SafetyInstructions

Observe the enclosed document Safety Instructions.

2.1 Classification

The warning signs used in the operating instructions are divided into four

different levels and are shown prior to specific work steps. Arranged in

descending order of importance, they have the following meaning:

2.2 Emergency information

In case of emergency, immediately interrupt the power and shielding gas.

Further measures can be found in the "Power supply" user manual or in the

documentation of further peripheral devices.

Contact

tip

0.6 0.8 1.0 1.2 1.4 1.6

T2 140.D435 140.D4361140.D438 140.D4392140.D440 140.D441

Cr/Zr/Cu 140.1520 140.1521 140.1523 140.1524 140.1525 140.1526

Tab. 6 Contact tip list

1Standard contact tip for AB20

2 Standard contact tip for AB35/50

DANGER

Describes imminent threatening danger. If not avoided, it will result in fatal or

extremely critical injuries.

WARNING

Describes a potentially dangerous situation. If not avoided, it may result in

serious injuries.

CAUTION

Describes a potentially harmful situation. If not avoided, it may result in slight

or minor injuries.

NOTE

Describes the risk of impairing work results or the risk that may result in

material damage to the equipment.

EN - 6

3 Putting into operation AB Series Torches

3 Putting into operation

3.1 Equipping the torch

3.1.1 Equipping spare parts onto the torch neck

Equip the torch neck according to the following figure:

3.1.2 Changing the torch neck or adjusting the torch neck´s direction

1Uncover the black cover cap on the handle.

2Loosen the torch neck lock bolt with an inner hexagonal wrench (4 mm), but

do not unscrew the bolt out.

3Pull out the torch neck, insert the new torch neck in and turn it to the correct

position.

4Fasten the lock bolt and cover the cover cap again.

DANGER

Risk of injury due to unexpected start-up.

For the entire duration of maintenance, servicing, dismounting and repair

work, the following instructions must be adhered to:

• Switch off the power supply.

• Close off the gas supply.

• Disconnect all electrical connections.

CAUTION

Risk of injury

Piercing or puncture caused by electrode tip.

• Do not reach into the danger zone and wear protective gloves.

1Gas nozzle

2Contact tip

3Gas diffuser

4Nozzle holder

5Torch neck

Fig. 1 Equipping the torch

12345

AB20

AB35

AB50

EN - 7

AB Series Torches 3 Putting into operation

3.2 Mounting the wire guide liner

1Lay the torch straight out and unscrew the gas nozzle as well as the contact

tip from the torch neck.

2Slide the wire guide liner into the torch up to the Panasonic connector; for

the torches with Euro or OTC connector, unscrew the position holder nut on

the connector, insert the wire guide liner in and then screw the position

holder nut back on again.

3Fold the torch side cable to a degree of 180°, cut off the wire guide liner

at the end of the tip holder.

4Pull out the wire guide liner.

5Sharpen the wire guide liner to an angle of approx. 40° and deburr the

cutting edge.

6Insert the wire guide liner into the torch again; for torches with Euro or OTC

connectors, please screw the position holder nut on the connector and tight

with a spanner.

7Screw the contact tip and gas nozzle back on again.

3.3 Connecting the torch to machine

1Insert the Panasonic connector into the wire feed unit, and tight the lock bolt

on the wire feed unit; for Euro or OTC connectors, screw the union nut tight.

2Properly mount the connections for shielding gas.

3.4 Setting the shielding gas quantity

3.5 Feed in wire

1Insert the wire in the wire feed unit as specified by the manufacturer.

2Press the "Wire Jog" push-button at the wire feed unit until the wire comes

out of the contact tip.

NOTE

• The type and quantity of the shielding gas quantity depends on the

welding task and the gas nozzle geometry.

• Make all shielding gas connections gas-tight.

• To prevent the shielding gas supply from becoming clogged by

impurities, the cylinder valve must be opened briefly, before connecting

the cylinder. This will blow out any impurities that may be present.

EN - 8

4 Operating elements AB Series Torches

4 Operating elements

1Press the trigger on the handle and keep it pressed = welding is started.

2Release the trigger = welding is stopped.

5Removalfromservice

1Wait until the shielding gas flow has subsided and switch off the power

supply.

2Close the valve of the shielding gas cylinder.

NOTE

• As the AB Series Torches torch is integrated into a welding system, the

operating instructions of the welding components, such as power supply,

must be observed during operation.

EN - 9

AB Series Torches 6 Maintenance and cleaning

6 Maintenance and cleaning

1Unscrew the torch on the wire feed unit and lay it straight out.

2Dismount the wire guide liner and replace it if necessary.

3Remove worn parts from the torch neck.

4Clean the wire guide liner from both sides with compressed air.

5Mount the wire guide liner back on the torch.

6Connect the torch on the wire feed unit.

DANGER

Risk of injury due to unexpected start-up.

For the entire duration of maintenance, servicing, dismounting and repair

work, the following instructions must be adhered to:

• Switch off the power supply and close off the gas supply.

• Pull out the mains plug.

WARNING

Risk of injury

Serious injuries caused by parts swirling around.

• When cleaning the wire guide liner with compressed air, wear suitable

protective clothing, in particular safety goggles.

EN - 10

6 Maintenance and cleaning AB Series Torches

NOTE

• When change contact-tip holder or torch neck, or connect Panasonic to

machine side, the contact surface between parts must be clean and free

from hard particles, otherwise the surface will be scraped and good

contact won’t be guaranteed.

• When assemble trigger contact spring onto torch handle, be care not to

bend the spring and make sure the two springs are assembled with the

contact points face to face. The groove on the spring must be set on the

stage shown as the following photo.

1The contact springs must be assembled with the groove set on the stage of the torch handle

Fig. 2 Assemble trigger contact spring

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