ABICOR BINZEL RAB MIG-MAG Welding Torch Instruction Manual

ABICOR BINZEL RAB MIG-MAG Welding Torch

Product Information

The MB/RAB product is a welding torch used for welding with a shielded gas. The torch comes with various features such as a hand grip, gas distributor, and a nozzle. The product has different types like MB ERGO, CO2 M21, and MB GRIP.

Product Usage Instructions

1. Transport and Storage: Store and transport the welding torch in a dry place with a temperature between -20°C to +60°C and a relative humidity of up to 90%.
2. Installation: Before using the welding torch, read and follow the instructions for use and installation provided in the manual. Always use appropriate personal protective equipment such as gloves and protective eyewear.
3. Adjusting the Shielding Gas: Adjust the shielding gas flow rate based on the prescribed levels in table 2, using the regulator.
4. Operating: Once the torch is set up, press the trigger to start welding. The torch has a two-stroke function that can be activated using the button on the handgrip.
5. Maintenance and Cleaning: Always disconnect
   the torch from the power source before cleaning or performing maintenance. Use only recommended cleaning agents and a soft-bristled brush to clean the nozzle and other parts of the torch. Always refer to the manual for more detailed instructions and safety precautions before operating the MB/RAB welding torch.

Introduction

© The manufacturer reserves the right, at any time and without prior notice, to make such changes 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

Designated Use

The MIG/MAG manual welding torches are used for safe welding of low- and high- alloy materials. They consist of a torch neck equipped with equipment parts and wear parts, handle or handle tube and cable assembly with central 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.

Technical Data

Tab. 1 Ambient temperature

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

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

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

Safety Instructions

Observe the enclosed document Safety Instructions.

Classification of the warnings

The warnings used in the operating instructions are divided into four different levels and are shown prior to potentially dangerous work steps. Arranged in descending order of importance, they have the following meaning:

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.

NOTICE
Describes the risk of impairing work results or the risk that may result in material damage to the equipment.

Emergency information

In case of emergency, immediately interrupt the Power, compressed-air and Gas. Further measures can be found in the “Power supply” user manual or in the documentation of further peripheral devices.

Putting into operation

DANGER
Risk of injury due to unexpected start-up.
The following instructions must be adhered to for the entire duration of maintenance, servicing, mounting, dismounting and repair work:

• Switch off the power supply and close off the gas supply.
• Switch off the compressed-air and pull the mains plug.

Equipping the torch

CAUTION Risk of injury

• Piercing or puncture caused by electrode tip.
• Do not reach into the danger zone and wear protective gloves.
• Equip the torch neck according to the following figure:

1. Type 15
2. Gas diffuser
3. Contact tip
4. Tip adaptor
5. Gas diffuser
6. Torch neck
7. Type 401/501
8. Type 401D/501D
9. Type 24/26/36/602/240D
10. Gas nozzle
11. Type 25

Installing the spiral wire liner

Spiral wire liner

To be used for steel wires.

1. Lay down the hose assembly straight and unscrew gas nozzle and contact tip from torch neck.
2. Unscrew liner retention nut from central plug and slide wire liner through the cable hose up to the liner collet.
3. Screw down liner retention nut by hand and cut off the excess length of the spiral wire liner flush with the torch neck or the tip adaptor.
4. Unscrew liner retention nut and pull out spiral wire liner.
5. Sharpen the spiral wire liner at the front to an angle of approx. 40° and debur the edge.
6. Slide sharpened spiral wire liner through the cable hose up to the liner collet and tighten the liner retention nut with wrench.
7. Screw in contact tip and install gas nozzle.

PA liner

PA liners = for aluminium, copper, nickel and stainless steels.

1. Sharpen the front of the PA liner to approx. 40° with the ABICOR BINZEL sharpener and slide PA liner through the cable hose until a noticeable resistance is felt in the contact tip.
2. Slide forward the liner collet, O-ring and liner retention nut on the PA liner and tighten the liner retention nut under compression.
3. Mark excess PA liner in front of the wire feed rollers and Cut the PA liner at the mark with the ABICOR BINZEL cutter.
4. Sharpen the liner after cutting.

NOTICE

For PA liners of outer diameter 4.00 mm, the capillary tube in the adaptor kit must be replaced by a guide tube.

Mounting the cable assembly

1. Connect Euro plug and adaptor kit at the wire feed unit and secure them with the retention nut.
2. Properly mount the connections for water supply/return, shielding gas and control line plug.

NOTICE

• Check the minimum coolant level of the cooling device.
• Make sure that the coolant supply and return have been installed properly. Coolant supply = blue, Coolant return = red.
• Do not use any deionized or demineralized water as coolant or for tightness or flow tests.
• This may impair the service life of your welding torch.
• We recommend the use of ABICOR BINZEL series BTC coolant for liquid-cooled welding torches.

NOTICE

Each time the device is commissioned or after each hose assembly change, the cooling system must be ventilated as follow: disconnect the coolant return hose from the re-circulating cooling unit, and hold it over a collecting device. Close the opening at the coolant return hose. Open it again by repeatedly and abruptly releasing it, until the coolant is flowing continuously and without air bubbles.

Setting the shielding gas quantity

NOTICE

• 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.

Feed in wire

1. Insert the wire in the wire feed unit as specified by the manufacturer.
2. Press the “Wire Jog” push-button at the wire feed unit until the wire comes out of the contact tip.

Handle operating elements

NOTICE

• As the MIG/MAG welding torch is integrated into a welding system, the operating instructions of the welding components, such as power supply, must be observed during operation.
• Using a standard welding torch, the two-position mode of the trigger can be activated. Further operating modes and handle modules depend on the corresponding welding power supply and must be ordered separately.

Trigger with two-position function

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

Operation

1. Open the shielding gas cylinder.
2. Switch on the power supply.
3. Setting the welding parameters.
4. Welding is started.

Removal from service

NOTICE

Liquid-cooled hose assemblies may start leaking if overheated. This is why the cooling unit should continue running for approx. 5 min. after welding.

1. Welding is stopped.
2. Wait until the shielding gas flow has subsided and switch off power supply.
3. Close the valve of the shielding gas cylinder.

Maintenance and cleaning

DANGER

Risk of injury due to unexpected start-up.
The following instructions must be adhered to for the entire duration of maintenance, servicing, mounting, dismounting and repair work:

• Switch off the power supply and close off the gas supply.
• Close off the compressed-air and pull the mains plug.

NOTICE

• The maintenance intervals given are standard values and refer to singleshift operation.
• Maintenance and cleaning work may only be carried out by qualified and trained specialists.
• Check coolant hoses, seals, and connections for damage and tightness. Replace as necessary.
• Always wear your personal protective equipment when performing maintenance and cleaning work.

1. Unscrew the hose assembly on the machine side and bring it into a stretched position.
2. Unscrew liner retention nut and pull out wire spiral liner or PA liner and replace it, if necessary.
3. Remove worn parts from the torch neck.
4. Clean wire cable feed hose from both sides with compressed air.
5. Mount spiral wire liner or PA liner and secure it with nut.
6. Connect cable hose assembly on the machine side with retention nut.

WARNING

• Risk of injury
• Serious injuries caused by parts swirling around.
• When cleaning the spiral wire with compressed air, wear suitable protective clothing, in particular safety goggles.

Importer UK

• ABICOR BINZEL (UK) ltd.
• Binzel House, Mill Lane, Winwick Quay
• Warrington WA2 8UA • UK
• T +44-1925-65 39 44
• F +44-1925- 65 48 6 [email protected]

Manufacturer

• Alexander Binzel Schweisstechnik
• GmbH & Co. KG
• Kiesacker • 35418 Buseck • GERMANY
• T +49 64 08 / 59–0
• F +49 64 08 / 59–191 [email protected]

www.binzel-abicor.com

References

• ABICOR BINZEL USA - MIG, Robotic, & Laser Welding Solutions
• ABICOR BINZEL USA - MIG, Robotic, & Laser Welding Solutions

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