ABICOR BINZEL MB ERGO 15 AK MIG Welding Torch Instruction Manual

: June 1, 2024
: ABICOR BINZEL

Table of Contents

MB ERGO 15 AK MIG Welding Torch
Designated Use
Technical Data
Safety Instructions
Putting into operation
Handle operating elements
Operation
Removal from service
Maintenance and cleaning
References
Read User Manual Online (PDF format)
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MB ERGO 15 AK MIG Welding Torch
Instruction Manual MB/RAB
MIG/MAG Welding torch MB/RAB

MB ERGO 15 AK MIG Welding Torch

TECHNOLOGY FOR THE WELDER´S WORLD.
Translation of the original operating instructions
© 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

Transport and storage	– 25 °C to + 55°C
Relative humidity	up to 90 % at 20 °C

Tab. 1 Ambient temperature

Type of voltage	DC
DC polarity of the electrodes	Usually positive
Shielding gas (DIN EN ISO 14175)	CO2 and mixed gas M21
Wire types	commercially available round wires
Voltage rating	1 3 V peak value
Protection type of the machine side connections (EN 60 529)	IP3X
Control device in handle	for 42 V and 0.1 to 1 A

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

Type	Type of cooling	Load	ED	Wire ∅	Gas flow	Cooling data
Supply temp.	Flow	Flow pressure
CO2	M21	max.	min.	min.	max.
MB ERGO		A	A	%	mm	l/min
14	air	160	140	60	0.6 – 0.9	10 – 18
15	air	180	150	60	0.6 – 1.0	10 – 18
25	air	230	200	60	0.8 – 1.2	10 – 18
24	air	250	220	35	0.8 – 1.2	10 – 18
26	air	230	200	35	0.8 – 1.2	10 – 18
36	air	300	270	60	0.8 – 1.2	10 – 20
40	air	350	320	35	1.0 – 2.4	10 – 20
240 D	liquid	300	270	100	0.8 – 1.2	10 – 20
Type	Type of cooling	Load	ED	Wire ∅	Gas flow	Cooling data
---	---	---	---	---	---	---
Supply temp.	Flow	Flow pressure
CO2	M21	max.	min.	min.	max.
MB ERGO		A	A	%	mm	l/min
401 D	liquid	400	350	100	0.8 – 1.6	10 – 20
401	liquid	450	400	100	0.8 – 1.6	10 – 20
501 D	liquid	500	450	100	1.0 – 1.6	10 – 20
501	liquid	550	500	100	1.0 – 1.6	10 – 20
602	liquid	600	550	100	1.0 – 2.0	10 – 20

MB GRIP
15 AK| air| 180| 150| 60| 0.6 – 1.0| 10 – 18| | | |
25 AK| air| 230| 200| 60| 0.8 – 1.2| 10 – 18| | | |
24 KD| air| 250| 220| 60| 0.8 – 1.2| 10 – 18| | | |
26 KD| air| 270| 240| 60| 0.8 – 1.2| 10 – 18| | | |
36 KD| air| 320| 290| 60| 0.8 – 1.2| 10 – 20| | | |
240 D| liquid| 300| 270| 100| 0.8 – 1.2| 10 – 20| 40| 1,5| 2.5| 3.5
401 D| liquid| 400| 350| 100| 0.8 – 1.6| 10 – 20| 40| 1,5| 2.5| 3.5
401| liquid| 450| 400| 100| 0.8 – 1.6| 10 – 20| 40| 1,5| 2.5| 3.5
501 D| liquid| 500| 450| 100| 1.0 – 1.6| 10 – 20| 40| 1,5| 2.5| 3.5
501| liquid| 550| 500| 100| 1.0 – 1.6| 10 – 20| 40| 1,5| 2.5| 3.5
RAB
15 AK| air| 180| 150| 60| 0,6 – 1,0| 10 – 18| | | |
25 AK| air| 230| 200| 60| 0,8 – 1,2| 10 – 18| | | |
24 KD| air| 250| 220| 35| 0,8 – 1,2| 10 – 18| | | |
36 KD| air| 300| 270| 60| 0,8 – 1,2| 10 – 20| | | |
240 D| liquid| 300| 270| 100| 0,8 – 1,2| 10 – 20| 40| 1| 2,5| 3,5
501 D| liquid| 500| 450| 100| 1,0 – 1,6| 10 – 20| 40| 1| 2,5| 3,5
501| liquid| 550| 500| 100| 1,0 – 1,6| 10 – 20| 40| 1| 2,5| 3,5

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

Standard length L	3.00 m, 4.00 m, 5.00 m
Coolant connection	Connector nipple NW 5
Cooling unit power	min. 800 W
Control line	2-wire

Tab. 4 Hose assembly data MB/RAB

Safety Instructions

Observe the enclosed document Safety Instructions.
3.1 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.

3.2 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.

4.1 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: ABICOR BINZEL MB ERGO
15 AK MIG Welding Torch - Gas diffuser Fig. 1 Equipping the torch

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
---|---|---

4.2 Installing the spiral wire liner
4.2.1 Spiral wire liner

To be used for steel wires.

Lay down the hose assembly straight and unscrew gas nozzle and contact tip from torch neck.
Unscrew liner retention nut from central plug and slide wire liner through the cable hose up to the liner collet.
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.
Unscrew liner retention nut and pull out spiral wire liner.
Sharpen the spiral wire liner at the front to an angle of approx. 40° and debur the edge.
Slide sharpened spiral wire liner through the cable hose up to the liner collet and tighten the liner retention nut with wrench.
Screw in contact tip and install gas nozzle.

4.2.2 PA liner

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

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.
Slide forward the liner collet, O-ring and liner retention nut on the PA liner and tighten the liner retention nut under compression.
Mark excess PA liner in front of the wire feed rollers and Cut the PA liner at the mark with the ABICOR BINZEL cutter.
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.

4.3 Mounting the cable assembly

Connect Euro plug and adaptor kit at the wire feed unit and secure them with the retention nut.
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.

4.4 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.

4.5 Feed in wire

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

5.1 Trigger with two-position function

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

Operation

Open the shielding gas cylinder.
Switch on the power supply.
Setting the welding parameters.
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.

Welding is stopped.
Wait until the shielding gas flow has subsided and switch off power supply.
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.

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

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
info@binzel-abicor.co.uk
Manufacturer:
Alexander Binzel Schweisstechnik
GmbH & Co. KG
Kiesacker • 35418 Buseck • GERMANY
T +49 64 08 / 59–0
F +49 64 08 / 59–191
info@binzel-abicor.com
www.binzel-abicor.com