ABICOR BINZEL PP 24D Push-Pull PP 401 D Watercooled MIG Torch Instruction Manual

ABICOR BINZEL PP 24D Push-Pull PP 401 D Watercooled MIG Torch

© 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

Identification

The push-pull welding torches of the “PP” series guarantee constant and thus problem-free wire feeding. This version is used predominantly for welding aluminium, for thin wires and for long cable assemblies. They conform to EN 60 974-7 and are not considered devices having their own functions. Arc welding can only be carried out in connection with a welding power supply. These operating instructions only describe PP welding torches. PP welding torches may only be operated using original ABICOR BINZEL spare parts.

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.

Safety

The enclosed safety instructions must be observed.

Designated use

• The device described in these instructions may be used only for the purpose described in these instructions in the manner described. In doing so, observe the operating, maintenance and servicing conditions.
• Any other use is considered contrary to the designated use.
• Unauthorized conversions or power increase modifications are not allowed.

Classification of the warnings
The warning signs 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 an imminent threatening danger. If not avoided, this will result in fatal or extremely critical injuries.
• WARNING Describes a potentially dangerous situation. If not avoided, this may result in serious injuries.
• CAUTION Describes a potentially harmful situation. If not avoided, this may result in slight or minor injuries.
• NOTICE Describes the risk of impairing work results or potential material damage to the equipment.

Emergency information
In the event of an emergency, immediately disconnect the following supplies:

• Electrical power supply
• Coolant supply
• Compressed air supply.
• Gas supply
  Further measures can be found in the operating instructions for the power source or the documentation for other peripheral devices.

Product Description

WARNING Hazards caused by improper use
If improperly used, the device can present risks to persons, animals and material property.

• Use the device according to its designated use only.
• Do not convert or modify the device to enhance its performance without authorisation.
• The device must only be used by qualified personnel (in Germany, see TRBS 1203).

Technical Data

Tab. 1 General Data

IP2X , IP3X (EN 60 529)
Shielding gas (DIN EN ISO 14175)| CO2 and mixed gas M21

Tab. 2 General torch data according to EN 60 974-7

Type| Type of cooling| **Load*| ED| Wire ø| Gas flow rate| Cooling data
---|---|---|---|---|---|---
 |  |  |  |  |  |  | Flow temp.| Flow| Flow pressure
 |  | CO2| M21|  |  |  | max.| min.| min.| max.
PP|  | (A)| (A)| (%)| (mm)| (l/min)| (°C)| (l/min)| (bar)| (bar)
24D| air| 230| 200| 35| 0.8 – 1.0| 10 – 18|  |  |  |
36D| air| 290| 260| 60| 0.8 – 1.2| 10 – 18|  |  |  |
240D| liquid| 270| 240| 100| 0.8 – 1.2| 10 – 20| 50| 1| 2.0| 3.5
401D**| liquid| 350| 320| 100| 0.8 – 1.6| 10 – 20| 50| 1| 2.0| 3.5

Tab. 3 Product-specific torch data as laid out in EN 60974-7 PP

cooled),central connector KZ-2 (air-cooled)

Tab. 4 Cable assembly

Signs and symbols used
In the operating instructions, the following signs and symbols are used:

information
1| Action(s) described in the text to be carried out in succession

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 source.
• Close the gas supply.
• Close off the compressed air supply.
• Disconnect all electrical connections.
• Switch off the entire welding system.

DANGER: Risk of injury and device damage when handled by unauthorised persons
Improper repair work and modifications to the product may lead to serious injuries and damage to the device. The product warranty will be rendered invalid if work is carried out on the product by unauthorised persons.
Operating, maintenance, cleaning and repair work must only be carried out by qualified personnel (in Germany, see TRBS 1203).

Equipping the torch

CAUTION Risk of injury
Puncture or cut-in wounds may be caused by the wire electrode.

• Keep your hands out of the danger zone.
• Wear the correct protective gloves.

Equip the torch neck according to one of the following figures:

Fig. 1 Equipping the torch

1. Types 24/36/240D
2. Contact tip
3. Tip adaptor
4. Gas diffuser
5. Torch neck
6. Type 401D
7. Gas nozzle

Mounting the liner
NOTICE New still unused liners or PA liners have to be shortened to the actual length of the cable assembly.

Liner
To be used for steel wires.

Fig. 2 Liner

1. Lay down the cable assembly (9) straight and unscrew nut (6) from central connector (4).
2. Slide the liner (8) through the wire conduit (3) until a noticeable resistance is felt in the inlet nipple (2).
3. Determine excess length x and pull out the liner (8) again.
4. Shorten the liner (8) by the dimension x.
5. Debur the cutting point and sharpen the spiral beginning to an angle of 40°.
6. Insert the liner cut to length (8) into the wire conduit (3).
7. Screw down nut (6) and secure with multiple wrench (5).

Liner (plastic)
For use with aluminium, copper, nickel and stainless steels

1. Wire conduit
2. Central connector
3. Nut
4. Wire feed rolls
5. ABICORBINZEL Cutter
6. O-ring
7. Clamp nipple
8. Liner (plastic)
9. ABICORBINZEL Sharpener
10. Inlet nipple

Fig. 3 Shortening the PA liner

1. Lay down the cable assembly straight and unscrew nut from central connector (2).
2. Sharpen the beginning of the PA liner (8) to approx. 40° using the ABICOR BINZEL sharpener (9).
3. Slide PA liner (8) through the wire conduit (1) into the inlet nipple (10) until a noticeable resistance is felt.
4. Slide clamp nipple (7), O-ring (6) and nut (3) on the PA liner (8) and tighten the nut (3) under tension.
5. Mark a PA liner (8) that is too long in front of the wire feed rolls (4) (wire feeder).
6. Cut the PA liner (8) at the mark directly in front of the wire feed rolls using the ABICOR BINZEL cutter (5) .
7. Sharpen the cutting point.

Connecting the cable assembly

WARNING Risk of burns
The welding torches will become overheated if the coolant level is too low.

• Wear protective gloves.
• Check the coolant level at regular intervals.

1. Join central connector and central socket at the wire feed unit and secure them with the connection nut.
2. Properly mount the connections for coolant supply/return, shielding gas and control lead plug.

Connecting the coolant

• Ensure that the coolant supply and return hoses have been correctly installed. Coolant supply = blue, coolant return = red.

• Do not use deionised or demineralised water as coolant or for leak and flow tests.
  This may shorten your welding torch’s service life.

• We recommend the use of ABICOR BINZEL series BTC coolant for liquid-cooled welding torches.

• Each time the device is commissioned or after each cable assembly change, the cooling system must be purged of any air. Disconnect the coolant return hose from the recirculating cooling unit and hold it over a collecting device. Close opening at the coolant
  return. Open it again by repeatedly and abruptly releasing it, until the coolant is flowing continuously and without air bubbles.

Connecting the PP control lead

The control lead is open on the machine side. The customer has to provide the connection of a suitable plug. If all data are provided, the machine can also be delivered ready-to-connect.
Otherwise choose a compatible plug for your power supply and solder it to the corresponding leads according to the connection diagram.

Control board connection (optional)

Tab. 6 Colour coding

Operating voltage 36 – 42 V AC
The control board guarantees a synchronous run between the push motor in the feed case and the pull motor in the manual torch. The green/white two-wire motor line must be connected in accordance with the following connection diagram:
Fig. 5 on page EN-11
Green to plus, white to minus:

Setting the shielding gas quantity

• The type and quantity of the shielding gas 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 expel any impurities that may be present.

Feeding in the wire

Fig. 6 Feeding in the wire

1. Torch neck
2. Clamping cap
3. Flat-head screw
4. Fixing plate
5. Potentiometer (optional)
6. Handle
7. Seat clamp

NOTICE
Each time the wire is changed, make sure that the beginning of the wire is free of burrs.
Make sure that the wire feed roll complies with the diameter of the inserted wire electrode.

1. Insert the wire in the wire feeder as specified by the manufacturer.
2. Remove clamping cap (2) from handle (6).
3. Swing out seat clamp (7) laterally.
4. Press the “Current-less wire feed” trigger at the wire feed unit until the wire emerges from the contact tip.
5. Lock seat clamp (7) and attach clamping cap (2).

The required contact pressure is pre-set via the knurled screw at the clamping cap or is readjusted during the welding process.

Handle operating elements

NOTICE As the MIG/MAG welding torches are integrated into a welding system, the operating instructions of the welding components, such as the welding power supply, must be observed during operation.

Trigger function

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

Potentiometer control (optional)
The optional potentiometer allows you to set or finely adjust various control functions (e.g. wire feed rate) at the handle. For the version equipped with remote control in the handle plate, the white/green/brown control leads must be connected to those of the potentiometer at the feed case.

NOTICE
The resistance values of both potentiometers must be absolutely identical.
Use and function of the potentiometer control in question depend on the power supply used.

Operation

1. Open the shielding gas cylinder.
2. Switch on the power supply.
3. Set the welding parameters.
4. Start welding.

NOTICE
Hose assemblies containing PVC hoses will start leaking if the return coolant temperature is exceeded. Make sure not to exceed a return coolant temperature of 60°C.

Putting out of operation

• When putting the system out of operation, ensure that the procedures for switching off each of the welding system components are observed.
• Liquid-cooled cable assemblies may start leaking if overheated. This is why the cooling unit should continue running for approx. 5 min. after welding.

1. Stop welding.
2. Wait until the shielding gas flow has subsided and then switch off the power supply.
3. Close the valve of the shielding gas cylinder.

Maintenance and cleaning

Scheduled maintenance and cleaning are prerequisites for a long service life and trouble-free 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 source.
• Close the gas supply.
• Close off the coolant supply.
• Disconnect the coolant supply and return hoses.
• Close off the compressed air supply.
• Disconnect all electrical connections.
• Switch off the entire welding system.

DANGER Risk of burns
Risk of burns from hot coolant and hot surfaces.

• Switch off the coolant recirculator before starting maintenance, servicing, assembly, disassembly or repair work.
• Allow the welding torches to cool down.
• Wear the correct protective gloves.

WARNING Risk of burns
The welding torches reach very high temperatures during welding.

• Allow the welding torches to cool down.
• Wear the correct protective gloves.

NOTICE

• The specified maintenance intervals are guidance values and refer to single-shift operation.
• Maintenance and cleaning work may only be carried out by qualified personnel (in Germany see TRBS 1203).
• Check the coolant hoses, seals and connectors for damage or leaks and replace if necessary.
• Always wear your personal protective equipment when performing maintenance and cleaning work.
• Remove any adhering weld spatter.
• Ensure that all threaded fittings are tight.

Replacing the wire feed roll

1. Lift off clamping cap (2) and swing out seat clamp (7).
2. Lift off the flat-head screw (3) using the crosstip screwdriver and lift it off together with the fixing plate (4).
3. Pull wire feed roll off the seat and replace it.
4. Swing in seat clamp (7) and attach clamping cap (2).

Replacing liner in torch neck

1. Torch neck
2. Nut
3. Inlet nozzle
4. Clamping cap
5. Counter nut M3
6. Seat clamp
7. Torch seat
8. Liner (plastic)

Fig. 7 Replacing liner in torch neck

1. Remove torch neck (1) from torch seat (7) by unscrewing the nut (2).

2. Lift off clamping cap (4) and swing out seat clamp (6) laterally.

3. Unscrew counter nut (5) from the inlet nozzle (3).

4. Remove inlet nozzle (3) from PP body toward the front by unscrewing it and replace it.
   NOTICE
   • In the case of bent torch necks, a liner (plastic) (8) (outer diameter D = 4.0 mm) must be mounted additionally between inlet nozzle (3) and contact tip.
   • The actual length of the liner (plastic) (8) must be adjusted, depending on the application.

5. Screw in inlet nozzle (3) until a short distance in front of the wire feed roll and secure it in this position with the counter nut (5).

6. The inlet nozzle (3) is mounted in reverse order.

Cleaning the wire guide

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

1. Unscrew the cable assembly on the machine side and bring it into a stretched position.
2. Unscrew the nut (6) and pull out the liner (8) or PA liner and replace it, if necessary.
3. Clean wire conduit (3) from both sides with compressed air.
4. Slide adjusted liner or PA liner into wire conduit (3) and secure it with the nut (6).
5. Connect cable assembly on the machine side to the wire feed unit.

Cleaning the torch neck

1. Remove gas nozzle.
2. Remove welding spatter and spray gas nozzle with ABICOR BINZEL anti-spatter agent.
3. Check wear parts for visible damage and replace them, if required.
4. Replace neck liner or wire guide when worn or soiled.
5. Clean the separating point and grease O-rings with silicone-free sealing grease.

Disposal

• Do not dispose of the device with household waste.
• For disposal, observe the local regulations, laws, provisions, standards and guidelines.

References

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

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