Abicor Binzel DAV User manual
EN - 2 BAL.0789.0 • 2020-03-02
DAV
EN 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
operating instructions as become necessary due to misprints, inaccuracies or product enhancements. Such changes will,
however, be incorporated into subsequent editions of the operating instructions.
All brand names and trademarks that appear in these operating instructions 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
1 Identification EN-3
1.1 Marking EN-3
1.2 EU declaration of conformity EN-3
2 Safety EN-4
2.1 Designated use EN-4
2.2 Obligations of the operator EN-4
2.3 Personal protective equipment (PPE) EN-4
2.4 Classification of the warnings EN-4
2.5 Warning and notice signs EN-5
2.6 Emergency information EN-5
3 Product description EN-6
3.1 Technical data EN-6
3.2 Abbreviations EN-7
3.3 Nameplate EN-7
3.4 Signs and symbols used EN-7
4 Scope of delivery EN-7
4.1 Transport EN-8
4.2 Storage EN-8
5 Functional description EN-8
6 Commissioning EN-9
6.1 Installation EN-9
6.2 Connecting the pneumatic system EN-9
6.3 Establishing the electrical connection
(optional) EN-10
6.4 Setting up the DAV EN-11
6.5 Pulling the wire EN-11
7Operation EN-12
8 Decommissioning EN-12
9 Maintenance and cleaning EN-13
9.1 Maintenance intervals EN-13
9.2 Replacing the cutter EN-14
10 Troubleshooting EN-15
11 Disassembly EN-16
12 Disposal EN-16
12.1 Materials EN-16
12.2 Consumables EN-16
12.3 Packaging EN-16
13 Accessories/options EN-17
13.1 Mounting kit EN-17
13.2 Compressed air hose EN-17
13.3 5/2 directional valve EN-17
DAV 1 Identification
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1 Identification
The DAV wire cutter is used in the welding industry and in the trade for robots performing MIG/MAG inert gas welding. The
DAV is used if the welding wire must be cut at the free end, e.g., cutting the welding bead or oxide layer to improve the
ignition properties, changing the torch neck at the ATS rotor with wire drawing, use of sensors to find seams and TCP
measuring equipment. These operating instructions describe the DAV wire cutter only. The DAV wire cutter must only be
operated using original ABICOR BINZEL spare parts.
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 EU declaration of conformity
EN - 4 BAL.0789.0 • 2020-03-02
2 Safety DAV
2Safety
Please observe the attached ‘Safety Instructions’ document.
2.1 Designated use
• The device described in these instructions may be used only for the purpose and in the manner described in these
instructions. When doing so, please observe the operating, maintenance and servicing conditions.
• Any other use is considered improper.
• Unauthorized modifications or changes to enhance the performance are not permitted.
2.2 Obligations of the operator
• Only the following personnel may work on the device:
• those who are familiar with the basic regulations on occupational safety and accident prevention;
• those who have been instructed on how to handle the device;
• those who have read and understood these operating instructions;
• who have read and understand the attached “Safety instructions” document;
• those who have been trained accordingly;
• those who are able to recognize possible risks because of their special training, knowledge, and experience.
• Keep other people out of the work area.
• Please observe the occupational health and safety regulations of the relevant country.
• Observe the regulations on occupational safety and accident prevention.
2.3 Personal protective equipment (PPE)
To prevent danger to the user, these instructions recommend the use of personal protective equipment (PPE).
• This consists of protective clothing, safety goggles, a class P3 respiratory mask, protective gloves and safety shoes.
2.4 Classification of the warnings
The warnings used in the operating instructions are divided into four different levels and shown prior to potentially dangerous
work steps. Arranged in descending order of importance, they have the following meanings:
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.
DAV 2 Safety
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2.5 Warning and notice signs
The following warning and notice signs can be found on the product:
These markings must always be legible. They may not be covered, obscured, painted over, or removed.
2.6 Emergency information
In the event of an emergency, immediately disconnect the following supplies:
• Electrical power supply
• Compressed air supply
Further measures can be found in the operating instructions for the power source or the documentation for other peripheral
devices.
Symbol Meaning
Automatic start!
Warning against hand injuries!
EN - 6 BAL.0789.0 • 2020-03-02
3 Product description DAV
3 Product description
3.1 Technical data
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 and modify the device to enhance its performance without authorization.
• Only qualified personnel are permitted to perform work on the device or system.
12 x end position prompt (optional) 2Free wire end
Fig. 1 Dimensions
Ambient temperature +5 C to +50 C
Relative humidity Up to 90% at 20°C
Tab. 1 Ambient conditions during operation
Storage in a closed environment, ambient temperature -10 C to +55 C
Ambient temperature for shipment +5 C to +50 C
Relative humidity Up to 90% at 20°C
Tab. 2 Ambient conditions for transport and storage
Weight Approx. 2.7 kg
Cutting capacity at 6 bar Solid wire up to 1.6 mm/filler wire up to 3.2 mm
Cutting time Approx. 0.5 sec.
Electrical connection values (solenoid valve) 24 V DC option/max. 1.1 A
Tab. 3 General information
Compressed air connection Plug-in nipple G1/8, ø 6 mm inner width 4 mm
Working pressure 6 to 8 bar
Tab. 4 Pneumatic system
X
1 2
29
50
101
62
80
30
120
241
212
M8
90
DAV 4 Scope of delivery
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3.2 Abbreviations
3.3 Nameplate
The DAV wire cutter is labeled with the following nameplate:
When making inquiries, note the following information:
• Device type, ID number, serial number, year of construction
3.4 Signs and symbols used
The following signs and symbols are used in the operating instructions:
4 Scope of delivery
The compressed air hoses required for the pneumatic connection are not included in the scope of supply. They can be
supplied as an accessory and cut lengths. The 2-lead control lead required for the electrical connection is not included in the
scope of supply and can be supplied by either the customer or by ABICOR BINZEL as an option.
Order the equipment parts and wear parts separately. The order data and ID numbers for the equipment parts and wear
parts can be found in the current product catalog. Contact details for support and placing orders can be found online at
www.binzel-abicor.com.
Non-contact cylinder switch Plug-in connection M12 x 1
Tab. 5 Optional non-contact end position prompt
ATS Torch neck replacement system
BRS Torch cleaning station
DAV Wire cutter
TCP Tool center point
Tab. 6 Abbreviations
1Nameplate 2DAV
Fig. 2 Nameplate
12
Symbol Description
• Bullet symbol for instructions and lists
Cross-reference symbol refers to detailed, supplementary or further information
1Step(s) described in the text to be carried out in succession
• Wire cutting device DAV complete • Operating instructions
Tab. 7 Scope of delivery
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5 Functional description DAV
4.1 Transport
Although the items delivered are carefully checked and packaged, it is not possible to fully rule out the risk of transport
damage.
4.2 Storage
Physical storage conditions in a closed environment:
Tab. 2 Ambient conditions for transport and storage on page EN-6
5 Functional description
The housing (5) is attached to the actuating side of the cylinder (9). The housing (5) consists of the slide (7) with the cutter
(6) and the counter support (3). When the wire cutter is activated, the cylinder (9) pushes the slide (7) forward. The counter
support (3) then clamps the free wire end with spring force at the fixed jaws (4). The cutter (6) on the slide (7) extends the
full cylinder stroke and cuts the wire. The position of the pneumatic cylinder is monitored by the optional end position
prompt (8) and torch clamp(1). At a minimum of 5 bar operating pressure, the cylinder (9) is set in pneumatic end positions.
Signal evaluation is managed by a higher-level safety circuit.
Goods-in inspection Use the delivery note to check that everything has been delivered.
Check the delivery for damage (visual inspection).
In case of complaints If the delivery has been damaged during transport, contact the last carrier immediately.
Retain the packaging for potential inspection by the carrier.
Packaging for returns Where possible, use the original packaging and the original packaging material. If you have
questions concerning packaging and safety during shipment, please consult your supplier,
carrier or transporter.
Tab. 8 Transport
1Optional torch clamp
2Cover
3Counter support with pressure spring
4Jaws
5Housing
6Cutter
7Slide
8Optional end position prompt with LED display
9Cylinder
10 Mounting bracket
Fig. 3 Functional description
AF 4
1 Nm
AF 2.5
3
4
5
6
78
9
10
12
DAV 6 Commissioning
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6 Commissioning
6.1 Installation
Install the DAV on a torch cleaning station, welding device or an ATS rotor.
1Use screws to fix the DAV to a vibration-free surface.
2Adjust the mounting bracket. To facilitate optimal accessibility and installation, the mounting bracket can be fixed to the
cylinder in four positions, each shifted by 90°.
6.2 Connecting the pneumatic system
The operating pressure equals a minimum of 6 bar to a maximum of 8 bar. The cutting capacity of the device is reduced if
the operating pressure is low.
4 Scope of delivery on page EN-7
DANGER
Risk of injury due to unexpected start
The following instructions must be adhered to during all maintenance, servicing, assembly, disassembly and repair work:
• Switch off the power source.
• Disconnect all electrical connections.
• Switch off the entire welding system.
NOTICE
• Only qualified personnel are permitted to perform work on the device or system.
NOTICE
• Use only cleaned and lubricated compressed air for the DAV.
Fig. 4 Connecting the pneumatic system
Cutter open/closed
EN - 10 BAL.0789.0 • 2020-03-02
6 Commissioning DAV
6.3 Establishing the electrical connection (optional)
A digital robot output of 24 V DC at max. > 1.1 A or a comparable switch contact is required for controlling the valves.
4 Scope of delivery on page EN-7
A recovery diode D1 (1N4007) is required for the switching of inductive loads. We recommend the coupling socket at the
solenoid valve as the installation site. With option: non-contact end position prompt.
WARNING
Electric shock
Dangerous voltage due to defective cables.
• Check all live cables and connections for proper installation and damage.
• Replace any damaged, deformed or worn parts.
NOTICE
• Before an electrical connection between the product and the power supply is established, check that the operating
voltage specified on the nameplate matches the actual voltage.
Fig. 5 Establishing the electrical connection
With option:
Non-contact end position
prompt
DAV 6 Commissioning
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6.4 Setting up the DAV
1Briefly switch off power to the wire feeder.
2Move the torch with free wire end and a length of X into the cutting area of the wire cutter (2).
The wire must make contact with the fixed jaws and the gas nozzle (1) must be positioned directly above the cutter. Program
the way points and commands as described in the flow chart.
Fig. 7 Flow chart on page EN-12
3Set the Cut robot signal.
4After a brief waiting period, reset the switching status.
5Move the torch upward and out of the wire cutter (2).
6.5 Pulling the wire
Applies only to the torch neck replacement system, e.g. ATS rotor.
1Remove the wire electrode that has been cut during the change procedure and which remains in the replacement neck.
The counter support’s clamping function is used here.
1Gas nozzle 2Wire cutter
Fig. 6 DAV wire cutter
NOTICE
• Worn-out cutting edges may cause malfunctions. A cost- and time-saving remedy is correcting the start-up position by a
few millimeters. Only when the entire cutting width of the cutter has been worn out, will a replacement be required.
9.2 Replacing the cutter on page EN-14
X
12
EN - 12 BAL.0789.0 • 2020-03-02
7Operation DAV
7Operation
8 Decommissioning
Fig. 7 Flow chart
Yes
No
Yes
No
No
Yes
No
Yes
No
Yes
No
Yes
Cut wire
With option: end position prompt
Depends on the
wire length to be
advanced and
the speed
Function:
Cutter closed
* With function:
Pull wire, extend
waiting period
Function:
Cutter open
Currentless wire
feeder
Valve
Y1 = 1
Approach
position
Wait t = 0.5s *
Valve
Y1 = 0
Withdraw from
cutter
END
Cutter
open?
Cutter
closed? Wait t = 0.5s *
Currentless wire
feeder
Cutter
open?
Cutter
closed?
Cutter
open?
Wait t = 0.5s *
Valve
Y1 = 0
Determine cause and rectify
Cutter
open?
NOTICE
• Only qualified personnel are permitted to perform work on the device or system.
• Consult the documentation for the welding components.
NOTICE
• As the DAV wire cutter is integrated into a welding system, the process for putting it out of operation depends on the
robot control system.
• Make sure that the shutdown procedures for all components integrated in the welding system are strictly observed.
DAV 9 Maintenance and cleaning
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9 Maintenance and cleaning
Scheduled maintenance and cleaning are prerequisites for a long service life and trouble-free operation.
9.1 Maintenance intervals
When using arc welding equipment, always observe the provisions of EN 60974-4 Inspection and testing, as well as any
national laws and regulations.
Check the following:
DANGER
Risk of injury due to unexpected start
The following instructions must be adhered to during all maintenance, servicing, assembly, disassembly and repair work:
• Switch off the power source.
• Disconnect all electrical connections.
• Switch off the entire welding system.
DANGER
Electric shock
Dangerous voltage due to defective cables.
• Check all live cables and connections for proper installation and damage.
• Replace any damaged, deformed or worn parts.
NOTICE
• Only qualified personnel are permitted to perform work on the device or system.
• Check and wear your personal protective equipment.
NOTICE
• The specified maintenance intervals are standard values and refer to single-shift operation.
• We recommend recording the inspections. The date of the inspection, the detected defects and the name of the
inspector must be recorded.
Weekly Monthly
Check cutter and replace as needed. Lubricate the device.
EN - 14 BAL.0789.0 • 2020-03-02
9 Maintenance and cleaning DAV
9.2 Replacing the cutter
The service life of the cutter depends on the filler wire to be cut.
1Carefully unscrew the cover (1) with lubricating nipple.
2Unscrew and replace the cutter (5).
3Screw the cover (1) back on again.
4Check the fixed jaws (3) for wear; reverse or replace if necessary.
NOTICE
• Worn-out cutting edges may cause malfunctions. A cost- and time-saving remedy is correcting the start-up position by a
few millimeters. Only when the entire cutting width of the cutter has been worn out, will a replacement be required.
1Cover
2Counter support with pressure spring
3Jaws
4Housing
5Cutter
6Slide
Fig. 8 Replacing the cutter
CAUTION
Risk of injury due to spring tension of counter support or cutter
• Interrupt the device’s compressed air supply.
• Keep your hands out of the danger zone.
1
2
3
4
5
6
DAV 10 Troubleshooting
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10 Troubleshooting
Observe the attached “Warrant” document. In the event of any questions and/or problems, please contact your retailer or
the manufacturer.
DANGER
Risk of injury and device damage when handled by unauthorized 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 unauthorized persons.
• Only qualified personnel are permitted to perform work on the device or system.
Fault Cause Troubleshooting
Cutter does not
activate
• Compressed air supply for 5/2 directional
valve interrupted
• Open the shut-off valve
• Check the hose connections and threaded
fittings
• 5/2 directional valve does not function
properly
• Check control lead connection
• Check the signal output of the robot control
• 5/2 directional valve stuck • Replace valve
Insufficient cutting
capacity
• Air pressure too low • Check setting at pressure regulator: min.
6 bar/max. 8 bar
•Dirtycuttingedge •Clean
• Actuator stiff due to poor or insufficient
maintenance
• Remove and clean movable parts
• Lubricate DAV with suitable lubricant
• Worn cutting edge • Clean more often
• Change approach position of interface
• Replace the cutter
Free wire end is
bent
• The wire has no contact with the fixed jaws • Correct the approach position of the torch
• Remove and clean movable parts
• Counter support jammed • Lubricate DAV
With end position
prompt option: no
signal
• Proximity switch loose or defective • Reposition and secure
• Cable loose or defective • Replace
Tab. 9 Troubleshooting
EN - 16 BAL.0789.0 • 2020-03-02
11 Disassembly DAV
11 Disassembly
1Loosen the screws and remove the DAV from the torch cleaning station.
Dispose of the components in accordance with legal regulations.
12 Disposal on page EN-16
12 Disposal
When disposing of the system, local regulations, laws, provisions, standards and guidelines must be observed. To correctly
dispose of the product, it must first be disassembled.
11 Disassembly on page EN-16
12.1 Materials
This product is mainly made of metallic materials that can be melted in steel and iron works and are thus almost infinitely
recyclable. The plastic materials used are labeled in preparation for their sorting and separation for later recycling.
12.2 Consumables
Oil, greases and cleaning agents must not contaminate the ground or enter the sewage system. These substances must be
stored, transported and disposed of in suitable containers. Observe the relevant local regulations and disposal instructions
in the safety data sheets specified by the manufacturer of the consumables. Contaminated cleaning tools (brushes, rags, etc.)
must also be disposed of in accordance with the information provided by the consumables’ manufacturer.
12.3 Packaging
ABICOR BINZEL has reduced the transport packaging to the necessary minimum. The ability to recycle packaging
materials is always considered during their selection.
DANGER
Risk of injury due to unexpected start
The following instructions must be adhered to during all maintenance, servicing, assembly, disassembly and repair work:
• Switch off the power source.
• Disconnect all electrical connections.
• Switch off the entire welding system.
NOTICE
• Only qualified personnel are permitted to perform work on the device or system.
• Check and wear your personal protective equipment.
• Personnel near the fume extraction system when it is being disassembled must wear personal protective equipment.
DAV 13 Accessories/options
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13 Accessories/options
13.1 Mounting kit
Includes all add-on components required to operate wire cutter properly.
13.2 Compressed air hose
High-quality pneumatic hose, cut length, ø 6 mm inner width 4 mm.
13.3 5/2 directional valve
Weight Approx. 0.265 kg
Ambient temperature +5°C to +50°C
Compressed air connection G1/8"
Working pressure 6–8 bar
Nominal flow Approx. 650 L/min
Required activation 24 V DC Imax > 1.1 A Inom. = 220 mA
Cable connection PG 7
Tab. 10 5/2 directional valve
Fig. 9 5/2 directional valve
Table of contents
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