Abicor Binzel ERGO Series User manual

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
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DIN EN
ISO 9001
S
EN Operating instructions
EN MIG/MAG Welding torch ERGO
GB 15579.7

EN - 2
English Translation of the original operating instructions Welding torch ERGO
EN English 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.
1 Designated use EN-3
2 Technical data EN-3
3 Safety instructions EN-4
3.1 Warnings EN-4
3.2 Emergency information EN-4
4 Putting into operation EN-5
4.1 Setting up the torch EN-5
4.2 Mounting the wire guide EN-6
4.2.1 Liner EN-6
4.2.2 PA liner EN-6
4.3 Connecting the cable assembly EN-6
4.4 Setting the shielding gas volume EN-7
4.5 Feeding in wire EN-7
5 Handle operating elements EN-7
5.1 Two-cycle trigger function EN-8
6 Operation EN-8
7 Putting out of operation EN-8
8 Maintenance and cleaning EN-8

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Welding torch ERGO 1 Designated use
1 Designated use
MIG/MAG manual welding torches are used to safely weld low and high-
alloy materials. They consist of the torch neck with equipment parts and wear
parts, handle or handle tube and cable assembly with central connector. They
conform to EN 60 974-7 and are not considered devices that independently
fulfil functions. Arc welding can only be carried out in connection with a
welding power source.
2 Technical data
Transport and storage -25°C to 55°C
Relative humidity Up to 90% at 20°C
Tab. 1 Ambient conditions during operation
Type of voltage DC
DC polarity of the electrodes Usually positive
Shielding gas (DIN EN 439) CO2and mixed gas M21
Wire types Commercially available round
wires
Voltage rating Peak value of 113 V
Protection type of the machine-side connections
(EN 60 529)
IP3X
Tab. 2 General torch data (EN 60 974-7)
Type Type of
cooling
Load DCY Wire Gas flow Cooling data
Supply
temp.
Flow Flow
pressure
CO2M21 Max. Min. Min. Max.
A A % mm l/min °C l/min bar bar
ERGO 15.1/.2 Air 180 150 60 0.6 - 1.0 10 - 18
ERGO 24.1/.2 Air 250 220 35 0.8 - 1.2 10 - 18
ERGO 25.1/.2 Air 230 200 60 0.8 - 1.2 10 - 18
ERGO 36.1/.2 Air 300 270 60 0.8 - 1.2 10 - 20
ERGO 501 D.1 Liquid 500 450 100 1.0 - 1.6 10 - 20 40 1 2.5 3.5
Tab. 3 Product-specific torch data (EN 60 974-7)

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3 Safety instructions Welding torch ERGO
3 Safety instructions
The attached safety instructions must be observed.
3.1 Warnings
In these operating instructions, potentially hazardous work steps are preceded
by the following warnings. Arranged in descending order of danger, they
mean:
3.2 Emergency information
In the event of an emergency, immediately disconnect the following supplies:
• Electricity, compressed air, shielding gas
Further measures can be found in the operating instructions for the power
source or the documentation for other peripheral devices.
Standard length L 3.00 m, 4.00 m, 5.00 m
Coolant connection Plug-in nipple, nom. diam. 5
Cooling unit power Min. 800 W
Control lead 2-core
Tab. 4 Cable assembly B
DANGER
Describes an 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 potential material damage to
the equipment.

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Welding torch ERGO 4 Putting into operation
4 Putting into operation
4.1 Setting up the torch
Set up the torch neck according to the following figure:
DANGER
Risk of injury due to unexpected start-up
The following instructions must be adhered to throughout all maintenance,
servicing, assembly, disassembly and repair work:
• Switch off the power source.
• Close the gas supply.
• Close the compressed air supply.
• Disconnect the mains plug.
CAUTION
Risk of injury
Puncture or cut-in wounds may be caused by the wire electrode.
• Wear protective gloves and never reach into the danger zone.
1Type ERGO 15
2Gas diffuser
3Contact tip
4Tip adaptor
5Gas diffuser
6Torch neck
7Type ERGO 501D
8Type ERGO 24/36
9Gas nozzle
10 Type ERGO 25
Fig. 1 Setting up the torch
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4 Putting into operation Welding torch ERGO
4.2 Mounting the wire guide
4.2.1 Liner
For using steel wires.
1Stretch out the cable assembly and remove the gas nozzle and contact tip
from the torch neck.
2Unscrew the nut from the central connector and slide the liner through the
wire conduit up to the retaining nipple.
3Tighten the nut again by hand and cut off any excess liner flush with the
torch neck or tip adaptor.
4Unscrew the nut and pull out the liner.
5Sharpen the start of the liner to an angle of approx. 40° and deburr the
edge.
6Slide the sharpened liner through the wire conduit up to the retaining nipple
then screw down the nut and tighten it using a switch key wrench.
7Screw in the contact tip and attach the gas nozzle.
4.2.2 PA liner
For using aluminium, copper, nickel and stainless steels.
1Use the ABICOR BINZEL sharpener to sharpen the start of the PA liner to
an angle of about 40°. Then slide the PA liner through the wire conduit until
you feel it reach the contact tip.
2Slide the clamp nipple, O-ring and nut onto the PA liner and tighten the nut
under tension.
3Mark any excess length of PA liner in front of the wire feed rolls and use the
ABICOR BINZEL cutter to cut it off at the mark.
4Sharpen the cutting point.
4.3 Connecting the cable assembly
1Attach the central connector to the central socket on the wire feed unit and
secure it with the connection nut.
2Properly mount the connections for coolant supply/return, shielding gas
and the control lead plug.
NOTICE
• For PA liners with an outer diameter of 4.00 mm, the capillary tube in the
distance adaptor must be replaced with a guide tube.

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Welding torch ERGO 5 Handle operating elements
4.4 Setting the shielding gas volume
4.5 Feeding in wire
1Insert the wire into the wire feed unit as specified by the manufacturer.
2Press the ‘zero-current wire feed’ trigger on the wire feed unit until the wire
emerges from the contact tip.
5 Handle operating elements
The trigger’s two-cycle mode can be activated when using a standard welding
torch. Further operating modes and handle modules depend on the
corresponding welding power source and must be ordered separately.
NOTICE
• Check the minimum fill level on the cooling unit.
• 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.
• For liquid-cooled welding torches, we recommend using
ABICOR BINZEL BTC coolant.
• The cooling system must be purged of any air each time the device is
commissioned and after every cable assembly change: disconnect the
coolant return hose from the coolant recirculator and hold it over a
collection receptacle. Close the opening on the coolant return hose then
re-open it by abruptly releasing it. Repeat until the coolant flows into the
collection receptacle continuously and without air bubbles.
NOTICE
• The type and amount of shielding gas used depend 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.
NOTICE
• Please also consult the operating instructions for the welding
components, e.g. the welding power source.

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6 Operation Welding torch ERGO
5.1 Two-cycle trigger function
1Press and hold the trigger on the handle = start welding.
2Release the trigger = stop welding.
6 Operation
1Open the shielding gas cylinder.
2Switch on the power source.
3Set the welding parameters.
4Start welding.
7 Putting out of operation
1Stop welding.
2Wait until the shielding gas post-flow time has passed and then switch off
the power source.
3Close the valve on the shielding gas cylinder.
8 Maintenance and cleaning
NOTICE
• As liquid-cooled cable assemblies start to leak when they overheat, the
cooling unit should continue running for approx. 5 min. after welding.
DANGER
Risk of injury due to unexpected start-up
The following instructions must be adhered to throughout all maintenance,
servicing, assembly, disassembly and repair work:
• Switch off the power source.
• Close the gas supply.
• Close the compressed air supply.
• Disconnect the mains plug.

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Welding torch ERGO 8 Maintenance and cleaning
1Unscrew the cable assembly on the machine side and lay it out in a
stretched position.
2Unscrew the nut and pull out the liner or PA liner and replace it, if necessary.
3Remove wear parts from the torch neck.
4Clean the wire conduit from both sides with compressed air.
5Mount the liner or PA liner and secure with the nut.
6Connect the cable assembly on the machine side to the wire feed unit.
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
and trained specialists.
• Check the coolant hose, seals and connectors for damage or leaks and
replace if necessary.
• Always wear your personal protective equipment when performing
maintenance and cleaning work.
WARNING
Risk of injury
Serious injuries can be caused by parts swirling around.
• When cleaning the wire guide with compressed air, always wear
personal protective clothing, in particular safety goggles.

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8 Maintenance and cleaning Welding torch ERGO