Abicor Binzel 2000K 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
EN Operating instructions
Electrode holders
EN Series 2000/2000K/2000P with welding line and
welding current connector

EN - 2 BAL.0329.0 • 2019-05-06
EH 2000/2000K/2000P
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
2 Safety EN-3
2.1 Designated use EN-3
2.2 Classification of the warnings EN-3
2.3 Emergency information EN-3
3 Product description EN-4
3.1 Technical Data EN-4
4 Putting into operation EN-5
4.1 Equipping the electrode holder EN-5
4.2 Connecting the electrode holder EN-5
5 Putting out of operation EN-5
6 Maintenance and cleaning EN-5
6.1 Daily cleaning EN-5
6.2 Daily maintenance EN-5
7 Spare parts EN-5
7.1 Electrode holders of the Series 2000 with
hexagonal terminal screw for cable lugs EN-5
7.2 Electrode holders of the Series 2000K with
clamping connection EN-6
7.3 Electrode holders of the Series 2000P with
potentiometer EN-7

EH 2000/2000K/2000P 1 Identification
BAL.0329.0 • 2019-05-06 EN - 3
1 Identification
Complete electrode holders of the Series 2000 are used for welding with a coated rod electrode. They consist of the
electrode holder, welding line and the welding line plug and are not considered devices having their own functions. Arc
welding can only be carried out in connection with a welding power source.
These operating instructions describe the handling of the spring loaded electrode holder. The spring loaded electrode holder
may 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.
2Safety
The enclosed safety instructions must be observed.
2.1 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.
2.2 Classification of the warnings
The warnings used in the operating instructions are divided into four different levels and are shown prior to potentially dan-
gerous work steps. Arranged in descending order of importance, they have the following meaning:
2.3 Emergency information
In the event of an emergency, immediately disconnect the following supplies:
• Electrical power supply
Further measures can be found in the operating instructions for the power source or in the documentation for other peripheral
devices.
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.

EN - 4 BAL.0329.0 • 2019-05-06
3 Product description EH 2000/2000K/2000P
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.
Transport and storage - 25 °C to + 65 °C
Relative humidity up to 90 % at 20 °C
Tab. 1 Ambient conditions
Type DE 2200 DE 2300 DE 2400 DE 2500
Max. load 1at a duty cycle of 60% 200 A 300 A 400 A 500 A
Max. load 1at a duty cycle of 35% 250 A 400 A 500 A 600 A
for electrode diameters 2 - 4 mm 2 - 6.3 mm 4 - 8 mm 4 - 10 mm
for welding line 16 - 25 mm235 - 50 mm250 - 70 mm270 - 95 mm2
Terminal screw for cable lug M8 M8 M10 M10
Tab. 2 Product-specific data of the electrode holders of the Series 2000 and 2000K according to
DIN EN 60974-11 type B without welding cable and welding cable plug
1applies only to welding cables with a large cross-section and length up to 5 m
Type DE 2300P DE 2400P
Max. load 1at a duty cycle of 35% 260 A 350 A
For electrode diameters 2 - 6.3 mm 4 - 8 mm
For welding line 35 mm250 mm2
Terminal screw for cable shoe M8 M10
Tab. 3 Product-specific data of the electrode holders of the Series 2000P according to
DIN EN 60974-11 type B with welding cable and welding cable plug
1applies only to welding cables with a large cross-section and length up to 5 m
Welding line 16 mm² 25 mm² 35 mm² 50 mm² 70 mm² 95 mm²
Max.load atadutycycleof60% 130A 180A 230A 300A 390A 480A
Max.load atadutycycleof35% 145A 200A 260A 350A 460A 580A
Tab. 4 Standard values for the current load of welding lines according to DINVDE 0298-4 during 10 min. of intermittent
operation
Type ABI-CM 10-25 ABI-CM 35-50 ABI-CM 50-70 ABI-CM 70-95
Load at a duty cycle of 60% 200 A 300 A 400 A 500 A
For welding line 16 - 25 mm² 35 - 50 mm² 50 - 70 mm² 70 - 95 mm²
Tab. 5 Product-specific data of the welding line plugs according to DIN EN 60974-12

EH 2000/2000K/2000P 4 Putting into operation
BAL.0329.0 • 2019-05-06 EN - 5
4 Putting into operation
1Connect the electrode holder to the welding power source.
4.1 Equipping the electrode holder
1Clamp the rod electrode into the provided clamping slots of the spring loaded electrode holder.
4.2 Connecting the electrode holder
1When using electrode holders with potentiometer supplement the signal line with a signal line plug compatible with the
welding power source and connect it to the welding power source.
2Switch on the welding power source.
5 Putting out of operation
1Switch off the welding power source.
2Separate the electrode holder from the welding power source.
6 Maintenance and cleaning
Scheduled maintenance and cleaning is a prerequisite for a long life and a trouble-free operation.
6.1 Daily cleaning
1Clean the electrode holder to remove weld spatter and impurities.
6.2 Daily maintenance
1Check the electrode holder for damage and replace damaged parts if necessary.
7 Spare parts
7.1 Electrode holders of the Series 2000 with hexagonal terminal screw for cable lugs
• Connecting the welding line to the electrode holder by means of cable lug
NOTICE
• Only qualified personnel are permitted to perform work on the device or system.
• Make sure that the rod electrode is tightened properly.
NOTICE
• Consult the documentation for the welding components.
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.
• Separate the electrode holder from the welding power source.
• Disconnect all electrical connections.
• Switch off the entire welding system.

EN - 6 BAL.0329.0 • 2019-05-06
7 Spare parts EH 2000/2000K/2000P
7.2 Electrode holders of the Series 2000K with clamping connection
• Combine the strands of the welding line by means of a crimping sleeve and clamp them with a set screw in the electrode
holder
1Electrode holder
2Welding line
3Welding line plug
4Handle
5Fore part
6Insulating jaw
Fig. 1 Electrode holders of the Series 2000 with cable lug connection
213
654
Type DE 2200 DE 2300 DE 2400 DE2500
1Electrode holder 512.060.1 512.070.1 512.080.1 512.090.1
2Endless welding line /
cross-section
16 mm2113.D001
25 mm2113.D002
35 mm2113.D003 113.D003
50 mm2113.D004 113.D004
70 mm2113.D005 113.D005
3Welding line plug 511.0305 511.0315 511.0315 511.0331
4Handle 512.D022 512.D033 512.D043 512.D043
5Fore part 512.D268 512.D284 512.D272 512.D274
6Insulating jaw 512.D021 512.D031 512.D041 512.D091
Tab. 6 Spare parts of the Series 2000 with cable lug connection
1Electrode holder K
2Welding line
3Welding line plug
4Handle
5Crimping sleeve
6Set screw
7Fore part
8Insulating jaw
Fig. 2 Electrode holders of the Series 2000K with clamping connection
123
4
56
7
8
Type DE 2200 K DE 2300 K DE 2400 K DE 2500 K
1Electrode holder K 512.D470.1 512.D471.1 512.D472.1 512.D480.1
2Endless welding line /
cross-section
16 mm2113.D001
25 mm2113.D002
35 mm2113.D003 113.D003
50 mm2113.D004 113.D004
70 mm2113.D005 113.D005
3Welding line plug 511.0305 511.0315 511.0315 511.0331
Tab. 7 Spare parts of the Series 2000K with clamping connection

EH 2000/2000K/2000P 7 Spare parts
BAL.0329.0 • 2019-05-06 EN - 7
7.3 Electrode holders of the Series 2000P with potentiometer
• Use of a rotary potentiometer (standard equipment 10 kOhm (1,0 - 2,2 - 4,7 kOhm upon request) for controlling
welding current directly at the handle of the electrode holder.
• Use of a special welding line with three integrated control leads.
• The three control leads (0,5 mm2) are, at the welding current plug, approx. 0,5 m longer and can be connected to the
welding power source by means of a suitable control lead plug.
Control leads connection
4Handle 512.D022 512.D033 512.D043 512.D043
5Ferrule for welding cable
cross-section
16 mm2511.D097
25 mm2511.0048
35 mm2511.D010 511.D010
50 mm2511.0065 511.0065
70 mm2511.0104 511.0104
6Set screw 009.0120 009.0120 009.0125 009.0125
7Fore part 512.D414 512.D418 512.D422 512.D424
8Insulating jaw 512.D021 512.D031 512.D041 512.D091
Type DE 2200 K DE 2300 K DE 2400 K DE 2500 K
Tab. 7 Spare parts of the Series 2000K with clamping connection
NOTICE
• Controlling of the electrode holder Series 2000P is only possible with the welding power sources which support the connection of
an external control.
Fig. 3 Diagram
green
brown
white
E
S
A
1Electrode holders P with potentiometer 2Complete welding cable 3Insulating jaw
Fig. 4 Electrode holders of the Series 2000P with potentiometer
1
3
2

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
BAL.0329.0 • 2019-05-06
ABICOR BINZEL Schweißtechnik Dresden GmbH & Co.KG
Postfach 28 01 38 • D–01159 Dresden
Tel.: ++49 (0) 351/ 4203–30
Fax: ++49 (0) 351 / 4203–340
Email: [e-mail]
Type DE 2300 POTI DE 2400 POTI
1Electrode holders P 512.D505.1 512.D506.1
2Complete welding cable 3 m 118.D001.1 118.D008.1
4 m 118.D002.1 118.D009.1
5 m 118.D003.1 118.D010.1
6 m 118.D004.1 118.D011.1
8 m 118.D005.1 118.D012.1
10 m 118.D006.1 118.D013.1
12 m 118.D007.1 118.D014.1
15 m 118.D015.1 118.D017.1
20 m 118.D016.1 118.D018.1
3Insulating jaw 512.D031 512.D041
Tab. 1 Spare parts of the Series 2000P with potentiometer