Abicor Binzel G3000 User manual

G3000
Air-Carbon
Arc Gouging Torch
Maximum 600 Amps
G4000
Air-Carbon
Arc Gouging Torch
Maximum 1000 Amps
Warnings and Safety,
Parts Breakdown,
Hook-up Procedure,
Specications and
Operation
SAFETY AND OPERATING REFERENCES
Code of Federal Regulations (OSHA) Section 29 part 1910.95, 132, 133,•
134, 139, 251, 252, 253, 254, and 1000
 U.S.GovernmentPrintingOfce,Washington,DC20402
ANSIZ49.1“SafetyinWeldingandCutting”• ANSI Z87.1 “Practice for Occupational and Educational Eye and Face• Protection”
ANSIZ88.2“StandardPracticesforRespiratoryProtection”American• National Standards Institute, 1430 Broadway, New York, NY 10018
AWSC5.3“RecommendedPracticesforAirCarbon-ArcGougingand• Cutting”
AWSF4.1RecommendedSafePracticesforWeldingandCuttingCon-• tainers”TheAmericanWeldingSociety,550NWLejeuneRd,P.O.Box
351040,Miami,FL33135
NFPA51B“FirePreventioninCuttingandWeldingProcesses”•
National Fire Protection Association, Battery Park, Quincy, MA 02269
CSAStandardW117.2“SafetyinWelding,CuttingandAlliedProcesses”• CanadianStandardsAssociation,178RexdaleBlvd.,Rexdale,Ontario,
CanadaM9W1R3
Lire American National Standard Z49.1, “Safety in Welding, Cutting, and Allied Processes,"
Disponible au American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126;
OSHA Safety and Health Standards, Disponible au U.S.Government Printing Office,
Washington, DC 20402
Lire et suivre les instructions du fabricant, les pratiques de votre employeur et les fiches signalétiques.
Seulement le personnel qualifié devrait installer, utiliser ou entretenir ce matériel et/ou cet équipement
UN CHOC ELECTRIQUE peut tuer..
• Porter toujours des gants secs et isolants.
• Ne jamais toucher une électrode ou des pièces
électriques sous tension.
• Mettre la soudeuse hors tension avant de
remplacer l’électrode et les pièces de torche.
LES ÉTINCELLES DE SOUDAGE peuvent causer
un incendie ou une explosion.
• Ne pas souder à proximité de matériaux
inflammables
• Ne pas souder sur des récipients fermés.
• Enlevez les matériels combustibles du lieu de travail
• Evitez des vêtements enduits de graisse ou d’huile
car une étincelle peut l’enflammer
LE BRUIT peut endommager l’ouïe
• Toujours porter un appareil de protection
auditioire si le bruit excédent les limites
spécifiées par l’OSHA.
LES FUMÉE ET LES VAPEURS DE GAZ peuvent être dangereuses pour la santé
• Eloigner la tète des endroits renfermant des vapeurs
• Assurez une ventilation suffisante ou aspirer les fumée et les vapeurs de gaz à la source
pour les maintenir hors de votre aire de travail et sous les limites permissibles
• La fumée causer par la soudure et le coupage peut réduire la qualité de l’air et
causer des blessures ou la mort. Toujours utiliser un appareil respiratoire à
alimentation d’air dans les zones confinées ou si l’air n’est pas sécuritaire
LE RAYONNEMENT DE L’ARC peut blesser les yeux et brûler la peau.
• Toujours porter l’équipement de protection pour des yeux, des oreilles et du corps.
• Toujours porter un casque de soudage muni d’un filtre de protection oculaire approprié.
• Protégez-vous ainsi que les autres contre les éclaboussures des rayons d'éclat d'arc en
utilisant des écrans, des barrières et des couvertures de soudure.
• Toujours porter des gants de protection ainsi que les vêtements de protection pour couvrir
la peau exposée. Cela aidera dans la prévention des brûlures causées par le
rayonnement de l’arc et les éclaboussures.
Lea y siga las instrucciones del fabricante, las prácticas seguras de su compañía y los datos de las Hojas de Seguridad del
Producto. Solo personal calificado debe instalar, usar o dar servicio a este material y/o equipo.
LOS RAYOS DELARCO pueden dañar sus ojos y quemar su piel.
• Siempre use la protección coreecta de vista, oído y cuerpo
• Siempre use una careta de soldadura con la sombra apropiada.
Protéjase a usted y a otros de los rayos del arco y de la escoria usando
pantallas protectoreas, barreras y cortinas para soldadura.
• Siempre use guantes protectores y ropa para cubrir la piel expuesta. Esto
ayudará en la prevención de quemaduras por arco y escoria.
HUMOS Y GASES pueden ser dañinos para su salud.
• Mantenga su cabeza fuera de los humos.
• Use suficiente ventilación o extracción desde el arco para evitar que los
humos y gases lleguen a su zona de respiración y área en general.
• Los humos de la soldadura y corte pueden terminar con la calidad del
aire, causar lesiones o la muerte. Siempre use un respirador en áreas
confinadas o si el aire que se respira no es seguro
CHOQUES ELECTRICOS pueden matar
• Siempre use guantes secos aislantes.
• No toque partes eléctricamente cargadas
• Siempre desconecte la fuente de poder
antes de instalar o cambiar electrodos,
boquillas y otras partes
CHISPAS DE SOLDADURA pueden causar
fuego o explosión.
• No suelde cerca de material flamable.
• No suelde en lugares cerrados.
• Retire combustibles del área de trabajo y/o
coloque un detector de incendio.
• Evite ropa con aceite o grasa pues una
chispa puede encenderlas.
RUIDO ALTO puede dañar el oído.
• Siempre use aparatos protectores de oído
para asegurar protección cuando los
niveles de ruido excedan los estándares
OSHA
Lea el Estándar Nacional Americano Z49.1, “Safety in Welding, Cutting,
and Allied Processes," disponible en la Sociedad Americana de Soldadura,
550 N.W. LeJeune Rd., Miami, FL 33126; los Estándares de Seguridad y Salud OSHA,
disponibles en la Oficina de Impresión del Gobierno de E.U., Washington, DC 20402
CUIDADO
Read and follow the manufacturer's instructions, employer's safety practices and Material Safety Data Sheets (MSDS).
Only qualified personnel should install, use or service this material and or equipment.
ELECTRIC SHOCK can kill.
•Always wear dry insulating gloves.
• Do not touch live electrical parts.
•Always disconnect power source
before hooking up or changing
electrodes, nozzles and other parts.
WELDING SPARKS can cause fire or
explosion.
• Do not weld near flammable material.
• Do not weld on closed containers.
• Remove combustibles from the work
area and / or provide a fire watch.
•Avoid oily or greasy clothing as a
spark may ignite them.
FUMES AND GASES can be hazardous to your health.
• Keep your head out of the fumes.
• Use enough ventilation or exhaust at the arc to keep fumes
and gases from your breathing zone and the general area.
• Fumes from welding and cutting can deplete air quality, cause
injury or death. Always wear an air supplied respirator in
confined areas or if breathing air is not safe.
ARC RAYS can injure eyes and burn skin.
•Always wear correct eye, ear and body protection.
•Always wear a welding helmet with the proper grade filter lens.
Protect yourself and others from spatter arc flash rays by using
protective screens, barriers and welding curtains.
•Always wear protective gloves and clothing to cover exposed
skin. This will aid in the prevention of arc and splatter burns.
LOUD NOISE can damage hearing.
•Always wear protective hearing
devices to ensure protection when
noise levels exceed OSHA
standards.
Read American National Standard Z49.1, "Safety in Welding, Cutting, and Allied
Processes," available from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126; OSHA Safety and Health Standards, available from U.S.
Government Printing Office, Washington, DC 20402.
LIT.9206 (5-09)
ABICOR BINZEL CORP. • 650 Medimmune Ct., Suite 110, Frederick, MD 21703 • 301-846-4196 • FAX: [phone] • 800-542-4867 • www.abicorusa.com

Binzel G3000 Replacement Parts
No. Description G3000 Part No.
1 Insulator Assembly (w/Screws) G94-433-193
2 Upper Arm G94-048-120
3 Lever Assembly (w/Screw) G94-476-080
4 Torch Body G94-103-232
5 Hinge Pin G94-632-101
6 Spring G94-800-191
7 O-Rings Only G94-710-036
8 Bonnet G94-104-012
9Spool with Bonnet G94-104-016
Spool Assy w/O-Rings G94-801-011
10 Insulating Boot G94-105-014
11 Air / Power Connector G94-170-150
12 Handle G94-370-179
13 Head G94-378-366
Binzel G4000 Replacement Parts
No. Description G4000 Part No.
1 Insulator Assembly (w/Screws) G94-433-183
2 Upper Arm G94-048-088
3 Lever Assembly (w/Screw) G94-476-066
4 Torch Body G94-103-206
5 Hinge Pin G94-632-094
6 Spring G94-800-077
7 O-Rings Only G94-710-036
8 Bonnet G94-104-012
9Spool with Bonnet G94-104-016
Spool Assy w/O-Rings G94-801-011
10 Insulating Boot G94-105-014
11 Air / Power Connector G94-170-150
12 Handle G94-370-163
13 Head G94-378-368
Binzel G3000 GougingTorch Packages
Description G3000 Part No.
Gouging Torch Only G01-065-001
Gouging Torch w/7' Cable (2.1m) G61-065-006
Gouging Torch w/10' Cable (3m) G61-065-007
7' Cable (2.1m) G70-088-107
10' Cable (3m) G70-088-110
Binzel G4000 GougingTorch Packages
Description G4000 Part No.
Gouging Torch Only G01-082-002
Gouging Torch w/7' Cable (2.1m) G61-082-008
Gouging Torch w/10' Cable (3m) G61-082-009
7' Cable (2.1m) G70-084-207
10' Cable (3m) G70-084-210
COPPER COATED POINTED ELECTRODES - A standard all purpose gouging electrode. Controlled copper coating improves electrical
conductivity providing more efcient, cooler operation and helps maintain electrode diameter at the point of the arc.
Part No. Size Qty / Box Amperage Air Pressure Air Flow
G22-023-003 1/8" x 12" (3.2mm x 305mm) 100 60 - 90 80psi 21cfm - 30cfm
G22-983-003 5/32" x 12" (4.0mm x 305mm) 50 90 - 150 80psi 21cfm - 30cfm
G22-033-003 3/16" x 12" (5.0mm x 305mm) 50 200 - 250 80psi 21cfm - 30cfm
G22-043-003 1/4" x 12" (6.5mm x 305mm) 50 300 - 400 80psi 21cfm - 30cfm
G22-053-003 5/16" x 12" (8.0mm x 305mm) 50 350 - 450 80psi 21cfm - 30cfm
G22-063-003 3/8" x 12" (9.5mm x 305mm) 50 450 - 600 80psi 21cfm - 30cfm
G22-082-003 1/2" x 14" (13.0mm x 355mm) 50 800 - 1000 80psi 21cfm - 30cfm
COPPER COATED JOINTED ELECTRODES - Eliminates stub loss and provides continuous electrode feed for automatic automated torches.
Jointed carbons are machined at each end to provide male and female ttings.
Part No. Size Qty / Box Amperage Air Pressure Air Flow
G24-064-003 3/8” x 17” (9.5mm x 430mm) 100 450 - 600 80psi 21cfm - 30cfm
G24-084-003 1/2” x 17” (13.0mm x 430mm) 100 800 - 1000 80psi 21cfm - 30cfm
G24-104-003 5/8” x 17” (16.0mm x 430mm) 100 1000 - 1250 80psi 21cfm - 30cfm
G24-124-003 3/4” x 17” (19.0mm x 430mm) 100 1250 - 1600 80psi 21cfm - 30cfm
Selecting the proper carbons: Depth = 1.5 x diameter of carbon width = 1/8” (3.2mm) + carbon diameter. Wider & deeper grooves can be accomplished using multiple passes.
LIT.9206 (5-09)
ABICOR BINZEL CORP. • 650 Medimmune Ct., Suite 110, Frederick, MD 21703 • 301-846-4196 • FAX: [phone] • 800-542-4867 • www.abicorusa.com

HOOK-UP & INSTALLATION
The hook-up and installation of your new Arc Gouging Torch is very similar to connecting a manual electrode holder, with the exception of the
shop air connection.The Arc Gouging Torch is easily installed by the following four descriptive steps:
STEP 1- Shop Air Connection:
Shop Air Connection (Never Use Oxygen) is completed by using an
air supply hose with 3/8” NPT connection (shown in expanded view).
The shop air hose is connected to the air/power tting on the Arc
Gouging Torch.The air valve on the torch will allow the operator to
control the air as required (refer to the air pressure and ow settings
chart on page 2.)
STEP 3- Welding DC Machine Connection (Positive (+) Lead):
The work lead can now be attached to the positive (+) terminal of your
DC welding machine. This is the most common connection which is
also referred to as Direct Current Electrode Positive (DCEP).
STEP 2- Torch Connection (Positive (+) Lead):
The work lead is now attached to the Arc Gouging torch, air/power
connector, using a ½”(12mm) bolt and nut. This work lead is attached
to the positive terminal of the power source.
STEP 4- Connection (Negative (-) Cable):
The negative (-) work lead is connected to the work piece by the most
common clamp method shown in gure 1. The cable must be connect-
ed to the negative (-) terminal of the welding machine.
Please review all the warnings and safety information on page 1 of this document.
After completion of hook-up, you are now ready to review the operation procedures (page 4) and begin using your arc gouging torch.
Welding Machine
Electrode
Work
Work Lead -
Stud
Terminal
Use Shop
Air Only
NEVER USE OXYGEN
Gouging Torch
Work Piece
Carbon
Electrode
Torch Lead +
-
+
USE
AIR ONLY
Shop Air In 3/8” NPT
Torch Lead +
To Torch
Direction Of Travel
SPECIFICATIONS
G3000 G4000
Amperage: Maximum 600 Amps Amperage: Maximum 1000 Amps
Compressed Air: Pressure - 80 PSI (5.6 kg/cm²)
Flow Rate - 21 - 28 cfm
Compressed Air: Pressure - 80 PSI (5.6 kg/cm²)
Flow Rate - 28 cfm
Torch & Cube Weight: 4.0 lbs (1.8 kg) Torch & Cube Weight: 5.4 lbs (2.4 kg)
Accepts Carbons: Pointed - 1/8” (3mm) to 3/8” (10mm)
Flat - 3/8” (10mm) to 5/8” (16mm)
Accepts Carbons: Pointed - 5/32” (4mm) to 1/2” (13mm)
Flat - 3/8” (10mm) to 5/8” (16mm)
Figure 1:Torch Hook-up
Electric shock can cause injury or death. Breathing air carbon arc gouging fumes can harm your health and can lead to disability.
Arc rays and hot sparks can injure eyes, and skin. Noise can damage hearing
BEFORE OPERATING THIS EQUIPMENT
• Do not service or repair equipment with power on.
• Do not touch exposed or frayed wires with power on.
• Do not service or repair equipment unless you are trained and qualified to do so.
“OBSERVE ALL SAFETY RULES.”
• Be sure equipment is turned off when not in use.
• See ANSI 749.1 “Safety in Welding and Cutting” published by The American Welding Society,
550 Lejeune Road, Miami Florida 33135 or contact your employer,
welding distributor, or manufacturer of this product.
• Inspect equipment to make sure all safety features are in good working order.
• Wear approved eye, ear, and body protection.
• Use enough ventilation and/or exhaust to keep fumes from the breathing zone.
Keep your head out of the fumes.
• Use only compressed air—NEVER USE OXYGEN.
• Be sure all other persons are clear of work area.
• Do not operate equipment with protective covers removed.
READ AND UNDERSTAND “PROTECT YOURSELF AND OTHERS”
LIT.9206 (5-09)
ABICOR BINZEL CORP. • 650 Medimmune Ct., Suite 110, Frederick, MD 21703 • 301-846-4196 • FAX: [phone] • 800-542-4867 • www.abicorusa.com

BASICS OF OPERATION
ARC GOUGING BASICS: Read all warning and safety informa-
tion prior to operation. The torch must be installed as indicated in
(Figure 1) hook-up & installation procedure. Install the desired carbon
electrode (max stick-out 6” (152.4mm) - min stick-out 3” (76.2mm) )
in the jaws of the arc gouging torch, with the head air-jet holes facing
in the direction of the arc.
Secure the torch comfortable in your hand with the carbon rod angled
15° - 70° from the base material (see gure 2). The compressed air
supply must be on prior to gouging. When gouging on at base material,
strike an arc by placing the electrode in contact with the base material.
Once the arc is established, maintain a short arc while moving in the
direction of travel (shown in gure 2) and don’t pull away from the
base material. Continue to steadily move forward (pushing the puddle
- not pulling), while maintaining a smooth electrical arc. The depth of
the gouge is controlled by the travel speed. If your application requires
a deep groove, use a slow travel speed. To obtain a shallow groove, a
faster travel speed can be used.Molten metal is removed with the com-
pressed air leaving a clean groove. Smooth and steady speed and feed
will result in a more uniform groove. Always be aware of the direction
of the molten metal to prevent potential contact with the operator and
or the surrounding areas.
HORIZONTAL, VERTICAL & OVERHEAD GOUGING POSITIONS: Horizontal, vertical and overhead positions all use the same
procedures listed in the basic operations. Position the torch in an angle to prevent molten metal to contact the operator and be aware of your
surrounding environment. Take special care to the direction of the molten metal removed in all positions.
TROUBLE SHOOTING
PROBLEM CAUSE / SOLUTION
Arc is unsteady… forcing the use
of a slower travel speed on shallow
grooves.
Amperage too low for the electrode diameter being used. In most cases the lowest recommended amperage is
enough, however, this requires greater operator skill. Choose mid-range amperage to improve arc stability. Use
the next smaller diameter electrode if the desired amperage cannot be obtained from the power source.
Electrode heating up rapidly, arc
jumping from side to side… er-
ratic groove.
The polarity of the torch hook-up is incorrect…most applications use DCEP (electrode positive). Check your
hook-up and installation for proper connections.There are very few metals that require a DCEN (electrode
negative).
Intermittent arc with noticeably
irregular groove surface.
Manual gouging travel speed is too slow.The operator should position the torch to produce a smooth forward
motion without resistance of the gloved hand to base material.
Carbon deposits at various spots
in groove or surface.
Shorted out carbon electrode on base metal. The travel speed may have been too fast compared to the amper-
age. Increase amperage or use a slower travel speed. Sometimes the pushing angle may be too small. Increase
or decrease the electrode-to-base material angle which adjusts arc area. Using a steady arc gap will reduce
the potential of short-outs.
Groove is too shallow...too deep…
and/or irregular.
The torch was not steadily operated. Torch must be operated with a steady and smooth feed to produce a
consistent groove.
Excessive slag adhesion to groove
edge.
Inadequate slag ejection. Maintain proper air pressure and ow. Air pressure should be set between 80 to
100psi in order to properly remove slag. It is important there is a sufcient volume of air (21cfm – 30cfm).
Sometimes it maybe necessary to select an air supply hose with an increased inside diameter to provide ad-
equate air volume. When gouging, keep the air stream parallel to the base material.
Gouging Torch
Air Stream
Ground Clamp
Base Material
Direction Of Travel
Carbon Electrode
Figure 2: Gouging Basic Operation
Wear proper eye, ear, and body protection.
Shut off all power before repairing or disconnecting torch.
ELECTRIC SHOCK CAN KILL!!
Arc gouging can burn eyes and skin, avoid smoke inhalation.
It is dangerous to your health. Noise can be harmful to your hearing.
USE WITH COMPRESSED AIR ONLY, NEVER USE OXYGEN.
This product, when used for welding or cutting,
produces fumes or gases which contain
chemicals known to the State of California
to cause birth defects and, in some cases, cancer.
(California Health & Safety Code 25249.5 et. seq.)
LIT.9206 (5-09)
ABICOR BINZEL CORP. • 650 Medimmune Ct., Suite 110, Frederick, MD 21703 • 301-846-4196 • FAX: [phone] • 800-542-4867 • www.abicorusa.com