Abicor Binzel AB20 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
Operating instructions
AB Series MIG/MAG Welding Torches

EN - 2
AB Series Torches
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.
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
1DesignatedUse EN-3
1.1 Marking EN-3
1.2 Technical Data EN-3
2SafetyInstructions EN-5
2.1 Classification EN-5
2.2 Emergency information EN-5
3 Putting into operation EN-6
3.1 Equipping the torch EN-6
3.1.1 Equipping spare parts onto the
torch neck EN-6
3.1.2 Changing the torch neck or
adjusting the torch neck´s direction EN-6
3.2 Mounting the wire guide liner EN-7
3.3 Connecting the torch to machine EN-7
3.4 Setting the shielding gas quantity EN-7
3.5 Feed in wire EN-7
4 Operating elements EN-8
5 Removal from service EN-8
6 Maintenance and cleaning EN-9

EN - 3
AB Series Torches 1 Designated Use
1DesignatedUse
The AB series manual welding torches are used for safety welding of carbon
steel and alloy steel materials. They consist of the torch neck with equipment
parts and wearing parts, handle and cable assembly with Panasonic connector
(or OTC/Euro connector). They correspond to the directive EN 60 974-7 and
are not considered to be devices having their own functions. Arc welding can
only be carried out in connection with a welding power supply.
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 Technical Data
Transport and storage - 25 °C to + 55°C
During welding -10°C to +40°C
Relative humidity up to 90 % at 20 °C
Tab. 1 Ambient temperature
Type of voltage DC
Polarity of the electrode Usually positive
Shielding gas (DIN EN ISO 14175) CO2 and mixed gas M21
Wire types commercially available round wires
Guide type Manual
Voltage rating 113 V peak value
Protection type of the machine side
connections (EN 60 529)
IP3X
Tab. 2 General torch data (EN 60 974-7)

EN - 4
1 Designated Use AB Series Torches
Type Type of
cooling
Type of
BIKOX
cable
CO2M21 Wire Flow
rate
duty cycle Load Duty cycle Load
AB Series
Torches
% A % A mm l/min
20.1 air V186 60 200 55 200 0.6 - 1.0 10 - 20
20.2 air R4 55 200 50 200 0.6 - 1.0 10 - 20
35.1 air V407 60 350 55 350 1.0 - 1.6 10 - 20
35.2 air V357 50 350 45 350 1.0 - 1.6 10 - 20
50.0 air R9A 60/35 500/600 50/25 500/600 1.2 - 1.6 15 - 20
50.1 air V657 60 450 50 450 1.2 - 1.6 15 - 20
50.2 air V557 50 450 40 450 1.2 - 1.6 15 - 20
Tab. 3 Product-specific torch data (EN 60 974-7)
Standard length L 3.00 m, 4.50 m, 6.00 m
Control lead 2-wire
Tab. 4 Cable assembly data
Torch
type
AB20 AB35 AB50
Torch
length
3m 4.5 m 6 m 3 m 4.5 m 6 m 3 m 4.5 m 6 m
Standard For wire 0.8-1.0 For wire 1.2-1.4 For wire 1.2-1.4
Wire
liner
394.D004 394.D005 394.D006 394.D007 394.D008 394.D009 394.D007 394.D008 394.D009
Optional For wire 1.6 For wire 1.6
Liner 394.D010 394.D011 394.D012 394.D010 394.D011 394.D012
Gaz
nozzel
145.D371 145.D373 145.D374
Nozzle
holder
768.D321 768.D322
Tip
holder
768.D585.0 768.D132 768.D133
Gas
diffusor
768.D326 768.D327
Torch
neck
768.D576.0 768.D578.0 768.D580.0
Tab. 5 Spare parts´ list

EN - 5
AB Series Torches 2 Safety Instructions
2SafetyInstructions
Observe the enclosed document Safety Instructions.
2.1 Classification
The warning signs used in the operating instructions are divided into four
different levels and are shown prior to specific work steps. Arranged in
descending order of importance, they have the following meaning:
2.2 Emergency information
In case of emergency, immediately interrupt the power and shielding gas.
Further measures can be found in the "Power supply" user manual or in the
documentation of further peripheral devices.
Contact
tip
0.6 0.8 1.0 1.2 1.4 1.6
T2 140.D435 140.D4361140.D438 140.D4392140.D440 140.D441
Cr/Zr/Cu 140.1520 140.1521 140.1523 140.1524 140.1525 140.1526
Tab. 6 Contact tip list
1Standard contact tip for AB20
2 Standard contact tip for AB35/50
DANGER
Describes 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.
NOTE
Describes the risk of impairing work results or the risk that may result in
material damage to the equipment.

EN - 6
3 Putting into operation AB Series Torches
3 Putting into operation
3.1 Equipping the torch
3.1.1 Equipping spare parts onto the torch neck
Equip the torch neck according to the following figure:
3.1.2 Changing the torch neck or adjusting the torch neck´s direction
1Uncover the black cover cap on the handle.
2Loosen the torch neck lock bolt with an inner hexagonal wrench (4 mm), but
do not unscrew the bolt out.
3Pull out the torch neck, insert the new torch neck in and turn it to the correct
position.
4Fasten the lock bolt and cover the cover cap again.
DANGER
Risk of injury due to unexpected start-up.
For the entire duration of maintenance, servicing, dismounting and repair
work, the following instructions must be adhered to:
• Switch off the power supply.
• Close off the gas supply.
• Disconnect all electrical connections.
CAUTION
Risk of injury
Piercing or puncture caused by electrode tip.
• Do not reach into the danger zone and wear protective gloves.
1Gas nozzle
2Contact tip
3Gas diffuser
4Nozzle holder
5Torch neck
Fig. 1 Equipping the torch
12345
AB20
AB35
AB50

EN - 7
AB Series Torches 3 Putting into operation
3.2 Mounting the wire guide liner
1Lay the torch straight out and unscrew the gas nozzle as well as the contact
tip from the torch neck.
2Slide the wire guide liner into the torch up to the Panasonic connector; for
the torches with Euro or OTC connector, unscrew the position holder nut on
the connector, insert the wire guide liner in and then screw the position
holder nut back on again.
3Fold the torch side cable to a degree of 180°, cut off the wire guide liner
at the end of the tip holder.
4Pull out the wire guide liner.
5Sharpen the wire guide liner to an angle of approx. 40° and deburr the
cutting edge.
6Insert the wire guide liner into the torch again; for torches with Euro or OTC
connectors, please screw the position holder nut on the connector and tight
with a spanner.
7Screw the contact tip and gas nozzle back on again.
3.3 Connecting the torch to machine
1Insert the Panasonic connector into the wire feed unit, and tight the lock bolt
on the wire feed unit; for Euro or OTC connectors, screw the union nut tight.
2Properly mount the connections for shielding gas.
3.4 Setting the shielding gas quantity
3.5 Feed in wire
1Insert the wire in the wire feed unit as specified by the manufacturer.
2Press the "Wire Jog" push-button at the wire feed unit until the wire comes
out of the contact tip.
NOTE
• The type and quantity of the shielding gas quantity 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 blow out any impurities that may be present.

EN - 8
4 Operating elements AB Series Torches
4 Operating elements
1Press the trigger on the handle and keep it pressed = welding is started.
2Release the trigger = welding is stopped.
5Removalfromservice
1Wait until the shielding gas flow has subsided and switch off the power
supply.
2Close the valve of the shielding gas cylinder.
NOTE
• As the AB Series Torches torch is integrated into a welding system, the
operating instructions of the welding components, such as power supply,
must be observed during operation.

EN - 9
AB Series Torches 6 Maintenance and cleaning
6 Maintenance and cleaning
1Unscrew the torch on the wire feed unit and lay it straight out.
2Dismount the wire guide liner and replace it if necessary.
3Remove worn parts from the torch neck.
4Clean the wire guide liner from both sides with compressed air.
5Mount the wire guide liner back on the torch.
6Connect the torch on the wire feed unit.
DANGER
Risk of injury due to unexpected start-up.
For the entire duration of maintenance, servicing, dismounting and repair
work, the following instructions must be adhered to:
• Switch off the power supply and close off the gas supply.
• Pull out the mains plug.
WARNING
Risk of injury
Serious injuries caused by parts swirling around.
• When cleaning the wire guide liner with compressed air, wear suitable
protective clothing, in particular safety goggles.

EN - 10
6 Maintenance and cleaning AB Series Torches
NOTE
• When change contact-tip holder or torch neck, or connect Panasonic to
machine side, the contact surface between parts must be clean and free
from hard particles, otherwise the surface will be scraped and good
contact won’t be guaranteed.
• When assemble trigger contact spring onto torch handle, be care not to
bend the spring and make sure the two springs are assembled with the
contact points face to face. The groove on the spring must be set on the
stage shown as the following photo.
1The contact springs must be assembled with the groove set on the stage of the torch handle
Fig. 2 Assemble trigger contact spring
1

EN - 11
AB Series Torches Notes
Notes

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
Alexander Binzel
Schweisstechnik GmbH & Co. KG
Postfach 10 01 53 • D–35331 Giessen
Tel.: ++49 (0) 64 08 / 59–0
Fax: ++49 (0) 64 08 / 59–191
Email: [e-mail]
BAL.0188.0 • 2018-04-12
Guangzhou ABITEC Welding Equipment Company Ltd.
An Enterprise of ABICOR BINZEL Group
Add: NO. 42 Dongpeng Road , East District, GETDD,
Guangzhou, P.R. China
Pos: 510530
Tel: [phone]
Fax: [phone]