Abicor Binzel FreedomDrive Abimig AT355 User manual

FreedomDrive
MIG/MAG EN 60 974-7
Operating Instructions
FreedomDrive™Push-Pull
www.binzel-abicor.com
TECHNOLOGY FOR THE WELDER’S WORLD.

FreedomDrive
Operating Instructions
© The manufacturer reserves the right, at any time and without prior notice, to make such
changes and amendments to these Operating 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 3
2 Technical Data 3
2.1 Abbreviations 4
2.2 Nameplate 4
3 Safety Instructions 5
3.1 Classification 5
3.2 Emergency information 5
4 Putting into operation 6
4.1 Equipping the MIG gun neck
ABIMIG AT
6
4.2 Equipping the MIG gun neck
ABIMIG WT
6
4.3 Installing the optional neck
liner in the MIG gun neck (A/C
option)
7
4.4 Installing the rear cable liner 8
4.5 Installing the front cable liner 11
4.6 Connecting the cable assembly 12
4.7 Connecting the FreedomDrive
control lead
14
4.8 Setting the shielding gas 14
4.9 Feeding the wire 15
5Operating elements 16
5.1 2-cycle function of the trigger 16
5.2 Wire feed speed knob in
FreedomDrive (option)
16
5.3 Wire feed speed knob in MIG
gun handle (option)
17
5.4 Range selector switch (option) 17
6 Putting into operation 18
7 Putting out of operation 19
8 Maintenance and cleaning 19
8.1 Replacing the drive rolls 20
8.2 Cleaning the wire conduit 20
8.3 MIG gun neck 21
9 Troubleshooting 22

3
FreedomDrive
1 Designated Use
The FreedomDrive hand-held welding MIG guns are used for welding
of standard wire electrodes. They conform to EN 60 974-7 and are not
considered devices having their own functions. Arc welding can only be
carried out in connection with a welding power supply. These operating
instructions only describe FreedomDrive welding MIG guns. Freedom-
Drive welding MIG guns may only be operating using original ABICOR
BINZEL spare parts.
2 Technical Data
Ambient temperature of welding - 10 ˚C to + 40 ˚C
Transport and storage - 25 ˚C to + 55 ˚C
Relative humidity up to 90 % at 20 ˚ C
Control device rating 1 A AC / 250 V AC
Tab. 1 General Data
Type of voltage DC direct voltage
Polarity of the electrode Usually positive
Wire types Commercially available round
wires
Type of use Manual
Voltage rating 113 V peak value
Protection type of the machine-side
connections
IP2X, IP3X (EN 60 529)
Shielding gas (DIN EN 439) CO2and mixed gas M21
Tab. 2 General MIG gun data according to EN 60 974-7
Type Type of
cooling
Load* Duty
Cycle
Wire ø Gas
flow
rate
Cooling data
CO2M21
Flow
temp.
max.
Flow
min.
Flow
Pressure
ABIMIG
A A % mm l/m ˚ C l/min
min.
bar
max.
bar
AT355 Air 340 320 60 0.8-1.6 10-20
WT440 Liquid 500 450 100 0.8-1.6 10-20 50 0.9 1.5 3.5
Tab. 3 Product-specific MIG gun data as laid out in EN 60974-7
* For pulse welding reduce rating by 35%

4
FreedomDrive
Standard length 20 and 30 feet
Cooling unit power min. 1200 W
Control lead Multi-wire w/circular connector
Weight/meter approx. 0.7 kg
Machine-side connection Euro or Direct
Tab. 4 Cable assembly
Size Groove
.030” / .035” (0.8 / 0.9 mm) U
0.47” / .062” (1.2 / 1.6 mm) U
.030” / .062” (0.8 / 1.6 mm) Knurled*
Tab. 5 Wire feed rolls
2 Technical Data
2.1 Abbreviations
MIG Metal Inert Gas
MAG Metal Active Gas
MAC Maximum allowable concentration of harmful substances
at the workplace
Voltage rating Classification of the insulation resistance, voltage strength
and protection type
FreedomDrive Hand-held Push-Pull welding MIG gun with integrated
drive and screwable interfaces between assist drive,
cable assembly and MIG gun neck with replaceable tip
adapter
Tab. 6 Abbreviations
2.2 Nameplate
The welding MIG gun system FreedomDrive is identified by a sticker on
the handle side housing. When making any inquiries, please remember
the following information.
• Certificate of conformity, production stamp on the MIG gun, for
example WT440, information on sticker.
*Must use in conjuction with one U-groove drive roll

5
FreedomDrive 3 Safety Instructions
3 Safety Instruction Please observe the attached safety instructions.
3.1 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:
Note
Describes the risk of impairing work results of the risk that the work may result
in material damage to the equipment.
!WARNING
Describes a potentially dangerous situation. If not avoided, it may result in
serious injuries
! DANGER
Describes imminent threatening danger. If not avoided, it will result in fatal or
extremely critical injuries.
!CAUTION
Describes a potentially harmful situation. If not avoided, it may result in slight
or minor injuries.
3.2 Emergency information
In case of emergency, immediately interrupt the following supplies:
• Electricity, compressed gas
Further measures can be found in the “Power supply’ operating instruc-
tions or in the documentation of further peripheral devices.

6
FreedomDrive
4.1 Equipping the MIG gun neck ABIMIG AT
4 Putting into operation
1Gas nozzle
2Contact tip
3Tip adapter
4Insulator
5MIG gun neck
Fig. 1 Equipping the ABIMIG AT MIG gun neck
1Screw, tip holder (3) and contact tip (2) onto the gun neck (5)
The insulator (4) protects otherwise exposed areas.
2Screw the gas nozzle (1) onto the tip holder (3).
4.2 Equipping the MIG gun neck ABIMIG WT
1Gas nozzle
2Spatter Protector
3Contact tip
4Tip adapter
5MIG gun neck
Fig. 2 Equipping the ABIMIG WT MIG gun neck
1Screw the replaceable tip adapter (4) onto the gun neck (5)
and tighten the tip adaptor (4) using the supplied wrench
2Screw the contact tip (3) into the tip adaptor (4)
3Tighten the contact tip (3) with the supplied wrench
4Insert the spatter protector (2) into the gas nozzle (1) from the
back prior to screwing the gas nozzle (1) onto the gun neck (5)
1
2
34
5
1 2 3 4 5
4 Putting into operation
! 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 compressed gas supply.
• Pull the mains plug.

7
FreedomDrive
Putting into operation 4
1MIG gun Neck
2Neck Liner
Fig. 3 MIG gun neck liner (optional)
2
x
1
4.3 Installing the optional neck liner in the air-cooled
MIG gun neck
The neck liners must be cut to length, according to the neck. Please be sure to
order the correct neck liner in order to avoid feeding issues
1Unscrew the gun neck (1) from the gun handle.
2Insert the gun neck liner (2) into the gun neck until the end
stops at the contact tip.
3Measure the length of the neck liner protruding from the neck
inlet (“x”). Subtract 1mm (1 coil) from the measurement (“x”), then
remove the neck liner and trim off the calculated amount from the
front end.
4Deburr the trimmed end of the neck liner
5 Insert the neck liner into the neck.
Note: When cut correctly, the neck liner should be flush with the
tail inlet of the neck when pressed inward
6Screw the gun neck (1) into the neck seat of the gun handle.

8
FreedomDrive
Note
• New unused liners have to be shortened to the actual length of the
cable assembly.
4.4 Installing the steel rear cable liner
To be used for steel wires.
1FreedomDrive cable assy
2Outlet viewing guide
3Rear connector
4Steel liner “Euro”
5Steel liner pass-through
6Liner retention nut
7Liner Collet
Fig. 4 Steel Rear Cable Liner
Installing Steel Rear Cable Liner:
1. Lay the MIG gun out straight and remove liner retention nut (6) from rear con-
nector, then insert the liner (4) bare end first, all the way into gun until it stops.
You should see the liner through the hole in the outlet viewing guide (2), which
will help you to make sure liner is fully installed.
Fig. 5 Properly Cut Liners
Initial measuring points Miller®properly cut liner
Lincoln®/Tweco 4®properly cut liner Euro properly cut liner
Lincoln®/
Tweco 4
Miller®/
Euro
x
x
1mm 2mm
2mm
4
5
6
7
1 3 4
2

9
FreedomDrive
4.4 Installing the steel rear cable liner (cont.)
To be used for steel wires.
7Liner Collet
2. While the MIG gun is laying out straight, measure the amount of liner potrud-
ing from the rear connector according to the correct measuring points as shown
in Fig. 5 (“Initial measuring points”). Record this measured dimension as “x”.
Remove the liner and trim off the correct amount (dimension “x” -1mm or -2mm
based on feeder connector type; Lincoln, Miller or Euro). Insert the liner back
into the MIG gun and verify the correct 2mm gap or 1mm protrusion at the liner
collet as shown in Fig. 5 for the various rear connection types.
3. Install the liner nut and tighten. The liner should now have a slight compres-
sion inside the cable to remain under tension as the cable is moved about the
workspace.
4. For pass-through liners (5) which extend through the retention nuts, the liner
should be cut flush with the retention nut on Lincoln and Hobart/Tweco direct
rear connections. For Miller rear connections, the liner should protrude 2mm (2
coils) beyond the liner nut as shown in Fig. 6.
Fig. 6
Miller®- Cut the steel liner such that the liner extends as close to the drive rolls as possible;
typically 2 coils beyond the liner retention nut.
Lincoln®- Cut the steel liner flush with rear of liner retention nut

10
FreedomDrive
Note
• New unused liners have to be shortened to the actual length of the
cable assembly.
4.4 Installing the plastic cable liner
To be used for aluminum, copper, nickel, and stainless steel wires.
Fig. 7 Plastic Rear Cable Liner
Installing Plastic Rear Cable Liner:
1. Lay the MIG gun out straight remove retention nut (6) from rear connector,
then insert the liner (4), tapered end first, all the way into gun until it stops. You
should see the liner through the hole in the inlet guide (2), which will help you
to make sure liner is fully installed.
2.While the gun is still laying out straight adjust the O-ring (5) and collet (7)
so that they will fit into the rear connector when retention nut is installed. There
should be a slight compression on the cable liner once installed.
3. Reinstall the retention nut (6) securely, then trim rest of liner (4) as close as
possible to the feeder drive rolls or outlet guide.
Note: In case of Euro connection guns, liners smaller than 4.3mm OD should
be fitted with the hollow brass support tube which is included with the Binzel
Euro adaptor kits.
For Lincoln and Hobart/Tweco direct connect rear ends, the liner should be
trimmed flush with the liner nut. For Miller direct connect rear ends, the liner
should extend as close as possible to the drive rolls; which is typically 2mm
beyond the liner retention nut. See Fig. 6.
1FreedomDrive cable assy
2Outlet viewing guide
3Rear connector
4Plastic liner
5O-ring
6Liner retention nut
7Liner Collet
4
67
5
1 3 4
2

11
FreedomDrive
1Front MIG gun
2Inlet guide
3Liner Combi/PA
4Liner Steel
5Liner Marking Tool
6Indication Groove
Note
• New unused liners have to be shortened to the actual length of the
cable assembly.
4.5 Installing the front cable liner
Fig. 8 Front Cable Liner
Installing Front Cable Liner:
Note: New MIG guns are supplied with a pre-cut and bagged liner and do not need to be cut prior
to install. See below for proper cutting & installation of replacement liners
1. With the front MIG gun (1) removed from the FreedomDrive, lay the MIG
gun (1) out straight and remove the inlet guide (2).
2. Insert the steel (4) or Combi/PA (3) liner, coil end first, into the rear of the
MIG gun (1) until it seats inside the tip holder, or inside the optional neck lin-
ers on air-cooled guns only.
3. At the rear of the gun, the liner should be carefully trimmed at 50mm from
the face of the rear connection block (see fig. 8). You can insert the liner mark-
ing tool (5) over the liner to assist in the marking of all liners and the cutting of
plastic liners (see fig. 8).
4. Place the inlet guide (2) over the liner and thread into the rear connec-
tion block using the supplied tip wrench until the thread shoulder bottoms out.
Gently snug the part. DO NOT OVER-TIGHTEN or damage will occur.
Note: There are two different sized inlet guides. The inlet guide for .030” -
.035” plastic wire liners is marked by a small groove (6) as shown in fig. 8.
The .030” - .35” steel/.045” - .062” steel & plastic inlet guide does not have
a groove. Complete MIG guns include the correct guide based on wire size
and type. When changing wire sizes, you must order the correct consumables,
including drive rolls and inlet guide.
3
2
6
5
1
4
7Liner Collet

12
FreedomDrive
4.6 Connecting the cable assemblies
Fig. 9 FreedomDrive to Cable Connections
The FreedomDrive unit is designed to pass through all operational functions;
wire, gas, power, control, and water (water-cooled version only). The various
pins and guides serve to align the mating surfaces during assembly.
Note: Do not mix water-cooled and air-cooled cables and FreedomDrive units.
Connecting to the Wire Feeder:
1. Insert the rear connector of the FreedomDrive cable into the receptacle at
the wire feed unit and secure by means provided (typically a thumb screw for
direct mount connections and a rotating nut for Euro connections)
(see 4.7, Fig. 10)
2. Properly mount the connections for water supply/return (if required), and
control lead (see 4.7, Fig. 10)
FreedomDrive
Back End
Rear Cable
Front Connector

13
FreedomDrive
!WARNING
Risk of burns
Liquid-cooled welding MIG guns will become overheated if the coolant
level is too low.
• Wear protective gloves.
• Check the coolant level at regular intervals.
Note
• Check the minimum coolant level of the cooling unit.
• Make sure that the coolant supply and return have been installed
properly. Coolant supply = blue, Coolant return = red.
• Do not use any deionized or demineralized water as coolant or for
tightness or flow tests.
This may impair the service life of your welding MIG gun.
• For liquid-cooled FreedomDrive welding MIG guns, we recommend
using ABICOR BINZEL coolants.
• Each time the device is commissioned or after each cable assembly
change, the cooling system must be purged of any air: Disconnect
the coolant return hose from the re-circulating cooling unit and hold it
over a collecting device. Close opening at the coolant return. Open
it again by repeatedly and abruptly releasing it, until the coolant is
flowing continuously and without air bubbles.

14
FreedomDrive
4.7 Connecting the FreedomDrive control lead
Fig. 10 Connecting the FreedomDrive Control Lead
Note: Connection varies by machine.
Connecting the FreedomDrive Control Lead:
1. Power source must be “off” and power cord disconnected from incoming
power.
2. Connect the FreedomDrive MIG gun to the wire feeder.
3. Connect the control lead to the wire feeder or the Universal control box,
depending on gun type.
4. Reconnect the power cord, turn on the machine and gas supply prior to
welding.
4.8 Setting the Shielding Gas:
Note
• The type and quantity of the shielding gas depends on the welding task
and the gas nozzle geometry.
• Make all shielding gas connections leak free.
• To prevent the shielding gas supply from becoming clogged by impuri-
ties, the cylinder valve must be opened briefly before connecting the
cylinder. This will blow out any impurities that may be present
FreedomDrive
Back End
Control Lead

15
FreedomDrive
12
5
Front
Rear
3
4.9 Feeding in the Wire
Fig. 11 Feeding in the Wire
Feeding in the Wire:
1. Install the wire into the wire feeder as specified by the wire feeder manufac-
turer.
2. Lay the MIG gun out as straight as possible. Open the access cover (2) on
the FreedomDrive housing (1) by sliding it towards the rear of the housing.
3. Insert the curved end of the provided tip wrench (4) into the drive tension
release knob (3) (see Fig. 11). Rotate the drive tension release knob (3) coun-
ter-clockwise 1/2 turn from full clockwise position.
4. Depress the incher button (5) located beneath the FreedomDrive access
cover until the wire is visible at the drive rolls, and release the incher button
quickly. It is not recommended to attempt feeding the wire into the inlet guide
in front of the drive rolls until the drive rolls are closed.
Note: Feeding the wire slowly will help to avoid bird nesting of the wire
5. Rotate the drive tension knob (3) clockwise until it stops.
Note: Required contact pressure is automatically preset via internal spring tension.
6. Depress the incher button (5) or the MIG gun’s handle trigger to continue
feeding wire out of the gun.
7. Close the access window (2) on the FreedomDrive.
Note: Each time the wire is inserted into the rear cable, make sure that the wire
end is free of burrs and sharp edges, which can damage the liner.
4

16
FreedomDrive
5 Operating Control Elements
5.1 2-Cycle Trigger and Incher Function
5.2 Wire Feed Speed Knob in FreedomDrive
(option based on MIG gun selection - see ordering chart)
WARNING: The handle mounted trigger and FreedomDrive mounted wire inch
buttons are connected. Both will command the FreedomDrive and wire feeder
motors to power on, and weld current to travel through the welding wire.
2-Cycle Trigger and Incher Function:
1. Press the trigger in the handle or the incher button on the FreedomDrive, and
keep it pressed to command the FreedomDrive motor and wire feeder motor
on.
2. Release the trigger or incher button and the drive motors are stopped
Note
• As the MIG/MAG welding MIG guns are integrated into a welding
system, the operating instructions of the welding components, such as
the welding power supply, must be observed during operation.
Fig. 12 Wire Feed Speed Knob in FreedomDrive
1. Rotate the wire feed speed knob in the direction of the ( - ) arrow to reduce
wire feed speed. Rotate the knob in the direction of the ( + ) arrow to increase
speed.
Note: Minimum and maximum speeds will vary by machine.
Wire Feed Speed Knob
+
--

17
FreedomDrive
5.3 Wire Feed Speed Knob in MIG gun Handle
5.4 FreedomDrive Wire Feed Speed Range Selector Switch
Fig. 13 Wire Feed Speed Knob in MIG gun Handle
1. Rotate the wire feed speed knob in the direction of the ( - ) indicator (couter-
clockwise) to reduce wire feed speed. Rotate the knob in the direction of the
( + ) indicator (clockwise) to increase speed.
Note: The handle mounted wire feed speed knob functions in conjuction with the range
selector switch, see section 5.4.
Fig. 14 FreedomDrive Wire Feed Speed Range Selector Switch
1. The wire feed speed range selector switch is only available on MIG guns
with handle mounted wire feed speed knobs. The range selector on the
FreedomDrive is necessary to allow fine adjustments to wire feed speed.
2. Turn the knob in the direction of the ( - ) arrow to decrease the wire feed
speed range. Turn the knob in the direction of the ( + ) arrow to increase the
wire feed speed range. There are three ranges available as indicated by the
dashed lines on the knob. The number of dashed lines centered in the knob
opening indicate the selected range setting.
1 Dash = Lowest WFS range
2 Dashes = Medium WFS range
3 Dashes = Highest WFS range
(option based on MIG gun selection - see ordering chart)
(option based on MIG gun selection - see ordering chart)
Wire Feed Speed Range Selector Switch
Wire Feed Speed Knob
+
--

18
FreedomDrive
6 Putting into Operation
1. Open the shielding gas cylinder.
2. Switch on the power supply
3. Set the welding parameters.
4. Start welding.
Note
• Liquid-cooled hose assemblies will start leaking if the return coolant
temperature is exceeded. Make sure not to exceed a return coolant
temperature of 60˚ C.

19
FreedomDrive
8 Maintenance and cleaning
! 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 compressed gas supply.
• Pull the mains plug.
! DANGER
Electric shock
Dangerous voltage due to defective cables.
• Switch off the power supply.
• Check all live cables and connections for proper installation.
• Replace any damaged, deformed or worn parts.
Note
• Maintenance and cleaning work may only be carried out by qualified
and trained specialists.
• Check coolant hoses, seals and connections for damage and tightness
and replace them, if necessary.
• Always wear your personal protective clothing when performing
maintenance and cleaning work.
7 Putting out operation
Note
• Liquid-cooled hose assemblies will start leaking if overheated. This is
why the cooling unit should continue running for approx. 5 min. after
welding.
1. Stop welding.
2. Wait until the shielding gas flow has subsided and then switch off the power
supply.
3. Close the valve of the shielding gas cylinder.

20
FreedomDrive
8.1 Replacing the drive rolls
aFig. 11 Feeding in the wire on page 15.
Note
• Make sure that the drive rolls comply with the diameter of the inserted
wire electrode.
1. Open the access cover (2) and unscrew the two slotted drive roll thumb
screws.
2. Rotate the tension knob (3) counter-clockwise to spread open the drive rolls.
3. Pull up on the drive rolls to remove them. If necessary, a pair of needle nose
pliers can be used.
4. Replace the drive rolls and secure them on the motor shaft using the slotted
thumb screws. The drive rolls are designed for two different wire sizes and are
stamped with the wire sizes on each end. The correct wire size stamp should be
facing up when properly installed.
Note: The knurled drive roll is unmarked and is suitable for all wire sizes when used in
conjunction with an appropriately sized grooved roll. The knurled drive roll should always
be installed on the side furthest away from the tension release knob.
5. Rotate the tension knob (3) clockwise until it stops and close the access cover
(2).
8.2 Cleaning the wire conduit
1. Unscrew both front and rear cable assemblies from the FreedomDrive and
wire feeder, and bring them into a stretched position.
aSee Fig. 7 on page 10.
2. Unscrew the retention nut (7) and pull out the liner (4)
!WARNING
Risk of injury
Serious injuries caused by parts swirling around.
• When cleaning the wire guide with compressed air, wear suitable
protective clothing, in particular safety goggles.
3. Clean the cable assembly (1), internally from both sides with compressed air.
4. Slide a new liner (4) into rear connector (3) and secure it with the retention
nut (7).
aSee section 4.4
5. Connect cable assembly to the wire feed unit.