Abicor Binzel ABIROB A500 User manual

Brand: Abicor Binzel

Model: ABIROB A500

Type: User manual

This manual is also suitable for

ABIROB A360

Abicor Binzel ABIROB A500 is a high-performance welding torch designed for professional welding applications. It features a robust construction with air-cooled technology, ensuring reliable operation even in demanding environments. The ABIROB A500 offers precise control and excellent arc stability, making it suitable for a wide range of welding processes, including MIG/MAG welding. With a duty cycle of 100% at 500A with mixed gas and a wire diameter range of .030"-.062", this torch delivers exceptional performance for heavy-duty welding tasks.

Technology for the Welder’s World

TYPE ABIROB A360 ABIROB A500

Duty Cycle(%) 100 100

Rating (A) with

Shielding Gas Co2 360 500

With Mixed Gas 290 400

Wire Diameter (mm) .030”-.062” .030”-.062”

NOTE: In case of Pulsed Arc the rating data is reduced up to 35%

All Torches are Air-Cooled

Available Torch Neck geometries for ABIROB are: 180˚, 22˚, 35˚, 45˚

ABIROB®INSTRUCTION MANUAL

INT.9017 NOVEMBER, 2004

ABIROB INSTRUCTION MANUAL

TABLE OF CONTENTS

Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Neckliner and Liner Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5,6

Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Troubleshooting

Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11,12

SAFETY MEASURES

PLEASE READ ALL SAFETY INSTRUCTIONS

Handling welding torches presents no danger if the appropriate safety regulations are

strictly adhered to. For example:

• Starting-up procedures must be reserved for those fully conversant with processes relat-

ing to arc welding equipment.

• Arc welding can prove damaging to eyes, skin, and hearing! It is therefore imperative

that the Accident Prevention Regulations UVV 26.0 and VGB 15 are fully observed and

that all protective clothing, eye and ear protectors specified are worn.

• The load data given are maximum limit figures. Overloading will inevitably

damage the torch irrevocably!

• Before changing wear parts, disconnect for the power supply.

• The operating instructions for the individual welding components - e.g. power source,

wire feed and cooling unit must be followed.

• Never pull the cable assembly across sharp edges or set down close to weld spatter or

on a hot workpiece.

• Those not involved in the welding process should be protected by curtains or

partitions from radiation and the danger of being dazzled.

• When handling gas cylinders, consult the instructions issued by the manufacturers and

the suppliers of the pressurized gas.

• Workpieces which have been degreased using chlorinated solvents must be sprayed

down with clean water before welding starts to avoid the risk of phosgene forming. For

the same reason, no degreasing baths containing chlorine must be placed close to the

welding point.

• All vapors given off by metals can cause harm and a special warning is attached to

lead, cadmium, copper, zinc, and beryllium. If necessary, take appropriate precautions

(by providing adequate ventilation or an extraction system) to ensure that the legal

maximum levels of toxic concentrations are not exceeded.

WARNING

Read and follow the manufacturer’s instructions, employer’s safety prac-

tices, and Material Safety Data Sheets (MSDSs).

Only qualified personnel should install, use, or service this material and/or

equipment

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.

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 spatter burns.

ELECTRIC SHOCK can kill.

• Always wear dry installing gloves

•Do not touch live electrical parts.

•Always disconnect power source before hooking up or changing electrodes,

nozzles and other parts.

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 general area.

•Fumes from cutting and welding can deplete air quality, causing injury or

death. Always wear an air supplied respirator in confined areas, or if breath-

ing air is not safe.

LOUD NOISE can damage hearing.

• Always wear protective hearing devices to ensure protection when noise levels

exceed OSHA standards.

Alexander Binzel Corporation

650 Medimmune Ct., Suite 110, Frederick, MD 21703-8619

Tel: 301.846.4196 Fax: 301.846.4497 www.abicorusa.com

Read American National Standard Z49.1, “Safety in Welding, and Cutting, and Allied

Processes,” available from American Welding Society, 550 N.W. LeJune Rd., Miami,

FL 33126; OSHA Safety and Health Standards, available from U.S. Government

Printing Office, Washington, DC 20402.

ID 123-4567CI

If Installing new Neckliner into Swanneck/Intermediate Module:

1. Unscrew Neck/Module from Cable Assembly.

2. Pull out old Neckliner from Module.

3. Then insert new pre-cut Neckliner into Module.

4. Install Neck/Module back onto Cable Assembly.

Installation of Steel Liners in Euro or Direct Mount Guns

1. Lay the torch out straight and remove the liner retaining nut from the adapter block at the wire feed

end of the cable assembly.

2. Insert and then carefully push the steel liner through the cable assembly until the steel liner stops at

the back of the intermediate module’s liner collet.

3. Measure the excess liner including the liner collet that is sticking out the adapter block of the cable assembly.

4. Pull the liner back out of the assembly and cut to the proper length as follows: cut off from the front

of the liner the length that was measured in the previous step minus a 1/4 inch (approximately 4

rings). This will leave an extra 1/8 inch of liner which will put the proper amount of tension on the

liner to allow for good wire feed.

5. Install and lightly tighten the liner retaining nut to complete the installation.

Installation of Plastic Liners in Euro or Direct Mount Guns

1. Lay the torch out straight and remove the liner retaining nut from the adapter plug at the wire feed end of

the cable assembly.

2. Insert and carefully push the plastic liner through the cable assembly until the plastic liner stops at the

back of the intermediate module’s liner collet.

continued on page 6

ABIROB INSTRUCTION MANUAL

NECKLINER AND LINER INSTRUCTIONS

SWANNECK/MODULE NECKLINER CABLE ASSEMBLY

CABLE

LINER

NUT

NECK INTERMEDIATE MODLE

Brass Guide Tube

Area Enlarged

Collet

Adapter

Plug O-Ring

(Prevent Gas Loss) Teflon®or PA

Liner Wire Feed

Roll

Liner Retaining Nut

CABLE

LINER

NUT

1/8”

NECK INTERMEDIATE MODLE

MOUNTING BRACKET

Area Enlarged

1/8”

MOUNTING BRACKET

ABIROB INSTRUCTION MANUAL

continued from page 4

3. At the adapter block end of the cable assembly, slide the brass collet and O-ring forward so that the

brass collet is in the recess of the adapter block. Install the liner retaining nut and lightly tighten the liner

retaining nut against the O-Ring and brass collet while putting a slight forward pressure on the plastic

liner to ensure it is still in the correct position (do not over tighten the liner retaining nut as erratic wire

feed can result due to the welding wire being pinched by the plastic liner). (Note: The O-ring prevents

gas loss at the rear of the gun.)

4. There will be excess plastic liner protruding from the adapter liner retainer nut that will need to be

trimmed as follows; If you are using a brass guide tube (the brass guide tube is only required for plastic

liners that need extra support “liners under 4.4mm in outside diameter”) feed the plastic liner through the

brass guide tube, making sure the brass guide tube is positioned slightly inside of the liner retaining nut.

Cut the excess liner using a sharp knife 1/8 inch (3mm) longer then where it exits the brass guide tube.

This should allow for a good fit to the wire feeder’s drive rolls (maintaining a very close fit to the drive

rolls will help in preventing bird nesting in the event of a wire jam). Insert the brass guide tube in to the

wire feeders adapter plug and tighten the adapter nut. If you do not need the brass guide tube, insert the

plastic liner protruding from the cable assembly into the adapter plug of your wire feeder. Release the

wire feeder’s pressure rolls so that the plastic liner can fit between the drive rolls. Tighten the adapter

block nut to the adapter plug. Mark and cut with a sharp knife where the plastic liner is almost touching

the drive roll (maintaining a very close fit to the drive rolls will help in preventing bird nesting in the event

of a wire jam).

IMPORTANT!

Avoid bending and stretching the cable assemblies at all costs. Choosing the right liner and correct part

number will depend on the type and diameter of wire in question.

Installing Bracket to Module

1. Loosen Hex screws on top of Mounting Bracket.

2. Slide Mounting Bracket over the Module making sure to match up the key way with the slot in the

Module

3. Then tighten screws tightly.

NECKLINER AND LINER INSTRUCTIONS

KEYWAY

ABIROB INSTRUCTION MANUAL

IMPORTANT!

The operational and functional safety of the entire system of welding equipment depends on careful

and conscientious maintenance which the operator can carry out himself provided he has been

trained to do so and follows all safety instructions.

ABIROB NECKS

1. Gas Nozzle

2. Tip

3. Diffuser/Tip Holder

4. Neck

5. O-Ring (Lg)

6. O-Ring (Sm)

7. IM Module

8. Neckliner

• Clean interface and apply

light coating of silicon-free grease to O-Rings (Binzel part number 192.0078).

• Check parts subject to wear for visible signs of damage and replace if necessary.

• To remove nozzle, turn counter clockwise.

DO NOT USE PLIERS UNDER ANY CIRCUMSTANCES!

• Use a Binzel multi purpose wrench to secure or remove contact tip.

AGAIN, DO NOT USE PLIERS!

DO NOT CLAMP THE TORCH!

• When screwing or unscrewing the nozzle insulator, use the proper wrench

• Replace the wire liner (spare part) if worn or dirty. Ensure that the replacement liner is the correct

size and type for the weld wire being used.

INFORMATION!

Neck change welding torches must be cleaned regularly and during every break in the welding process if

there is heavy build-up of spatter.

For preventive maintenance purposes the ABICOR Torch has been prepared for automatic cleaning for which

BINZEL offers cleaning equipment and various kinds of accessories.

In the automatic cleaning process, weld spatter is loosened and then blown out. The interior of the gas nozzle

is sprayed with BINZEL silicon-free anti-spatter agent.

USE ONLY GENUINE AND ORIGINAL CLEANING EQUIPMENT!

NOTE!

After service and maintenance and every time a collision takes place, check the TCP with the

Alignment Jig

SERVICE AND MAINTENANCE

12 3 4 56

R3A-180

123 4 56

R5A-180

Intermediate Module

NOZZLE TIP DIFFUSER NECK O-RING O-RING

IM MODULE

NECKLINER

ABIROB INSTRUCTION MANUAL

To get the best possible service from your ABIROB torch and insure proper servicing, the following peripher-

al equipment will be needed.

Alignment Jig for ABIROB Necks

Along with the advantages which the design

of the ABIROB brings, the Alignment Jig is

used to check the geometry of the neck outside

the welding booth and make slight adjustments

where necessary.

It is recommended that all new swanneck are

checked and aligned before installation. This

will eliminate any alignment problems which

may have occurred during shipping.

CAT Torch Mount

This provides a secure link between robot and

tool. The CAT robot mount is a 3-dimensional

safety coupling to protect the tool on the robot

or on the handling equipment. Any collision

automatically activates the safety switch built

into the robots emergency stop circuit. The

CAT’s accessory program offers a wide range

of mounts and extensions to reach the neces-

sary TCP.

Cleaning Stations

Spatter from welding process lodges inside the

gas nozzles and this leads to insufficient gas

coverage, and in time, to spatter bridging and

eventually to a short circuit. The result can be a

damaged torch. The cleaning station prevents

this from happening and operates with speed

and precision to reduce manual intervention,

increase the service life of the wear parts

and cut robot downtimes.

ACCESSORIES

837.0500 (A360/A500 standard length necks)

837.0510(A360/A500 long “L” necks)

ABIROB INSTRUCTION MANUAL

TROUBLESHOOTING: POROSITY (SUMMARY)

Causes of Porosity Possible Solutions

BASE METAL CONTAMINATION

Impurities on base metal. a. Remove contamination; clean surfaces

b. Use of specific wire/gas mix for specific

types of impurities.

FILLER METAL CONTAMINATION

Impurities on filler metal (wire). a. Replace wire.

b. Install wire-cleaning system.

c. Prevent industrial dust/dirt/grit from

contaminating wire during storage or use.

d. Prevent build-up of aluminum oxide on

exposed aluminum wire surface by using up

quickly.

e. Remove wire from wire drive unit and store

in a sealed plastic bag when not in use for

long periods.

ATMOSPHERIC CONTAMINATION

Drafts, wind, fans, etc. a. Protect weld from drafts (curtains/screens).

b. Use tapered or bottleneck gas nozzles when

drafts cannot be avoided.

GAS MIXING APPARATUS

1. Too high a gas flow, causing turbulence, 1a. Reduce gas flow.

and/or sucking air at hose connections; 1b. Tighten all hose connection points.

creating venturi effect at end of gas nozzle.

2. Too low a gas flow, causing insufficient gas coverage. 2. Increase gas flow.

3. Damaged or kinked gas lines. 3. Repair or replace

4. Too high an oxygen content. 4. Adjust mixer.

5. Leaks in gas distribution system. 5. Repair leaks.

6. Other impurities in gas – moisture, etc. 6. Overhaul system; fit filters and/or dryers.

7. Inconsistent gas flow (cfh) at the torch connection. 7. Regulate pressure into flow meter for

consistent cfh delivery of gas.

GAS TURBULENCE

1. Excessive spatter build-up in gas nozzle and 1. Clean nozzle and tip regularly; spray with

on contact tip. anti-spatter fluid.

2. Nozzle damage, causing uneven gas coverage. 2. Replace nozzle.

3. Torch gas ports clogged or deformed. 3. Clean or replace.

4. Super-heated nozzle, causing shielding gas to expand 4. Check duty cycle rating of torch.

rapidly and create return effect at end of nozzle.

Results in contamination of gas by atmosphere.

5. Gas diffuser/nozzle insulator missing. 5. Replace.

6. Too high a gas flow causing venturi effect. 6. Reduce gas flow.

WELDING PARAMETERS, ETC.

1. Too long a wire stick-out; gas nozzle too far 1. Use longer nozzle or adjust stick-out (3/8”

from weld puddle. minimum or 15 times wire diameter).

2. Bad torch position – too sharp a torch incline 2. Correct torch angle.

causing venturi effect at the end of the nozzle

leading to atmospheric contamination.

3. Excessively wide weld pool for nozzle I.D. 3. Width of the weld pool should be 1.3 times

nozzle I.D.; use suitable wider gas nozzle.

4. Arc voltage too high. 4. Reduce voltage.

5. Too high a travel speed. 5. Reduce speed.

NOTE: Most POROSITY is caused by gas problems, followed by base metal contamination.

ABIROB INSTRUCTION MANUAL

TROUBLESHOOTING: SPATTER

Problems/Causes Possible Solutions

SPATTER

Too fast or too slow wire feed for the arc voltage Set the wire feed rate and voltage in accordance with good

welding practices as recommended by a qualified welding

engineer.

Too long an arc. Adjust the wire feed and voltage so that the arc is in

accordance with good welding practice for the joint to be

welded. The distance from the contact tip to the workpiece

should be 15 times the welding wire diameter. If the arc is

too long there will be spatter, usually in the direction of the weld.

Damaged contact tip. If the contact tip becomes worn the welding wire will not be

in constant contact with the tip and the arc will become

unstable. A contact tip contaminated with spatter will cause

uneven wire feed resulting in further spatter.

Inclination of welding gun too great. The angle of the gas nozzle relative to the workpiece should

be between 45 to 90 degrees. If the angle is too small, the

wire runs parallel to the weld pool, resulting in spatter in the

direction of welding.

Faulty power source. Have the power source checked for faulty conditions such as

broken wires and faulty contacts.

Incorrect start. A great deal of spatter occurs if the stick-out is too great and

if the welding gun is held too far from the workpiece when

striking the arc. Try to start with as short a stick-out as

possible and with the welding gun as close to the starting

point as possible. If a large ball end is formed on the end of

the welding wire, remove it by cutting the wire with sharp

wire cutters. It is helpful if the wire is cut to a point. Always

remove the ball end before striking an aluminum arc. Check

the welding ground connection.

Incorrect pulse parameters. Check the user manual for your power supply or consult a

qualified welding engineer.

Uneven wire feed. Uneven wire feed gives rise to heavy spatter. Find the cause

of the disturbance and correct the condition before proceeding.

Impurities on the base metal. Paint, mill scale, rust and other contamination on the base

metal form an insulating layer causing an unstable arc that

results in heavy spatter. Clean the surfaces to be welded.

Poor ground contact. Inspect ground cable for loose connections, fraying and cuts.

Correct any problem areas found and attach the ground

cable directly to the workpiece after having cleaned the

contact surface first. POOR GROUND CONTACT IS THE

MOST COMMON CAUSE OF UNSTABLE MIG WELDING

CONDITIONS.

Too long stick-out (short-arc welding). The stick-out should be 15 times the diameter of the wire

electrode being used. With increasing stick-out, the current is

reduced and the arc voltage rises, giving a longer unstable

arc and increased spatter.

Incorrect polarity. Check for correct polarity. Follow the electrode

manufacturer’s recommendations.

ABIROB INSTRUCTION MANUAL

TROUBLESHOOTING: GENERAL GUIDE

Problems/Causes Possible Solutions

ERRATIC WIRE FEED

Slipping feed rolls. Check that the feed roll size is correct for the wire size being used. Increase the

drive roll pressure until the wire feed is even. Do not apply excessive pressure as this

can damage the wire surface, causing copper coating to loosen from steel wires or

metal shavings to be formed from soft wires like aluminum. These metal fragments

or shavings can be drawn into the wire feed conduit and will rapidly clog the gun

liner. When welding with flux-cored wires, excessive drive roll pressure may open

the wire seam and allow flux or metal powders to escape.

Clogged or worn gun liner. a. Dust, particles of copper, drawing lubricants, metal or flux and other forms of

contamination can all clog the gun liner so that the wire feed is slowed or impeded.

A liner that has been in use for an extended period of time becomes worn and filled

with dirt and must be replaced.

b. When changing the welding wire, remove the swanneck from the front end of the

gun and blow out the gun liner with clean, dry compressed air from the back of the

gun. Repeat with the neck liner. Note: Wear safety goggles when using compressed

air to clean the liners. Make sure proper safety procedures are followed in order to

avoid possible serious eye injury.

Liners too long or too short. Check the lengths of the neck and gun liners and trim or replace if too long or too

short. The efficient feeding of the welding wire is dependent on the liners fitting

correctly. Consult the liner installation instructions on pages 2-6 or contact your local

Authorized ABICOR Binzel Distributor for additional help.

Spatter on wire. An unprotected coil of wire quickly collects dust and other airborne contamination. If

grinding is being performed in the vicinity, particles can become attached to the

wire, severely interfering with the wire feed. Replace with clean wire and keep it

protected with a cover. Make sure spare wire rolls are stored in a clean, dry place.

Coil brake incorrectly adjusted. Set the brake so that the coil immediately stops rotating as soon as welding is

interrupted. If the brake is applied too hard it will cause the feed rolls to slip, resulting in

uneven wire feed. If it is too loose, overrun of the wire will occur, causing wire tangles,

inconsistent tension on the feed mechanism and irregular arc characteristics.

UNSTABLE ARC

Incorrect setting of voltage and/ Set the wire feed in relation to the arc voltage in such a way that the arc is stable

or current. and burns evenly. In spray arc welding, set the wire feed so that there are no short

circuits and the filler metal is transferred in a spray across the arc. Find the cause of

the interference and correct it. (See ERRATIC WIRE FEED above)

Problems in wire feeding.. When the internal diameter of the contact tip becomes worn from the passage of

Worn contact tip. wire through it, the wire may no longer stay in continuous electrical contact with

the tip. This results in an unstable arc and an increase in spatter.

Paint, mill scale, silicon scale, rust or flux deposits from previous weld runs may form

an insulating layer causing an unstable arc. Clean the surfaces to be welded.

Impurities on the base metal. Securely attach the ground cable as close to the point of welding as possible on the

workpiece. Clean the surfaces thoroughly to ensure good contact.

Poor contact between ground cable Check to insure the welding power connection on the power source is tight, the

and workpiece. connection on the wire feeder is tight, the connection to the adaptor block is tight,

Loose power connection and the connection of the gun to the adaptor block is tight.

Stick-out too long. Adjust the contact tip to work distance to a minimum of 3/8” for short arc

welding. A more precise distance is 15 times the wire diameter.

ABIROB INSTRUCTION MANUAL

TROUBLESHOOTING: GENERAL GUIDE

Problems/Causes Possible Solutions

AIR-COOLED GUN RUNNING TOO HOT

Poor ground. Inspect ground cable for loose connections, fraying and cuts. Correct any

problem areas found. Clean clamping area to insure good contact. Securely

attach the ground cable to the workpiece, as close as possible to the point of

welding. Make sure there is a good connection to the welding power source.

Loose power connection. Check to make sure the power connection on the power source is tight, the

connection on the wire feeder is tight, the connection to the adaptor block is

tight, and the connection of the gun to the adaptor block is tight.

Loose Bikox connection. Remove handle assembly and adaptor support. Check to insure the Bikox

connection to the swanneck is tight and the Bikox connection to the adaptor

block is tight.

Damaged Bikox assembly. Visually inspect the Bikox assembly for cuts and tears. Replace the Bikox

assembly if necessary.

Consumable items loose or worn. Remove nozzle from gun and inspect contact tip and tip holder/gas diffuser for

wear and tightness; replace or tighten as necessary

Capacity of gun being exceeded. Note complete weld parameters, including welding current (Amps), welding

voltage, wire feed speed, type and size of wire, type of gas and flow rate of gas

and consult your local Authorized ABICOR Binzel Distributor.

Dirty connection Remove swanneck and inspect interface for dirt build-up. Periodic cleaning

is necessary.

Alexander Binzel Corporation

650 Medimmune Ct., Suite 110

Frederick, MD 21703-8619

Tel: 301.846.4196

Fax: 301.846.4497

www.abicorusa.com

Binzel S.A. de C.V.

Municipio de pabellon de Arteaga 102

Valle de Aguascalientes 20358 San

Francisci de los Romo, Ags. Mexico

R.F.C.: BSC 980824 R84

Tel: +52(449) 9730133

Fax: +52(449) 9731388

E-mail: www.binzel.com.mx

Abicor Binzel Canada, Inc.

55 Mills Road, Units 1-3

Ajax, Ontario L1S 2H2 Canada

Tel: 905.428.1611

Fax: 905.428.1598

Email: [email protected]

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Abicor Binzel ABIROB A500 User manual

Brand: Abicor Binzel

Model: ABIROB A500

Type: User manual

This manual is also suitable for

ABIROB A360

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Abicor Binzel ABIROB A500 User manual

This manual is also suitable for

Abicor Binzel ABIROB A500 User manual

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