Abicor Binzel DE 2300, DE 2200, DE 2500, DE 2400, DE 2200 K Operating Instructions 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 .
EN Operating instructions
Electrode holders
EN Series 2000/2000K/2000P with welding line and
welding current connector
www.binzel-abicor.com
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
EN - 2 BAL.0329.0 • 2019-05-06
EH 2000/2000K/2000P 1 Identification
DANGER
WARNING
CAUTION
NOTICE
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 dangerous work steps. Arranged in descending order of importance, they have the following meaning:
Describes an imminent threatening danger. If not avoided, this will result in fatal or extremely critical injuries.
Describes a potentially dangerous situation. If not avoided, this may result in serious injuries.
Describes a potentially harmful situation. If not avoided, this may result in slight or minor injuries.
Describes the risk of impairing work results or potential material damage to the equipment.
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.
BAL.0329.0 • 2019-05-06 EN - 3
3 Product description EH 2000/2000K/2000P
WARNING
3 Product description
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.
3.1 Technical Data
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
Max. load
for electrode diameters 2 - 4 mm 2 - 6.3 mm 4 - 8 mm 4 - 10 mm
for welding line 16 - 25 mm
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
1
1
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
at a duty cycle of 60% 200 A 300 A 400 A 500 A
at a duty cycle of 35% 250 A 400 A 500 A 600 A
2
35 - 50 mm
2
50 - 70 mm
2
70 - 95 mm
2
Type DE 2300P DE 2400P
Max. load
For electrode diameters 2 - 6.3 mm 4 - 8 mm
For welding line 35 mm
Terminal screw for cable shoe M8 M10
Tab. 3 Product-specific data of the electrode holders of the Series 2000P according to
Welding line 16 mm² 25 mm² 35 mm² 50 mm² 70 mm² 95 mm²
Max. load at a duty cycle of 60% 130A 180A 230A 300A 390A 480A
Max. load at a duty cycle of 35% 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
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
1
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
operation
at a duty cycle of 35% 260 A 350 A
2
50 mm
2
EN - 4 BAL.0329.0 • 2019-05-06
EH 2000/2000K/2000P 4 Putting into operation
NOTICE
NOTICE
DANGER
4 Putting into operation
• Only qualified personnel are permitted to perform work on the device or system.
• Make sure that the rod electrode is tightened properly.
1 Connect the electrode holder to the welding power source.
4.1 Equipping the electrode holder
1 Clamp the rod electrode into the provided clamping slots of the spring loaded electrode holder.
4.2 Connecting the electrode holder
1 When 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.
2 Switch on the welding power source.
• Consult the documentation for the welding components.
5 Putting out of operation
1 Switch off the welding power source.
2 Separate the electrode holder from the welding power source.
6 Maintenance and cleaning
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.
Scheduled maintenance and cleaning is a prerequisite for a long life and a trouble-free operation.
6.1 Daily cleaning
1 Clean the electrode holder to remove weld spatter and impurities.
6.2 Daily maintenance
1 Check 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
BAL.0329.0 • 2019-05-06 EN - 5
7 Spare parts EH 2000/2000K/2000P
213
654
123
4
56
7
8
1 Electrode holder
2 Welding line
3 Welding line plug
4 Handle
5 Fore part
6 Insulating jaw
Fig. 1 Electrode holders of the Series 2000 with cable lug connection
Type DE 2200 DE 2300 DE 2400 DE2500
1 Electrode holder 512.060.1 512.070.1 512.080.1 512.090.1
2
2 Endless welding line /
cross-section
16 mm
25 mm
35 mm
50 mm
70 mm
113.D001
2
113.D002
2
113.D003 113.D003
2
2
113.D004 113.D004
113.D005 113.D005
3 Welding line plug 511.0305 511.0315 511.0315 511.0331
4 Handle 512.D022 512.D033 512.D043 512.D043
5 Fore part 512.D268 512.D284 512.D272 512.D274
6 Insulating jaw 512.D021 512.D031 512.D041 512.D091
Tab. 6 Spare parts of the Series 2000 with cable lug connection
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
1 Electrode holder K
2 Welding line
3 Welding lin e plug
4 Handle
5 Crimping sleeve
6 Set screw
7 Fore part
8 Insulating jaw
Fig. 2 Electrode holders of the Series 2000K with clamping connection
Type DE 2200 K DE 2300 K DE 2400 K DE 2500 K
1 Electrode holder K 512.D470.1 512.D471.1 512.D472.1 512.D480.1
2
2 Endless welding line /
cross-section
16 mm
25 mm
35 mm
50 mm
70 mm
113.D001
2
113.D002
2
113.D003 113.D003
2
2
113.D004 113.D004
113.D005 113.D005
3 Welding line plug 511.0305 511.0315 511.0315 511.0331
Tab. 7 Spare parts of the Series 2000K with clamping connection
EN - 6 BAL.0329.0 • 2019-05-06
EH 2000/2000K/2000P 7 Spare parts
NOTICE
green
brown
white
E
S
A
1
3
2
Type DE 2200 K DE 2300 K DE 2400 K DE 2500 K
4 Handle 512.D022 512.D033 512.D043 512.D043
5 Ferrule for welding cable
cross-section
6 Set screw 009.0120 009.0120 009.0125 009.0125
7 Fore part 512.D414 512.D418 512.D422 512.D424
8 Insulating jaw 512.D021 512.D031 512.D041 512.D091
Tab. 7 Spare parts of the Series 2000K with clamping connection
16 mm2511.D097
2
25 mm
35 mm
50 mm
70 mm
511.0048
2
511.D010 511.D010
2
2
511.0065 511.0065
511.010 4 511.010 4
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.
• Controlling of the electrode holder Series 2000P is only possible with the welding power sources which support the connection of
an external control.
• Use of a special welding line with three integrated control leads.
• The three control leads (0,5 mm
welding power source by means of a suitable control lead plug.
Control leads connection
Fig. 3 Diagram
2
) are, at the welding current plug, approx. 0,5 m longer and can be connected to the
1 Electrode holders P with potentiometer 2 Complete welding cable 3 Insulating jaw
Fig. 4 Electrode holders of the Series 2000P with potentiometer
BAL.0329.0 • 2019-05-06 EN - 7
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 .
Type DE 2300 POTI DE 2400 POTI
1 Electrode holders P 512.D505.1 512.D506.1
2 Complete 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
3 Insulating jaw 512.D031 512.D041
Tab. 1 Spare parts of the Series 2000P with potentiometer
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: abd@binzel-abicor.com
www.binzel-abicor.com
BAL.0329.0 • 2019-05-06
Loading...