T ec h n o lo gy f o r t h e W e l d e r’s Wo r l d. PPi Dual Drive PPi Dual Drive Push-Pull MIG/MAG EN 60 974-7 Operating Instructions www.binzel-abicor.
PPi Dual Drive 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 2.1 2.
PPi Dual Drive 1 Designated Use The PPi hand-held welding torches 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 PPi welding torches. PPi welding torches may only be operating using original ABICOR BINZEL spare parts.
2 Technical Data PPi Dual Drive Standard length 15 and 25 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 Tab. 5 Wire feed rolls 2.
PPi Dual Drive 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: ! DANGER Describes imminent threatening danger. If not avoided, it will result in fatal or extremely critical injuries.
4 Putting into operation 4 Putting into operation PPi Dual Drive ! 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. 4.1 Equipping the torch neck PPi 36D 1 2 1 Gas nozzle 2 Contact tip 3 4 5 3 Tip adapter 4 Gas diffuser 5 Torch neck Fig.
PPi Dual Drive 4.3 Installing the cable liner To be used for aluminum, copper, nickel and stainless steel wires. Note • New unused liners have to be shortened to the actual length of the cable assembly. 3 2 1 8 PPi DUAL DRIVE R 4 7 1 Torch neck 2 Inlet guide 3 Rear connector 4 O-ring 5 Liner collet 6 Retention nut 6 5 7 Liner 8 Cable assembly Fig. 3 Installing Cable Liner: 1.
4 Putting into operation PPi Dual Drive 4.4 Installing the neck liner in the torch neck The neck liners are pre-cut to length, according to the neck. Please be sure to order the correct neck liner in order to avoid feeding issues 2 6 1 5 PPi DUAL DRIVE R 4 1 Neck liner 2 Neck inlet guide PPi 36D 3 Torch seat 3 4 Nut 5 Complete torch neck 6 Neck inlet guide PPi 401D Fig. 4 Mounting the neck liner in the torch neck 1.
PPi Dual Drive 4.5 Connecting the cable assembly 1. Insert the rear connector into the receptacle at the wire feed unit and secure it by means provided by feeder manufacturer (typically a thumb screw for direct mount torches). 2. Properly mount the connections for water supply/return, shielding gas and control lead plug as required. (See pg 9 Fig. 5) ! WARNING Risk of burns Liquid-cooled welding torches will become overheated if the coolant level is too low. • Wear protective gloves.
4 Putting into operation 4.6 Connecting the PPi control lead DRIVE ROLL ACCESS COVER DRIVE ROLLS & RETAINING THUMB SCREWS PPi Dual Drive CONTROL LEAD CABLE ASSEMBLY HANDLE NECK PPi DUAL DRIVE R WIRE SPEED GAS DIFFUSER TIP HOLDER TRIGGER CONTROL 1 REAR CONNECTOR1 DRIVE ROLL TENSION RELEASE CONTACT TIP GAS NOZZLE 1 - Options vary by machine Fig. 5 Connecting the PPi control lead 1. Power source must be “off” and power cord disconnected. 2.
PPi Dual Drive 5 Handle operating elements Note • • Each time the wire is changed, make sure that the wire end is free of burrs or sharp edges which can gouge the neck liner. Make sure that the wire feed rolls and consumables comply with the diameter of the inserted wire electrode. a 8.1 Replacing the wire feed roll on page 12 1. Insert the wire in the wire feeder as specified by the manufacturer. 2. Open the housing cover (2) at the handle. 3.
8 Maintenance and cleaning 7 Putting out operation PPi Dual Drive 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. 8 Maintenance and cleaning ! DANGER Risk of injury due to unexpected start-up.
PPi Dual Drive 8.1 8 Maintenance and cleaning Replacing the drive rolls a Fig. 6 Feeding in the wire on page 10. Note • Make sure that the drive rolls comply with the diameter of the inserted wire electrode. 1. Open the housing cover (2) and unscrew the two drive roll slotted thumb screws. 2. Rotate the tension knob (3) counter-clockwise. 3. Pull up on the drive rolls to remove them. If necessary, a small flat blade screwdriver can be used to pry up on the drive rolls. 4.
8 Maintenance and cleaning 8.4 Cable replacement 1 3 PPi Dual Drive 4 2 1 Handle screws 2 Swivel connector 3 Velcro® cover 5 4 Electrical harness connector 5 Cable screws 6 6 O-rings Fig. 7 Cable replacement 1. Remove the three rear most screws (1) in the handle, and pull back on the cable swivel connector to disengage it from the handle. 2. Open the Velcro® cover (3) for about two feet behind the swivel connection and then pull the swivel connection back about one foot from the handle. 3.
9 PPi Dual Drive 9 Troubleshooting Troubleshooting Note • • If the measures described below are not successful, please consult your dealer or the manufacturer. Please also consult the operating instructions for the welding components, such as power supply.
PPi Dual Drive ! Danger • Read and follow the manufacturer’s instructions, employer’s safety practices 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.
