Abicor Binzel ABICOOLER 1300 Bedienungsanleitung
EN - 2
ABICOOLER 1300
EN Translation of the original operating instructions
1 Identification.................................................................................................................................EN-3
1.1 Marking .............................................................................................................................................EN-3
1.2 Nameplate.........................................................................................................................................EN-3
1.3 Signs and symbols used ...................................................................................................................EN-3
1.4 Classification of the warnings ..........................................................................................................EN-3
2 Safety ..............................................................................................................................................EN-4
2.1 Designated use..................................................................................................................................EN-4
2.2 Obligations of the operator .............................................................................................................EN-4
2.3 Warning and notice signs ................................................................................................................EN-4
2.4 Basic safety instructions ....................................................................................................................EN-5
2.5 Safety instructions for the power supply .........................................................................................EN-6
2.6 Personal protective equipment (PPE)...............................................................................................EN-6
2.7 Emergency information.....................................................................................................................EN-6
3 Scope of delivery........................................................................................................................EN-6
4 Product description ....................................................................................................................EN-7
4.1 Assembly and use .............................................................................................................................EN-7
4.2 Technical data...................................................................................................................................EN-8
5 Transport and installation.......................................................................................................EN-9
6 Commissioning.......................................................................................................................... EN-10
6.1 Fuse protection for the device....................................................................................................... EN-10
6.2 Initial commissioning.......................................................................................................................EN-11
6.2.1 Bleed the device..............................................................................................................................EN-11
6.2.2 Bleeding the cable assembly ........................................................................................................ EN-13
6.2.3 Commissioning the flow control.................................................................................................... EN-13
7 Operation.................................................................................................................................... EN-14
7.1 Prior to initial commissioning and after a longer standstill......................................................... EN-14
8 Decommissioning..................................................................................................................... EN-14
9 Maintenance and cleaning .................................................................................................. EN-15
9.1 Maintenance and cleaning intervals............................................................................................ EN-15
9.2 Change the coolant ....................................................................................................................... EN-16
9.3 Replacing the fuse.......................................................................................................................... EN-16
9.4 Replacing the handles ................................................................................................................... EN-17
10 Troubleshooting ....................................................................................................................... EN-18
11 Disassembly ............................................................................................................................... EN-19
12 Disposal ....................................................................................................................................... EN-19
12.1 Disposing of materials ................................................................................................................... EN-19
12.2 Disposing of consumables.............................................................................................................EN-20
12.3 Packaging ....................................................................................................................................... EN-20
13 Appendix ....................................................................................................................................EN-20
13.1 Connecting diagram for flow control ........................................................................................... EN-20
13.2 ABICOOLER 1300 circuit diagram for 115 V............................................................................. EN-21
13.3 ABICOOLER 1300 circuit diagram for 230 V............................................................................ EN-22
13.4 Spare parts ..................................................................................................................................... EN-23
14 Warranty..................................................................................................................................... EN-23
ABICOOLER 1300 1 Identification
EN - 3
1 Identification
The ABICOOLER 1300 cooling unit is used by industry and the trade sector exclusively for the cooling of
liquid-cooled welding torches. These operating instructions only describe the ABICOOLER 1300 cooling
unit. When used in these operating instructions, the terms “device”, “product”, and “cooling unit” always
refer to the ABICOOLER 1300 cooling unit. The device may be used only with original ABICOR BINZEL
spare parts. The device is available in 230 V and 115 V versions.
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 Nameplate
The device is labeled by means of a nameplate on the housing.
► You will need the device type, device number and serial number as indicated on the nameplate for
inquiries.
1.3 Signs and symbols used
The following signs and symbols are used in the operating instructions:
1.4 Classification of the warnings
The warnings used in the operating instructions are divided into four different levels and shown prior to
potentially dangerous work steps. The following signal words are used depending on the type of hazard:
Fig. 1 Nameplate
General instructions.
Action(s) to be carried out in succession.
Lists.
Cross-reference symbol refers to detailed, supplementary or further information.
Caption, item description.
1
A
DANGER
W
Describes an imminent threatening danger. If not avoided, it may cause severe injuries or death.
WARNING
W
Describes a potentially dangerous situation. If not avoided, this may result in death or serious injuries.
EN - 4
2 Safety ABICOOLER 1300
2 Safety
This chapter describes the essential safety requirements and warns of residual hazards that should be kept
in mind to operate the product safely. Non-observance of the safety instructions may result in risks to the life
and health of personnel, and environmental damage or material damage.
2.1 Designated use
The device described in these operating instructions may be used only for the purpose and in the manner
described in these operating instructions. The device is used in industry and in the trade only for cooling
liquid-cooled welding torches. Any other use is considered improper. Unauthorized modifications or
changes to enhance the performance are not permitted.
► Do not exceed the maximum load data as defined by the documentation supplied. Excessive loads lead
to irreparable damage.
► Do not make any constructive changes to this product.
► Do not use or store the device outdoors where it is wet.
2.2 Obligations of the operator
► Ensure that only qualified personnel are permitted to perform work on the device or system.
Authorized personnel are:
— those who are familiar with the basic regulations on occupational safety and accident prevention;
— those who have been instructed on how to handle the device;
— those who have read and understood these operating instructions;
— those who have been trained accordingly;
— those who are able to recognize possible risks because of their special training, knowledge, and
experience.
► Keep untrained persons out of the work area.
2.3 Warning and notice signs
The following warning, notice and mandatory signs can be found on the product:
These markings must always be legible. They may not be covered, obscured, painted over, or removed.
CAUTION
W
Describes a potentially harmful situation. If not avoided, this may result in slight or minor injuries.
NOTICE
Describes the risk of impairing work results or material damage and indicates irreparable damage to the
device or equipment.
► Wear eye protection.
Warning against hot surfaces. Risk of burns.
► Do not touch hot surfaces.
Electrical voltage caution. Danger of electric shock.
► Only a trained electrician should open the device.
► Interrupt the electrical power supply before opening the device.
ABICOOLER 1300 2 Safety
EN - 5
2.4 Basic safety instructions
The product has been developed and manufactured in accordance with state-of-the-art technology and the
recognized safety standards and regulations. Inevitable technical residual risks to the user, third parties,
devices, or other material property are posed by the product. The manufacturer will accept no liability for
damage caused by non-observance of the documentation.
► Before using the system for the first time, please read the provided documentation carefully.
► Do not operate the product unless it is functioning properly and ensure compliance with all documents.
► Before carrying out specific work, for example, commissioning, operation, transport and maintenance,
read the documentation carefully.
► Use suitable means to protect yourself and bystanders from the hazards listed in the documentation.
► Store the documentation within easy reach of the device for reference and enclose all documents when
passing on the product.
► Consult the documentation for additional welding components.
► Information about how to handle gas cylinders can be found in the instructions provided by the gas
manufacturer and the relevant local regulations, e.g., regulations that apply to compressed air.
► Observe the local accident prevention regulations.
► Only trained specialists should commission, operate, and service the device. Qualified personnel are
persons who, based on their special training, knowledge, experience and due to their knowledge of the
relevant standards, are able to assess the tasks assigned to them and identify possible dangers.
► Keep the work area in order. Ensure good lighting of the work area.
► Switch off the power supply, gas supply, and compressed air and unplug the power plug for the entire
duration of maintenance, commissioning, and repair activities.
► For disposal, observe the local regulations, laws, provisions, standards and guidelines.
Safety instructions for electrical components
► Check electric tools for damage and for its proper functioning in accordance with its designated use.
► Do not expose electric tools to rain and avoid a moist or wet environment.
► Protect yourself from electric shock by using insulating mats and wearing dry clothing.
► Do not use the electric tools in areas subject to fire or explosion hazards.
Safety instructions for welding
► Arc welding may cause damage to the eyes, skin and hearing. Note that other hazards may arise when
the device is used with other welding components. Therefore, always wear the prescribed personal
protective equipment as defined by local regulations.
► Any metal vapors, especially lead, cadmium, copper and beryllium are harmful. Ensure sufficient
ventilation or extraction. Do not exceed the current threshold limit values (TLV).
► To prevent the formation of phosgene gas, rinse workpieces that have been degreased with chlorinated
solvents using clean water. Do not place degreasing baths containing chlorine in the vicinity of the
welding area.
► Adhere to the general fire protection regulations and remove flammable materials from the vicinity of
the welding work area prior to starting work. Provide appropriate fire extinguishing equipment in the
workplace.
Safety instructions for personal protective equipment
► Do not wear loose fitting clothing or jewelry.
► Use a hair net for long hair.
► Wear safety goggles, protective gloves, and a respiratory mask, if necessary.
EN - 6
3 Scope of delivery ABICOOLER 1300
2.5 Safety instructions for the power supply
► Ensure that the mains connecting cable is not damaged, for example, by being driven over, crushed or
torn.
► Check the mains connecting cable for damage and wear at regular intervals.
► If it is necessary to replace the mains connecting cable, only models indicated by the manufacturer may
be used.
► Only a trained electrician should replace the mains connecting cable and the mains plug.
► Splash-water protection and mechanical stability must be ensured when replacing the mains plug of the
mains connecting cable.
2.6 Personal protective equipment (PPE)
► Wear your personal protective equipment (PPE).
► Ensure that others in close proximity are also wearing personal protective equipment.
Personal protective equipment consists of protective clothing, safety goggles, a class P3 respiratory mask,
protective gloves, and safety shoes.
2.7 Emergency information
In the event of an emergency, immediately disconnect the following supplies: Electrical power supply.
3 Scope of delivery
The unit is delivered empty, without coolant. The coolant must be ordered separately. The following
components are included in the scope of supply:
— 1× ABICOOLER 1300 cooling unit
— 1× control lead for flow control
— 1× discharge hose
— 1× operating instructions
► Order the equipment parts and wear parts separately.
► The order data and ID numbers for the equipment parts and wear parts can be found in the current
product catalog.
► For more information about points of contact, consultation, and orders, visit www.binzel-abicor.com.
Although the items delivered are carefully checked and packaged, it is not possible to fully rule out the risk
of transport damage.
Goods-in inspection
► Check for order completeness by checking the delivery note.
► Check the delivered goods for damage (visual inspection).
Claim process
► If goods are damaged, contact the final carrier.
► Keep the packaging for possible checks by the carrier.
Returns
► Use original packaging and packing material for returns.
If you have questions concerning the packaging or how to secure the device, contact your supplier, carrier
or transport company.
ABICOOLER 1300 4 Product description
EN - 7
4 Product description
4.1 Assembly and use
The device is used for cooling liquid-cooled welding torches. The device supplies and monitors the coolant.
All required components and connections have been installed in the housing. The coolant is pumped via
a closed cooling circuit through the welding torch and cooled down via an integrated air heat exchanger.
We recommend the use of a coolant filter as well. A flow control is integrated as standard in the device,
however, it must be connected via the supplied flow control line.
6.2.3 Commissioning the flow control on page EN-12
13.1 Connecting diagram for flow control on page EN-19
Fig. 2 Assembly and use
AControl lead connection for flow control
BCoolant filler neck
COn/off switch
DABICOOLER 1300 cooling unit
EFuse
FCoolant supply (blue-colored quick coupling)
GCoolant return (red-colored quick coupling)
HDrain coupling
ICoolant tank
JFilling level indication
Fig. 3 Overview of the coolant circuit
AHeat exchanger
BCoolant return (red)
CCoolant supply (blue)
DDrain coupling
EPump
FCoolant tank
A B C D E
FGHIJ
A
B
C
D
EF
EN - 8
4 Product description ABICOOLER 1300
4.2 Technical data
*Mathematical approximate values.
Fig. 4 Dimensions
Tab. 1 General information
50 Hz 60 Hz
Cooling capacity (H2O) Q = 1 l/min 1.24 kW 1.30 kW
Cooling capacity (BTC-15*) Q = 1 l/min 1.14 kW 1.19 kW
Cooling capacity (BTC-20 NF*) Q = 1 l/min 1.09 kW 1.14 kW
Cooling capacity (BTC-50 NF*) Q = 1 l/min 0.98 kW 1.02 kW
Heat exchanger 3-row
Supply voltage 115/230 V AC
Q = 1 l/min at +25 °C 1050 W with BTC
Max. delivery height of pump head 35 m
Max. flow rate of pump head 10 l/min
Max. coolant outlet pressure/pump
pressure
3.9 bar
Pump type Centrifugal pump
Coolant tank capacity 8.0 l
Coolant BTC series or other ABICOR BINZEL coolant
Max. conductivity of coolant MIG/MAG: 0–350 µS/cm, TIG: 0–250 µS/cm,
plasma: 0–30 µS/cm (observe manufacturer’s
specifications if necessary).
Sound level 58.5 dB(A)
Protection type IP 23 (suitable for indoor use only)
Dimensions (L×W×H) 670 × 300 × 320 mm
Weight 22 kg
Weight (including coolant) 30 kg
Tab. 2 Ambient conditions for transport, storage and operation
Ambient temperature
(operation, storage in a closed
environment)
−10 °C to +40 °C
Ambient temperature (transport) −25 °C to +55 °C
Relative humidity Up to 90% at 20 °C
702
590
301
242
316
ABICOOLER 1300 5 Transport and installation
EN - 9
5 Transport and installation
WARNING
W
Risk of injury due to improper transport and installation
Improper transport and installation can cause the device to tip or fall over. This may result in serious
injuries.
► Check and wear your personal protective equipment.
► Ensure that all supply lines and cables do not encroach into the area in which employees are working.
► Place the device on a suitable base (flat, solid, dry) on which it will not topple over.
► Note the weight of the device when lifting it.
4.2 Technical data on page EN-7
► Use an appropriate lifting tool with load handling attachment for transporting and installing the
device.
► Avoid abrupt lifting and setting down.
► Do not lift the device over persons or other devices.
WARNING
W
Health risk caused by inhaling harmful dust
Cooled air is blown out of the device. This can lead to dust that has collected on the floor during the
welding process to be stirred up. Inhaling harmful dust can damage the respiratory tract.
► Check and wear your personal protective equipment.
► Place the device on a clean, dust-free surface.
NOTICE
Risk of material damage due to improper transport and installation
Improper transport or installation can cause the device to tip or fall over. This can result in material
damage and irreparable damage to the device.
► Protect the device against weather conditions, such as rain and direct sunlight.
► Use the device only in dry, clean and well-ventilated rooms.
► Ensure a clearance of 50 cm around the device when installing it to ensure optimal circulation of
cooled air.
► Prevent dust and other foreign substances from entering the device.
► Note the maximum angle of tilt of 10°.
1Place the handles on the device.
2Fix them with (4) screws and install the device in a suitable place.
Tab. 2 Ambient conditions for transport, storage and operation on
page EN-7
EN - 10
6 Commissioning ABICOOLER 1300
6 Commissioning
6.1 Fuse protection for the device
► Device (115 V and 230 V) with a T2A fuse (5 × 20 mm).
WARNING
W
Electric shock due to defective cables
Damaged or improperly installed cables can lead to fatal electric shock.
► Check all live cables and connections for proper installation and damage.
► Damaged, deformed or worn parts should only be replaced by a qualified electrician.
NOTICE
Material damage due to contaminated coolant
Contamination in the coolant can lead to damage and increased wear in the device.
► Keep the coolant tank cap closed.
► We recommend that you use a coolant filter (not included in the scope of supply).
NOTICE
Material damage due to a lack of coolant
If there is insufficient coolant, the device's pump can overheat and cause irreparable damage.
► Ensure that coolant is added to the device before commissioning it.
► Ensure that the device is bled during commissioning.
► Ensure that the coolant pump does not run dry.
► Observe the fill level indicator on the device.
► Use the flow control to continuously monitor the proper function of the entire cooling system. If the flow
rate is too low, the flow control instigates the immediate switch-off of the connected devices and
prevents thermal overload.
NOTICE
Material damage when bridging multiple devices
The use of several devices (in sequence or in parallel) can result in material damage.
► Do not bridge the device with other cooling units.
Fig. 5 Fuse protection
AFuse
A
Andere Handbücher für ABICOOLER 1300
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