Abicor Binzel ABICOOLER 2000 advanced Bedienungsanleitung

Operating Instructions

ABICOOLER 2000 advanced

ABICOOLER 2000

Coolant recirculator

2000 advanced/2000

EN English 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

the 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 operating instructions.

All trademarks and registered trademarks mentioned in the Operating Instructions are the property of their respective

owners/manufacturers.

Contact details for the ABICOR BINZEL national agents and partners worldwide can be found on our website at

www.binzel-abicor.com.

1 Identification

EN-3

12 Disposal

EN-19

1.1 Marking

EN-3

12.1 Materials

EN-20

2 Safety

EN-3

12.2 Consumables

EN-20

2.1 Designated use

EN-3

12.3 Packaging

EN-20

2.2 Obligations of the operator

EN-3

13 Appendix

EN-21

2.3 Personal protective equipment (PPE)

EN-3

13.1 2000 advanced spare parts

EN-21

2.4 Classification of the warnings

EN-4

13.2 2000 spare parts

EN-23

2.5 Warning and notice signs

EN-4

13.3 Connecting diagram of the flow monitor

EN-25

2.6 Emergency information

EN-4

(Applicable to model 2000)

3 Product description

EN-5

13.3.1 Flow monitor assembly instructions

EN-25

3.1 Technical data

EN-5 (Applicable to model 2000)

3.2 Nameplate

EN-7

13.4 Switch box (applicable to model 2000)

EN-27

4 Scope of delivery EN-8 13.5 Description of default parameters

4.1 Transport EN-8

(Applicable to model 2000 advanced)

EN-28

4.2 Storage

EN-8

13.6 Description of aviation plug pins

5 Functional description

EN-9 (Applicable to model 2000 advanced)

EN-28

6 Startup and commissioning

EN-11

13.7 Detailed description of the operation

interface

6.1 Transport and installation

EN-12

(Applicable to model 2000 advanced)

EN-29

6.2 Connecting the cooling unit

EN-13 13.7.1 Original interface for startup

6.2.1 Fuse protection for the cooling unit

EN-13 (Applicable to model 2000 advanced)

EN-29

6.3 Before initial startup and commissioning

EN-13

13.7.2 User settings interface

6.3.1 Venting EN-14 (Applicable to model 2000 advanced)

EN-29

7 Operation

EN-15

13.7.3 Administrator settings interface

7.1 Before initial startup and commissioning

(Applicable to model 2000 advanced)

EN-29

and after long shutdown EN-15

13.8 Maintenance schedule

EN-30

8 Shutdown

EN-15

9 Maintenance and cleaning

EN-15

9.1 Maintenance interval

EN-16

9.2 Filter element cleaning

EN-17

10 Troubleshooting

EN-17

10.1 Forced pressurization of the circulation

loop EN-18

11 Disassembly

EN-19

EN-2

2000 advanced/2000 1 Identification

1 Identification

The 2000 advanced/2000 cooling unit is used for the cooling of liquid-cooled welding torches in the industry and

raw material processing industry. It can only be used with original ABICOR BINZEL spare parts. These operating

instructions only describe the 2000 advanced/2000 cooling unit.

1.1 Marking

This product meets the applicable product launch requirements. All corresponding markings required for launch

are affixed to the product.

2 Safety

The enclosed safety instructions must be observed.

2.1 Designated use

• The device described in these instructions may be used only for the purpose and in the manner described in

these instructions. In doing so, observe the operating, maintenance and servicing conditions.

• Any other use is considered improper.

• Unauthorized modifications or changes to increase the performance are not permitted.

2.2 Obligations of the operator

• Only the following personnel are allowed to operate the equipment:

• Familiar with the basic regulations related to occupational safety and accident prevention;

• Have received operating instructions for the equipment;

• Have read and understood these operating instructions;

• Have read and understood the content of the section “Safety Tips”;

• Having received corresponding training;

• Able to identify potential hazards based on their professional training, understanding and experience.

• Keep other persons out of the work area.

• Please comply with the occupational safety regulations of the corresponding countries and regions.

• Please comply with the regulations on occupational safety and accident prevention.

2.3 Personal protective equipment (PPE)

To avoid danger to the user, these instructions recommend the use of personal protective equipment (PPE).

• The PPE includes protective clothing, safety goggles, class P3 respiratory masks, protective gloves and safety

shoes.

EN-3

Safety 2000 advanced/2000

2.4 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. They are arranged in descending order of importance as follows:

DANGER

It indicates an imminent threatening danger. If not avoided, it may result in serious injuries or deaths.

WARNING

It indicates a potentially dangerous situation. If not avoided, it may result in serious injuries.

CAUTION

It indicates a potentially harmful situation. If not avoided, it may result in minor injuries.

NOTICE

It indicates a risk of impairing work results or damaging the equipment.

2.5 Warning and notice signs

The following warning and notice signs can be found on the product:

Symbol Meaning

Coolant circulation inlet

Coolant circulation outlet

Coolant filling inlet of the cooling unit

Please read and observe the operating instructions

Coolant discharging outlet of the cooling unit

These markings must always be legible. They must not be covered, obscured, scribbled over or removed.

2.6 Emergency information

In case of emergency, immediately disconnect the following supplies:

• Power supply

Further measures can be found in the “Power Supply” operating instructions or in the documents for other

peripheral devices.

EN-4

2000 advanced/2000 3 Product Description

3 Product description

The cooling unit is used for coolant-cooled welding torches.

Any other use is considered improper. The manufacturer cannot be held liable for any damage arising from such

use.

WARNING

Hazards caused by using the device contrary to its designated use

If used contrary to its designated use, the device can present risks to persons, animals and material property.

• Use the device according to its designated use only.

• Do not reconvert or modify the device without authorization to improve its performance.

• The equipment or system may only be operated by the personnel with corresponding capabilities.

3.1 Technical data

Figure 1 Dimensions of the 2000 advanced cooling unit

Figure 2 Dimensions of the 2000 cooling unit

EN-5

3 Product Description 2000 advanced/2000

2000 advanced 2000

Heat exchanger 3-row

Power supply AC 220 50 Hz/AC 110 60 HZ

Cooling capacity Q=1l/min at + 25℃1800 W (water)

Pump lift

Approx. 35 m

Maximum flow

7L/min

Pump type

Centrifugal pump

Max. coolant outlet pressure/coolant pump

pressure

3.7 bar

Coolant tank capacity

10 L

Coolant

BTC series

Ingress protection rating

IP 23 (applicable to the inner cavity only)

Dimensions

543 x 286 x 395 mm

Weight 23.4 kg 23.1 kg

Ambient temperature -10°C - +40°C

Relative humidity Up to 90% at 20°C

Table 1 2000 advanced/2000 cooling unit

Ambient temperature -10°C - +40°C

Relative humidity Up to 90% at 20°C

Table 2 Ambient conditions for operation

Storage in a closed environment, ambient temperature

-10°C - +40°C

Ambient temperature for transport -25°C to +55°C

Relative humidity Up to 90% at 20°C

Table 3 Ambient conditions for transport and storage

Unit of measurement in drawings or diagrams Millimeter [mm]

Table 4 Dimensions

EN-6

2000 advanced/2000 3 Product Description

3.3 Nameplate

The cooling unit is identified by a nameplate on one side of the housing as follows:

Figure 3 2000 advanced/2000 nameplate

Figure 4 Nameplate content of 2000 advanced (example)

When making enquiries, please note that the following information shall be provided:

• Product number

• Equipment identification number

• Date of manufacture

EN-7

4 Scope of Delivery 2000 advanced/2000

4 Scope of delivery

The cooling unit is delivered empty, i.e. without coolant. The coolant is ordered and delivered in separate

containers.

• ABICOOLER 2000 advancd/2000 • Connection plug for communication

• Complete coolant filter (1 set) • Funnel (1 piece)

Table 5 Scope of delivery

Order the spare parts and wear parts separately.

The order data and product numbers for the spare parts and wear parts can be found in the current catalogue.

Contact details for advice and orders can be found online at www.binzel-abicor.com.

4.1 Transport

Although the scope of delivery is carefully checked and packaged, it is not possible to exclude the risk of transport

damage.

Goods-in inspection

Use the delivery note to check whether everything has been delivered.

Check the delivery for damage (visual inspection).

In case of complaints

If the delivery has been damaged during transport, contact the final carrier

immediately. Retain the packaging for any possible inspection by the carrier.

Packaging for returns

Where possible, use the original packaging and the original packaging material.

If you have questions concerning the packaging or how to secure the equipment,

please consult your supplier, carrier or transport company.

Table 6 Transport

4.2 Storage

For ambient conditions for storage in a closed environment, see:

Table 3 Ambient conditions for transport and storage on page EN-6

EN-8

2000 advanced/2000 5 Functional Description

5 Functional description

The advanced/2000 cooling unit conveys and detects the cooling medium. All required components and

connections have been installed in the housing. A temperature and flow monitor is integrated into the cooling unit

by default. The cooling unit comes with a coolant filter, which must be installed on the cooling unit before use.

1 Coolant filling inlet 2 Coolant circulation outlet (blue) 3 Coolant circulation inlet (red)

4 Coolant discharging outlet neck 5 Level indicator 6 On/off switch

5 Communication signal connector 8 Display 9 ∅6 Compressed air connector

Figure 5 Components of the 2000 advanced coolant recirculator

EN-9

Water Filling

4 Scope of Delivery 2000 advanced/2000

1 Coolant filling inlet 2 Coolant circulation outlet (blue) 3 Coolant circulation inlet (red)

4 Coolant discharging outlet neck 5 Level indicator 6 On/off switch

5 Flow monitor connector 8 Fuse 9 ∅6 Compressed air connector

Figure 6 Components of the 2000 coolant recirculator

NOTICE

• To permanently monitor the correct functioning of the entire cooling system, we recommend that you connect

the communication connector/flow monitor connector (7) to the control device.

Figure 7/8 Overview of the coolant circulation loop on page EN-11

• If the flow rate of the cooling unit (2000 advanced) is lower or higher than the set value, an alarm signal will be

given, and the cooling unit will choose whether to stop according to the settings (See Table 11 on page EN-27

for parameter settings).

EN-10

Water Filling

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