ESAB COOL 1 Bedienungsanleitung

0740 800 210 Valid for serial no. 033-xxx-xxxx101102

COOL 1

Service manual

S0740 800 210/E101102/P18

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Rights reserved to alter specifications without notice.

READ THIS FIRST 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TECHNICAL DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component description 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOL1 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION OF OPERATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Cooling unit 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5AP1:1 Monitoring the coolant flow 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5AP1:2 Pump motor and fan ON/OFF 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5AP1 Component positions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is ESD? 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service aid 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUCTIONS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing to welding equipment 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly instructions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections and control devices 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant connection 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water flow guard 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and cleaning 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the coolant 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caracteristics 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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READ THIS FIRST

Maintenance and repair work should be performed by an experienced person, and

electrical work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault-tracing and repair.

Use the wiring diagram as a form of index for the description of operation. The circuit

boards are divided into numbered blocks, which are described individually in more detail in

the description of operation. Component names in the wiring diagram are listed in the

component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see page 16.

This manual contains details of design changes that have been made up to and including

October 2010.

The manual is valid for COOL 1 with serial no. 033-xxx-xxxx

The COOL 1 is designed and tested in accordance with international and European

standards IEC/EN 60974.

On completion of service or repair work, it is the responsibility of the person(s)

performing the work to ensure that the product still complies with the requirements of

the above standard.

CAUTION!

Read and understand the instruction manual before

installing or operating.

CAUTION !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

SObserve precautions for handling electrostatic-

sensitive devices.

SUse proper static-proof bags and boxes.

ESD

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TECHNICAL DATA

COOL 1

Power consumption 24V DC / 2A

Cooling power 1.3 kW (Rating at 40 K and 1 l/min)

Equivalent continuous A-weighted

sound pressure level

< 70 dB (A)

Coolant Ready mixed (50% water and 50% mono-ethylene glycol)

Coolant quantity 4.5 l

Maximum flow 2.0 l/min

Maximum pressure 4 bar

Operating temperature -10° to +40°C

Transportation temperature -20° to +55°C

Dimensions lxwxh 610 x 256 x 256 mm

Weight empty 12 kg

Enclosure class IP23

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

WIRING DIAGRAM

Component description

Component Description

5Cooling unit

5AP1 Circuit board with control electronics

5M1 Pump with motor, 24V DC

5S1 Coolant pressure switch (enclosed in pump 5M1)

5EV1 Cooling fan, 24V DC

5SL1 Flow guard. Monitoring coolant flow (option)

5XP.. Plug connector (Pin)

5XS.. Socket connector (Sleeve)

5XT.. Terminal block

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COOL1

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DESCRIPTION OF OPERATION

This description of operation describes the function of circuit boards and other components

in the equipment.

5 Cooling unit

5AP1:1 Monitoring the coolant flow

Circuit diagram for coolant flow guard

COOL1 is prepared for optional coolant flow monitoring. Replace the jumper cable 513 with

the flow guard sensor, 5SL1, and connect it to terminal block 5XT1 (CN4) on cooling unit

board, 5AP1. The sensor switch opens at flow rate < 0.7 l/min. The MMC panel of the

system displays fault code 29 ,(no cooling water flow), if the input to the processor is high.

(Measure at point SP3 on 20AP1)

Supervision of hoses connection, ELP (ESAB Logic Pump) is not installed in COOL1.

5AP1:2 Pump motor and fan ON/OFF

The pump motor, 5M1, and cooling fan, 5EV1, are connected in parallell and powered from

the power supply board, 2AP3, in the power source. The power is 25V DC and named

25V_WP in the cooling unit board, 5AP1.

An output from the processsor on control board 20AP1 connects input 20XS5:2 (WP2) to

0V. (Measure at point SP1 on 20AP1). Transistor Q2 in cooling unit board, 5AP1, connects

pump motor and fan to 0V, and the pump and fan start.

The pump, 5M1, has an enclosed coolant pressure switch, 5S1, which switches off the

power to the pump motor if the coolant pressure is too high. This can occur if a hose is

folded which make flow to fail or stop. The cooling fan however is still powered and running.

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Pump motor and fan ON/OFF

Circuit diagram for pump motor and cooling fan

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5AP1 Component positions

Component positions on the cooling unit board, 5AP1.

Terminal block CN4 is also named 5XT1 in the diagram.

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SERVICE INSTRUCTIONS

What is ESD?

A sudden transfer or discharge of static electricity from one object to another. ESD stands for

Electrostatic Discharge.

How does ESD damage occur?

ESD can cause damage to sensitive electrical components, but is not dangerous to people.

ESD damage occurs when an ungrounded person or object with a static charge comes into

contact with a component or assembly that is grounded. A rapid discharge can occur,

causing damage. This damage can take the form of immediate failure, but it is more likely

that system performance will be affected and the component will fail prematurely.

How do we prevent ESD damage?

ESD damage can be prevented by awareness. If static electricity is prevented from building

up on you or on anything at your work station, then there cannot be any static discharges.

Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static

charge, so you should not bring unnecessary nonconductive items into the work area.

It is obviously difficult to avoid all such items, so various means are used to drain off any

static discharge from persons to prevent the risk of ESD damage. This is done by simple

devices: wrist straps, connected to ground, and conductive shoes.

Work surfaces, carts and containers must be conductive and grounded. Use only antistatic

packaging materials. Overall, handling of ESD-sensitive devices should be minimized to

prevent damage.

CAUTION !

STATIC ELECTRICITY can damage circuit

boards and electronic components.

SObserve precautions for handling electrostatic-

sensitive devices.

SUse proper static-proof bags and boxes.

ESD

Service aid

Antistatic service kit

Ordering no. 0740 511 001

The kit makes it easier to protect sensitve

components from electrostatic discharge.

Contents:

SA conductive mat (size 610 x 610 mm)

SA 1.5 metre long ground cable with a

crocodile clip

SAn adjustable wrist strap and cable with

an inbuilt protective resistor

Antistatic service kit

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INSTRUCTIONS

This chapter is an extract from the instruction manual for the COOL1.

SAFETY

CAUTION!

Read and understand the instruction manual before

installing or operating.

INSTALLATION

The installation must be executed by a professional.

Location

Position the cooling unit such that its air inlets and outlets are not obstructed.

Power supply and control

COOL1 is powered and controlled from the power source via socket connector XS4 in the

bottom of the power source. The plug connector 5XP1 on top of the cooler is connected to

XS4.

Installing to welding equipment

See assembly instructions on page 11.

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