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Abicor Binzel ABICOOLER 1300 Operating Instructions Manual

Cooling unit
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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
ABICOOLER 1300
EN Cooling unit
w w w . b i n z e l - a b i c o r . c o m

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Summary of Contents for Abicor Binzel ABICOOLER 1300

  • Page 1 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 ABICOOLER 1300 EN Cooling unit w w w . b i n z e l - a b i c o r . c o m...

  • Page 2: Table Of Contents

    ​ ABICOOLER 1300 Table of contents 1 Identification .......................... Signs and symbols used ............................Classification of the warnings ..........................Product label ................................Nameplate ................................2 Safety............................. Intended Use ................................Obligations of the operator ............................ Warning and information signs ..........................Safety instructions ..............................
  • Page 3 ABICOOLER 1300 13 Disposal..........................29 13.1 Disposing of waste equipment..........................29 13.2 Disposal of coolant..............................29 13.3 Disposal of materials ............................... 29 13.4 Disposal of consumables............................29 13.5 Disposing of packaging ............................29 14 Spare parts..........................29 15 Circuit diagram 115 V ......................31 16 Circuit diagram 230 V ......................

  • Page 4: Identification

    1 Identification ABICOOLER 1300 Identification These operating instructions describe the 115 V and 230 V versions of 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.

  • Page 5: Classification Of The Warnings

    ABICOOLER 1300 1 Identification Classification of the warnings The warning notices used are divided into four different levels and are printed in front of potentially dangerous work steps. Depending on the type of danger, the following signal words are used: DANGER Describes an imminent danger.

  • Page 6: Nameplate

    Intended Use The device is exclusively used to cool liquid-cooled welding torches. ► Only operate the unit with original ABICOR BINZEL spare parts. ► Do not exceed the maximum load data given in the documents. Excess loads will lead to irreparable damage.

  • Page 7: Warning And Information Signs

    ABICOOLER 1300 2 Safety Warning and information 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. ► Wear face protection.

  • Page 8: Safety Instructions For Electrical Components

    2 Safety ABICOOLER 1300 2.4.2 Safety instructions for electrical components ► Check electric tools for damage and ensure that they function properly and in accordance with their designated use. ► Do not expose electric tools to rain and avoid a moist or wet environment.

  • Page 9: Scope Of Delivery

    Scope of delivery The device is delivered without coolant. The coolant must be ordered separately. The following components are included in the scope of delivery: – 1× ABICOOLER 1300 cooling unit – 1× flow control cable – 1× discharge hose –...

  • Page 10: Product Description

    4 Product description ABICOOLER 1300 Product description Structure and function Figure 2 Structure and function Control lead connection for flow control Coolant filler neck <I/O> switch Fuse Coolant supply connection (blue) Coolant return (red) Drain coupling Coolant tank Filling level indication The device is used for cooling liquid-cooled welding torches.

  • Page 11: Technical Data

    ABICOOLER 1300 5 Technical data Figure 3 Overview of the coolant circuit Air head exchanger Coolant return (red) Coolant supply (blue) Drain coupling Pump Coolant tank Technical data Ambient conditions Ambient temperature –23°C to +55°C Relative humidity Up to 90% at +20°C Table 1...
  • Page 12 Max. flow rate of pump 10 l/min Max. coolant outlet pressure/pump 3.9 bar pressure Coolant BTC series or other ABICOR BINZEL coolant Coolant conductivity (MIG/MAG torch) 0 to 350 µS/cm Coolant conductivity (TIG torch) 0 to 250 µS/cm Coolant conductivity (plasma torch) 0 to 30 µS/cm (observe manufacturer’s specifications...

  • Page 13: Transport And Installation

    ABICOOLER 1300 6 Transport and installation Transport and installation CLICK HERE FOR VIDEO WARNING Risk of injury due to improper transport and setup Improper transport and setup can lead to the unit tilting or falling. Serious injuries can be the result.
  • Page 14 6 Transport and installation ABICOOLER 1300 Place the handles on the device. Fix them with (4) screws and install the device in a suitable place. EN - 14 BAL.0838.0 • V01...

  • Page 15: Commissioning

    ABICOOLER 1300 7 Commissioning Commissioning WARNING Electric shock due to damaged or improperly installed cable The use of damaged or improperly installed cables may result in a potentially fatal electric shock. ► Check all live cables and connections for proper installation and damage.

  • Page 16: Installing The Fuse

    25% monoethylenglycol and 75% demineralized water (permitted operating temperature –10°C to +40°C), if ABICOR BINZEL BTC coolant or other ABICOR BINZEL coolant is not available. NOTE Material damage due to contaminated or conductive coolant The use of contaminated or conductive coolant can lead to damage and increased wear to the device.

  • Page 17: Bleeding The Cooling Circuit

    ABICOOLER 1300 7 Commissioning Fill with coolant up to the <MAX> mark. Screw on the tank cap. Bleed the cooling circuit ð 7.3 Bleeding the cooling circuit (Page 17). Bleeding the cooling circuit CLICK HERE FOR VIDEO Proper cooling is ensured only if the entire cooling system has been bled. The device must bled at the time of initial commissioning and every time the device is emptied.

  • Page 18: Connecting And Bleeding The Cable Assembly

    7 Commissioning ABICOOLER 1300 Press air out of the tool for device bleeding. If coolant is also drawn up when the piston is pulled up, proceed as follows: Open the tank cap. Press the coolant out of the tool for device bleeding into the coolant tank.

  • Page 19: Connecting A Flow Control

    ABICOOLER 1300 7 Commissioning Connecting a flow control CLICK HERE FOR VIDEO A flow control is integrated into the device as standard and must be connected via the flow control cable supplied. The available connection is suitable only for two-step operation. If a flow control is used, the device switches off the welding current if the coolant level is low and the torch trigger is pressed.
  • Page 20 7 Commissioning ABICOOLER 1300 Disconnect one trigger cable. Remove the cap from the connection housing. Guide the flow control cable with the cable ends through the opening. Pull the heat-shrinking tube over both cable ends and connect the trigger cable to the flow control cable.

  • Page 21: Operation

    ABICOOLER 1300 8 Operation Insert the flow control cable’s plug into the control lead connector on the device. Operation WARNING Risk of burns due to hot coolant If the coolant tank is opened during or immediately after operation, coolant may spray out and cause burns or irritation to skin and mucous membranes.

  • Page 22: Decommissioning

    ► Each time the cover plates are opened, have a safety inspection performed in accordance with DIN IEC 60974 Part 4: “Periodic inspection and testing” by ABICOR BINZEL or another authorized specialist. CAUTION Risk of injury due to unexpected start If power is supplied during maintenance, cleaning or disassembly, rotating parts can start running unexpectedly and lead to injuries from cuts.

  • Page 23: Maintenance And Cleaning Intervals

    After each time the housing is ► Have a safety inspection performed in accordance with opened DIN EIC 60974 Part 4: “Periodic inspection and testing” by ABICOR BINZEL or another authorized specialist. Table 4 Maintenance and Cleaning Intervals EN - 23 BAL.0838.0 • V01...

  • Page 24: Changing The Coolant

    10 Maintenance and cleaning ABICOOLER 1300 10.2 Changing the coolant CLICK HERE FOR VIDEO WARNING Risk of burns due to hot coolant If the coolant tank is opened during or immediately after operation, coolant may spray out and cause burns or irritation to skin and mucous membranes.

  • Page 25: Replacing The Fuse

    ABICOOLER 1300 10 Maintenance and cleaning Screw on the tank cap. 10.3 Replacing the fuse Depending on the version, the following fuse is required: Version Fuse 230 V T2A fine wire fuse (5 × 20 mm) 115 V T4A fine wire fuse (5 × 20 mm) Table 5 Fuses ð...

  • Page 26: Replacing The Handles

    10 Maintenance and cleaning ABICOOLER 1300 10.4 Replacing the handles Loosen the screws (4×) from the handles and remove them. Remove both handles. Place the new handles on the device. Fix the handles with the screws (4×). EN - 26...

  • Page 27: Faults And Troubleshooting

    11 Faults and troubleshooting Faults and troubleshooting ► Consult the documentation of all components used. ► Contact your retailer or ABICOR BINZEL in the event of questions or problems. WARNING 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.

  • Page 28: Disassembly

    12 Disassembly ABICOOLER 1300 Fault Cause Troubleshooting Coolant circuit is interrupted. ► Check the coolant hoses for damage and replace them if necessary. Air in the coolant circuit. ► Bleeding the cooling circuit ð 7.3 Bleeding the cooling circuit (Page 17) Cooling capacity too low.

  • Page 29: Disposal

    ► Observe the local laws and regulations on disposal provisions in the safety data sheets of the consumables manufacturer. 13.5 Disposing of packaging ABICOR BINZEL has reduced the transport packaging to a minimum. The ability to recycle packaging materials was always considered during their selection. ► Heed local laws and directives on disposal. Spare parts...
  • Page 30 14 Spare parts ABICOOLER 1300 Item designation Version T2A fine wire fuse, 5 × 20 mm 230 V T4A fine wire fuse, 5 × 20 mm 115 V Rubber foot D = 25 × 24 black 115 V/230 V Handle 179 black 115 V/230 V Heat exchanger 115 V/230 V Motor/pump 230 V incl. fan 115 V/230 V Autotransformer 115 V Rubber pad A 20 x 15 – M6x16 115 V/230 V...

  • Page 31: Circuit Diagram 115 V

    ABICOOLER 1300 15 Circuit diagram 115 V Circuit diagram 115 V F1 – fuse H1 – indicator light M1 – water pump S1 – main switch S2 – water ow switch T1 – transformer X1 – cable clamp X2 – 2-pin socket EN - 31 BAL.0838.0 •...

  • Page 32: Circuit Diagram 230 V

    16 Circuit diagram 230 V ABICOOLER 1300 Circuit diagram 230 V F1 – fuse H1 – indicator light M1 – water pump S1 – main switch S2 – water ow switch T1 – transformer X1 – cable clamp X2 – 2-pin socket EN - 32 BAL.0838.0 •...
  • Page 33 ABICOOLER 1300 16 Circuit diagram 230 V BAL.0838.0 • V01...
  • Page 34 16 Circuit diagram 230 V ABICOOLER 1300 BAL.0838.0 • V01...
  • Page 35 ABICOOLER 1300 16 Circuit diagram 230 V BAL.0838.0 • V01...
  • Page 36 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 . Alexander Binzel Schweisstechnik GmbH & Co. KG Kiesacker • 35418 Buseck • GERMANY T +49 64 08 / 59–0 F +49 64 08 / 59–191 info@binzel-abicor.com...

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