ESAB COOL 2 Instruction manual

COOL 2

Instruction manual

0463 348 101 GB 20230112

Valid for: Serial number: 230-, 324-xxx-xxxx

TABLE OF CONTENTS

1

SAFETY - CE

1.1 Meaning of symbols

1.2 Safety precautions

2

INTRODUCTION

2.1 Equipment

3

TECHNICAL DATA

4

INSTALLATION

4.1 Location

4.2 Power supply

4.3 Installing welding equipment

5

OPERATION

5.1 Connections and control devices

5.2 Usage of the cooling unit

5.3 Coolant connection

5.4 Coolant pressure controller

6

MAINTENANCE

6.1 Inspection and cleaning

6.2 Filling the coolant

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5

5

5

8

8

9

10

10

10

10

11

11

11

11

11

12

12

12

7

FAULT TRACING

8

ORDERING SPARE PARTS

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ASSEMBLY INSTRUCTIONS
DIAGRAM
PUMP DATA
ORDERING NUMBERS
ACCESSORIES

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13

14
15
19
20
21
22

Rights reserved to alter specifications without notice.

0463 348 101 © ESAB AB 2023

1 SAFETY - CE

1 SAFETY - CE

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!
Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!
Means potential hazards which could result in personal injury or loss of life.

CAUTION!
Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

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1 SAFETY - CE

4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

If equipped with ESAB cooler

Use ESAB approved coolant only. Non-approved coolant might damage the equipment and
jeopardize product safety. In case of such damage, all warranty undertakings from ESAB
cease to apply.

For ordering information, see the "ACCESSORIES" chapter in the instruction manual.

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.

NOTE!
Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.

As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.

For further information contact the nearest ESAB dealer.

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1 SAFETY - CE

ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

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2 INTRODUCTION

2 INTRODUCTION

Cooling unit COOL 2 is intended for cooling water-cooled MIG/MAG welding torches.

Cool 2 cooling unit is comatible with the following power sources:

• Warrior™ 400i CC/CV, 500i CC/CV, 350iMV and 400iMV

• Aristo® 500ix

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.

2.1 Equipment

The cooling unit is supplied with:

• Instruction manual

• Quick start guide

• Safety instruction manual

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3 TECHNICAL DATA

3 TECHNICAL DATA

COOL 2

Power consumption 40 V AC / 2A, 50/60 Hz

Cooling power 1 kW

Noise

< 70 dB(A)

(Constant sound pressure when idling)

Coolant "ESAB's ready mixed coolant, see the

"ACCESSORIES" chapter.

Coolant quantity 4.5 l

Maximum water flow 1.8l/min (0.48gal/min)

Max pressure lift for torch Q

max

4.6bar (66.7PSI)

Operating temperature -10° to +40°C (-14° to +104°F)

Transportation temperature -20° to +55°C (-4° to +131°F)

Dimensions (l × w × h) 680 × 325 × 230 mm (26.8 × 13 × 9.1inch)

Weight empty 15 kg (33.1lbs)

Enclosure class IP23

The cooling unit is rated 500 A at 60% duty cycle at 25°C (77°F) ambient temperature.

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 intended for indoor and outdoor use.

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4 INSTALLATION

4 INSTALLATION

The installation must be carried out by a professional.

CAUTION!

This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.

4.1 Location

Position the cooling unit such that it's cooling air inlets and outlets are not obstructed.

4.2 Power supply

The cooling unit is supplied from the power source, see the"OPERATION" chapter.

4.3 Installing welding equipment

Installation instruction for this product can be found in the "ASSEMBLY INSTRUCTIONS"
chapter".

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5 OPERATION

5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!

5.1 Connections and control devices

1. Switch for On/Off

2. Coolant filling

3. Min/max of coolant

4. Connection RED for coolant (return)
to cooling unit

5. Connection BLUE for coolant from
cooling unit

5.2 Usage of the cooling unit

CAUTION!
Important! Turn OFF the cooling unit when welding MMA or using air cooled MIG/TIG

welding torches to avoid excessive wear of the pump. Otherwise the pump will work
against a closed valve.

Turn ON the cooling unit when using a water cooled MIG welding torch to avoid
damages on the cable set.

5.3 Coolant connection

For problem free operation it is recommended that the height from the cooling unit to the
water-cooled MIG/MAG torch is a maximum of 8.5 m.

5.4 Coolant pressure controller

The pump has an enclosed pressure relief valve. The valve opens gradually when the
pressure is too high. This can occur if a hose is folded, which causes the flow to fail or stop.

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6 MAINTENANCE

6 MAINTENANCE

NOTE!

Regular maintenance is important for safe and reliable operation.

CAUTION!

Only persons with the appropriate electrical knowledge (authorised personnel) may
remove the safety plates.

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period.

6.1 Inspection and cleaning

WARNING!

The mains supply must be disconnected before cleaning.

Dust, grinding, swarf etc

The air stream through the cooling unit carries particles that become trapped in the cooling
element, particularly in dirty working environments. This results in reduced cooling capacity.
For this reason, blow clean using compressed air at regular intervals.

The coolant system

The recommended coolant must be used in the system otherwise clumps can be created that
block the pump, water connections or elements. Flushing can only be performed via red
water connection. Then drain the tank manually, i.e. empty via the tank's filling hole.

6.2 Filling the coolant

Only use ESAB's ready mixed coolant, see the "ACCESSORIES" chapter.

• Fill with coolant. (The fluid level must

not exceed the upper marking but
neither must it be below the lower
marking.)

NOTE!

Coolant must be topped up if connecting a welding torch or coolant hoses that are 5
metres in length or longer. When adjusting the water level by topping up, the coolant
hoses do not need to be disconnected.

CAUTION!

The coolant must be handled as chemical waste.

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7 FAULT TRACING

7 FAULT TRACING

Try these recommended checks and inspections before sending for an authorized service
technician.

Type of fault Corrective action

Poor cooling effect • Clean the cooling element using

compressed air.

• Check the coolant level.

• Check that the on/off switch on the
cooling unit is set to ON.

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8 ORDERING SPARE PARTS

8 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.

The COOL2 is designed and tested in accordance with International and European
standards IEC/EN 60974-2 and IEC/EN 60974-10, Canadian standards
CAN/CSA-E60974-1 and US standards ANSI/IEC 60974-1. 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 standards.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see

esab.com. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.

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ASSEMBLY INSTRUCTIONS

ASSEMBLY INSTRUCTIONS

For Warrior power sources:

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ASSEMBLY INSTRUCTIONS

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ASSEMBLY INSTRUCTIONS

For Aristo 500ix power source:

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ASSEMBLY INSTRUCTIONS

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DIAGRAM

DIAGRAM

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PUMP DATA

PUMP DATA

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ORDERING NUMBERS

ORDERING NUMBERS

Ordering Number Denomination Type

0465 427 880 Cooling unit COOL 2

0459 839 092 Spare parts list COOL 2

The three last digits in the document number of the manual show the version of the manual.
Therefore they are replaced with * here. Make sure to use a manual with a serial number or
software version that corresponds with the product, see the front page of the manual.

Technical documentation is available on the Internet at: www.esab.com

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ACCESSORIES

ACCESSORIES

0465 720 002 ESAB ready mixed coolant

(10l/2.64gal)
Use of any other cooling liquid than the
prescribed one might damage the
equipment. In case of such damage, all
warranty undertakings from ESAB cease
to apply.

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ACCESSORIES

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© ESAB AB 2023

ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone [phone]

manuals.esab.com

For contact information visit esab.com