ESAB OCF 2 Instruction manual

GB

OCF 2

Instruction manual

Valid for serial no. 803 xxx--xxxx0457 680 001 GB 050819

1 DIRECTIVE 3........................................................

2SAFETY 3...........................................................

3 INTRODUCTION 4...................................................

3.1 Equipment 4................................................................

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

5 INSTALLATION 5....................................................

5.1 Unpacking and siting 5.......................................................

6 OPERATION 9.......................................................

6.1 Flow monitor 9..............................................................

7 MAINTENANCE 10....................................................

7.1 Inspection and cleaning 10....................................................

8 TROUBLESHOOTING 10..............................................

9 ORDERING SPARE PARTS 10..........................................

DIAGRAM 11............................................................

ORDERING NUMBER 12.................................................

Rights reserved to alter specifications without notice.

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1DIRECTIVE

DECLARATION OF CONFORMITY

Esab Welding Equipment AB, 695 81 Laxå, Sweden, declares that cooling unit OCF
2 from serial number 803 onwards, conforms to standard EN 60204--1, in accord­ance with the requirements of directive (73/23/EEC) and appendix (93/68/EEC) and
standard EN 50199 in accordance with the requirements of directive (89/336/EEC)
and appendix ( 93/68/EEC).

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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336

2SAFETY

WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU­TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS -- Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.

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

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

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3 INTRODUCTION

The OCF 2 cooling unit comes in four versions, designed for use with LTN/LTR
160/200/255, DTE 200/255, LTS160/250, and semi-- automated power sources.

3.1 Equipment

Check the coolant level before use.
If necessary, top up with water and glycol.

S OCF 2L and OCF 2D are equipped with a transformer which is fed by the

welding power source.
Can be supplied with a flow monitor (0467 118 001).

S OCF 2M has relays to allow supply via the welding power source.

S OCF 2A is fitted with an earthed plug complying with Swedish regulations.

Can be stood on edge if it is fitted with feet (4 off. 0467 695 001).

4 TECHNICAL DATA

Model OCF 2L OCF 2D*) OCF 2M OCF 2A
Voltage 400 V 400 V 230 V 230 V
Power consumption 250 W 250 W 250 W 250 W
Cooling effect 2000 W 2000 W 2000 W 2000 W
Power source LTN/LTR

200,255

Drive Internal from

welding power
source

Coolant Water/Glycol Water/Glycol Water/Glycol Water/Glycol
Coolant capacity 5L 5L 5L 5L
Max. pressure 3 bar 3 bar 3 bar 3 bar
Max. water flow 4l/min 4l/min 4l/min 4l/min
Air flow 200 m3/h 200 m3/h 200 m3/h 200 m3/h
Fuse, slow 1.6 A 1.6 A
Enclosure class IP 23 IP 23 IP 23 IP 23
Weight 22 kg 25 kg 19,5 kg 19,5 kg
Dimensions 470x260x190 500x290x190 470x260x190 470x260x190

DTE 200/255 LTS 160/250 L TN/LTR 160,

Automated.

Internal from
welding power
source

Internal from
welding power
source

Internal from
power supply

*) OCF 2D is a special version with larger external dimensions, but otherwise the same as OCF 2L.

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.

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5 INSTALLATION

WARNING!

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.

S OCF 2L/OCF 2D To be installed by an electrician.
S OCF 2M/OCF 2A Maybeinstalledbyuser.

The only tool that is required for installation is a cross--head screwdriver.

5.1 Unpacking and siting

OCF 2 with a LTS 160/250 on top, with another free--standing, upright.

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5.1.1 Connection
OCF 2L to LTN/LTR 200,255, NOT FITTED with connecting cable for cooling unit.

1. Unplug if necessary.

2. Remove the lower screws from the sides of the power source.

3. Remove the rear panel from the power source.

4. Hole D=38 to be drilled in base plate, see fig.1.

fig.1

5. NOTE! Clean any metal swarf from the weldin g power source.

6. Remove the front panel from the welding power source.

7. Connect the connecting cable for the cooling unit to the welding power source,
see fig.2.

066--to X02 (5--pin connector) according to drawing for relevant machine.

067--to X02 (5--pin connector) according to drawing for relevant machine

905--to earth terminal according to drawing for relevant machine

LTR 200/255

B4--to cable B4 from circuit board AP01 acc. to drawing for relevant machine

LTN 200/255

B4--to K2 on circuit board AP01 according to drawing for relevant machine

057--to ST01 thermal cut-- out according to drawing for relevant machine

065

XS24

B4

057

XS25

fig.2

8. Place the power source on the cooling unit and raise the rear edge.

9. Feed the connectors from the cooling unit through the hole in the bottom panel.

10. Remove the clamp from the terminal inside the power source and join the
connectors see fig.3.

11. Refit the rear panel.

12. Tighten the screws in the bottom through the cover on the cooling unit.

13. Connect the water--cooled torch and do a test run.

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fig.3

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OCF 2L to LTN/LTR 200,255, and OCF 2D to DTE. FITTED with connecting cable

for cooling unit.

1. Unplug if necessary.

2. Remove the lower screws from the sides of the power source.

3. Remove the rear panel from the power source.

4. Remove the spring washer from the bottom panel (only applies to DTE):

5. Place the power source on the cooling unit and raise the rear edge.

6. Feed the connectors from the cooling unit through the hole in the bottom panel.

7. Remove the clamp from the terminal inside the p ower source and join the
connectors see fig.3.

8. Refit the rear panel.

9. Tighten the screws in the bottom through the cover on the cooling unit.

10. Connect the water--cooled torch and do a test run.

fig.3

OCF 2M to LTS 160/250.

1. Unplug if necessary.

2. Remove the lower cross--head screws from the sides of the power source.

3. Place the power source on the cooling unit.

4. Tighten the knobs (M5) at the sides through the cover of the cooling unit.

5. Connect the power cable and the flow monitor to the power source.

6. Connect the water--cooled torch and do a test run.

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OCF 2A to LTN/LTR 160.

1. Remove the lower cross--head screws from the sides of the power source.

2. Place the power source on the cooling unit.

3. Tighten the screws in the bottom through the cover on the cooling unit.

4. Plug the power cable into an earthed wall socket 230 V, 6 A.

5. Connect the water--cooled torch and do a test run.

OCF 2A free--standing

1. If the cooling unit is to stand upright, fit the feet to the right side panel.

2. Turn the cover upside down to provide a flat surface and screw it in place with
M5 screws.

3. Place the cooling unit on its side or stand it upright, secure with M5 screws.

4. Fit an earthed plug. (the existing plug complies with Swedish regulations)

5. Plug the power cable into an earthed wall socket 230 V, 6 A.

6. Connect the water--cooled torch and do a test run.

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6OPERATION

Glycol

The cooling unit contains poisonous glycol which must not be drunk or poured down
the drain or into the soil or water. Regularly top up the tank to a level 1 cm below the
top if water is lost during hose changes.

Avoid using glycol if the conditions are not cold enough to warrant it.

Pure water gives the best cooling effect.

6.1 Flow monitor

Applies to OCF 2M and options.
The flow monitor is connected in series with

the thermal cut--out inside the power source.
If the water flow is restricted or stopped this
will trigger the flow monitor and prevent
further welding.

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7 MAINTENANCE

Note!

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

7.1 Inspection and cleaning

The flow of air through the cooling unit carries small particles that stick to the cooling
element, especially in a dirty working environment. This can reduce cooling
performance. You should therefore clean the element regularly using compressed
air.

Replace the coolant about once a year. Refill with glycol mixture if the cooling unit is
to be used or stored in freezing conditions.

8 TROUBLESHOOTING

In case of major faults, contact your nearest ESAB authorised service workshop or
dealer.

Fault Action

Thermal cut--out lamp on power source comes
on

Pump or fan not working S Check both fuses
Pump not working S Major fault, see above.
Fan not working S Major fault, see above.
No water flow S Raise left panel.

Poor cooling effect S Clean cooling element with compressed air

S Check cooling unit is running.
S Check that safety plug is fitted.
S If water is flowing, the flow monitor may be

faulty, counts as major fault, see above.

Switch off, disconnect blue coupling, blow
through coolant hose to empty system.

9 ORDERING SPARE PARTS

Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.

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Diagram

Schema 0457 722

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Ordering number

Ordering no. Denomination Type

0457 216 880 Cooling unit OCF 2L

0457 216 881 Cooling unit OCF 2D

0457 216 882 Cooling unit OCF 2M

0457 216 883 Cooling unit OCF 2A

0457 816 880 Conversion kit For LTN / LTR 200, 255 not fitted with connectiong

cable for cooling unit OCF 2L

0457 680 990 Spare parts list OCF 2L, OCF 2D, OCF 2M, OCF 2A

The spare parts list is available on the Internet at www.esab.com
Under ”Products” and ”Welding & cutting equipment”, you will find a link to the page where you can
both search for and download instruction manuals and spare parts lists.

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ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Prague
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Copenhagen--Valby
Tel:[phone]
Fax:[phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]

ITALY

ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]

THE NETHERLANDS

ESAB Nederland B.V.
Utrecht
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel:[phone]
Fax:[phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]

SPAIN

ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]

ESAB International AB
Gothenburg
Tel:[phone]
Fax:[phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem-- MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

JAPAN

ESAB Japan
Tokyo
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
Shah Alam Selangor
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel:[phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Representative offices

BULGARIA

ESAB Representative Office
Sofia
Tel/Fax: [phone]

EGYPT

ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Representative Office
Bucharest
Tel/Fax: [phone]

RUSSIA-- CIS

ESAB Representative Office
Moscow
Tel:[phone]
Fax: [phone]

ESAB Representative Office
St Petersburg
Tel:[phone]
Fax: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone [phone]

www.esab.com

041227