Abicor Binzel ABICOOLER 1300 User manual

EN Original operating instructions
FR Mode d'emploi d'origine
ABICOOLER 1300
EN Cooling unit
FR Refroidisseur
TECHNOLOGY FOR THE WELDER`S WORLD .
www.binzel-abicor.com

Table of contents ABICOOLER 1300
EN - 2 BAL.1041.0 • V1
Table of contents
1 Identification........................................................................................................................................... 4
1.1 Signs and symbols used................................................................................................................................................................. 4
1.2 Classification of the warnings........................................................................................................................................................ 5
1.3 Product label................................................................................................................................................................................... 5
1.4 Nameplate...................................................................................................................................................................................... 6
2 Safety ..................................................................................................................................................... 7
2.1 Designated use ............................................................................................................................................................................... 7
2.2 Obligations of the operator........................................................................................................................................................... 7
2.3 Warning and information signs..................................................................................................................................................... 8
2.4 Safety instructions ........................................................................................................................................................................... 9
2.4.1 Basic safety instructions .................................................................................................................................................. 9
2.4.2 Safety instructions for electrical components................................................................................................................ 9
2.4.3 Safety instructions for welding ....................................................................................................................................... 9
2.4.4 Safety instructions for protective equipment ................................................................................................................. 10
2.4.5 Safety instructions for use of electrical devices............................................................................................................. 10
2.4.6 Safety instructions for the electrical power supply....................................................................................................... 10
2.4.7 Safety instructions for emergencies................................................................................................................................ 10
3 Scope of delivery .................................................................................................................................... 11
4 Product description ................................................................................................................................. 12
4.1 Structure and function .................................................................................................................................................................... 12
5 Technical data ......................................................................................................................................... 13
5.1 Ambient conditions......................................................................................................................................................................... 13
5.2 Product data.................................................................................................................................................................................... 13
6 Transport and installation ....................................................................................................................... 14
7 Commissioning........................................................................................................................................ 16
7.1 Installing the fuse ............................................................................................................................................................................ 17
7.2 Adding coolant............................................................................................................................................................................... 17
7.3 Bleeding the cooling circuit ........................................................................................................................................................... 18
7.4 Connecting and bleeding the cable assembly ............................................................................................................................ 19
7.5 Connecting a flow control ............................................................................................................................................................. 20
8 Operation ............................................................................................................................................... 22
9 Decommissioning .................................................................................................................................... 23
10 Maintenance and cleaning ...................................................................................................................... 24
10.1 Maintenance and cleaning intervals ............................................................................................................................................ 24
10.2 Changing the coolant..................................................................................................................................................................... 25
10.3 Replacing the fuse .......................................................................................................................................................................... 26
10.4 Replacing the handles.................................................................................................................................................................... 26
11 Faults and troubleshooting...................................................................................................................... 28
12 Disassembly............................................................................................................................................ 30
13 Disposal .................................................................................................................................................. 31
13.1 Disposing of waste equipment ...................................................................................................................................................... 31
13.2 Disposal of coolant......................................................................................................................................................................... 31
13.3 Disposal of materials...................................................................................................................................................................... 31
13.4 Disposal of consumables ............................................................................................................................................................... 31

ABICOOLER 1300 Table of contents
BAL.1041.0 • V1 EN - 3
13.5 Disposing of packaging................................................................................................................................................................. 31
14 Spare parts ............................................................................................................................................. 32
15 Circuit diagram 115V.............................................................................................................................. 33

1 Identification ABICOOLER 1300
EN - 4 BAL.1041.0 • V1
1 Identification
These operating instructions describe 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.
The device is exclusively used to cool liquid-cooled welding torches.
Further information and additional documentation for the product can be found in the download portal at
www.abidoc.binzel-abicor.com.
1.1 Signs and symbols used
In these operating instructions, the following signs and symbols are used:
General instructions.
Steps to be carried out in succession.
Lists.
The cross-reference refers to detailed, supplementary or further information.
Caption, item description.

ABICOOLER 1300 1 Identification
BAL.1041.0 • V1 EN - 5
1.2 Classification of the warnings
The warnings used are divided into four different categories and are indicated prior to potentially dangerous
work steps.
The following signal words are used depending on the type of hazard:
DANGER
Describes an imminent threatening danger.
If not avoided, it may cause severe injuries or death.
WARNING
Describes a potentially dangerous situation.
If not avoided, this may result in death or serious injuries.
CAUTION
Describes a potentially harmful situation.
If not avoided, this may result in slight or minor injuries.
NOTICE
Indicates possible material damage.
Follow the instructions to prevent irreparable damage to the device or equipment. Workresults
may be impaired.
1.3 Product label
This product fulfills the requirements that apply to the market to which it has been introduced. A corresponding
marking has been affixed to the product, if required.

1 Identification ABICOOLER 1300
EN - 6 BAL.1041.0 • V1
1.4 Nameplate
The device is labeled by means of a nameplate.
► For inquiries, please have at hand the device type, device number, and year of construction as indicated
on the nameplate.
Figure1Name plate

ABICOOLER 1300 2 Safety
BAL.1041.0 • V1 EN - 7
2 Safety
This chapter describes the essential safety requirements and warns of residual hazards that should be kept in
mind, to kept the product safely. Non-observance of the safety instructions may result in risks to the life and
health of personnel as well as cause environmental or material damage.
2.1 Designated use
The device is exclusively used to cool liquid-cooled welding torches.
Any other use is considered improper. Unauthorized modifications or changes to enhance the performance
are not permitted.
► Only operate the device with original ABICOR BINZEL spare parts.
► Do not exceed the maximum load data specified in the documentation. Excessive loads lead to
irreparable damage.
► Do not make any structural modifications to the product.
► Do not use or store the device where it is wet.
► Only use the device outdoors with suitable protection against weather conditions.
2.2 Obligations of the operator
► Keep non-suitably qualified people out of the work area.
► Ensure that only suitably qualified personnel perform work on the device or system.
Suitably qualified personnel are:
– those who are familiar with the basic regulations on occupational safety and accident prevention;
– those who have been instructed on how to handle the device;
– those who have read and understood all related documentation;
– those who have been trained accordingly;
– those who are able to recognize possible risks because of their special training, knowledge, and
experience.
► Each time the housing is 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.

2 Safety ABICOOLER 1300
EN - 8 BAL.1041.0 • V1
2.3 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.
Warning against hot surfaces. Risk of burns.
► Do not touch hot surfaces.
Risk of burns an irritation due to coolant spatter.
Warning of electrical voltage.
Type of fuse

ABICOOLER 1300 2 Safety
BAL.1041.0 • V1 EN - 9
2.4 Safety instructions
2.4.1 Basic safety instructions
The product has been developed and manufactured in accordance with the latest technology and recognized
safety standards and directives. Due to the product design, unavoidable technical residual risks exist to the
user, third parties, devices, and other material property. The manufacturer will accept no liability for damage
caused by non-observance of the documentation.
► Please read the documentation carefully before using the product for the first time and comply with the
instructions contained.
► Only operate the product in technically perfect condition and ensure compliance with all documentation.
► Read the documentation carefully before carrying out specific work, for example, commissioning,
operation, transport, and maintenance.
► Use suitable means to protect yourself and bystanders from the hazards listed in the documentation.
► Store the documentation within easy reach of the device for reference and enclose all documents when
passing on the product.
► Consult the documentation on additional welding components.
► Information about how to handle gas cylinders can be found in the instructions provided by the gas
manufacturer and the relevant local regulations, e.g.,the Pressure Equipment Directive.
► Observe the local accident prevention regulations.
► Only trained specialists should commission, operate, and service the device. Qualified personnel are
persons who, based on their special training, knowledge, experience and due to their knowledge of the
relevant standards, are able to assess the tasks assigned to them and identify possible dangers.
► Ensure the work area is well lit and keep it neat and tidy.
► Disconnect the power supply and shut off the gas and compressed air supply for the entire duration of
maintenance, servicing and repair work.
► For disposal, observe the local regulations, laws, provisions, standards, and directives.
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.
► Protect yourself from electric shock by using insulating mats and wearing dry clothing.
► Do not use the electric tools in areas subject to fire or explosion hazards.
2.4.3 Safety instructions for welding
► Arc welding may cause damage to the eyes, skin and hearing. Please note that other hazards may arise
when the device is used with other welding components. Therefore, always wear the prescribed personal
protective equipment as defined by local laws and regulations.
► All metal vapors, especially from lead, cadmium, copper, and beryllium, are harmful. Ensure sufficient
ventilation or extraction. Do not exceed the current occupational exposure limits (OEL).
► To prevent the formation of phosgene gas, rinse workpieces that have been degreased with chlorinated
solvents using clean water. Do not place degreasing baths containing chlorine in the vicinity of the
welding area.
► Adhere to the general fire protection regulations and remove flammable materials from the vicinity of the
welding work area prior to starting work. Provide appropriate fire extinguishing equipment in the
workplace.

2 Safety ABICOOLER 1300
EN - 10 BAL.1041.0 • V1
2.4.4 Safety instructions for protective equipment
► Do not wear loose fitting clothing or jewelry.
► Use a hair net for long hair.
► Observe the local laws and regulations that apply to protective equipment.
► Wear your personal protective equipment.
► Ensure that others in close proximity are also wearing personal protective equipment.
► Wear your personal protective equipment as appropriate for the hazard.
2.4.5 Safety instructions for use of electrical devices
► Please read all the instructions before using this device.
► Keep hair, loose clothing, fingers and all body parts away from the openings and movable parts.
Improper use or connection can result in life-threating electric shock or fire. This may result in serious injuries.
► Use the device according to its designated use only.
► Only use manufacturer-approved component parts.
► Check all live cables and connections for proper installation and damage.
► If the device does not function correctly, was dropped or damaged, is left outdoors or fell into water, have
it checked by an authorized specialist store.
► Do not touch the device with wet hands.
► Do not insert any objects into the device’s openings.
► Do not use the device if an opening is blocked.
► Keep the device free of dust, fluff, hair and anything that could impair the flow of air.
2.4.6 Safety instructions for the electrical power supply
► Ensure that the power supply cable is not damaged, for example, by being driven over, crushed or torn.
► Check the power supply cable for damage and wear at regular intervals.
► Only operate the device with an undamaged mains connector.
► Protect the mains connector (according to the current) on the mains side. ð5 Technical data(Page13)
► If it is necessary to replace the power supply cable, only models indicated by the manufacturer may be
used.
► Only a qualified electrician should replace the power supply cable and the mains plug.
► Splash-water protection and mechanical stability must be ensured when replacing the mains plug of the
power supply cable.
► To replace or lengthen the power supply cable, use only a cable of the type and with the same cross-
section as the original.
2.4.7 Safety instructions for emergencies
► In the event of an emergency, immediately interrupt the electrical power supply.

ABICOOLER 1300 3 Scope of delivery
BAL.1041.0 • V1 EN - 11
3 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
– 1× tool for device bleeding
– 1×operating instructions
► Order the equipment parts and wear parts separately.
► The order data for the equipment parts and wear parts can be found in the current catalog.
► For more information about points of contact, consultation, and orders, visit www.binzel-abicor.com.
Although the items delivered are carefully checked and packaged, it is not possible to fully exclude the risk of
transport damage.
Goods-in inspection
► Use the delivery note to check that everything has been delivered.
► Check the delivery for damage (visual inspection).
Complaints
► If goods are damaged, contact the final carrier.
► Keep the packaging for a possible check by the carrier.
Returns
► Use the original packaging and packing material for returns.
► If you have questions concerning packaging and safety during shipment, contact your supplier, carrier, or
transport company.

4 Product description ABICOOLER 1300
EN - 12 BAL.1041.0 • V1
4 Product description
4.1 Structure and function
1 2 3 4
56789
Figure2Structure and function
1Control lead connection for flow control 2Coolant filler neck
3<I/O> switch 4Fuse
5Coolant supply connection (blue) 6Coolant return (red)
7Drain coupling 8Coolant tank
9Filling level indication
The device is used for cooling liquid-cooled welding torches. The device supplies and monitors the coolant. All
required components and connections have been installed in the housing. The coolant is pumped via a closed
coolant circuit through the welding torch and cooled down via an integrated air heat exchanger. We
recommend the use of a coolant filter as well. A flow control is integrated into the device as standard but must
be connected via the supplied flow control cable.
1
2
3
4
56
Figure3Overview of the coolant circuit
1Air head exchanger 2Coolant return (red)
3Coolant supply (blue) 4Drain coupling
5Pump 6Coolant tank

ABICOOLER 1300 5 Technical data
BAL.1041.0 • V1 EN - 13
5 Technical data
5.1 Ambient conditions
Ambient temperature –23°C to +55°C
Relative humidity Up to 90% at +20°C
Table1Ambient conditions for transport
Ambient temperature –10°C to +40°C
Relative humidity Up to 90% at +20°C
Table2Ambient conditions for storage and operation
5.2 Product data
ABICOOLER 1300 (60Hz )
Cooling capacity (H2O) Q=1l/min 1.30kW
Cooling capacity (BTC-15 1) Q=1l/min 1.19kW
Cooling capacity (BTC-20 NF 1) Q=1l/min 1.14kW
Cooling capacity (BTC-50 NF 1) Q=1l/min 1.02kW
Air head exchanger 3-row
Nominal voltage 115V
Line frequency 60Hz
Pump type Centrifugal pump
Max. delivery height of pump 35m
Max. flow rate of pump 10l/min
Max. coolant outlet pressure/pump pressure 3.9bar
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 if
necessary)
Coolant tank volume 8.0l
Sound pressure level 58.8dB(A)
Protection type IP23 (for indoor use only)
Weight 22 kg
Weight (incl. coolant) 30 kg
1Mathematical approximate values
Table3Product data

6 Transport and installation ABICOOLER 1300
EN - 14 BAL.1041.0 • V1
6 Transport and installation
WARNING
Risk of injury due to improper transport and installation
Improper transport and installation can cause the device to tip or fall over. This may result in
serious injuries.
► Check and wear your personal protective equipment.
► Place the device on a suitable base (flat, solid, dry) on which it will not topple over.
► Note the weight of the device when lifting it. ð5 Technical data(Page13)
► Use an appropriate lifting tool with load handling attachment for transporting and installing
the device.
► Avoid abrupt lifting and setting down.
► Do not lift the device over persons or other devices.
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. Harmful dust can damage the respiratory tract when
inhaled.
► Check and wear your personal protective equipment.
► Place the device on a clean, dust-free surface.
NOTICE
Risk of material damage due to improper transport and installation
Improper transport or installation can cause the device to tip or fall over. This can result in
material damage and irreparable damage to the device.
► Protect the device against weather conditions, such as rain and direct sunlight.
► Use the device only in dry, clean and well-ventilated rooms.
► Maintain a minimum distance of 0.5m from the wall or other objects when installing the
device to ensure that it is sufficiently ventilated.
► Prevent dust and other foreign substances from entering the device.
► Ensure a maximum angle of tilt of10°.
1. Place the handles on the device.

ABICOOLER 1300 6 Transport and installation
BAL.1041.0 • V1 EN - 15
2. Fix them with (4) screws and install the device in a suitable
place.

7 Commissioning ABICOOLER 1300
EN - 16 BAL.1041.0 • V1
7 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.
► Have any damaged, deformed, or worn parts replaced by a qualified electrician only.
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.
► Check and wear your personal protective equipment.
► Keep the coolant tank closed during operation.
► Wait at least 5seconds after switching off before opening the tank cap on the coolant tank.
NOTICE
Material damage due to contaminated coolant
Contamination in the coolant can lead to damage and increased wear in the device.
► Keep the tank cap closed when the device is in operation.
► We recommend that you use a coolant filter (not included in the scope of supply).
NOTICE
Material damage due to a lack of coolant
If there is insufficient coolant, the device’s pump can overheat and become irreparably
damaged.
► Ensure that coolant is added to the device before commissioning it.
► Ensure that the device is bled during commissioning.
► Ensure that the coolant pump does not run dry.
► Observe the fill level indicator on the device.
► Use the flow control to continuously monitor the proper function of the entire cooling system. If
the flow rate is too low, the flow control instigates the immediate switch-off of the connected
devices and prevents thermal overload.
NOTICE
Material damage when bridging multiple devices
The use of several devices (in sequence or in parallel) can result in material damage.
► Do not bridge the device with other cooling units.

ABICOOLER 1300 7 Commissioning
BAL.1041.0 • V1 EN - 17
7.1 Installing the fuse
ð10.3 Replacing the fuse(Page26)
7.2 Adding coolant
NOTICE
Material damage due to unsuitable coolant
The use of unsuitable coolant can result in a limited cooling capacity and increased device wear.
The warranty does not cover damage to the device.
► Use BTC series coolant or a different ABICOR BINZEL coolant.
► When using a different coolant, ensure that it does not contain aggressive, abrasive or
resinous components.
► Use only demineralized water (permitted operating temperature +5°C to +40°C) or, after
cleaning the device, a mixture of 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.
NOTICE
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.
► Keep the tank cap closed when the device is in operation.
► To remove any deposits and contaminations, flush the coolant circuit with clean water before
filling the coolant circuit with BTC coolant or another coolant from ABICOR BINZEL.
► We recommend that you use a coolant filter (not included in the scope of supply).
► Regularly check the status of the coolant.
► Observe the recommended maximum conductivity of the coolant. ð5 Technical data
(Page13)
► Ensure that the coolant supply and return hoses have been correctly installed.
Propylene glycol residues may be present in the system as a result of the production process.
1. To remove any deposits and contamination, rinse the
coolant circuit with clean water.
2. Unscrew the tank cap.
3. Fill with coolant up to the <MAX> mark.
4. Screw on the tank cap.
5. Bleed the cooling circuit ð7.3 Bleeding the cooling circuit
(Page18).

7 Commissioning ABICOOLER 1300
EN - 18 BAL.1041.0 • V1
7.3 Bleeding the cooling circuit
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.
1. Connect the quick coupling of the tool for device bleeding
to the coolant supply connection coupling (blue).
2. Pull the piston of the tool for device bleeding up all the way.
3. Pull off the quick coupling of the tool for device bleeding.
4. Press air out of the tool for device bleeding.
If coolant is also drawn up when the piston is pulled up,
proceed as follows:
5. Open the tank cap.
6. Press the coolant out of the tool for device bleeding into the
coolant tank.
7. Close the tank cap.
8. Reconnect the quick coupling of the tool for device
bleeding.
9. Repeat the procedure twice.

ABICOOLER 1300 7 Commissioning
BAL.1041.0 • V1 EN - 19
7.4 Connecting and bleeding the cable assembly
Proper cooling is ensured only if the entire cooling system has been bled. The cable assembly must bled at the
time of initial commissioning and every time the device is fully bled.
1. Connect the intermediate cable assembly's coolant hoses to the device, ensuring that the cooling circuit is
closed.
2. Remove the tank cap and keep the coolant tank open until the bleeding process is complete.
3. Remove the coolant return hose from the coolant return connector (red) and hold it over the opening of the
coolant tank.
4. Plug in the mains plug.
5. Set the <I/O> switch to <I>.
6. Seal the coolant hose or kink it and then open it abruptly. Repeat this process until coolant flows
continuously and without bubbles.
7. Set the <I/O> switch to <O>.
8. Connect the coolant return hose to the coolant return connector (red).
9. Check the coolant level and fill as needed.
10.Screw on the tank cap.

7 Commissioning ABICOOLER 1300
EN - 20 BAL.1041.0 • V1
7.5 Connecting a flow control
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. The flow control is
preset to 0.6–0.8l/min.
1
2 3
4
5
Torch control switch
on the welding power source
Figure4Connecting diagram for flow control
1Torch trigger 2Flow control connector on the front of the
device
3Flow control 4Connection housing
5Welding power source
1. Open the device connection housing.
2. Disconnect one trigger cable.