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.