Abicor Binzel CT-1000 User manual

CT-1000
LIQUID COOLING SYSTEM
EXCLUSIVELY FOR
MADE IN
BRITAIN
Max fill level
Min level
&2/'
+27
See manual before
use. Only use an
approved coolant.
Instruction Manual
CT-1000 Liquid Cooling System
110 volt / 230 volt
CAUTION BEFORE INSTALLING OR OPERATING THIS MACHINE ENSURE
ALL INSTRUCTIONS AND WARNINGS HAVE BEEN READ AND UNDERSTOOD.

Description
CT-1000 liquid cooling system is a British made quality machine, designed to give a long trouble
free life and are intended for industrial applications only.
It is designed for cooling welding torches for MIG, TIG, and PLASMA and smaller resistance weld-
ing machines and similar applications. The CT-1000 unit is fitted with a long lasting quality rotary
pump with fan. The fan provides airflow through a heat exchanger to cool the fluid.
The cooler is fitted with a water tank with an inspection window on the side panel. Recommended
applications are, MIG to 500A/600A, TIG to 500A / resistance welding up to 60KVA.
The cooler is equipped with a on off switch to stop the pump and fan. A built in stall protection cir-
cuit shuts down the supply to the pump motor/fan in the event of pump locking up, this prevents
the motor from burning out & ensures compliance with the latest European standards. This water
cooler must not be run dry.

Safety
Before using make sure all operators are familiar with the welding process and have had appropriate
training relating to the risks involved.
The Health and Safety Executive publish good info regarding this, please see www.hse.gov.uk/weld-
ing/other-welding-risks.htm
When welding or cutting in an environment with increased risk of electric shock extra precautions
must be observed. Typical conditions with increased risk of electric shock are working in wet or
damp conditions, working inside vessels, working in cramped conditions and exposed to conductive
parts, etc. DO NOT TAKE ANY RISKS
This water cooler must be used upright. It must be placed in a stable position to ensure it cannot
topple over. If the cooler topples over there is a risk of electric shock. Wherever possible this unit
should be fixed into position. There are 4 x M5 female threads on the underside of the cooler inside
the rubber feet for mounting purposes. If using these take care not to obstruct the air flow under the
cooler, it needs at least 35mm from the underside grills to any other objects & a minimum of 100mm
from the side fan grill to anything else.
This cooler is designed for use indoors and must not be used in the rain or a wet environment.
This cooler has a splash proof on/off switch fitted which is designed to duct away any water
splashes from the internal electrics to prevent electric shock, however in the event of a large fluid
spill directly over the switch the cooler should be checked by a competent person for safety before
using again.
Declaration of conformity
This equipment is manufactured to comply with 2006/95/EEC, BS EN 60974-2
This equipment is manufactured to comply with 89/336/EEC, BS EN 60974-10
This equipment is manufactured to RoHS directive 2006/95/EU
Date 3/11/2014
R P Rycroft R Ryoft Technical Arc Ltd York UK
Technical Specifications
Model CT-1000 110V 230V
Supply volts (U1) +/-10% 110V/115V 50HZ 230V 50HZ
Input current (I1max) 2.0 Amps 1.0 Amps
Fuse size (slow blow) 3 A 1.25 A
Pressure max (pmax) 3.3 bar 3.3 bar
Max flow rate Litres/min 10 10
Typical operating flow rate 2 2
Cooling capacity@25C amb@20 rise 1000W 1000W
Cooling capacity@25C amb@40C rise 2000W 2000W
Maximum coolant temperature 70C 70C
Total fluid capacity 2.5 litres 2.5 litres
Degree of protection IP21 IP21

Installation
Cooling liquid
Before filling with fluid this cooler should be unplugged and isolated from any electrical supply. Be careful not to spill,
wipe up any splashes fluid straight away.
We strongly recommend BTC-20 NF. This lubricates the pump correctly & protects against freezing of the fluid down to
-20C. Do not use organic acid technology (OAT) or other types of automotive antifreeze it can damage the pump.
The cooler tank should be filled to the top of the inspection window and no more & kept at that level in use. We recom-
mend draining & refilling the system every 12 months to ensure correct lubrication, frost protection & long lifespan.
Plumbing etc
The inlet and outlet fittings are marked on the cooler, we recommend using 6 or 8mm PVC hose for connections to
these. Rubber hoses are not recommended as these can perish and cause blockages etc. Ensure all fitting are tight
and do not leak. When fitting this unit onto older machines & hoses its important to note that poor internal condition of
hoses & in particular rubber hoses can cause rubber particles to detach & subsequently contaminate the new cooling
system & pump. In some circumstances this can cause pump blockage. In addition old cooling pipes etc should be
flushed out prior to connecting the new water cooler
Electrical
This machine must be connected to the electricity supply by a competent person
Connect the input flex to a suitable supply. This supply may be a separate supply or possibly picked up from within the
machine make sure this supply voltage matches the voltage model of the cooler. If this supply is picked up from within
the welding machine ensure that there is sufficient capacity available to supply the cooler otherwise the welding ma-
chine may be damaged.
Ensure the green/yellow wire is connected to the earth terminal in the mains plug or a good earth point in the machine
this applies to all models & is the most important connection. The other two are normally blue & brown wires which
must be connected to the appropriate voltage, on 230V coolers the brown should be the live connection & blue the
neutral, on 110V supplies polarity is not important. On 400V coolers the blue & brown are normally connected to any
two phases from a 3 phase supply. Ensure the supply to this water cooler is protected with a fuse, the value is stated
in the specifications above.
If a flow switch is fitted to this cooler it needs to be linked into the control circuits of the welding machine to disable the
welding set if water is not flowing. This flow switch is designed to switch only low voltage and low current, please see
the specification on the flow switch before fitting. Do not attempt to connect this switch to mains voltage.
If in doubt consult a qualified electrician.
Other
Wherever possible this unit should be fixed into position. There are 4 x M5 female threads on the underside of the
cooler inside the rubber feet for mounting purposes. If the cooler topples over there is a risk of electric shock.
Always run the cooler with the tank lid fitted securely.
Ensure none of the ventilation slots on the underside are obstructed, 35mm clearance all around the underside of the
base is required to allow sufficient airflow. The fan on the side panel should ideally have at minimum of 100mm clear-
ance from anything & ideally over 200mm otherwise cooling capacity will be reduced.
The pump motor is protected from a stall condition by an electronic device which prevents the motor from burning out.
This operates after between 15-45 seconds after a pump stall & overload is detected & will remain shut down until
input power is removed. To reset this wait for approx. 1 minute with power off.
For any application where there is a risk of expensive torch failure due to water flow failure or critical applications a
flow switch should be fitted to shut down the welding process in the event of a flow failure.

Operation
Initial operation & priming
When the cooler is first installed and switched on the pump initially has no fluid in & will sound rough & may
make a rattling sound as it needs to prime, the pump should self-prime within 5-10 seconds. If not switch off
straight away & remove the top outlet fitting & connect a short hose to the outlet which should be pointed
back into the top of the tank or to a bucket. Switch on again & fluid should flow within 10 seconds. Switch off
as soon as flowing & reconnect correct hoses. The pump is now primed & should not require further priming
unless the system is drained or air is allowed to get into the pump inlet due to low fluid level etc.
In the unlikely event of the above not working it may be necessary to repeat above & apply a very small
amount of air pressure into the tank (do not use unregulated compressed air as tank could explode). Do not
run the pump for more than 30 seconds if sounding rough & not primed.
Always run the cooler with the tank lid fitted securely. It is likely that the tank will need topping up once the
fluid has circulated through the hoses etc. Do not allow the tank level to drop to the bottom of the inspection
window keep filled close to the top of this window. Check the cooler and pipe fittings for any leaks after a few
minutes of running. Check the fluid level regularly, and top up with the correct mixture of fluid. Do not use this
cooler in the rain or wet conditions.
Daily operation
The operator should check for correct water flow operation every time this unit is switched on. The
fluid level should be regularly checked & kept topped up with the correct mixture of fluid.
It is important to ensure that the pump motor & fan assembly is rotating as soon as it is switched on,
in some circumstances the pump can lock up particularly if the cooler has been stood unused for a
few weeks this is due to mineral deposits from water inside the head & tends to occur if the fluid is of
poor quality or only water. If the pump motor does not appear to be turning at switch on then flick the on off
switch rapidly a few times, this can sometimes free a locked rotor. If the pump still does not turn then it will be
necessary to manually free off the rotor. For this the electrical supply must be isolated & one of the fan guard
screws is removed to allow access to the fan blade, carefully turn the blade impeller until it feels free (take
care not to bend the aluminum blades at all). The guard must be replaced before switching on. In addition
the pump motor is protected from a stall condition by an electronic device which prevents the motor
from burning out. This operates after between 15-45 seconds after a pump stall & overload is de-
tected & will remain shut down until power is removed. To reset this wait for approx. 1 minute with
power off.
.
Maintenance
The operator should carry out daily checks of all cables and connections etc; any faults must be reported to a
competent person and the machine taken out of service until repaired. Make sure all electrical supplies are
disconnected before carrying out any maintenance on this unit. Check the cooler and pipe fittings for any
leaks daily. This cooler should be part of a regular maintenance plan carried out by a competent person and
documented. As part of this maintenance plan electrical safety tests should be carried out, the cooler should
also be drained, flushed out with clean water and refilled with the correct fluid mix no less than once every
year. The radiator will collect dust between the aluminum fins & should be gently cleaned using compressed
air to maintain the cooling capacity. Note modifications to this product, incorrect maintenance or incorrect use
can result in premature failure which would not be covered under warranty.
If the unit is correctly maintained it should give a long trouble free life.

CT-1000
LIQUID COOLING SYSTEM
EXCLUSIVELY FOR
MADE IN
BRITAIN