Abicor Binzel ABICOOLER 2000 advanced User manual

Operating Instructions
ABICOOLER 2000 advanced
ABICOOLER 2000
Coolant recirculator

2000 advanced/2000
EN English translation of the original operating instructions
The manufacturer reserves the right, at any time and without prior notice, to make such changes and amendments to
the operating instructions which may become necessary due to misprints, inaccuracies or improvements to the
product.
Such changes will however be incorporated into subsequent editions of the operating instructions.
All trademarks and registered trademarks mentioned in the Operating Instructions are the property of their respective
owners/manufacturers.
Contact details for the ABICOR BINZEL national agents and partners worldwide can be found on our website at
www.binzel-abicor.com.
1 Identification
EN-3
12 Disposal
EN-19
1.1 Marking
EN-3
12.1 Materials
EN-20
2 Safety
EN-3
12.2 Consumables
EN-20
2.1 Designated use
EN-3
12.3 Packaging
EN-20
2.2 Obligations of the operator
EN-3
13 Appendix
EN-21
2.3 Personal protective equipment (PPE)
EN-3
13.1 2000 advanced spare parts
EN-21
2.4 Classification of the warnings
EN-4
13.2 2000 spare parts
EN-23
2.5 Warning and notice signs
EN-4
13.3 Connecting diagram of the flow monitor
EN-25
2.6 Emergency information
EN-4
(Applicable to model 2000)
3 Product description
EN-5
13.3.1 Flow monitor assembly instructions
EN-25
3.1 Technical data
EN-5 (Applicable to model 2000)
3.2 Nameplate
EN-7
13.4 Switch box (applicable to model 2000)
EN-27
4 Scope of delivery EN-8 13.5 Description of default parameters
4.1 Transport EN-8
(Applicable to model 2000 advanced)
EN-28
4.2 Storage
EN-8
13.6 Description of aviation plug pins
5 Functional description
EN-9 (Applicable to model 2000 advanced) EN-28
6 Startup and commissioning
EN-11
13.7 Detailed description of the operation
interface
6.1 Transport and installation
EN-12
(Applicable to model 2000 advanced)
EN-29
6.2 Connecting the cooling unit
EN-13 13.7.1 Original interface for startup
6.2.1 Fuse protection for the cooling unit EN-13 (Applicable to model 2000 advanced) EN-29
6.3 Before initial startup and commissioning
EN-13
13.7.2 User settings interface
6.3.1 Venting EN-14 (Applicable to model 2000 advanced) EN-29
7 Operation
EN-15
13.7.3 Administrator settings interface
7.1 Before initial startup and commissioning
(Applicable to model 2000 advanced)
EN-29
and after long shutdown EN-15
13.8 Maintenance schedule
EN-30
8 Shutdown
EN-15
9 Maintenance and cleaning
EN-15
9.1 Maintenance interval
EN-16
9.2 Filter element cleaning
EN-17
10 Troubleshooting
EN-17
10.1 Forced pressurization of the circulation
loop EN-18
11 Disassembly
EN-19
EN-2

2000 advanced/2000 1 Identification
1 Identification
The 2000 advanced/2000 cooling unit is used for the cooling of liquid-cooled welding torches in the industry and
raw material processing industry. It can only be used with original ABICOR BINZEL spare parts. These operating
instructions only describe the 2000 advanced/2000 cooling unit.
1.1 Marking
This product meets the applicable product launch requirements. All corresponding markings required for launch
are affixed to the product.
2 Safety
The enclosed safety instructions must be observed.
2.1 Designated use
• The device described in these instructions may be used only for the purpose and in the manner described in
these instructions. In doing so, observe the operating, maintenance and servicing conditions.
• Any other use is considered improper.
• Unauthorized modifications or changes to increase the performance are not permitted.
2.2 Obligations of the operator
• Only the following personnel are allowed to operate the equipment:
• Familiar with the basic regulations related to occupational safety and accident prevention;
• Have received operating instructions for the equipment;
• Have read and understood these operating instructions;
• Have read and understood the content of the section “Safety Tips”;
• Having received corresponding training;
• Able to identify potential hazards based on their professional training, understanding and experience.
• Keep other persons out of the work area.
• Please comply with the occupational safety regulations of the corresponding countries and regions.
• Please comply with the regulations on occupational safety and accident prevention.
2.3 Personal protective equipment (PPE)
To avoid danger to the user, these instructions recommend the use of personal protective equipment (PPE).
• The PPE includes protective clothing, safety goggles, class P3 respiratory masks, protective gloves and safety
shoes.
EN-3

Safety 2000 advanced/2000
2.4 Classification of the warnings
The warnings used in the operating instructions are divided into four different levels and are shown prior to
potentially dangerous work steps. They are arranged in descending order of importance as follows:
DANGER
It indicates an imminent threatening danger. If not avoided, it may result in serious injuries or deaths.
WARNING
It indicates a potentially dangerous situation. If not avoided, it may result in serious injuries.
CAUTION
It indicates a potentially harmful situation. If not avoided, it may result in minor injuries.
NOTICE
It indicates a risk of impairing work results or damaging the equipment.
2.5 Warning and notice signs
The following warning and notice signs can be found on the product:
Symbol Meaning
Coolant circulation inlet
Coolant circulation outlet
Coolant filling inlet of the cooling unit
Please read and observe the operating instructions
Coolant discharging outlet of the cooling unit
These markings must always be legible. They must not be covered, obscured, scribbled over or removed.
2.6 Emergency information
In case of emergency, immediately disconnect the following supplies:
• Power supply
Further measures can be found in the “Power Supply” operating instructions or in the documents for other
peripheral devices.
EN-4

2000 advanced/2000 3 Product Description
3 Product description
The cooling unit is used for coolant-cooled welding torches.
Any other use is considered improper. The manufacturer cannot be held liable for any damage arising from such
use.
WARNING
Hazards caused by using the device contrary to its designated use
If used contrary to its designated use, the device can present risks to persons, animals and material property.
• Use the device according to its designated use only.
• Do not reconvert or modify the device without authorization to improve its performance.
• The equipment or system may only be operated by the personnel with corresponding capabilities.
3.1 Technical data
Figure 1 Dimensions of the 2000 advanced cooling unit
Figure 2 Dimensions of the 2000 cooling unit
EN-5

3 Product Description 2000 advanced/2000
2000 advanced 2000
Heat exchanger 3-row
Power supply AC 220 50 Hz/AC 110 60 HZ
Cooling capacity Q=1l/min at + 25℃1800 W (water)
Pump lift
Approx. 35 m
Maximum flow
7L/min
Pump type
Centrifugal pump
Max. coolant outlet pressure/coolant pump
pressure
3.7 bar
Coolant tank capacity
10 L
Coolant
BTC series
Ingress protection rating
IP 23 (applicable to the inner cavity only)
Dimensions
543 x 286 x 395 mm
Weight 23.4 kg 23.1 kg
Ambient temperature -10°C - +40°C
Relative humidity Up to 90% at 20°C
Table 1 2000 advanced/2000 cooling unit
Ambient temperature -10°C - +40°C
Relative humidity Up to 90% at 20°C
Table 2 Ambient conditions for operation
Storage in a closed environment, ambient temperature
-10°C - +40°C
Ambient temperature for transport -25°C to +55°C
Relative humidity Up to 90% at 20°C
Table 3 Ambient conditions for transport and storage
Unit of measurement in drawings or diagrams Millimeter [mm]
Table 4 Dimensions
EN-6

2000 advanced/2000 3 Product Description
3.3 Nameplate
The cooling unit is identified by a nameplate on one side of the housing as follows:
Figure 3 2000 advanced/2000 nameplate
Figure 4 Nameplate content of 2000 advanced (example)
When making enquiries, please note that the following information shall be provided:
• Product number
• Equipment identification number
• Date of manufacture
EN-7

4 Scope of Delivery 2000 advanced/2000
4 Scope of delivery
The cooling unit is delivered empty, i.e. without coolant. The coolant is ordered and delivered in separate
containers.
• ABICOOLER 2000 advancd/2000 • Connection plug for communication
• Complete coolant filter (1 set) • Funnel (1 piece)
Table 5 Scope of delivery
Order the spare parts and wear parts separately.
The order data and product numbers for the spare parts and wear parts can be found in the current catalogue.
Contact details for advice and orders can be found online at www.binzel-abicor.com.
4.1 Transport
Although the scope of delivery is carefully checked and packaged, it is not possible to exclude the risk of transport
damage.
Goods-in inspection
Use the delivery note to check whether everything has been delivered.
Check the delivery for damage (visual inspection).
In case of complaints
If the delivery has been damaged during transport, contact the final carrier
immediately. Retain the packaging for any possible inspection by the carrier.
Packaging for returns
Where possible, use the original packaging and the original packaging material.
If you have questions concerning the packaging or how to secure the equipment,
please consult your supplier, carrier or transport company.
Table 6 Transport
4.2 Storage
For ambient conditions for storage in a closed environment, see:
Table 3 Ambient conditions for transport and storage on page EN-6
EN-8
2000 advanced/2000 5 Functional Description

5 Functional description
The advanced/2000 cooling unit conveys and detects the cooling medium. All required components and
connections have been installed in the housing. A temperature and flow monitor is integrated into the cooling unit
by default. The cooling unit comes with a coolant filter, which must be installed on the cooling unit before use.
1 Coolant filling inlet 2 Coolant circulation outlet (blue) 3 Coolant circulation inlet (red)
4 Coolant discharging outlet neck 5 Level indicator 6 On/off switch
5 Communication signal connector 8 Display 9 ∅6 Compressed air connector
Figure 5 Components of the 2000 advanced coolant recirculator
EN-9
Water Filling

4 Scope of Delivery 2000 advanced/2000
1 Coolant filling inlet 2 Coolant circulation outlet (blue) 3 Coolant circulation inlet (red)
4 Coolant discharging outlet neck 5 Level indicator 6 On/off switch
5 Flow monitor connector 8 Fuse 9 ∅6 Compressed air connector
Figure 6 Components of the 2000 coolant recirculator
NOTICE
• To permanently monitor the correct functioning of the entire cooling system, we recommend that you connect
the communication connector/flow monitor connector (7) to the control device.
Figure 7/8 Overview of the coolant circulation loop on page EN-11
• If the flow rate of the cooling unit (2000 advanced) is lower or higher than the set value, an alarm signal will be
given, and the cooling unit will choose whether to stop according to the settings (See Table 11 on page EN-27
for parameter settings).
EN-10
Water Filling