ESAB COOL 2 User manual

Instruction manual
0463 348 001 GB 20170302 Valid for: serial no. 324-xxx-xxxx
COOL 2

TABLE OF CONTENTS
0463 348 001 © ESAB AB 2017
1SAFETY ......................................................................................................... 4
1.1 Meaning of symbols ................................................................................. 4
1.2 Safety precautions ................................................................................... 4
2INTRODUCTION............................................................................................ 6
2.1 Equipment ................................................................................................. 6
3TECHNICAL DATA ........................................................................................ 7
4INSTALLATION.............................................................................................. 8
4.1 Location..................................................................................................... 8
4.2 Power supply ............................................................................................ 8
4.3 Installing welding equipment .................................................................. 8
5OPERATION .................................................................................................. 9
5.1 Connections and control devices ........................................................... 9
5.2 Usage of the cooling unit......................................................................... 9
5.3 Coolant connection .................................................................................. 9
5.4 Coolant pressure controller .................................................................... 9
6MAINTENANCE............................................................................................. 10
6.1 Inspection and cleaning........................................................................... 10
6.2 Filling the coolant..................................................................................... 10
7FAULT TRACING........................................................................................... 11
8ORDERING SPARE PARTS .......................................................................... 12
ASSEMBLY INSTRUCTIONS............................................................................... 13
DIAGRAM ............................................................................................................. 15
PUMP DATA.......................................................................................................... 16
ORDERING NUMBERS........................................................................................ 17
ACCESSORIES .................................................................................................... 18
Rights reserved to alter specifications without notice.

1 SAFETY
0463 348 001 -4- © ESAB AB 2017
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
1.2 Safety precautions
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0463 348 001 -5- © ESAB AB 2017
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation
in accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be
disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
0463 348 001 -6- © ESAB AB 2017
2 INTRODUCTION
Cooling unit COOL 2 is intended for cooling water-cooled MIG/MAG welding torches.
Accessories for the product can be found in the "ACCESSORIES" chapter of this
manual.
2.1 Equipment
The cooling unit is supplied with installation instructions and instruction manual.

3 TECHNICAL DATA
0463 348 001 -7- © ESAB AB 2017
3 TECHNICAL DATA
COOL 2
Power consumption 40 V AC / 2A, 50/60 Hz
Cooling power 1 kW
Noise
(Constant sound pressure when idling)
< 70 dB(A)
Coolant "ESAB's ready mixed coolant, see the
"ACCESSORIES" chapter.
Coolant quantity 4.5 l
Maximum water flow 1.8 l/min
Max pressure lift for torch Qmax 4.6 bar
Operating temperature -10° to +40°C
Transportation temperature -20° to +55°C
Dimensions (l × w × h) 680 × 330 × 230 mm
Weight empty 15 kg
Enclosure class IP23
The cooling unit is rated 500 A at 60% duty cycle at 77°F (25°C) ambient temperature.
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 intended for indoor and outdoor use.

4 INSTALLATION
0463 348 001 -8- © ESAB AB 2017
4 INSTALLATION
The installation must be carried out by a professional.
CAUTION!
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.
4.1 Location
Position the cooling unit such that it's cooling air inlets and outlets are not obstructed.
4.2 Power supply
The cooling unit is supplied from the power source, see the"OPERATION" chapter.
4.3 Installing welding equipment
Installation instruction for this product can be
found in the "ASSEMBLY INSTRUCTIONS"
chapter".

5 OPERATION
0463 348 001 -9- © ESAB AB 2017
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
5.1 Connections and control devices
1. Switch for On/Off
2. Coolant filling
3. Min/max of coolant
4. Connection RED for coolant (return) to
cooling unit
5. Connection BLUE for coolant from
cooling unit
5.2 Usage of the cooling unit
CAUTION!
Important! Turn OFF the cooling unit when welding MMA or using air cooled
MIG/TIG welding torches to avoid excessive wear of the pump. Otherwise the
pump will work against a closed valve.
Turn ON the cooling unit when using a water cooled MIG welding torch to avoid
damages on the cable set.
5.3 Coolant connection
For problem free operation it is recommended that the height from the cooling unit to the
water-cooled MIG/MAG torch is a maximum of 8.5 m.
5.4 Coolant pressure controller
The pump has an enclosed pressure relief valve. The valve opens gradually when the
pressure is too high. This can occur if a hose is folded, which causes the flow to fail or stop.

6 MAINTENANCE
0463 348 001 - 10 - © ESAB AB 2017
6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
CAUTION!
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.1 Inspection and cleaning
WARNING!
The mains supply must be disconnected before cleaning.
Dust, grinding, swarf etc
The air stream through the cooling unit carries particles that become trapped in the cooling
element, particularly in dirty working environments. This results in reduced cooling capacity.
For this reason, blow clean using compressed air at regular intervals.
The coolant system
The recommended coolant must be used in the system otherwise clumps can be created that
block the pump, water connections or elements. Flushing can only be performed via red
water connection. Then drain the tank manually, i.e. empty via the tank's filling hole.
6.2 Filling the coolant
Only use ESAB's ready mixed coolant, see the "ACCESSORIES" chapter.
• Fill with coolant. (The fluid level must not
exceed the upper marking but neither
must it be below the lower marking.)
NOTE!
Coolant must be topped up if connecting a welding torch or coolant hoses that
are 5 metres in length or longer. When adjusting the water level by topping up,
the coolant hoses do not need to be disconnected.
CAUTION!
The coolant must be handled as chemical waste.

7 FAULT TRACING
0463 348 001 - 11 - © ESAB AB 2017
7 FAULT TRACING
Try these recommended checks and inspections before sending for an authorized service
technician.
Type of fault Corrective action
Poor cooling effect • Clean the cooling element using
compressed air.
• Check the coolant level.
• Check that the on/off switch on the
cooling unit is set to ON.

8 ORDERING SPARE PARTS
0463 348 001 - 12 - © ESAB AB 2017
8 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
The COOL2 is designed and tested in accordance with International and European
standards IEC/EN 60974-2 and IEC/EN 60974-10, Canadian standards
CAN/CSA-E60974-1 and US standards ANSI/IEC 60974-1. On completion of service or
repair work, it is the responsibility of the person(s) performing the work to ensure that the
product still complies with the requirements of the above standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back
cover of this document. When ordering, please state product type, serial number, designation
and spare part number in accordance with the spare parts list. This facilitates dispatch and
ensures correct delivery.

ASSEMBLY INSTRUCTIONS
0463 348 001 - 13 - © ESAB AB 2017
ASSEMBLY INSTRUCTIONS

ASSEMBLY INSTRUCTIONS
0463 348 001 - 14 - © ESAB AB 2017

DIAGRAM
0463 348 001 - 15 - © ESAB AB 2017
DIAGRAM

PUMP DATA
0463 348 001 - 16 - © ESAB AB 2017
PUMP DATA

ORDERING NUMBERS
0463 348 001 - 17 - © ESAB AB 2017
ORDERING NUMBERS
Ordering Number Denomination Type
0465 427 880 Cooling unit COOL 2
0459 839 092 Spare parts list COOL 2
Technical documentation is available on the Internet at www.esab.com.

ACCESSORIES
0463 348 001 - 18 - © ESAB AB 2017
ACCESSORIES
0465 720 002 ESAB ready mixed coolant (10 l /
2.64 gal)
Use of any other cooling liquid than the
prescribed one might damage the
equipment. In case of such damage, all
warranty undertakings from ESAB
cease to apply.

ACCESSORIES
0463 348 001 - 19 - © ESAB AB 2017

ESAB subsidiaries and representative offices
www.esab.com
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: [phone]
Fax: [phone]
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: [phone]
Fax: [phone]
BULGARIA
ESAB Kft Representative Office
Sofia
Tel: [phone]
Fax: [phone]
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]
DENMARK
Aktieselskabet ESAB
Herlev
Tel: [phone]
Fax: [phone]
FINLAND
ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]
ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: [phone]
Fax: [phone]
GERMANY
ESAB Welding & Cutting GmbH
Langenfeld
Tel: [phone]
Fax: [phone]
HUNGARY
ESAB Kft
Budapest
Tel: [phone]
Fax: [phone]
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: [phone]
Fax: [phone]
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
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]
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: [phone]
Fax: [phone]
RUSSIA
LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: [phone]
Fax: [phone]
SPAIN
ESAB Ibérica S.A.
San Fernando 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 Europe GmbH
Baar
Tel: [phone]
Fax: [phone]
UKRAINE
ESAB Ukraine LLC
Kiev
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
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: [phone]
Fax: [phone]
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
USJ
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]
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: [phone]
Fax: [phone]
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: [phone]
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com