Instruction manual
0445 030 101 GB 20171016
Valid for: serial no. 720-xxx-xxxx
EC1000
TABLE OF CONTENTS
0445 030 101 © ESAB AB 2017
1
SAFETY ......................................................................................................... 4
1.1 Meaning of symbols ................................................................................. 4
1.2 Safety precautions ................................................................................... 4
1.3 User responsibility ................................................................................... 5
2
INTRODUCTION............................................................................................ 7
2.1 Equipment ................................................................................................. 7
3
TECHNICAL DATA ........................................................................................ 8
4
INSTALLATION.............................................................................................. 9
4.1 Location..................................................................................................... 9
4.2 Installing welding equipment .................................................................. 10
4.3 Torch installation...................................................................................... 10
5
OPERATION .................................................................................................. 11
5.1 General ...................................................................................................... 11
5.2 Connections and control devices ........................................................... 11
5.3 Coolant connection .................................................................................. 11
5.4 ELP (ESAB Logic Pump).......................................................................... 11
5.5 Control of the cooling fan and the water pump..................................... 12
5.6 Coolant pressure controller .................................................................... 12
6
MAINTENANCE............................................................................................. 13
6.1 Inspection and cleaning........................................................................... 13
6.2 Filling the coolant..................................................................................... 16
7
TROUBLESHOOTING ................................................................................... 18
8
ORDERING SPARE PARTS .......................................................................... 19
DIAGRAM ............................................................................................................. 20
PUMP CHARACTERISTIC ................................................................................... 21
COOLING CHARACTERISTIC............................................................................. 22
ORDERING NUMBERS........................................................................................ 23
ACCESSORIES .................................................................................................... 24
Rights reserved to alter specifications without notice.
1 SAFETY
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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
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.
1 SAFETY
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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.
1.3 User responsibility
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
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
1 SAFETY
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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
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2 INTRODUCTION
Cooling unit EC1000 is intended for cooling water-cooled TIG 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:
• Instruction manual
• Interface kits front and back to attach the cooler to the power source (including
screws)
3 TECHNICAL DATA
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3 TECHNICAL DATA
EC1000
Power consumption 24 V DC, 3.0A
Cooling power 0.9 kW
Noise
(Constant sound pressure when idling)
< 70 dB(A)
Coolant ESAB's ready mixed coolant, see the
"ACCESSORIES" chapter in the instruction
manual.
Coolant quantity 1.5 l
Maximum water flow 1.8 l/min
Max pressure lift for torch Q
max
4.5 bar (65psi)
Operating temperature -10°C to +40°C (+14°Fto +104°F)
Transportation temperature -20°C to +55°C (-4°Fto +131°F)
Dimensions (l × w × h) 540 × 200 × 170 mm
(21.26×7.874×6.693in)
Weight empty 8 kg (17.6lb)
Enclosure class IP23
The cooling unit is rated 300 A at 40% duty cycle at 25°C (77°F) ambient temperature.
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.
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
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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.
A. Minimum 200 mm (8”)
B. Minimum 200 mm (8”)
4 INSTALLATION
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4.2 Installing welding equipment
NOTE!
Take care so that the interface cable does not get squeezed between the power
source and the cooling unit!
NOTE!
Power supply of the cooling unit is done from the welding power source via the
CAN cable (see the "OPERATION" chapter).
4.3 Torch installation
1. Fill with coolant into the cooling unit water tank.
2. Connect the TIG welding torch. Make sure the torch is
located at the same height as the cooling unit, so that the
coolant will spread quickly throughout the system.
3. Turn on the mains power supply to the welding power
source.
4. Select TIG welding on the power source.
5. Press the welding torch trigger switch.
6. Let the cooling unit water pump run for three minutes.
7. Check that the coolant level is between the upper and
lower markings on the water tank. Fill up if needed.
5 OPERATION
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5 OPERATION
5.1 General
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual and the "SAFETY" chapter of the manual for the power source.
Read it through before you start using the equipment!
Cooling unit EC1000 automatically starts when welding starts. After welding has stopped,
cooling continues for a few minutes after which the cooling unit enters energy save mode.
5.2 Connections and control devices
1. Connection BLUE for coolant from cooling
unit
3. Coolant filling
2. Connection RED for coolant (return) to
cooling unit
4. Connection to power source (interface
cable)
5.3 Coolant connection
For problem free operation it is recommended that the height from the cooling unit to the
water-cooled TIG torch is a maximum of 8 m. When connecting a TIG torch it should be in
the same height as the cooling unit to let the coolant quickly spread through the system.
NOTE!
After connecting a torch, check that the coolant level is correct. When adjusting
the coolant level by topping up, the coolant hoses do not need to be
disconnected.
5.4 ELP (ESAB Logic Pump)
The cooling unit is equipped with a detection system called ELP (ESAB Logic Pump) which
checks that the coolant hoses are connected. When connecting a water-cooled TIG torch,
cooling starts.
5 OPERATION
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5.5 Control of the cooling fan and the water pump
Cooling unit EC1000 is equipped with a thermal sensor to monitor the temperature of the
cooling liquid and facilitate control of the cooling unit functionality. The function of the cooling
unit is as follows:
• When welding starts, the cooling fan and the water pump automatically starts.
• If the cooling liquid temperature exceeds +45°C (+113°F), the cooling fan and the
water pump starts, even though no welding is going on.
• If the cooling liquid temperature is below +45°C (+113°F) and welding stops, the
cooling fan and the water pump continue running for 3 minutes to speed up cooling of
the equipment. After 3 minutes the cooling fan and the water pump stop.
• If the cooling liquid temperature is +45°C (+113°F) or more and welding stops, the
cooling fan and the water pump continue running to speed up cooling of the
equipment. When the cooling liquid temperature has decreased below +35°C
(+95°F), the fan and the pump proceed for 3 minutes more after which they stop. If
the cooling liquid temperature has not decreased below +35°C (+95°F) within 7
minutes after welding has stopped (due to high ambient temperature), the fan and the
pump proceed for 3 minutes more after which they will stop anyway. This means that
the fan and the pump will stop maximum 10 minutes after welding has stopped,
regardless of the cooling liquid temperature.
• If the cooling liquid temperature exceeds +65°C (+149°F), a thermal protection
function automatically stops the welding, error code "Err2" appears in the power
source display and the overheating indicator on the display is lit. The cooling fan and
the water pump will continue running. When the cooling liquid temperature has
decreased below +55°C (+131°F), error code "Err2" is cleared and the overheating
indicator on the display goes out. Finally, when the cooling liquid temperature has
decreased below +35°C (+95°F), the fan and the pump proceed for 3minutes more
after which they stop. If the cooling liquid temperature has not decreased below
+35°C (+95°F) within 10 minutes after welding has stopped (due to high ambient
temperature), the fan and the pump will stop anyway.
5.6 Coolant pressure controller
The pump is equipped with a mechanical pressure relief valve. The valve opens gradually
when the pressure is too high (4.8bar/ 70psi). This can occur if a hose is folded, which
causes the flow to fail or stop.
6 MAINTENANCE
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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
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.
In order to sustain the performance and increase the lifetime of the cooling unit, it is
mandatory to clean it using compressed air at regular intervals. How often depends on:
• The welding process
• The arc time
• The surrounding environment (grinding etc.)
Equipment and prerequisites
• Screwdrivers, Torx T25 and T30
• Dry compressed air, at a pressure of 4bar (58psi)
• Recommended personal safety equipment, such as ear plugs, safety glasses, masks,
gloves and safety shoes
• The cleaning should be carried out in a suitably prepared workspace.
6 MAINTENANCE
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Cleaning procedure
1. Disconnect the interface cable between the power source and the cooling unit and
remove the power source.
2. Remove the cooling unit side panels and then the top panel.
6 MAINTENANCE
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3. Clean the inner parts of the cooling unit, using dry compressed air with a pressure of
4bar (58psi), in the order specified below:
a) Blow compressed air from the top downwards at the water pump and the ELP
(ESAB Logic Pump).
b) Blow compressed air sideways at the water pump and the ELP assembly.
c) Clean the heat exchanger, the cooling fan and the thermal sensor thoroughly, by
blowing compressed air sideways from the left at the heat exchanger and
through the cooling fan.
d) When having removed as much dust as possible from within the heat
exchanger and the fan, remove any remaining dust by also blowing compressed
air from the right side at the heat exchanger, the cooling fan and the thermal
sensor.
e) Blow compressed air sideways from both the left and the right side at the cooler
board.
f) Blow compressed air in all directions at and around the water tank.
NOTE!
Make sure that there is no dust left in any part of the cooling unit.
6 MAINTENANCE
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4. Reattach the cooling unit top panel. Route the internal CAN cable behind the cable
bracket in the top panel. Then reattach the side panels. Tighten the screws using the
correct tightening torque according to the illustration below.
NOTE!
Make sure the top panel is fitted in the correct direction! The yellow arrow
on the top panel decal should point towards the front of the cooler, i.e.
towards the short side where the coolant connectors are located.
5. Install the power source on top of the cooling unit and reconnect the interface cable,
see the"INSTALLATION" chapter.
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.)
The recommended coolant must be used in the system otherwise clumps can be created that
block the pump, water connections or elements. 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.
6 MAINTENANCE
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NOTE!
After connecting a torch, check that the coolant level is correct. When adjusting
the coolant level by topping up, the coolant hoses do not need to be
disconnected.
CAUTION!
The coolant must be handled as chemical waste.
7 TROUBLESHOOTING
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7 TROUBLESHOOTING
Try these recommended checks and inspections before sending for an authorized service
technician.
Type of fault Corrective action
The torch is overheated. • Check the coolant flow and that no
coolant hose is folded or damaged.
• Make sure the recommended duty cycle
for the weld current has not been
exceeded (see the TECHNICAL DATA
chapter in this manual and in the power
source instruction manual).
• Clean the cooling element using
compressed air.
• Check the coolant level.
The water pump and the cooling fan are not
running.
• Check that the coolant hoses are
connected properly to the quick
connectors on the cooling unit.
• Check that the interface cable between
the power source and the cooling unit is
connected properly.
Error code "Err 2" is presented in the power
source display, which means that the
temperature of the coolant fluid is too high.
• Clean the cooling element using
compressed air.
• Wait until the coolant temperature has
decreased below +55°C (+131°F) and
the error code disappears.
• Make sure the recommended duty cycle
for the weld current has not been
exceeded (see the TECHNICAL DATA
chapter in this manual and in the power
source instruction manual).
8 ORDERING SPARE PARTS
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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 EC1000 is designed and tested in accordance with International and European
standards IEC/EN 60974-1, 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.
DIAGRAM
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DIAGRAM
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