ESAB COOL 2 Standalone is a standalone cooling unit designed for cooling water-cooled MIG/MAG welding torches used with Warrior 750i CC/CV power source. It delivers up to 1 kW of cooling power and can circulate coolant at a maximum flow rate of 1.8 l/min with a pressure lift of up to 4.6 bar, making it suitable for demanding welding applications. The unit features a compact and durable design, with an IP23 enclosure rating for indoor and outdoor use. It operates at a noise level of less than 70 dB(A) and has a 4.5 l coolant capacity.
ESAB COOL 2 Standalone is a standalone cooling unit designed for cooling water-cooled MIG/MAG welding torches used with Warrior 750i CC/CV power source. It delivers up to 1 kW of cooling power and can circulate coolant at a maximum flow rate of 1.8 l/min with a pressure lift of up to 4.6 bar, making it suitable for demanding welding applications. The unit features a compact and durable design, with an IP23 enclosure rating for indoor and outdoor use. It operates at a noise level of less than 70 dB(A) and has a 4.5 l coolant capacity.
COOL 2 Standalone
Service manual
0463 767 001 GB 20201104
Valid for: Serial number: 028-xxx-xxxx
Ordering no. Product Notes Serial no.
0465 427 881 COOL 2 Standalone Europe, CE 038-xxx-xxxx
0463 767 001
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© ESAB AB 2020
1 READ THIS FIRST
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4
2 BEFORE STARTING SERVICE
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5
3 INTRODUCTION
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6
3.1 Design structure of the cooling unit
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6
3.2 Block diagram
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4 WIRING DIAGRAM
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7
5 TECHNICAL DATA
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9
6 DESCRIPTION OF OPERATION
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6.1 5AP1 Cooler board
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6.2 Power supply
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6.3 Pump motor and fan ON/OFF
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6.4 5AP1 Component positions
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6.5 5M1 Pump with motor
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11
7 IN-SERVICE INSPECTION AND TESTING
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12
7.1 Testing the pump and fan outlet
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8 SPARE PARTS AND ACCESSORIES
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13
1 READ THIS FIRST
0463 767 001
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© ESAB AB 2020
1 READ THIS FIRST
Maintenance and repair work must be performed by an experienced person, and electrical work only
by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for help in
connection with fault-tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit boards are
divided into numbered blocks, which are described individually in more detail in the description of
operation. Component names in the wiring diagram are listed in the component description.
Use the spare parts list as a guide to where the components are located in the equipment. The spare
parts list is published as a separate document, see the "SPARE PARTS AND ACCESSORIES"
chapter in this manual.
This manual contains details of design changes that have been made up to and including
October2020.
The manual is valid for:
• COOL 2 Standalone with serial number 038-xxx-xxxx
NOTE!
The unit is tested by ESAB in a general set-up. The responsibility for safety and function, of
the specific set-up, lies with the integrator.
The COOL 2 Standalone is designed and tested in accordance with the standards stated in the
instruction manual. 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 involved
standards.
CAUTION!
Read and understand the instruction manual before installing or
operating.
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic sensitive
devices.
• Use proper static-proof bags and boxes.
2 BEFORE STARTING SERVICE
0463 767 001
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© ESAB AB 2020
2 BEFORE STARTING SERVICE
ESAB can offer a number of service tools that will simplify the service.
Antistatic service kit
Ordering no. 0740 511 001
The kit makes it easier to protect sensitive
components from electrostatic discharge.
Contents:
• A conductive mat (size 610×610mm /
24×24in.)
• A 1.5m (3.28ft) long ground cable with a
crocodile clip
• An adjustable wrist strap and cable with a
built-in protective resistor
3 INTRODUCTION
0463 767 001
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© ESAB AB 2020
3 INTRODUCTION
Cooling unit COOL 2 Standalone is intended for cooling water-cooled MIG/MAG welding torches used
along with Warrior™ 750i CC/CV power source.
3.1 Design structure of the cooling unit
The COOL 2 Standalone cooling unit consists of a cooler board, a water pump, a cooling fan and a
heat exchanger. The cooler board is powered and controlled from the power source. The power from
the power source is converted in the cooler board, to the appropriate supply voltage for the water
pump and the cooling fan. The water pump is circulating the coolant through the heat exchanger and
onwards in the system. The cooling fan is used to cool down the coolant during its way through the
heat exchanger
3.2 Block diagram
4 WIRING DIAGRAM
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© ESAB AB 2020
4 WIRING DIAGRAM
The cooling unit is a function module and is described in the component descriptions below. Wire
numbers and component names in the wiring diagram show to which module the components belong.
Wires/cables within modules are marked 100–6999.
Wires/cables between modules are marked 7000 – 7999.
Components outside modules - e.g. capacitors - are named such as C1–C99, connectors
XS1–XS99 (S=socket), XP1–XP99 (P=plug), XT1–XT99(T= terminal).
Circuit boards within each module have names such as 5AP1–5AP99.
5 = module association, 1–69
AP = circuit board
1 = individual identification number, 0–99
Transistors within particular modules have identification numbers such as 5Q1 – 5Q99.
5 = module association, 1 – 69
Q = transistor
1 = individual identification number, 0 – 99
Component Description
5 = Cooling unit
5AP1 = Cooler board
5M1 = Water pump with motor, 24VDC
5EV1 = Cooling fan, 24VDC
5QF1 = Main switch
4 WIRING DIAGRAM
0463 767 001
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© ESAB AB 2020
COOL 2 Standalone, valid for serial 038-xxx-xxxx
5 TECHNICAL DATA
0463 767 001
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© ESAB AB 2020
5 TECHNICAL DATA
COOL 2 Standalone
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 in the instruction manual.
Coolant quantity 4.5 l
Maximum water flow 1.8 l/min
Max pressure lift for torch Q
max
4.6 bar
Operating temperature -10° to +40°C
Transportation temperature -20° to +55°C
Dimensions (l × w × h) 680 × 330 × 325 mm
Weight empty 16 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.
6 DESCRIPTION OF OPERATION
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© ESAB AB 2020
6 DESCRIPTION OF OPERATION
This section describes the function of the circuit board and other components in the equipment.
6.1 5AP1 Cooler board
6.2 Power supply
The 40V AC voltage is rectified to Vin (+55VDC) and from Vin control voltages Vcc (+22VDC) and
Vcc2 (+16.5VDC) are created.
Vin is also switched to +24V. The converter is an asynchronus buck converter.
+24V is the supply voltage for the pump and the fan.
6 DESCRIPTION OF OPERATION
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© ESAB AB 2020
Vcc supplies the PWM circuit IC1 and Vcc2 supplies the current sensor CS1.
Voltage tolerances: The listed voltages and tolerances below refer to connector and pin numbers
according to Section 4 "Wiring diagram", page 7 .
CN5:1 – CN3:1 (Vcc) +22V DC (±1V)
CN5:2 – CN3:1 (Vcc2) +16.5V DC (±1V)
CN6:3 – CN3:1 (Vin) +55V DC (±5V)
CN3:2 – CN3:1 (+24V) +24V DC (±0.5V)
(Pump and fan outlet) (maximum load ca 2.0 A)
6.3 Pump motor and fan ON/OFF
The pump motor, 5M1, and the cooling fan, 5EV1, are connected in parallell and powered from the
power supply block (see above). The supply voltage is +24VDC.
The pump and the fan are protected by a 2AT glass-tube fuse(S1).
6.4 5AP1 Component positions
6.5 5M1 Pump with motor
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.
7 IN-SERVICE INSPECTION AND TESTING
0463 767 001
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© ESAB AB 2020
7 IN-SERVICE INSPECTION AND TESTING
7.1 Testing the pump and fan outlet
If the pump and the fan are not running, first check the fuse S1 on the cooler board. If the fuse is
intact, you can test the pump and fan outlet from the cooler board as follows:
1. Turn off the main switch.
2. Disconnect the pump and the fan from the cooler board.
3. Connect a 12Ω/50W resistor to CN3.
4. Turn on the main switch.
5. Measure the DC voltage over the 12Ω resistor. The voltage should be
+24VDC(±0.5V).
CAUTION!
Do not forget to turn off the main switch, disconnect the 12Ω resistor and connect the
pump and the fan again after the test.
8 SPARE PARTS AND ACCESSORIES
0463 767 001
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© ESAB AB 2020
8 SPARE PARTS AND ACCESSORIES
For spare parts, see the spare parts list for the product. For accessories, see the instruction manual
for the product. These documents can be downloaded from the Internet: www.esab.com
Document type File name Product
Spare parts list 0463 765001 COOL 2 Standalone
Instruction manual 0446 806* COOL 2 Standalone
The three last digits in the document number of the manual show the version of the manual. Therefore
they are replaced with * here. Make sure to use a manual with a serial number or software version that
corresponds with the product, see the front page of the manual.
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ESAB COOL 2 Standalone is a standalone cooling unit designed for cooling water-cooled MIG/MAG welding torches used with Warrior 750i CC/CV power source. It delivers up to 1 kW of cooling power and can circulate coolant at a maximum flow rate of 1.8 l/min with a pressure lift of up to 4.6 bar, making it suitable for demanding welding applications. The unit features a compact and durable design, with an IP23 enclosure rating for indoor and outdoor use. It operates at a noise level of less than 70 dB(A) and has a 4.5 l coolant capacity.
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