The ESAB COOL 2 is a water-cooling unit designed to provide efficient cooling for various industrial applications, such as welding, plasma cutting, and laser cutting. With a powerful cooling capacity of 1 kW and a maximum water flow rate of 1.8 liters per minute, it ensures optimal temperature control and prevents overheating of equipment. The compact and durable design of the COOL 2 allows for easy installation and integration into existing systems. Its user-friendly interface and straightforward operation make it suitable for a wide range of users.
The ESAB COOL 2 is a water-cooling unit designed to provide efficient cooling for various industrial applications, such as welding, plasma cutting, and laser cutting. With a powerful cooling capacity of 1 kW and a maximum water flow rate of 1.8 liters per minute, it ensures optimal temperature control and prevents overheating of equipment. The compact and durable design of the COOL 2 allows for easy installation and integration into existing systems. Its user-friendly interface and straightforward operation make it suitable for a wide range of users.
0740 800 225 Valid for serial no. 251-xxx-xxxx 20130215
COOL 2
Service manual
- 2 -TOCe
Rights reserved to alter specifications without notice.
READ THIS FIRST 3.................................................................
INTRODUCTION 4...................................................................
TECHNICAL DATA 5.................................................................
WIRING DIAGRAM 6.................................................................
Component description 6..........................................................
COOL 2 7.........................................................................
DESCRIPTION OF OPERATION 8.....................................................
5AP1 Cooler board 8..............................................................
Power supply 9...........................................................
Pump motor and fan ON/OFF 9............................................
5AP1 Component positions 9....................................................
5M1 Pump with motor 10...........................................................
Coolant pressure controller 10...............................................
SERVICE INSTRUCTIONS 11..........................................................
What is ESD? 11...................................................................
Service aid 12......................................................................
Testing the pump and fan outlet 13..................................................
SPARE PARTS 14....................................................................
NOTES 15...........................................................................
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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 page 14.
This manual contains details of design changes that have been made up to and including
November 2012.
The manual is valid for: COOL 2 with serial no. 251-xxx-xxxx
The COOL 2 is designed and tested in accordance with international standard
IEC 60974-2, 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.
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S Observe precautions for handling electrostatic-
sensitive devices.
S Use proper static-proof bags and boxes.
ESD
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INTRODUCTION
Design structure of the cooling unit
The 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.
Power source
Power board
Cooling unit housing
40VAC
Coolant return to cooling unit
Coolant out from cooling unit
Coolant filling
5AP1 Cooler board
5EV1 Cooling fan
5M1 Water pump
5QF1 Main switch
5 Cooling unit
ON
OFF
Heat
exchanger
Coolant
container
Block diagram of the cooling unit
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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 ESABs ready mixed coolant
Coolant quantity 4.5 l
Maximum water flow 1.8 l/min
Maximum pressure lift for torch Q
max
66.7 PSI (4.6 bar)
Operating temperature -14° to +104°F (-10° to +40°C)
Transport and storage temperature - 4° to +131°F (-20° to +55°C)
Dimensions lxwxh 26.8 x 13 x 9.1 inch (680 x 325 x 230 mm)
Weight empty 33.1 lbs (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 designed for indoor and outdoor use.
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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
Component Description
5 Cooling unit
5AP1 Cooler board
5M1 Water pump with motor, 24V DC
5EV1 Cooling fan, 24V DC
5QF1 Main switch
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DESCRIPTION OF OPERATION
This section describes the function of the circuit board and other components in the
equipment.
5AP1 Cooler board
S1
0V
CN1:1
CN1:2
CN1:3
CN1:4
Vin
0V
+24 V
CN2:1
CN2:2
CN2:3
CN3:2
CN3:1
CS1
Vcc2
0V
0V
Vcc
Vcc
0VA
IC2
0V
CN5:1
CN5:2
0VA
CN6:1
CN6:3
CN6:2
OnOff
0V
GND
COMP
FB
SENSE
OUTPUT
Vi
I
V
IC1
0V
Vcc
Vin
0V
Pump
5M1
Fan
5EV1
CN4:1
40 V AC
Vin
5AP1
From
power
source
From
power
source
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Power supply
The 40V AC voltage is rectified to Vin (+55V DC) and from Vin control
voltages Vcc (+22V DC) and Vcc2 (+16.5V DC) 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.
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 the wiring diagram on 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)
(Pump and fan outlet)
+24V DC (±0.5V)
(maximum load ca 2.0 A)
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 +24V DC.
The pump and the fan are protected by a 2AT glass-tube fuse (S1).
5AP1 Component positions
ZZ1
1SC
ZZ2
C5
C7
C8
C9
5D
IC1
R10
11R
21R
R13 R14
R15
R17
81R
R19
R21
R22
R23
R24
R25
R26
R27
R28
R29
Q5
R30
R31
R32
R1
R2
R4
5R
R6
R7
8R
9R
C10
1C
2D
1D
3D
4D
CN1 CN3
CN2
L2
1L
D7
Q7
Q6
02R
C2
Q1
Q2
3Q
4Q
21C
CN4
C13
C3
C16
C15
2CI
41C
CN5
3R
33R
C6
D6
71C
R34
D9
R35
8D
R16
C11
C4
S1
1PT
3PT
2PT
+
+
+
+
CN6
CN5CN6
CN4S1CN2CN3CN1
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SERVICE INSTRUCTIONS
What is ESD?
A sudden transfer or discharge of static electricity from one object to another. ESD
stands for Electrostatic Discharge.
How does ESD damage occur?
ESD can cause damage to sensitive electrical components, but is not dangerous to
people. ESD damage occurs when an ungrounded person or object with a static
charge comes into contact with a component or assembly that is grounded. A rapid
discharge can occur, causing damage. This damage can take the form of immediate
failure, but it is more likely that system performance will be affected and the
component will fail prematurely.
How do we prevent ESD damage?
ESD damage can be prevented by awareness. If static electricity is prevented from
building up on you or on anything at your work station, then there cannot be any
static discharges. Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics)
generate and hold static charge, so you should not bring unnecessary nonconductive
items into the work area.
It is obviously difficult to avoid all such items, so various means are used to drain off
any static discharge from persons to prevent the risk of ESD damage. This is done
by simple devices: wrist straps, connected to ground, and conductive shoes.
Work surfaces, carts and containers must be conductive and grounded. Use only
antistatic packaging materials. Overall, handling of ESD-sensitive devices should be
minimized to prevent damage.
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S Observe precautions for handling electrostatic-
sensitive devices.
S Use proper static-proof bags and boxes.
ESD
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Service aid
We can offer the following service tool to simplify the service.
Antistatic service kit
Ordering no. 0740 511 001
The kit makes it easier to protect sensitive
components from electrostatic discharge.
Contents:
S A conductive mat (size 610 x 610 mm)
S A 1.5 metre long ground cable with a
crocodile clip
S An adjustable wrist strap and cable
with an inbuilt protective resistor
Antistatic service kit
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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 12 W / 50 W resistor to CN3.
4. Turn on the main switch.
5. Measure the DC voltage over the 12 W resistor.
The voltage should be +24V DC (±0.5V).
CAUTION! Do not forget to turn off the main switch, disconnect the 12 W
resistor and connect the pump and the fan again after the test.
www.esab.com
110915© ESAB AB
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 70 233 075
Fax: +32 15 257 944
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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The ESAB COOL 2 is a water-cooling unit designed to provide efficient cooling for various industrial applications, such as welding, plasma cutting, and laser cutting. With a powerful cooling capacity of 1 kW and a maximum water flow rate of 1.8 liters per minute, it ensures optimal temperature control and prevents overheating of equipment. The compact and durable design of the COOL 2 allows for easy installation and integration into existing systems. Its user-friendly interface and straightforward operation make it suitable for a wide range of users.
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