COOL 1

Service manual

0740 800 210 101102 Valid for serial no. 033-xxx-xxxx

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 READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COOL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5AP1:1 Monitoring the coolant flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5AP1:2 Pump motor and fan ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5AP1 Component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installing to welding equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Connections and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Coolant connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Water flow guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Filling the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Caracteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Rights reserved to alter specifications without notice.

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 READ THIS FIRST
Maintenance and repair work should 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 16.
This manual contains details of design changes that have been made up to and including
October 2010.

The manual is valid for COOL 1 with serial no. 033-xxx-xxxx

The COOL 1 is designed and tested in accordance with international and European
standards IEC/EN 60974.
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 standard.

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.
ESD S Use proper static-proof bags and boxes.

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 TECHNICAL DATA
COOL 1
Power consumption 24V DC / 2A
Cooling power 1.3 kW (Rating at 40 K and 1 l/min)
Equivalent continuous A-weighted < 70 dB (A)
sound pressure level
Coolant Ready mixed (50% water and 50% mono-ethylene glycol)
Coolant quantity 4.5 l
Maximum flow 2.0 l/min
Maximum pressure 4 bar
Operating temperature -10° to +40°C
Transportation temperature -20° to +55°C
Dimensions lxwxh 610 x 256 x 256 mm
Weight empty 12 kg
Enclosure class IP23

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.

WIRING DIAGRAM

Component description

Component Description
5 Cooling unit
5AP1 Circuit board with control electronics
5M1 Pump with motor, 24V DC
5S1 Coolant pressure switch (enclosed in pump 5M1)
5EV1 Cooling fan, 24V DC
5SL1 Flow guard. Monitoring coolant flow (option)
5XP.. Plug connector (Pin)
5XS.. Socket connector (Sleeve)
5XT.. Terminal block

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 COOL1

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 DESCRIPTION OF OPERATION
This description of operation describes the function of circuit boards and other components
in the equipment.

5 Cooling unit

5AP1:1 Monitoring the coolant flow

Circuit diagram for coolant flow guard

COOL1 is prepared for optional coolant flow monitoring. Replace the jumper cable 513 with
the flow guard sensor, 5SL1, and connect it to terminal block 5XT1 (CN4) on cooling unit
board, 5AP1. The sensor switch opens at flow rate < 0.7 l/min. The MMC panel of the
system displays fault code 29 ,(no cooling water flow), if the input to the processor is high.
(Measure at point SP3 on 20AP1)
Supervision of hoses connection, ELP (ESAB Logic Pump) is not installed in COOL1.

5AP1:2 Pump motor and fan ON/OFF

The pump motor, 5M1, and cooling fan, 5EV1, are connected in parallell and powered from
the power supply board, 2AP3, in the power source. The power is 25V DC and named
25V_WP in the cooling unit board, 5AP1.
An output from the processsor on control board 20AP1 connects input 20XS5:2 (WP2) to
0V. (Measure at point SP1 on 20AP1). Transistor Q2 in cooling unit board, 5AP1, connects
pump motor and fan to 0V, and the pump and fan start.
The pump, 5M1, has an enclosed coolant pressure switch, 5S1, which switches off the
power to the pump motor if the coolant pressure is too high. This can occur if a hose is
folded which make flow to fail or stop. The cooling fan however is still powered and running.

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 Pump motor and fan ON/OFF

Circuit diagram for pump motor and cooling fan

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 5AP1 Component positions

Component positions on the cooling unit board, 5AP1.

Terminal block CN4 is also named 5XT1 in the diagram.

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 SERVICE INSTRUCTIONS

CAUTION !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S Observe precautions for handling electrostatic-
sensitive devices.
ESD S Use proper static-proof bags and boxes.

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.

Service aid

Antistatic service kit

Ordering no. 0740 511 001
The kit makes it easier to protect sensitve
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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 INSTRUCTIONS
This chapter is an extract from the instruction manual for the COOL1.

SAFETY

CAUTION!
Read and understand the instruction manual before
installing or operating.

INSTALLATION
The installation must be executed by a professional.

Location
Position the cooling unit such that its air inlets and outlets are not obstructed.

Power supply and control

COOL1 is powered and controlled from the power source via socket connector XS4 in the
bottom of the power source. The plug connector 5XP1 on top of the cooler is connected to
XS4.

Installing to welding equipment

See assembly instructions on page 11.

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 Assembly instructions
COOL1 + Aristo 300, Aristo 400 or Aristo 500

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 Water flow guard (Option)

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 OPERATION
General safety regulations for the handling of the equipment can be found in the
instruction manual. Read through before you start using the equipment!

Connections and control devices

1 Filling the coolant

2 BLUE connection for coolant from cooling
unit
3 Connection RED for coolant (return) to
cooling unit.

Coolant connection
For problem free operation it is recommended that the height from the cooling unit to the water-
cooled MIG/MAG gun is maximum 8.5 m.

Water flow guard

The water flow guard blocks the power source if the coolant stops flowing(< 0.7 l/min.). The
water flow guard is an accessory.

MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.

CAUTION!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.

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 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 filing hole.

Filling the coolant

ESAB's coolant is recommended for use. See accessories in instruction manual.
S 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 gun 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.
The temperature of the coolant must not exceed 70° C

CAUTION!
The coolant must be handled as chemical waste.

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 Caracteristics
Pump data

p = Pump pressure (MPa)

Q = Flow rate (l/min)

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 Cooling caracteristic (at 1 l/min)

P = Power (kW)
K = Temperature difference between inlet water temperature and ambient temperature (K)

SPARE PARTS
The spare parts list is published in a separate document that can be downloaded from the
internet: www.esab.com
Filename Product
0459 839 048 COOL 1

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 NOTES

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 ESAB subsidiaries and representative offices

Europe NORWAY Asia/Pacific Representative offices

AUSTRIA AS ESAB BULGARIA
Larvik CHINA
ESAB Ges.m.b.H Shanghai ESAB A/P ESAB Representative Office
Vienna-Liesing Tel: +47 33 12 10 00 Sofia
Fax: +47 33 11 52 03 Shanghai
Tel: +43 1 888 25 11 Tel: +86 21 2326 3000 Tel/Fax: +359 2 974 42 88
Fax: +43 1 888 25 11 85 Fax: +86 21 6566 6622
POLAND EGYPT
BELGIUM ESAB Sp.zo.o. INDIA ESAB Egypt
S.A. ESAB N.V. Katowice ESAB India Ltd Dokki-Cairo
Brussels Tel: +48 32 351 11 00 Calcutta Tel: +20 2 390 96 69
Tel: +32 2 745 11 00 Fax: +48 32 351 11 20 Tel: +91 33 478 45 17 Fax: +20 2 393 32 13
Fax: +32 2 745 11 28 Fax: +91 33 468 18 80
PORTUGAL ROMANIA
THE CZECH REPUBLIC ESAB Lda INDONESIA ESAB Representative Office
ESAB VAMBERK s.r.o. Lisbon P.T. ESABindo Pratama Bucharest
Vamberk Tel: +351 8 310 960 Jakarta Tel/Fax: +40 1 322 36 74
Tel: +420 2 819 40 885 Fax: +351 1 859 1277 Tel: +62 21 460 0188
Fax: +420 2 819 40 120 Fax: +62 21 461 2929 RUSSIA
SLOVAKIA LLC ESAB
DENMARK ESAB Slovakia s.r.o. JAPAN Moscow
Aktieselskabet ESAB Bratislava ESAB Japan Tel: +7 095 543 9281
Herlev Tel: +421 7 44 88 24 26 Tokyo Fax: +7 095 543 9280
Tel: +45 36 30 01 11 Fax: +421 7 44 88 87 41 Tel: +81 45 670 7073
Fax: +45 36 30 40 03 Fax: +81 45 670 7001 LLC ESAB
SPAIN St Petersburg
FINLAND ESAB Ibérica S.A. MALAYSIA Tel: +7 812 336 7080
ESAB Oy Alcalá de Henares (MADRID) ESAB (Malaysia) Snd Bhd Fax: +7 812 336 7060
Helsinki Tel: +34 91 878 3600 USJ
Tel: +358 9 547 761 Fax: +34 91 802 3461 Tel: +603 8023 7835
Fax: +358 9 547 77 71 Fax: +603 8023 0225 Distributors
SWEDEN For addresses and phone
FRANCE ESAB Sverige AB SINGAPORE numbers to our distributors in
ESAB France S.A. Gothenburg ESAB Asia/Pacific Pte Ltd other countries, please visit our
Cergy Pontoise Tel: +46 31 50 95 00 Singapore home page
Tel: +33 1 30 75 55 00 Fax: +46 31 50 92 22 Tel: +65 6861 43 22
www.esab.com
Fax: +33 1 30 75 55 24 ESAB international AB Fax: +65 6861 31 95
Gothenburg
GERMANY Tel: +46 31 50 90 00 SOUTH KOREA
ESAB GmbH Fax: +46 31 50 93 60 ESAB SeAH Corporation
Solingen Kyungnam
Tel: +49 212 298 0 SWITZERLAND Tel: +82 55 269 8170
Fax: +49 212 298 218 ESAB AG Fax: +82 55 289 8864
Dietikon
GREAT BRITAIN Tel: +41 1 741 25 25 UNITED ARAB EMIRATES
ESAB Group (UK) Ltd Fax: +41 1 740 30 55 ESAB Middle East FZE
Waltham Cross Dubai
Tel: +44 1992 76 85 15 North and South America Tel: +971 4 887 21 11
Fax: +44 1992 71 58 03 Fax: +971 4 887 22 63
ARGENTINA
ESAB Automation Ltd CONARCO
Andover Buenos Aires
Tel: +44 1264 33 22 33 Tel: +54 11 4 753 4039
Fax: +44 1264 33 20 74 Fax: +54 11 4 753 6313
BRAZIL
HUNGARY
ESAB S.A.
ESAB Kft
Contagem-MG
Budapest
Tel: +55 31 2191 4333
Tel: +36 1 20 44 182
Fax: +55 31 2191 4440
Fax: +36 1 20 44 186
CANADA
ITALY ESAB Group Canada Inc.
ESAB Saldatura S.p.A. Missisauga, Ontario
Mesero (Mi) Tel: +1 905 670 02 20
Tel: +39 02 97 96 81 Fax: +1 905 670 48 79
Fax: +39 02 97 28 91 81
MEXICO
THE NETHERLANDS ESAB Mexico S.A.
ESAB Nederland B.V. Monterrey
Amersfoort Tel: +52 8 350 5959
Tel: +31 33 422 35 55 Fax: +52 8 350 7554
Fax: +31 33 422 35 44
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48

ESAB AB
SE-695 81 LAXÅ
SWEDEN
Phone +46 584 81 000

www.esab.com

081016
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