ESAB | CoolMidi 1000 | Service manual | ESAB CoolMidi 1000 User manual

ESAB CoolMidi 1000 User manual
CoolMidi 1000
Service manual
0740 800 195
090428
Valid for serial no. 835-xxx-xxxx
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CoolMidi 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5:1 Pump motor On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5:2 Monitoring the cooling water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5:3 Monitoring the cooling water flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CoolMidi 1000 + MIG 3001i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CoolMidi 1000 + MIG 4001i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CoolMidi 1000 + TIG 3001i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CoolMidi 1000 + Flow guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water flow guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling caracteristic (at 1 l/min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
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15
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 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 15.
This manual contains details of design changes that have been made up to and including
April 2009.
The manual is valid for: CoolMidi 1000 with serial no. 835-xxx-xxxx.
The CoolMidi 1000 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.
TECHNICAL DATA
CoolMidi 1000
Mains voltage
400V 10%, 50/60 Hz
Primary current
Imax 50 Hz
Imax 60 Hz
0.7 A
0.75 A
Motor speed (pump/fan)
at 50 Hz
at 60 Hz
2800 rpm
3200 rpm
Cooling power
at 400 V, 50 Hz
at 400 V, 60 Hz
1.1 kW at 40° C temperature difference and flow 1 l/min
1.0 kW at 40° C temperature difference and flow 1 l/min
Equivalent continuous A-weighted
sound pressure level
< 70 dB (A)
Coolant
Ready mixed, 50% water / 50% mono-ethylene glycol
Coolant quantity
5l
Maximum water flow
4.0 l/min
Fuse (delayed-action)
2x1AT
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CoolMidi 1000
Max pressure lift for welding torch
Qmax
7m
Maximum water pressure
at 50 Hz
at 60 Hz
0.30 MPa (3.0 bar)
0.38 MPa (3.8 bar)
Operating temperature
-10 to + 40° C
Transportation temperature
-20 to + 55° C
Dimensions lxwxh
630 x 245 x 300 mm
690 x 245 x 300 mm (including filler pipe)
Weight
water-filled
empty
19 kg
14 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
CAUTION !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostaticsensitive devices.
S
Use proper static-proof bags and boxes.
Component
Description
5FU1
Fuse, 1A (delayed action)
5FU2
Fuse, 1A (delayed action)
5L1
EMC suppressor (ferrite tube)
5M1
Pump motor with cooling fan, 400 V AC
5S2
Microswitch. Monitoring cooling water connection
5SL1
Flow guard. Monitoring cooling water flow. (Option)
5XP17
Plug connector (Pin)
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CoolMidi 1000
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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
5:1
Pump motor On/Off
The pump motor, 5M1, is powered with 400 V AC from two phases of the mains
power in the power source. Relay RE (24 V DC) on the relay board, 20AP2, is
controlled by the control board 20AP1 in the power source.
5:2
Monitoring the cooling water connection
The water cooling unit is equipped with a detection system ELP (ESAB Logic
Pump), which checks that the water hoses are connected.
Microswitch 5S2 in the water lock connector closes when a cooling water hose is
connected to the blue water connector on the front of the cooling unit. The pump
stops if the switch opens.
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5:3
Monitoring the cooling water flow
CoolMidi 1000 is prepared for optional cooling water flow monitoring. Replace
jumper cable 542 with flow guard sensor, 5SL1, on terminal block 5XT1. The MMC
panel of the system displays a fault code if the input is open. Fault code 29 = No
cooling water flow.
INSTALLATION
A connection kit must be used when the water cooler is assembled to Mig 3001i or
Tig 3001i.
The connection kit includes: A new EMC board for the power source, a relay board and a
cable set. (The new EMC board is needed for the power supply to the water cooler.)
See the assembly instructions on pages 8 and 10.
Mig 4001i does not need a connection kit, see the assembly instructions on page 9.
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Assembly instructions
CoolMidi 1000 + MIG 3001i
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CoolMidi 1000 + MIG 4001i
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CoolMidi 1000 + TIG 3001i
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CoolMidi 1000 + Flow guard
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INSTRUCTIONS
This chapter is an extract from the instruction manual for the CoolMidi 1000.
SAFETY
CAUTION!
Read and understand the instruction manual before
installing or operating.
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
1
Connection for mains cable / control
cable from power source
2
Filling the coolant
3
Connection BLUE, with ELP* for
coolant from cooling unit
4
Connection RED for coolant to
cooling unit
*ELP = ESAB Logic Pump, see headline
Water connection
Water connection
The cooling unit is equipped with a detection system ELP (ESAB Logic Pump) which
checks that the (blue) water hose is connected. When connecting a water-cooled TIG torch
to the cooler the water flow starts.
Detection only works with power sources that are equipped with the ELP function.
To ensure problem-free operation, the installation height from the cooling unit to the welding
gun must be max. 7 m. Heights in excess of this can cause problems, such as long starting
times, air bubbles, vacuums, etc.
If an installation height in excess of 7 m is required, we recommend an installation kit
comprising a non-return valve and a solenoid valve, refer to accessories in the spare parts
list. Once these valves have been installed, the hose package must be horizontal during the
initial startup so that everything fills with water. Then raise the wire feed unit and hose
package to the high height. Continued safe operation at installation heights of up to 12 m
can now commence.
Water flow guard
The water flow guard blocks the power source if the coolant stops flowing
(minimum water flow 0.7 l/min). The water flow guard is an accessory.
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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.
Inspection and cleaning
WARNING! The mains supply must be disconnected before 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.
For this reason, blow clean using compressed air at regular intervals.
Dismantle the right side panel and blow the cooler clean with compressed air.
Change the coolant approximately once a year.
Filling the coolant
ESAB's ready mixed coolant is recommended for use. See spare parts list / accessories.
S
Fill with coolant.
(The fluid level must not exceed the
upper marking but neither must it be
below the lower marking)
S
Disconnect the coolant hose for outgoing
water (torch / welding gun's blue
connection) in order for any trapped air
to disappear.
S
Connect the coolant hose again.
Note! Coolant must be topped up if connecting a
torch, welding gun or connection cables that are 5
meters in length or longer.
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
Pump pressure (MPa)
Flow rate (l/min)
Cooling caracteristic (at 1 l/min)
P = Power (kW)
K = The temperature difference between inlet water temperature and ambient temperature (K)
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SPARE PARTS
The spare parts list is published in a separate document that can be downloaded from the
internet: www.esab.com
Product
CoolMidi 1000
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Filename
0459 839 030
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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.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
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.
Mesero (Mi)
Tel: +39 02 97 96 81
Fax: +39 02 97 28 91 81
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
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
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
Asia/Pacific
Representative offices
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
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
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA
LLC ESAB
Moscow
Tel: +7 095 543 9281
Fax: +7 095 543 9280
LLC ESAB
St Petersburg
Tel: +7 812 336 7080
Fax: +7 812 336 7060
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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
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
ESAB AB
SE-695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
081016
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