The ABICOOLER 2000 advanced and ABICOOLER 2000 are coolant recirculators designed for use with liquid-cooled welding torches. These cooling units are essential for maintaining optimal operating temperatures of welding equipment, thereby extending the lifespan of the torch and ensuring consistent performance. The devices are manufactured by ABICOR BINZEL, a company specializing in welding technology.
Function Description
The primary function of the ABICOOLER 2000 series is to circulate coolant through liquid-cooled welding torches, dissipating heat generated during the welding process. This prevents overheating of the torch, which could otherwise lead to damage or reduced efficiency. The cooling unit operates by pumping coolant from a tank, through the welding torch, and back to a heat exchanger where the heat is released to the ambient air.
The ABICOOLER 2000 advanced model offers enhanced features compared to the standard ABICOOLER 2000. Both models include a temperature and flow monitor integrated into the cooling unit, which helps in overseeing the cooling medium. A coolant filter is also installed to ensure the cleanliness of the circulating coolant, preventing blockages and wear in the system.
Key components of the cooling unit include:
- Coolant filling inlet (1): For adding coolant to the system.
- Coolant circulation outlet (blue) (2): Where cooled coolant exits to the torch.
- Coolant circulation inlet (red) (3): Where heated coolant returns from the torch.
- Coolant discharging outlet neck (4): For draining coolant from the system.
- Level indicator (5): To monitor the coolant level.
- On/Off switch (6): For powering the unit.
- Communication signal connector (7): For connecting to the welding power source, enabling features like automatic shutdown if coolant flow is insufficient.
- Display (8): Provides real-time information on water flow and temperature (on advanced models).
- Compressed air connector (9): For maintenance tasks like flushing the system.
The cooling unit is designed for continuous operation, with a one-way circulation mode for the circulating pipeline. If the cooling unit is idle for a long time (one year), the coolant in the circulating pipeline may separate naturally, or the coolant may be discharged from the water pump due to product maintenance, resulting in abnormal operation.
Important Technical Specifications
The ABICOOLER 2000 advanced and ABICOOLER 2000 share many core specifications, with some distinctions:
| Feature |
2000 advanced |
2000 |
| Heat exchanger |
3-row |
3-row |
| Power supply |
AC 220 50 Hz/AC 110 60 Hz |
AC 220 50 Hz/AC 110 60 Hz |
| Cooling capacity Q=1l/min at + 25°C |
1800 W (water) |
1800 W (water) |
| Pump lift |
Approx. 5.5 m |
Approx. 5.5 m |
| Maximum flow |
7 L/min |
7 L/min |
| Pump type |
Centrifugal pump |
Centrifugal pump |
| Max. coolant outlet pressure/coolant pump pressure |
3.7 bar |
3.7 bar |
| Coolant tank capacity |
10 L |
10 L |
| Coolant |
BTC series |
BTC series |
| Ingress protection rating |
IP 23 (applicable to the inner cavity only) |
IP 23 (applicable to the inner cavity only) |
| Dimensions |
543 x 286 x 395 mm |
543 x 286 x 395 mm |
| Weight |
23.4 kg |
23.1 kg |
| Ambient temperature (operation) |
-10°C - +40°C |
-10°C - +40°C |
| Relative humidity (operation) |
Up to 90% at 20°C |
Up to 90% at 20°C |
| Ambient temperature (transport/storage) |
-25°C to +55°C |
-25°C to +55°C |
| Relative humidity (transport/storage) |
Up to 90% at 20°C |
Up to 90% at 20°C |
The nameplate provides critical information such as the device type, serial number, manufacturer, power input (P1max), maximum pressure (pmax), and current (Imax). For the 2000 advanced model, the power input is 1.8 kW and the maximum pressure is 0.37 MPa.
Usage Features
The ABICOOLER 2000 series is designed for ease of use and integration into welding systems.
- Designated Use: The device is intended for cooling liquid-cooled welding torches and must be used in accordance with the instructions to prevent damage, ensure safety, and maintain warranty.
- Safety Features: The units incorporate warnings for potential hazards, including electrical shock and risks associated with improper handling of components. Safety symbols indicate coolant circulation inlet/outlet, coolant filling/discharging, and the need to read instructions.
- Flow Monitor: The advanced model includes a flow monitor that disconnects the welding current if the coolant level is low or if the flow rate falls below a preset threshold (0.6 – 0.8 l/min). This protects the welding torch from damage due to insufficient cooling.
- Display Interface (Advanced Model): The display shows real-time water flow (l/min) and temperature (°C). It also features "START" and "STOP" buttons, an "ALARM" indicator, and a "SET" button for accessing settings pages.
- User Settings Interface (Advanced Model): Allows users to configure parameters such as energy consumption, temperature upper/lower limits, flow monitor settings, and language.
- Administrator Settings Interface (Advanced Model): Provides access to more advanced configurations, including current upper/lower limits, output options, pump options, and detailed monitor settings.
- Connection: The cooling unit connects to the welding power source via a communication signal connector. The coolant hoses are connected to the torch, ensuring a closed-loop circulation system.
- Ventilation: The equipment must be operated in environments with sufficient ventilation to ensure proper heat dissipation.
Maintenance Features
Regular maintenance is crucial for the longevity and efficient operation of the ABICOOLER 2000 series.
- Maintenance Schedule: A detailed schedule outlines daily, weekly, monthly, every six months, and annual tasks.
- Daily: Check the coolant level.
- Weekly: Check if the coolant filter is contaminated and clean or replace it if necessary.
- Monthly: Clean the finned radiator using compressed air to remove dust. Check the coolant supply and return hoses for dirt and replace if necessary.
- Every six months: Change the coolant. Flush the finned radiator against the direction of supply/return flow. Flush the coolant tank. Check the tightness of connectors and tighten hose clamps if necessary.
- Annually: Perform inspection and testing during operation.
- Filter Element Cleaning: The filter element should be cleaned approximately every 500 working hours or when sediment is observed. The process involves unscrewing the filter bowl, removing the filter element and O-ring, cleaning them, and then reassembling.
- Coolant Management: Use only ABICOR BINZEL BTC coolant. Mixing with other coolants or using tap water can damage the unit and void the warranty. The coolant supply pipe is blue, and the return pipe is red.
- Venting: After filling the coolant, the system must be vented to remove any air residues. This is done by opening the water inlet cap, pressing the pump button, and observing the coolant level.
- Troubleshooting: The manual provides a comprehensive troubleshooting guide for common issues such as the cooling unit not functioning, low water flow, high water temperature, low cooling capacity, high running noise, and leakage. Each issue is linked to potential causes and recommended solutions.
- Disassembly and Disposal: Instructions are provided for safe disassembly and disposal of the unit, emphasizing the need to switch off power, disconnect electrical connections, and dispose of materials according to local regulations. BTC coolants must not be disposed of with normal household waste.
The ABICOOLER 2000 advanced and ABICOOLER 2000 are robust and reliable coolant recirculators designed to support demanding welding applications by ensuring efficient and consistent cooling of welding torches. Adherence to the operating and maintenance instructions is key to maximizing their performance and lifespan.
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