Service manual Mastercool 30
Version 1.0
1.11.2011
9
Kemppi Oy
4. SERVICE INSTRUCTIONS
4.1. Cooling liquid
With Mastercool 30 it is possible to use two kind of cooling liquids: Water mixed with ethanol or glycol.
Ethanol based coolant is recommended for better torch durability. It also keeps the pump clean and
smoothly running. Ethanol can be mixed with water up to 40% vol, higher volume gets flammable.
Lower % vol (no less that 15% vol) may be used if cooler is not running in subzero temperatures.
Cooler is tested with glycol based coolant and system can stay fully operational. The problem is that
glycol may corrode torch metal parts because of electricity (welding voltage in torch). Another thing is that
glycol builds up small particles in the long run and these might get the pump pressure valves stuck if
coolant is not changed frequently.
4.2. Cooler maintenance
Water cooler needs maintenance to keep it running in long term use. Water tank and pump should be
cleaned frequently. Time frame depends on the used coolant and coolers working hours. Ethanol keeps
system more clear than glycol. It is best to check in certain periods of time the coolant condition and
change if needed. Once water tank is getting dirty it should be flush with clean water.
Pump has pressure valves ant they may get dirty as well. If water circulation is slowing down and errors
are faced even with short water hoses, it is preferred to maintain the pump itself. See the following
chapters for more information.
4.2.1. Detaching and fastening the pump
Detaching the pump:
•
Open the side panel
•
Disconnect the pump motor connectors
•
Detach the copper pipe
•
Detach the water hose clamp
•
Note! Additional support by finger is needed while losing the hose clamp screw
to avoid damaging the nib
•
Detach the pump from the cooler frame
Attaching the pump back to the cooler is made in the opposite rule. Note that additional support is needed
while the water hose clamp is tightened. If used dual component water hose see the next chapter to get
reliable connection.
Hose clamp
Copper pipe
