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EWM cool50-2 U40, Operating Instructions Manual, Page: 1 / 26

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Operating  instructions 

 
 
 
 

 

 

 

 

 

EN 

Air-cooling  units for water-cooled welding  torches

 

 

 

cool50-2 U40 
cool50-2 U42 

 
  

 

099-008603-EW501 

Observe  additional  system documents! 

27.07.2016 

 
 

 
 

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Summary of Contents for cool50-2 U40

Page 1: ...nits for water cooled welding torches cool50 2 U40 cool50 2 U42 099 008603 EW501 Observe additional system documents 27 07 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group com ...

Page 2: ...found at www ewm group com Liability relating to the operation of this equipment is restricted solely to the function of the equipment No other form of liability regardless of type shall be accepted This exclusion of liability shall be deemed accepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are...

Page 3: ...12 5 5 Connecting the supply lines 13 5 5 1 Welding torch connection 14 5 6 Connecting the wire feed unit 15 5 7 Welding torch cooling system 16 5 7 1 Approved coolants overview 16 5 7 2 Maximal hose package length 16 5 7 3 Adding coolant 17 6 Maintenance care and disposal 18 6 1 General 18 6 2 Cleaning 18 6 3 Maintenance work intervals 19 6 3 1 Daily maintenance tasks 19 6 3 1 1 Visual inspection...

Page 4: ...combination with the Power source operating instructions for the product being used Read and observe the operating instructions for all system components especially the safety instructions Figure 2 1 The illustration shows a general example of a welding system Item Documentation A 1 Wire feeder A 2 Conversion instructions A 3 Power source A 4 Cooling unit voltage converter tool box etc A 5 Trolley...

Page 5: ...ap tip Switch off machine Release do not activate Switch on machine Press and hold switch Wrong Turn Correct Numerical value adjustable Menu entry Signal light lights up in green Navigating the menu Signal light flashes green Exit menu Signal light lights up in red Time representation e g wait 4 s activate Signal light flashes red Interruption in the menu display other setting options possible Too...

Page 6: ... damaged itself during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to IEC 60974 1 Set up and transport the machine on level solid ground Secure add on parts using suitable equipment The units are designed for operation in an upright position Operation in non permissible positions can cause equipment damage Only transport and operate in an upright position Acces...

Page 7: ...or any damages arising from improper usage The equipment must only be used in line with its designated purpose and by trained or expert personnel Do not improperly modify or convert the equipment These cooling modules are designed solely for cooling welding torches We can only guarantee smooth and trouble free operation when used in conjunction with the welding machines welding torches coolants an...

Page 8: ...cument of the specific declaration of conformity is included with every product 3 2 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used in environments with an increased electrical hazard 3 2 4 Service documents spare parts and circuit diagrams WARNING Do not carry out any unauthorised repairs or modifications To avoid i...

Page 9: ...4 1 Frontview Figure 4 1 Item Symbol Description 0 1 Screw connector Connects cooling module and welding machine 2 Coolant tank cap 3 Coolant tank 4 Cooling air inlet 5 Machine feet 6 Quick connect coupling blue Coolant supply to the welding torch 7 Quick connect coupling red Coolant return from the welding torch ...

Page 10: ...uick connect coupling red Coolant return from the welding torch 2 Automatic cut out of coolant pump key button press to reset a triggered fuse 3 Quick connect coupling blue Coolant supply to the welding torch 4 Cooling air outlet 5 Connector plug 8 pole Cooling unit control lead 6 Connector plug 4 pole Cooling unit voltage supply ...

Page 11: ...e used for the coolant connections In the event of insufficient coolant pressure or coolant throughput the welding machine is shut down to prevent damage to the welding torch The cooling modules are fitted with an air cooled heat exchanger This means that the cooling output depends on the ambient temperature The lower the ambient temperature and therefore the air intake temperature the higher the ...

Page 12: ... connectors that are not locked Attention must be paid to cleanliness and correct installation when mounting a power source with a cooling module The cooling module could become loose if not properly mounted thereby causing serious injuries Remove dirt from the feet of the power source s unit and the screw connectors of the cooling module before mounting Check that the connections are locked in pl...

Page 13: ...ions for the water cooled welding torch to the cooling module If air cooled welding torches are used the control and supply line between the cooling module and welding machine must be disconnected Figure 5 2 Item Symbol Description 0 1 Power source 2 Connector plug 8 pole Cooling unit control lead 3 Connector plug 4 pole Cooling unit voltage supply Control and supply lead to the welding machine Th...

Page 14: ...e package 3 Quick connect coupling blue Coolant supply to the welding torch 4 Quick connect coupling red Coolant return from the welding torch 5 Power source Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return and supply line blue to quick connect coupling blue coolant supply ...

Page 15: ...e hose package 5 Power source 6 Quick connect coupling red Coolant return from the welding machine or wire feed unit 7 Quick connect coupling blue Coolant supply to the welding machine or wire feed unit Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return and supply line blue to quick connect ...

Page 16: ...overview of coolants Do not mix different coolants When changing the coolant the entire volume of liquid must be changed Dispose of the coolant in accordance with local regulations and the material safety data sheets German waste code number 70104 May not be disposed of in household waste Prevent entry into sewers Absorb with liquid binding material sand gravel acid binding agents universal bindin...

Page 17: ...oolant to the filter sieve insert close sealing cover again After the initial filling wait for at least one minute when the machine is switched on so that the hose package is filled with coolant completely and without bubbles With frequent changes of torch and during the initial filling process the cooling unit tank should be topped up as necessary The level of coolant must never fall below the mi...

Page 18: ...who is able to implement the required safety procedures In the event of failure of any one of the following tests the machine must not be operated again until it has been repaired and a new test has been carried out Repair and maintenance work may only be performed by qualified authorised personnel otherwise the right to claim under warranty is void In all service matters always consult the dealer...

Page 19: ... Wheels and their securing elements Transport elements strap lifting lugs handle Other general condition 6 3 1 2 Functional test Operating message safety and adjustment devices Functional test Welding current cables check that they are fitted correctly and secured Gas tubes and their switching equipment solenoid valve Gas cylinder securing elements Check correct mounting of the wire spool Check th...

Page 20: ...opean Parliament and the Council of Juli 4th 2021 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a waste container on wheels indicates that the equipment must be collected separately This machine is to be placed for disposal or recycling in the waste separation systems provided for this purpose Accordi...

Page 21: ...pment for the material and process gas in use is a fundamental requirement for perfect operation Please observe the welding machine operating instructions Legend Symbol Description Fault Cause Remedy Coolant error no coolant flowing Insufficient coolant flow Check coolant level and refill if necessary Eliminate kinks in conduit system hose packages Extend and lay out the torch hose package Reset a...

Page 22: ...olant circuit 22 099 008603 EW501 27 07 2016 7 2 Vent coolantcircuit To vent the cooling system always use the blue coolant connection which is located as deep as possible inside the system close to the coolant tank Figure 7 1 ...

Page 23: ... can cause a shock and lead to accidents Never touch live components such as welding current sockets or stick tungsten or wire electrodes Always place torches and electrode holders on an insulated surface Wear the full personal protective equipment depending on the application The machine may only be opened by qualified personnel Continuing non use and impurities in the coolant may result in the t...

Page 24: ... 4 l Coolant See Design and functions coolant chapter Dimensions L W H in mm 610 x 300 x 330 Cooling mode protection classification F IP 23 Weight without coolant 20 5 kg EMC class A Constructed to standards IEC 60974 1 2 10 8 2 cool50 2 U42 Supply voltage from the welding machine 400 V Mains frequency 50 60 Hz Cooling capacity 1000 W 1 l min Max flow rate 20 l min Max coolant outlet pressure 4 5 ...

Page 25: ... Generalaccessories Type Designation Item no TYP 1 Frost protection tester 094 014499 00000 KF 23E 10 Coolant 10 C 9 3 l 094 000530 00000 KF 23E 200 Coolant 10 C 200 litres 094 000530 00001 KF 37E 10 Coolant 20 C 9 3 l 094 006256 00000 KF 37E 200 Coolant 20 C 200 l 094 006256 00001 ...

Page 26: ...Appendix A Overview of EWM branches 26 099 008603 EW501 27 07 2016 10 Appendix A 10 1 Overviewof EWM branches ...

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