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Rectifying faults

Fixing the pump shaft (coolant circuit)

099-008598-EW501

04.04.2016

27

7.3

Fixing the pump shaft (coolant circuit)

DANGER

Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.

• Appoint only skilled persons for repair work (trained service personnel)!

Electric shock!
Welding machines use high voltages which can result in potentially fatal electric shocks
and burns on contact. Even low voltages can cause you to get a shock and lead to
accidents.

•  Do not touch any live parts in or on the machine!
•  Connection cables and leads must be free of faults!
•  Switching off alone is not sufficient!
•  Place welding torch and stick electrode holder on an insulated surface!
•  The unit should only be opened by specialist staff after the mains plug has been

unplugged!

• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!

Continuing non-use and impurities in the coolant may result in the the coolant pump not being in proper
working order.

Figure 7-2

• Switch off machine at the main switch.

• Insert a plain slot screwdriver with a maximum tip width of 6.5 mm through the maintenance opening

and place in the centre of the pump shaft. Turn the screwdriver clockwise until the pump shaft can be
easily rotated again.

• Remove

screwdriver.

• Switch on the power source at the main switch.

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Содержание cool50 U40

Страница 1: ...its for water cooled welding torches cool50 U40 cool50 U40 115V 099 008598 EW501 Observe additional system documents 04 04 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit www ewm group com ...

Страница 2: ... 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 observed during installation operation usage and maintenance of the equipment An incorrectly performed installation can result in material damage and injure persons as a result For this re...

Страница 3: ... Installation 16 5 4 Cooling module assembly disassembly 17 5 5 Connecting the supply lines 18 5 6 Mains connection 19 5 6 1 cool50 U40 115V 19 5 6 1 1 Mains configuration 19 5 7 Welding torch connection 20 5 8 Welding torch cooling system 21 5 8 1 List of coolants 21 5 8 2 Maximal hose package length 21 5 8 3 Adding coolant 22 6 Maintenance care and disposal 23 6 1 General 23 6 2 Maintenance work...

Страница 4: ...Contents Notes on the use of these operating instructions 4 099 008598 EW501 04 04 2016 10 Appendix A 30 10 1 Overview of EWM branches 30 ...

Страница 5: ...he hazard is also highlighted using a symbol in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading with a general warning symbol The risk is explained using a symbol on the edge of the page CAUTION Working and operating procedures which must be followed p...

Страница 6: ...users must observe Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu 4 s Time display example wait 4s press Interruption in the menu display other setting options possible Tool not required do not use Tool required use ...

Страница 7: ... operating instructions for all system components especially the safety instructions Risk of accidents due to non compliance with the safety instructions Non compliance with the safety instructions can be fatal Carefully read the safety instructions in this manual Observe the accident prevention regulations and any regional regulations Inform persons in the working area that they must comply with ...

Страница 8: ...g currents Stray welding currents can destroy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are securely connected and check regularly Always ensure a proper and secure electrical connection to the workpiece Set up attach or suspend all conductive power source components like casing transport vehi...

Страница 9: ... user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the user must consider the following see also EN 60974 10 Appendix A Mains control signal and telecommunication lines Radios and televisions Computers and other control systems Safety equipment The health of neighbouring persons especiall...

Страница 10: ...up to an angle of 10 according to EN 60974 A2 Set up and transport the machine on level solid ground Secure add on parts using suitable equipment Replace damaged wheels and their fixing elements Fix external wire feed units during transport avoid uncontrolled rotation Damage due to supply lines not being disconnected During transport supply lines which have not been disconnected mains supply leads...

Страница 11: ...ing salt sea air Non permissible ambient conditions Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Keep the cooling air inlet and outlet clear Observe the minimum distance of 0 5 m from obstacles 2 4 1 1 In operation Temperature range of the ambient air 25 C to 40 C Relative air humidity Up to 50 at 40 C Up to 90 at 20 C 2 4 1 2 T...

Страница 12: ...ntrolled by the welding machine only The welding machine automatically detects and displays a lack of coolant see the welding machine operating instructions The cooling units are supplied with voltage by the welding machine or an external power source The coolant pump is protected against overload by an overcurrent release The coolant connections are realised with self locking quick connect coupli...

Страница 13: ...specifically authorised by the manufacturer The original copy of the declaration of conformity is enclosed with the unit 3 3 3 Service documents spare parts and circuit diagrams DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or modified by specialist skilled persons The warranty becomes null and void in the even...

Страница 14: ...4 1 Front view 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 ...

Страница 15: ... 0 1 cool50 U40 115V 2 cool50 U40 3 Automatic cut out of coolant pump key button press to reset a triggered fuse 4 Cooling air outlet 5 Machine feet 6 Connector plug 8 pole Cooling unit control lead 7 Connector plug 4 pole Cooling unit voltage supply 8 Connection cable 3 pole 115V Cooling unit voltage supply see 5 6 chapter ...

Страница 16: ...he power components the following precautions should be observed Ensure that the working area is adequately ventilated Do not obstruct the air inlets and outlets of the machine Do not allow metal parts dust or other objects to get into the machine 5 3 Installation WARNING Risk of accident due to improper transport of machines that may not be lifted Do not lift or suspend the machine The machine ca...

Страница 17: ...s 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 place before...

Страница 18: ...V Cooling unit voltage supply see 5 6 chapter Control and supply lead to the welding machine The cooling module and welding machine are connected using two leads Insert the control lead plug on the welding machine Insert the power supply lead plug on the welding machine Control cable to welding machine and supply cable to power supply on site The connection between cooling unit welding machine and...

Страница 19: ...ician When operating the generator always ensure it is earthed as stated in the operating instructions The resulting network has to be suitable for operating devices according to protection class 1 5 6 1 1 Mains configuration The machine may only be connected to a one phase system with two conductors and an earthed neutral conductor Figure 5 3 Legend Item Designation Colour code L Outer conductor ...

Страница 20: ...h 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 4 Item Symbol Description 0 1 Welding torch 2 Welding torch hose 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 connec...

Страница 21: ...protection tester Replace coolant as necessary if frost protection is inadequate The disposal of coolant must be carried out according to official regulations and observing the relevant safety data sheets German waste code number 70104 Coolant must not be disposed of together with household waste Coolant must not be discharged into the sewerage system Recommended cleaning agent water if necessary ...

Страница 22: ...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...

Страница 23: ...s machine is largely maintenance free and requires a minimum of care There are some points which should be observed to guarantee fault free operation of your welding machine Among these are regular cleaning and checking as described below depending on the pollution level of the environment and the length of time the unit is in use 6 2 Maintenance work intervals 6 2 1 Daily maintenance tasks 6 2 1 ...

Страница 24: ...d for this purpose According to German law law governing the distribution taking back and environmentally correct disposal of electric and electronic equipment ElektroG from 16 03 2005 used machines are to be placed in a collection system separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private hous...

Страница 25: ...machine equipment 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 pac...

Страница 26: ...olant circuit 26 099 008598 EW501 04 04 2016 7 2 Vent coolant circuit 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 ...

Страница 27: ...ts Do not touch any live parts in or on the machine Connection cables and leads must be free of faults Switching off alone is not sufficient Place welding torch and stick electrode holder on an insulated surface The unit should only be opened by specialist staff after the mains plug has been unplugged Only wear dry protective clothing Wait for 4 minutes until the capacitors have discharged Continu...

Страница 28: ... machine 8 1 cool50 U40 cool50 U40 115V cool50 U40 115V cool50 U40 Supply voltage from the welding machine 115 V 230 V Mains frequency 50 60 Hz Cooling output 1000 W 1 l min Max flow rate 5 l min Max coolant outlet pressure 3 5 bar Max tank capacity Approx 4 l Coolant see 5 8 1 chapter Dimensions L W H in mm 610 x 298 x 330 Cooling mode protection classification F IP 23 Weight without coolant 16 5...

Страница 29: ...General accessories 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 ...

Страница 30: ...Appendix A Overview of EWM branches 30 099 008598 EW501 04 04 2016 10 Appendix A 10 1 Overview of EWM branches ...

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