EWM cool50-2 U40 User manual

Operating instructions
EN
Air-cooling units for water-cooled welding torches
cool50-2 U40
cool50-2 U42
099-008603-EW501
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27.07.2016
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the site of operation.
•Safety and warning labels at the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to the state of the art and any regulations and
standards applicable. It may be operated, serviced and repaired by trained personnel only.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be 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 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 reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Str. 8
D-56271 Mündersbach, Germany
The copyright tothis document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change, errors excepted.

Contents
Notes on the use of these operating instructions
099-008603-EW501
27.07.2016
3
1 Contents
1Contents ......................................................................................................................................3
2Safety instructions.......................................................................................................................4
2.1 Notes on the use of these operating instructions.....................................................................4
2.1.1 Complete documentation ........................................................................................4
2.1.2 Explanation of icons ...............................................................................................5
2.2 Transport and installation......................................................................................................6
3Intended use ................................................................................................................................7
3.1 For operation only with the following equipment......................................................................7
3.2 Documents which also apply .................................................................................................8
3.2.1 Warranty................................................................................................................8
3.2.2 Declaration of Conformity .......................................................................................8
3.2.3 Welding in environments with increased electrical hazards .......................................8
3.2.4 Service documents (spare parts and circuit diagrams) ..............................................8
3.2.5 Calibration/Validation..............................................................................................8
4Machine description –quick overview.........................................................................................9
4.1 Front view............................................................................................................................9
4.2 Rear view...........................................................................................................................10
5Design and function...................................................................................................................11
5.1 General..............................................................................................................................11
5.2 Machine cooling .................................................................................................................11
5.3 Installation .........................................................................................................................11
5.4 Cooling module assembly/disassembly ................................................................................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
6Maintenance, 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....................................................................................19
6.3.1.2 Functional test.......................................................................................19
6.3.2 Monthly maintenance tasks...................................................................................19
6.3.2.1 Visual inspection....................................................................................19
6.3.2.2 Functional test.......................................................................................19
6.3.3 Annual test (inspection and testing during operation) ..............................................20
6.4 Disposing of equipment.......................................................................................................20
6.4.1 Manufacturer's declaration to the end user.............................................................20
6.5 Meeting the requirements of RoHS ......................................................................................20
7Rectifying faults.........................................................................................................................21
7.1 Checklist for rectifying faults................................................................................................21
7.2 Vent coolant circuit .............................................................................................................22
7.3 Fixing the pump shaft (coolant circuit)..................................................................................23
8Technical data ...........................................................................................................................24
8.1 cool50-2 U40......................................................................................................................24
8.2 cool50-2 U42......................................................................................................................24
9Accessories...............................................................................................................................25
9.1 General accessories ...........................................................................................................25
10 Appendix A................................................................................................................................26
10.1 Overview of EWM branches ................................................................................................26

Safety instructions
Notes on the use of these operating instructions
4
099-008603-EW501
27.07.2016
2 Safety instructions
2.1 Notes on the use oftheseoperatinginstructions
2.1.1 Complete documentation
This document is part of the complete documentation and valid only in 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
A.6
Welding torch
A.7
Remote control
A.8
Control
A
Complete documentation

Safety instructions
Notes on the use of these operating instructions
099-008603-EW501
27.07.2016
5
2.1.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/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)
Tool not required/do not use
Tool required/use