EWM cool82 U44 User manual

Operating instructions
EN
Air-cooling units for water-cooled welding torches
cool82 U44
cool82 U45
099-008268-EW501
Observe additional system documents!
21.02.2022

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 sa-
fety instructions and warning notices!
• Observe the accident prevention regulations and any regional regulations!
• The operating instructions must be kept at the location where the machine is operated.
• Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
• The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and re-
pair the machine.
• Technical changes due to further development in machine technology may lead to a dif-
fering welding behaviour.
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/en/specialist-dealers.
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 ac-
cepted 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-Strasse 8
56271 Mündersbach Germany
Tel.: [phone], Fax: -244
Email: [e-mail]
www.ewm-group.com
The copyright to this document remains the property of the manufacturer.
Copying, 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.
Data security
The user is responsible for backing up data of all changes from the factory setting. The user is liable for
erased personal settings. The manufacturer does not assume any liability for this.

Contents
Notes on using these operating instructions
099-008268-EW501
21.02.2022
3
1 Contents
1Contents .......................................................................................................................................... 3
2For your safety ............................................................................................................................... 4
2.1 Notes on using these operating instructions .......................................................................... 4
2.2 Explanation of icons ............................................................................................................... 5
2.3 Safety instructions .................................................................................................................. 6
2.4 Transport and installation ...................................................................................................... 9
3Intended use ................................................................................................................................. 11
3.1 Applications .......................................................................................................................... 11
3.2 Use and operation solely with the following machines ........................................................ 11
3.3 Documents which also apply ............................................................................................... 11
3.3.1 Warranty ............................................................................................................... 11
3.3.2 Declaration of Conformity ..................................................................................... 11
3.3.3 Service documents (spare parts and circuit diagrams) ........................................ 11
3.3.4 Part of the complete documentation ..................................................................... 12
4Machine description – quick overview ...................................................................................... 13
4.1 Front view ............................................................................................................................ 13
4.2 Rear view ............................................................................................................................. 14
5Design and function ..................................................................................................................... 15
5.1 Assembly/disassembly......................................................................................................... 15
5.2 Preparations ......................................................................................................................... 15
5.2.1 Cooling module assembly .................................................................................... 16
5.2.2 Connecting the supply lines ................................................................................. 17
5.3 Transport and installation .................................................................................................... 17
5.3.1 Machine cooling .................................................................................................... 17
5.3.2 Ambient conditions ............................................................................................... 17
5.3.3 Welding torch cooling system ............................................................................... 18
6Functional characteristics ........................................................................................................... 19
6.1.1.1 Permitted torch coolant ......................................................................... 19
6.1.1.2 Maximal hose package length .............................................................. 19
6.1.1.3 Adding coolant ...................................................................................... 19
7Functional characteristics ........................................................................................................... 21
7.1.1 Welding torch connection ..................................................................................... 21
8Maintenance, care and disposal ................................................................................................. 22
8.1 General ................................................................................................................................ 22
8.1.1 Cleaning ............................................................................................................... 22
8.1.2 Dirt filter ................................................................................................................ 22
8.2 Maintenance work, intervals ................................................................................................ 23
8.2.1 Daily maintenance tasks....................................................................................... 23
8.2.2 Monthly maintenance tasks .................................................................................. 23
8.2.3 Annual test (inspection and testing during operation) .......................................... 23
8.3 Disposing of equipment ....................................................................................................... 24
9Rectifying faults ........................................................................................................................... 25
9.1 Checklist for rectifying faults ................................................................................................ 25
9.2 Vent coolant circuit ............................................................................................................... 25
9.3 Fixing the pump shaft (coolant circuit) ................................................................................. 26
10 Technical data .............................................................................................................................. 27
10.1 cool82 U44 ........................................................................................................................... 27
10.2 cool82 U45 ........................................................................................................................... 28
11 Accessories .................................................................................................................................. 29
11.1 Options ................................................................................................................................. 29
11.2 Welding torch cooling system .............................................................................................. 29
11.2.1 Coolant - type blueCool ........................................................................................ 29
11.2.2 Coolant - type KF .................................................................................................. 29
12 Appendix ....................................................................................................................................... 30
12.1 Searching for a dealer.......................................................................................................... 30

For your safety
Notes on using these operating instructions
4
099-008268-EW501
21.02.2022
2 For your safety
2.1 Notes on using these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning sym-
bol.
• The 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 warn-
ing symbol.
• The risk is explained using a symbol on the edge of the page.
Technical aspects which the user must observe to avoid material or equipment damage.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the u-
ser must observe.
Activate and release / Tap / Tip
Switch off machine
Release
Switch on machine
Press and hold
Switch
Incorrect / Invalid
Turn
Correct / Valid
Numerical value – adjustable
Input
Signal light lights up in green
Navigation
Signal light flashes green
Output
Signal light lights up in red
Time representation (e.g.: wait 4 s / ac-
tuate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use