EWM cool82 U44 User manual

Operating instructions
EN
Air-cooling units for water-cooled welding torches
cool82 U44
cool82 U45
099-008268-EW501
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29.06.2017
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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 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
repair the machine.
•Technical changes due to further development in machine technology may lead to a
differing 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.
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-Straße 8
56271 Mündersbach
Germany
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.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2For your safety.......................................................................................................................................4
2.1 Notes on the use of these operating instructions ..........................................................................4
2.2 Explanation of icons.......................................................................................................................5
2.3 Part of the complete documentation..............................................................................................6
3Intended use...........................................................................................................................................7
3.1 Applications....................................................................................................................................7
3.1.1 For operation only with the following equipment............................................................7
3.2 Documents which also apply.........................................................................................................7
3.2.1 Warranty.........................................................................................................................7
3.2.2 Declaration of Conformity...............................................................................................8
3.2.3 Service documents (spare parts and circuit diagrams)..................................................8
4Machine description –quick overview ................................................................................................9
4.1 Front view ......................................................................................................................................9
4.2 Rear view.....................................................................................................................................10
5Design and function.............................................................................................................................11
5.1 Assembly/disassembly ................................................................................................................11
5.1.1 Preparations.................................................................................................................11
5.1.2 Cooling module assembly............................................................................................12
5.1.3 Connecting the supply lines .........................................................................................14
5.2 Transport and installation ............................................................................................................15
5.2.1 Machine cooling............................................................................................................15
5.2.2 Ambient conditions.......................................................................................................15
5.2.2.1 In operation...................................................................................................15
5.2.2.2 Transport and storage...................................................................................15
5.2.3 Welding torch cooling system.......................................................................................16
5.2.3.1 Approved coolants overview.........................................................................16
5.2.3.2 Maximal hose package length ......................................................................16
5.3 Functional characteristics............................................................................................................16
5.3.1 Adding coolant..............................................................................................................17
5.3.2 Welding torch connection.............................................................................................17
6Maintenance, care and disposal.........................................................................................................18
6.1 General........................................................................................................................................18
6.2 Cleaning.......................................................................................................................................18
6.2.1 Dirt filter........................................................................................................................18
6.3 Maintenance work, intervals........................................................................................................19
6.3.1 Daily maintenance tasks ..............................................................................................19
6.3.2 Monthly maintenance tasks..........................................................................................19
6.3.3 Annual test (inspection and testing during operation)..................................................19
6.4 Disposing of equipment ...............................................................................................................20
6.5Meeting 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).........................................................................................22
8Technical data ......................................................................................................................................24
8.1 Welding torch cooling unit............................................................................................................24
9Accessories..........................................................................................................................................25
9.1 General accessories....................................................................................................................25
9.2 Options.........................................................................................................................................25
10 Appendix A ...........................................................................................................................................26
10.1 Overview of EWM branches ........................................................................................................26

For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of 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
symbol.
•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
warning symbol.
•The risk is explained using a symbol on the edge of the page.
Special technical points which users must observe.
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
user must observe.
Activate and release/tap/tip
Switch off machine
Release
Switch on machine
Press and keep pressed
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

For your safety
Part of the complete documentation
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2.3 Part of the complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with all other parts of these instructions! Read and observe the operating
instructions for all system components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 2-1
Item
Documentation
A.1
Options conversion instructions
A.2
Power source
A.3
Cooling unit, voltage converter, tool box etc.
A.4
Transport cart
A.5
Welding torch
A.6
Remote control
A.7
Control
A
Complete documentation

Intended use
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for 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!
3.1 Applications
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 and accessory components from our range.
3.1.1 For operation only with the following equipment
•alpha Q 352, 552 Expert 2.0 puls MM
•alpha Q 352, 552 puls MM RC
•alpha Q 352, 552 Expert 2.0 puls MM Masterpull
•Phoenix 352, 452, 552 Expert 2.0 puls MM RC
•Phoenix 352, 452, 552 puls MM RC
•Phoenix 352, 452, 552 Expert 2.0 puls MM RC Masterpull
•Tetrix 352, 452, 552 Synergic
•Tetrix 352, 452, 552 Synergic RC
•Tetrix 352, 452, 552 Synergic RC CW
•Tetrix 352, 452, 552 RC
•Tetrix 352, 452, 552 RC CW
•tigSpeed 352 Synergic RC HW
3.2 Documents which also apply
3.2.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!

Intended use
Documents which also apply
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3.2.2 Declaration of Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
•Low Voltage Directive (LVD)
•Electromagnetic Compatibility Directive (EMC)
•Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment –Inspection and Testing during Operation", and/or prohibited modifications which
have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the
specific declaration of conformity is included with every product.
3.2.3 Service documents (spare parts and circuit diagrams)
WARNING
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)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.

Machine description –quick overview
Front view
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4 Machine description – quick overview
4.1 Front view
Figure 4-1
Item
Symbol
Description 0
1
Tension closure
Connection between the add-on module and the welding machine
2
Coolant tank cap
3
Coolant tank
4
Cooling air inlet
5
Machine feet
6
Automatic cut-out of coolant pump key button
press to reset a triggered fuse

Machine description –quick overview
Rear view
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4.2 Rear view
Figure 4-2
Item
Symbol
Description 0
1
Cooling air outlet
2
Connector plug, 8-pole
Cooling unit control lead
3
Connector plug, 5-pole
Cooling unit voltage supply
4
Quick connect coupling, blue
Coolant supply to the welding torch
5
Quick connect coupling, red
Coolant return from the welding torch
6
Coolant drain hose
Device for draining the coolant

Design and function
Assembly/disassembly
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5 Design and function
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
•Follow safety instructions on the opening pages of the operating instructions.
•Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
•Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!
Read and observe the documentation to all system and accessory components!
5.1 Assembly/disassembly
CAUTION
Improperly secured equipment!
Equipment, equipment combinations and accessories incorrectly fastened onto
transport systems can tip over during transport and cause injuries!
•Only used the original parts supplied to fasten the equipment.
•Use the systems only for transporting the machines > see 3.1.1 chapter.
•Check the fixing points before each transport and at regular intervals.
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
•Disconnect all supply lines before transport!
5.1.1 Preparations
Figure 5-1
Item
Symbol
Description 0
1
Cooling unit
2
Threaded grooved pin
M5 x 16 mm
•Remove threaded grooved pins, M5 x 16
The screws will be needed again for mounting.

Design and function
Assembly/disassembly
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5.1.2 Cooling module assembly
Figure 5-2
•Position the welding machine on the module as shown in fig.
Figure 5-3
•Turn the wing-tip handle clockwise (B2) to close the fastening.
•Engage the locking hook in the recesses in the side walls of the welding machine.
Figure 5-4
•Lay the wing-tip handle down flat (C2).

Design and function
Assembly/disassembly
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Figure 5-5
Item
Symbol
Description 0
1
Welding machine
2
Cooling unit
3
Threaded grooved pin
M5 x 16 mm
•Attach the welding machine to the cooling unit using M5 x 16 threaded grooved pins.

Design and function
Assembly/disassembly
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Figure 5-6
Item
Symbol
Description 0
1
Welding machine
2
Cooling unit
3
Threaded grooved pin
M5 x 16 mm
•Attach the welding machine to the cooling unit using M5 x 16 threaded grooved pins.
5.1.3 Connecting the supply lines
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
•Follow safety instructions on the opening pages of the operating instructions.
•Commissioning may only be carried out by persons who have the relevant expertise of
working with arc welding machines!
•Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead,
interfaces) may only be connected when the machine is switched off!

Design and function
Transport and installation
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Overloading the coolant pump!
The cooling unit must not be put into operation without a welding torch connected, as otherwise
the coolant pump will be destroyed due to thermal overload (the coolant cannot circulate in the
coolant circuit).
•Connect the coolant connections 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!
Coolant connections
•Plug in the welding torch coolant connections and fit tightly onto the rapid-action closure couplings:
red rapid-action closure coupling return of coolant from the welding torch
blue rapid-action closure coupling supply of coolant to the welding torch.
Control and supply lead to the welding machine
•The cooling module and welding machine are connected using two leads.
•Insert control lead plug into the welding machine.
•Insert supply lead plug into the welding machine.
5.2 Transport and installation
WARNING
Risk of accident due to improper transport of machines that must not be lifted!
Do not lift or suspend the machine! The machine can drop and cause injuries! The
handles, straps or brackets are suitable for transport by hand only!
•The machine must not be suspended or lifted using a crane.
5.2.1 Machine cooling
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!
5.2.2 Ambient conditions
T he machine must not be operated in the open air and must only be set up and operated on a
suitable, stable and level base!
•The operator must ensure that the ground is non-slip and level, and provide sufficient lighting
for the place of work.
•Safe operation of the machine must be guaranteed at all times.
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
•Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
•Avoid ambient air containing salt (sea air)!
5.2.2.1 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
5.2.2.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
•-30 °C to +70 °C
Relative air humidity
•Up to 90% at 20 °C

Design and function
Functional characteristics
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5.2.3 Welding torch cooling system
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch > see 5.2.3.1 chapter.
Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the
frost protection is adequate to prevent damage to the machine or the accessory components.
•The coolant must be checked for adequate frost protection with the TYP 1 frost protection
tester .
•Replace coolant as necessary if frost protection is inadequate!
Coolant mixtures!
Mixtures with other liquids or the use of unsuitable coolants result in material damage and
renders the manufacturer's warranty void!
•Only use the coolant described in this manual (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 binding agents,
sawdust).
5.2.3.1 Approved coolants overview
Coolant
Temperature range
KF 23E (Standard)
-10 °C to +40 °C
KF 37E
-20 °C to +10 °C
5.2.3.2 Maximal hose package length
Pump 3.5 bar
Pump 4.5 bar
Machines with or without separate wire feeder
30 m
60 m
Compact machines with additional intermediate
drive (example. miniDrive)
20 m
30 m
Machines with separate wire feeder and additional
intermediate drive (example: miniDrive)
20 m
60 m
Data as a rule refer to the entire hose package length
including welding torch. The pump output is shown on the type plate (parameter: Pmax).
Pump 3.5 bar: Pmax = 0.35 MPa (3.5 bar)
Pump 4.5 bar: Pmax = 0.45 MPa (4.5 bar)
5.3 Functional characteristics
Overloading the coolant pump!
The cooling unit must not be put into operation without a welding torch connected, as otherwise
the coolant pump will be destroyed due to thermal overload (the coolant cannot circulate in the
coolant circuit).
•Connect the coolant connections 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!
The cooling modules (pump and fan) are controlled by the welding machine only.
The welding machine automatically detects and displays a lack of coolant
(see the welding machine operating instructions).

Design and function
Functional characteristics
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5.3.1 Adding coolant
If the cooling system is empty or only insufficiently filled with coolant, the coolant pump is
automatically switched off after approx. one minute (protection against destruction). At the same
time, the welding data display signals the lack of coolant or low coolant level.
•Reset the coolant error, fill coolant and repeat the operation.
The unit is supplied ex works with a minimum level of coolant.
Figure 5-7
Item
Symbol
Description 0
1
Coolant tank cap
2
Coolant filter sieve
3
Coolant tank
4
"Min" mark
Minimum coolant level
•Unscrew and remove the coolant tank sealing cover.
•Check filter sieve insert for dirt, clean if necessary and reinsert into position.
•Top up coolant to the filter sieve insert, close sealing cover again.
The level of coolant must never fall below the “min” mark.
If there is less coolant in the coolant tank than the minimum required you may need to vent the
coolant circuit. In this case the welding machine will automatically shut down the coolant pump
and signal an error, > see 7.2 chapter.
5.3.2 Welding torch connection
•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).

Maintenance, care and disposal
General
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6 Maintenance, care and disposal
6.1 General
DANGER
Risk of injury due to electrical voltage after switching off!
Working on an open machine can lead to fatal injuries!
Capacitors are loaded with electrical voltage during operation. Voltage remains present
for up to four minutes after the mains plug is removed.
1.Switch off machine.
2.Remove the mains plug.
3.Wait for at last 4 minutes until the capacitors have discharged!
WARNING
Incorrect maintenance, testing and repair!
Maintenance, testing and repair of the machine may only be carried out by skilled and
qualified personnel. A qualified person is one who, because of his or her training,
knowledge and experience, is able to recognise the dangers that can occur while testing
welding power sources as well as possible subsequent damage, and who is able to
implement the required safety procedures.
Observe the maintenance instructions > see 6.3 chapter.
•In the event that the provisions of one of the below-stated tests are not met, 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 who supplied the
machine. Return deliveries of defective equipment subject to warranty may only be made through your
dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
Under the specified ambient conditions and normal working conditions this machine is essentially
maintenance-free and requires just a minimum of care.
Contamination of the machine may impair service life and duty cycle. The cleaning intervals depend on
the ambient conditions and the resulting contamination of the machine. The minimum interval is every six
months.
6.2 Cleaning
•Clean the outer surfaces with a moist cloth (no aggressive cleaning agents).
•Purge the machine venting channel and cooling fins (if present) with oil- and water-free compressed
air. Compressed air may overspeed and destroy the machine fans. Never direct the compressed air
directly at the machine fans. Mechanically block the fans, if required.
•Check the coolant for contaminants and replace, if necessary.
6.2.1 Dirt filter
The duty cycle of the welding machine decreases as an effect of the reduced cooling air volume.
Depending on the amount of dirt building up (at least every two months), the dirt filter has to be
uninstalled and cleaned regularly (e.g. by purging with compressed air).

Maintenance, care and disposal
Maintenance work, intervals
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6.3 Maintenance work, intervals
6.3.1 Daily maintenance tasks
Visual inspection
•Mains supply lead and its strain relief
•Gas cylinder securing elements
•Check hose package and power connections for exterior damage and replace or have repaired by
specialist staff as necessary!
•Gas tubes and their switching equipment (solenoid valve)
•Check that all connections and wearing parts are hand-tight and tighten if necessary.
•Check correct mounting of the wire spool.
•Wheels and their securing elements
•Transport elements (strap, lifting lugs, handle)
•Other, general condition
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 that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
•Remove any spatter.
•Clean the wire feed rollers on a regular basis (depending on the degree of soiling).
6.3.2 Monthly maintenance tasks
Visual inspection
•Casing damage (front, rear and side walls)
•Wheels and their securing elements
•Transport elements (strap, lifting lugs, handle)
•Check coolant tubes and their connections for impurities
Functional test
•Selector switches, command devices, emergency stop devices, voltage reducing devices, message
and control lamps
•Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
•Check coolant tubes and their connections for impurities
•Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative
impact on the welding result, ultimately causing damage to the torch.
6.3.3 Annual test (inspection and testing during operation)
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition
to the regulations on testing given here, the relevant local laws and regulations must also be observed.
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!

Maintenance, care and disposal
Disposing of equipment
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6.4 Disposing of equipment
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and electronic
components, which must be disposed of.
•Do not dispose of in household waste!
•Observe the local regulations regarding disposal!
•According to European provisions (guideline 2012/19/EU of the European 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.
•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
households can be disposed of free of charge.
•Information about giving back used equipment or about collections can be obtained from the
respective municipal administration office.
•EWM participates in an approved waste disposal and recycling system and is registered in the Used
Electrical Equipment Register (EAR) under number WEEE DE 57686922.
•In addition to this, returns are also possible throughout Europe via EWM sales partners.
6.5 Meeting the requirements of RoHS
We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and
that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives
on the Declaration of Conformity on your machine).