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Summary of Contents for EWM cool82 U44
- Page 1 Operating instructions Air-cooling units for water-cooled welding torches cool82 U44 cool82 U45 099-008268-EW501 Observe additional system documents! 21.02.2022...
- Page 2 +49 2680 181-0. 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.
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Page 3: Table Of Contents
Checklist for rectifying faults ....................25 Vent coolant circuit ....................... 25 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 .................... -
Page 4: For Your Safety
For your safety Notes on using these operating instructions For your safety 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. •... -
Page 5: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the u- Activate and release / Tap / Tip ser must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid... -
Page 6: Safety Instructions
For your safety Safety instructions Safety instructions WARNING 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! •... - Page 7 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
- Page 8 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
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Page 9: Transport And Installation
For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines. - Page 10 For your safety Transport and installation CAUTION 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! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.
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Page 11: Intended Use
3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 12: Part Of The Complete Documentation
Intended use Documents which also apply 3.3.4 Part of the complete documentation This document is 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. -
Page 13: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Tension closure Connection between the add-on module and the welding machine Coolant tank cap Coolant tank > see 5.3.3 chapter Cooling air inlet Machine feet Automatic cut-out of coolant pump key button press to reset a triggered fuse... -
Page 14: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Cooling air outlet Connector plug, 8-pole Cooling unit control lead Connector plug, 5-pole Cooling unit voltage supply Quick connect coupling, blue Coolant supply to the welding torch Quick connect coupling, red Coolant return from the welding torch Coolant drain hose... -
Page 15: Design And Function
Design and function Assembly/disassembly Design and function WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •... -
Page 16: Cooling Module Assembly
Design and function Preparations 5.2.1 Cooling module assembly Figure 5-2 • Position the welding machine on the module as shown in fig. Figure 5-3 • Engage the locking hook in the recesses in the side walls of the welding machine. •... -
Page 17: Connecting The Supply Lines
Design and function Transport and installation 5.2.2 Connecting the supply lines WARNING Risk of injury from electrical voltage! Touching live parts, such as welding current sockets, may be fatal. • Note the safety information on the first pages of the operating instructions. •... -
Page 18: Welding Torch Cooling System
Design and function Transport and installation In operation Temperature range of the ambient air: • -25 °C to +40 °C (-13 °F to 104 °F) Relative humidity: • up to 50 % at 40 °C (104 °F) • up to 90 % at 20 °C (68 °F) Transport and storage Storage in a closed room, temperature range of the ambient air: •... -
Page 19: Functional Characteristics
All information relates to the total hose package length of the complete welding system and presents exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight kink-free installation is to be ensured, taking into account the max. delivery height. - Page 20 Functional characteristics Transport and installation Item Symbol Description Coolant filter sieve Coolant tank > see 5.3.3 chapter "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. •...
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Page 21: Functional Characteristics
Functional characteristics Transport and installation 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). -
Page 22: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal 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. -
Page 23: Maintenance Work, Intervals
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! 099-008268-EW501 21.02.2022... -
Page 24: Disposing Of Equipment
Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html. -
Page 25: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dea- ler. -
Page 26: Fixing The Pump Shaft (Coolant Circuit)
Rectifying faults Fixing the pump shaft (coolant circuit) Figure 9-2 • Position a suitable collection container for collecting the escaping coolant at the quick-connect coup- ling and switch on the machine for approx. 5s. • Lock the quick-connect coupling by pushing back the locking ring. Fixing the pump shaft (coolant circuit) WARNING Do not carry out any unauthorised repairs or modifications! -
Page 27: Technical Data
Technical data cool82 U44 Technical data The limit value determination of technical data results from considering the combined overall system (cooling unit and welding machine). 10.1 cool82 U44 Supply voltage (from the welding machine) 230 V Frequency 50/60 Hz Cooling capacity at 1 l/min (+25°C/77°F) -
Page 28: Cool82 U45
Technical data cool82 U45 10.2 cool82 U45 Supply voltage (from the welding machine) 230 V Frequency 50/60 Hz max. Cooling capacity 1800 W Cooling capacity at 1 l/min (+25°C/77°F) 1600 W Ambient temperature -25 °C to +40 °C max. Flow rate 20 l/min 5.3 gal./min max. -
Page 29: Accessories
Accessories Options Accessories 11.1 Options Type Designation Item no. ON FILTER COOL Air inlet dirt filter, retrofit option 092-008771-00000 11.2 Welding torch cooling system 11.2.1 Coolant - type blueCool Type Designation Item no. blueCool -10 5 l Coolant up to -10 °C (14 °F), 5 l 094-024141-00005 blueCool -10 25 l Coolant up to -10 °C (14 °F), 25 l... -
Page 30: Appendix
Appendix Searching for a dealer Appendix 12.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-008268-EW501 21.02.2022...
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