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Summary of Contents for EWM Cool 55 C U40
- Page 1 Operating instructions Cooling unit for torch cooling Cool 55 C U40 Cool 55 C U42 099-008866-EW501 Observe additional system documents! 29.02.2024...
- 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
Vent coolant circuit ....................... 27 Fixing the pump shaft (coolant circuit) ................. 28 8 Technical data ..........................29 Cool 55 C U40 ........................29 Cool 55 C U42 ........................30 9 Accessories ..........................31 Welding torch cooling system ....................31 9.1.1... -
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 Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn... -
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 may lead to shortness of breath and poisoning! The ultraviolet radia- tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso- nous phosgene. • Ensure 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 / rear view Machine description – quick overview Front view / rear view Figure 4-1 099-008866-EW501 29.02.2024... - Page 14 Machine description – quick overview Front view / rear view Item Symbol Description Screw connector Connects cooling module and welding machine Cooling air inlet Dirt filter optional > see 9.3 chapter Quick connect coupling, red Coolant return from the welding torch Quick connect coupling, blue Coolant supply to the welding torch Cooling air inlet...
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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: Transport And Installation
Design and function Transport and installation 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! •... -
Page 17: Welding Torch Cooling System
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 18: Adding Coolant
Design and function Transport and installation 5.2.3.4 Adding coolant After switching on the machine, the coolant pump runs for a defined time (filling the hose package). If the machine does not detect sufficient coolant flow during this time, the coolant pump is switched off (protec- tion against damage caused by dry running). -
Page 19: Welding Torch Connection
Design and function Transport and installation 5.2.4 Welding torch connection The cooling circuit (cooling unit <> welding torch) must not be interrupted. Otherwise, the coo- lant pump can be destroyed by thermal overload (the coolant cannot circulate). When using air- cooled welding torches, one of the following measures must be taken depending on the ma- chine version: •... -
Page 20: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General WARNING Improper maintenance, testing and repairs! Maintenance, testing and repair of the machine may only be carried out by skilled and qualified personnel (authorised service personnel). A competent person is someone who, based on training, knowledge and experience, can recognize the hazards and pos- sible consequential damage that may occur when testing power sources and can take the necessary safety precautions. -
Page 21: Maintenance Schedule
Maintenance, care and disposal Maintenance schedule Maintenance schedule Maintenance step Only personnel designated as inspectors or repairers due to their trai- ning are allowed to carry out the relevant work step! Inapplicable checkpoints are omitted. • Check and clean the welding torch. Deposits in the welding torch may cause short circuits, impair the welding result and lead to welding torch damage! •... -
Page 22: Coolant Error
Maintenance, care and disposal Maintenance schedule 6.3.1 Coolant error Figure 6-1 • Switch off the machine and disconnect the mains plug. Position a suitable collecting container under the drain plug of the coolant tank. • Unscrew the drain plug of the coolant tank (remove the tank cap to ventilate). Figure 6-2 •... -
Page 23: Dirt Filter
Insert the cleaned filter screen into the filler neck and screw the drain plug with seal back into the tank. • Fill the tank with original EWM coolant up to the maximum level. After filling, refit the tank cap and vent the coolant circuit > see 7.2 chapter. -
Page 24: Heat Exchanger (Torch Cooling)
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! 099-008866-EW501 29.02.2024... -
Page 25: 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 26: 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 27: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-1 • Switch off the machine and fill the coolant tank to the maximum level. • Unlock the quick-connect coupling with a suitable tool (connection open). 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 7-2 •... -
Page 28: Fixing The Pump Shaft (Coolant Circuit)
Rectifying faults Fixing the pump shaft (coolant circuit) Fixing the pump shaft (coolant circuit) WARNING No improper repairs and modifications! To prevent injuries and damage to the machine, only competent personnel (authorised service personnel) are allowed to repair or modify the machine. Unauthorised manipulations will invalidate the warranty! •... -
Page 29: Technical Data
Technical data Cool 55 C U40 Technical data The limit value determination of technical data results from considering the combined overall system (cooling unit and welding machine). Cool 55 C U40 Supply voltage (from the welding machine) 400 V Frequency 50/60 Hz Cooling capacity at 1 l/min (+25°C/77°F) -
Page 30: Cool 55 C U42
Technical data Cool 55 C U42 Cool 55 C U42 Supply voltage (from the welding machine) 400 V Frequency 50/60 Hz Cooling capacity at 1 l/min (+25°C/77°F) 1200 W Ambient temperature -25 °C to +40 °C max. Flow rate 20 l/min 5,3 gal/min max. -
Page 31: Accessories
Accessories Welding torch cooling system Accessories Welding torch cooling system Type Designation Item no. HOSE BRIDGE UNI Tube bridge 092-007843-00000 LFMG HANNA DIST 3 Conductivity meter 094-026184-00000 9.1.1 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... -
Page 32: Appendix
Appendix Searching for a dealer Appendix 10.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-008866-EW501 29.02.2024...
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