Kemppi cool x Operating Manual

TEST

Cool X

Operating manual

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Manuel d’utilisation

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OPERATING MANUAL

English

Cool X

2

EN

CONTENTS

1. Preface ...........................................................................................3

1.1 General ....................................................................................................................................... 3

1.2 Product introduction ............................................................................................................ 3

2. Installation ..................................................................................... 4

2.1 Removal from packaging .................................................................................................... 4

2.2 Locating the machine ........................................................................................................... 4

2.3 Serial number ........................................................................................................................... 4

2.4 Installation and main parts ................................................................................................. 4

2.4.1 Assembling the equipment ............................................................................................ 4

2.4.2 Main parts of cooling unit ............................................................................................... 4

2.5 Preparing for operation........................................................................................................ 5

3. Operation ...................................................................................... 6

3.1 Cooler operation ..................................................................................................................... 6

3.2 Overheat signal lamp ............................................................................................................ 6

3.3 Storage ....................................................................................................................................... 6

4. Maintenance .................................................................................. 7

4.1 Daily maintenance ................................................................................................................. 7

4.2 Every sixth months ................................................................................................................ 7

4.3 Trouble shooting ....................................................................................................................7

4.4 Disposal of the machine ...................................................................................................... 7

5. Ordering codes .............................................................................. 8

6. Technical data ................................................................................ 8

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© Kemppi Oy / 1515

EN

1. PREFACE

1.1 General

Congratulations on choosing the Cool X cooling unit. Used correctly, Kemppi products can
signicantly increase the productivity of your welding, and provide years of economical
service.

This operating manual contains important information on the use, maintenance and safety of
your Kemppi product. The technical specications of the equipment can be found at the end
of the manual.

Please read the manual carefully before using the equipment for the rst time. For your
own safety and that of your working environment, pay particular attention to the safety
instructions in the manual.

For more information on Kemppi products, contact Kemppi Oy, consult an authorised Kemppi
dealer, or visit the Kemppi web site at www.kemppi.com.

The specications presented in this manual are subject to change without prior notice.

Important notes

Items in the manual that require particular attention in order to minimise damage and
personal harm are indicated with the ’NOTE!’ notation. Read these sections carefully and follow
their instructions.

Disclaimer

While every eort has been made to ensure that the information contained in this guide
is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi
reserves the right to change the specication of the product described at any time without
prior notice. Do not copy, record, reproduce or transmit the contents of this guide without
prior permission from Kemppi.

1.2 Product introduction

Cool X is a cooling unit designed for FastMig X welding equipment and to be used for cooling
the welding gun. The operation of Cool X is controlled by a microprocessor.

Cool X

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EN

2. INSTALLATION

2.1 Removal from packaging

The equipment is packed in durable packages specially designed for them. Check the
equipment before taking it into use, to make sure that the equipment or a part of it have not
got damaged during the transportation. Also check that the delivery corresponds your order
and that you have received all the necessary instructions for installing and operating the
equipment. The packaging material can be recycled.

2.2 Locating the machine

Place the machine on a horizontal, stable and clean ground. Protect the machine from heavy
rain and burning sunshine. Check that there is enough space for cooling air circulation in front
of and behind the machine.

2.3 Serial number

The serial number of the machine is marked on the machine CE-marking. Identicating the
serial number is the only proper means of maintaining and identifying parts for a specic
product. It is important to make correct reference to the serial number of the product when
making repairs or ordering spare parts.

2.4 Installation and main parts

2.4.1 Assembling the equipment

The equipment is assembled in the following order:

1. Transport unit PM500 6185291

2. Cooling unit Cool X 6068200
Assembly the transport unit according to the instructions in the package. Fasten the cooling

unit to the transport unit by using the screws and bolts delivered with the equipment.

2.4.2 Main parts of cooling unit

A

B

C

D

E

F

G

H

Front machine

A. Housing
B. Test switch
C. Overheat control lamp
D. Filling hole

Back side

E. Mains voltage connection cable
F. Control cable
G. Cooling water output hose
H. Cooling water input hose

5

© Kemppi Oy / 1515

EN

2.5 Preparing for operation

NOTE! Cooling liquid is injurious! Avoid also contact with skin or eyes. In case of injury, seek for

medical advice.

See also 2.4.2. Main parts of cooling unit.

1. Connect the mains voltage and control connectors of the cooler unit to the
corresponding connectors on the base of the power supply. The connection can be
established through the base of the power supply when the devices are separated or
through the right side of the Cool X unit by removing the right side plate.

TEST

2. Attach the power supply on the cooler.

3. Connect the cooling water hoses with the wire feed unit, follow colour markings.

4. Fill the reservoir with cooling liquid. It is preferred to use Kemppi brand cooling liquid.
Also water can be used, if the temperature doesn't go below 0 degrees Celsius. The
capacity of the reservoir is 3 litres.

5. Switch on the power supply.

6. Press and hold down the test switch until the torch hoses are lled with liquid.

7. Refer to the graphical instruction below in order to deselect or select water-cooling
function. FastMig X operation is set to 'AUTO' from the factory. Note that welding will be
prevented if cooler function is enabled and no cooler is tted.

NOTE! When Cool X is connected to the FastMig X power source for the rst time, the cooler

function is normally active. To deselect the cooler function, follow the instructions below
depending on the power source type in use.

Cool X

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EN

FastMig X

The factory default setting for FastMig Pulse is AUTO. If a cooling unit is not connected and
the operator tries to establish air-cooled operation together with an air-cooled gun, Err 27
is displayed. To establish air-cooled operation, select cooler ‘OFF’. This is done in the ‘System
Cong Menu’ as follows: Press the Menu button on the X 37 power source panel. Move the
menu display arrow (via panel's left-hand up-down arrow keys) to select ‘System Cong Menu’
and then press the select button. Choose ‘Water Cooling:Auto’ and change via control knob to
setting ‘Water Cooling:OFF’, then press Back/Exit. Cooler will then be set to the ‘OFF’ state for
air-cooled operation. Reset power source via on/o switch and continue welding.

When selected, the operation of the cooling unit is automatic, starting when welding
commences. When welding stops the pump will continue operation for approx. 5 min, so
reducing the gun and the cooling liquid to ambient temperature.

After completing the preparations explained above, the device is ready for welding. Before
welding, read the operating instructions.

3. OPERATION

3.1 Cooler operation

See also 2.4.2. Main parts of cooling unit
The Cool X cooler operation is controlled by the microprocessor of the power supply. The

cooler pump starts to operate when the welding begins. After the welding has stopped, the
pump will operate 1 to 5 minutes longer depending on the welding time. During this time the
liquid will cool down to the ambient temperature and cools down the welding gun.

Check the tank liquid level regularly and add liquid, if necessary.
If the tanks coolant liquid level runs low, welding is stopped and an error code appears on the

FastMig panel. See trouble-shooting 4.3.

3.2 Overheat signal lamp

The overheat signal lamp is lighting when temperature control of the machine has detected
cooling water overheat. The ventilator cools down the machine and when the lamp goes out
welding can be started again.

3.3 Storage

The machine must be stored in a clean and dry room. Protect the machine from rain and keep
it away from direct sunshine in places where temperature exceeds +25° C. Check that there is
free space in front of and behind the machine for air circulation.

7

© Kemppi Oy / 1515

EN

4. MAINTENANCE

NOTE! Watch out for mains voltage when handling electric cables!

In planning product maintenance machine utilization degree and circumstances should be
considered. Careful use and preventive maintenance help to avoid unnecessary production
disturbances and breaks.

4.1 Daily maintenance

The following maintenance opeations should be carried out daily:

• Check water level and input ow, add liquid if needed.

• Check cables and connections. Tighten, if necessary and replace defect parts.

• Check that there are no leakages in the cooling water hoses.

4.2 Every sixth months

The following maintenance opeations should be carried out at least every sixth months:

• Clean o dust and dirt. Change the cooling liquid and wash up the pipes and water
reservoir with pure water.

• Check seals, cables and connections. Tighten, if necessary and replace defect parts.

4.3 Trouble shooting

See also 3.2. Overheat signal lamp.

Overheat signal lamp is lit.

The unit is overheated.

• Check water circulation.

• Check that there is enough free space behind the machine for cooling air circulation.

Error code Err 27 on the FastMig panel

• Check the liquid hoses for damages.

• Remove any hose blockages.

• Check water circulation, add liquid if needed.

For further information and assistance, contact your nearest Kemppi service workshop.

4.4 Disposal of the machine

Do not dispose of electrical equipment with normal waste!
In observance of European Directive 2002/96/EC on waste electrical and electronic

equipment, and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and taken to an appropriate
environmentally responsible recycling facility.

The owner of the equipment is obliged to deliver a decommissioned unit to a regional
collection centre, per the instructions of local authorities or a Kemppi representative. By
applying this European Directive you will improve the environment and human health.

Cool X

8

EN

5. ORDERING CODES

Cooling unit Cool X

6068200

Welding cooling liquid

In 10 litre cans SP9810765

6. TECHNICAL DATA

Cool X

Operating voltage

400V -15%. …+20%

Connection capacity

100 % ED 250 W

Cooling power

1 kW

Start pressure, max.

0.4 MPa

Cooling liquid

Kemppi brand cooling liquid

Tank volume

ca. 3 l

External dimensions

LxWxH 570 x 230 x 280 mm

Weight

11 kg

Operating temperature range

-20 … +40 °C

Storage temperature range

-40 … +60 °C

EMC class

A

Degree of protection

IP23S

www.kemppi.com

1906820

1515

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