Lincoln Electric COOL ARC 35 IM959, COOL ARC 35 Operator's Manual

IM959

¤¤

N80

COOL ARC®35

For use with machines having Code Numbers:

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
wi th sa fet y in mi nd. However ,
you r over a ll sa f ety ca n be
increased by proper installation ...
and thoughtful operation on your
part. DO NOT INSTALL, OPER-

ATE OR REPAIR THIS EQUIP­MEN T WIT H O UT RE ADING
THIS MANUAL AND THE SAFE­TY PRECAUTIONS CONTAINED
THR O U GHOUT . And , most

importantly, think before you act
and be careful.

January, 2010

11427

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

IP 21S

IEC 60974-2

Copyright © Lincoln Global Inc.

i

SAFETY

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

i

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel n ear an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In s om e cases it may be necessa ry to remove safety

gu a rds t o pe r for m req uire d ma i nte n anc e . Re move
guards only when necessary and replace them when the
ma i nten ance re q uiri ng thei r r e mov a l i s c ompl ete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric curre nt flowi ng thr ough any con du ctor causes
local ized Electr ic and Magnetic Fiel ds (EMF). Welding
curre nt creates EMF fields aro und welding cabl es and
welding machines

2.b. EMF fie ld s may int er fe re with some pac em ak er s, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Nev er coil the electrode lead around y ou r body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

SAFETY

SAFETY

ii

ELE CTRIC S HOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or w et clo thing. Wear dry, hole-fre e

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
mu s t be pe rfo r med un der el ect r ica l ly hazar dous
con ditions (in damp lo cations or while we aring wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
elect rode reel, welding head, nozz le or semi automatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simult an eously touch elec tr ically “hot” part s of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gas es . When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

we l ding w ith e lect rode s whi c h req u ire s pec i al
ve n til atio n su ch as stain les s or hard f a cin g (se e
in str uct ion s on cont ain er o r MSD S) or on lead or
cadmi um plated steel and other meta ls or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some c ir cu m­st a nce s, outdo ors , a resp ira t or may be requ i red .
Additional precautions are also required when welding
on galvanized steel.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.d. Shielding gases used for arc welding can displace air and

cause i nj ur y or d ea th . Always u se enough ventilation,
especially in confined areas, to insure breathing air is safe.

vapors

to

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
ma t eria l saf e ty da ta sh eet ( MSDS ) and f oll o w you r
employer’s safety practices. MSDS forms are available from
yo u r w e ldi n g d i str i buto r or f r om t he m anu f act u rer .

5.f. Also see item 1.b.

Jan ‘09

iii

SAFETY

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Re m embe r th a t we l din g spa r ks an d ho t
materials from welding can easily go through small cracks
an d open ings to adj ace nt a rea s. A voi d wel din g near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standar d Z49. 1) and the operat ing i nformatio n for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Co n tain ers and Pi ping Th at Have He ld Haza rdou s
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
incre ase the possibil ity of t he welding curren t passing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

the w el di ng sparks fro m starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. U s e onl y com p res s ed ga s cyl i nde r s
containing the correct shielding gas for the
pr o cess use d an d pro p erl y op e rat i ng
re g ulat ors de s ign e d f or th e gas an d

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always k ee p cylinders in an uprig ht position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and fo ll ow t he i nstru ction s on com press ed g as
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instruc­tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi b ie n que les p récautions de s ûr eté
générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans

les positio ns assis ou couché pour lesquelles une
grand e partie du corps p eut être en contac t avec la
masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circ uit accidental peut provoqu er un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec l es
vapeurs du solvant pour produire du phosgéne (gas forte­ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se pro­téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protég er l’autre pers onnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflamma­bles.

4. Des go uttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis­positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.

3. Ava nt de fair es des tra vaux à l’in ter ieu r de po ste , la
debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

TThhaannkk YYoouu

vv

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

vi

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

Safety Precautions.................................................................................................A-2

Connecting the COOL ARC® 35 to a power source .......................................A-2

Connecting a water-cooled torch ....................................................................A-2

Operation .........................................................................................................Section B

Product Description

Front Panel......................................................................................................B-1

User Interface Display.....................................................................................B-2

User Interface Push Button .............................................................................B-3

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance ......................................................................................D-1

Periodic Maintenance .....................................................................................D-1

Heat Exchanger ..............................................................................................D-1

Reservoir Coolant Level..................................................................................D-1

Coolant Treatment Recommendation .............................................................D-1

Inspect Condition of Coolant...........................................................................D-2

...............................................................................B-1

vi

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide ................................................................E-1

Troubleshooting Guide ..........................................................................................E-2

Wiring Diagrams..............................................................................................Section F

Wiring Diagram ......................................................................................................F-1

Parts List.................................................................................................................P-573

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – COOL ARC®35

A-1

Product No. / Model

Input

Current Draw

Maximum Operating Pressure and Flow Rate

(Open Flow, Without Welding Torch Restriction)

Typical Operating Pressure and Flow Rate

(With Welding Torch Restriction)

Reservoir Size

For Use Below Freezing:

DO NOT USE: Automotive anti-freeze that contains rust inhibitors or leak stoppers.

Recommended Coolant

These coolants will damage the pump and block the small internal passageways of
the heat exchanger, affecting cooling performance. To acquire the proper coolant
contact a local welding distributor.
DO NOT USE: Pre-packaged welding industry coolants. These coolants may contain
oil-based substances, which attack the plastic components of the cooler. Once added
to the cooler, these substances are impossible to purge from the water lines and heat
exchanger.

K2630-1 COOL ARC® 35

350VDC (From V310-T AC/DC & V311-T AC/DC)

0.35 Amps

50 psi (345 kPa) (3.5 bar)Max.

1.2 gal/min. (4.6 liter/min) Max.

53-57 psi (365-393 kPa)

.45-.60 gal/min. (1.7-2.3 liter/min)

1.3 gal. ( 5 liters)

For Use Above Freezing: Clean tap, distilled or de-ionized water.

50% water and 50% pure ethylene glycol (reagent
or industrial grade) mixture.

Weight

Dimensions

Shipping

Reservoir
Full (Water)

L

W

H

Temperature Conversion

Chart

Celcius ºC*

20
30
40
50
60
70
80
90

Fahrenheit ºF

68

86
104
122
140
158
176
194

29.8 lbs. (13.5 kg)

42.0 lbs. (19.0 kg)

24.5 in. (622 mm)

11.0 in. (280 mm)

10.0 in. (256 mm)

COOL ARC® 35

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Disconnect input power by remov­ing plug from V310-T/V311-T before
working inside Cooler.

• Do not touch electrically “hot”
parts inside Cooler.

• Have qualified personnel do the installation,
maintenance and troubleshooting work.

----------------------------------------------------------------------

Connecting the COOL ARC® 35 to a power
source:

1. Disconnect all power to the power source.

2. Turn the power source on its side revealing the Cooler
Access Panel on the bottom.

3. Loosen the fasteners and remove the Panel. Keep the fas­teners to reattach the Panel.

4. Place the COOL ARC® 35 near the V310-T/V311-T and push
the lead harness from the cooler through the grommet in the
Access Panel that was just removed from the power source
(making sure that the direction of the leads going through the
panel is correct).

5. Attach the two plugs from the COOL ARC® 35 harness into
the mating receptacles inside the power source where the
Cooler Access Panel was removed (making sure that these
connectors “lock” into the mating receptacles).

6. Slide the Access Panel up the harness toward the power
source and reattach using the fasteners that were removed.

NOTE: Make sure that the grommet or the harness itself does

not put any stress on the connectors when closing up the Panel.

Connecting a water-cooled torch:

1. Disconnect all power to the power source.

2. Assemble the torch per the instructions included
with the torch and Twist-mate Adapter.

3. Connect the HOT water return hose (normally RED)
to the Coolant Inlet on the front of the cooler.
Depending on the type of hose connectors on the
torch, it may be necessary to use brass couplers
that are included with the cooler.

4. Connect the COLD water to the torch hose (normal­ly BLUE) to the Coolant Outlet on the front of the
cooler.

5. Attach the twist-mate from the torch to the DC neg­ative (-) Electrode/Gas output terminal on the power
source.

6. Turn the power ON to the power source.

7. The cooler Display will illuminate and go through
initialization. The cooler will enter into standby
mode if a Stick welding mode is selected.

8. Press the push button on the cooler to begin the
priming procedure. The cooler display will show
dashed lines moving in a circular motion.

9. The torch is now ready for water-cooled welding
applications.

Note: If E43 alarm codes are encountered, the torch

has not been properly primed. Run the priming
procedure again by pressing the cooler push
button.

7. Place the power source on top of the cooler locating the feet
of the power source into the mating foot prints in the cooler
case front and back.

8. Secure the power source to the cooler with the four fasteners
that were included with the cooler.

9. Unscrew the coolant reservoir cap and remove the clear plug
(keep for transporting the cooler when filled with coolant).
The clear plug should never be installed when operating the
cooler - it will prevent proper venting. Fill the reservoir with
coolant per the Recommended Coolant section on the TECH-
NICAL SPECIFICATIONS page. The reservoir is full when
the coolant reaches a level just below the cap.

10. The system is now ready for water cooled torch

applications.

COOL ARC® 35

B-1

COOLANT OUTLET

COOLANT INLET

DISPLAY

PUSH BUTTON

OPERATION

PRODUCT DESCRIPTION

The new COOL ARC® 35 is an intelligent cooling unit
equipped with a variable speed three phase rotary
pump and an embedded microprocessor PC board
which controls the pump operation, fan operation, and
the overall functioning of the unit.

The cooler operation is enabled by the power source
and utilizes a “cool as needed” approach, so the pump
and fan speed vary based on real coolant tempera­ture. Furthermore, error signals and related codes are
managed by the power source.

The COOL ARC® 35 manages both the coolant tem­perature and pressure in order to maximize the cool­ing of the torch, while using as little energy as possi­ble. If the coolant temperature goes above the maxi­mum limit 185°F (85°C) or the coolant flow is stopped
or the coolant is missing, an alarm is generated and
an error code is sent to the power source. The power
source, consequently, displays the alarm ID code on
the user interface and places the power source and
cooler in a safe condition in order to avoid any dam­age being done to the cooling components or to the
welding torch. Any alarm condition must be reset by
the user by clearing the alarm code at the power
source user interface before restarting operation, oth­erwise; the overall welding system is kept in a standby
condition (safety mode).

B-1

FRONT PANEL

(See Figure B.1)

The COOL ARC® 35 is enabled only when DC TIG or
AC TIG modes are selected. The cooler does not
operate when STICK modes are selected.

Due to the “cool as needed” functionality (when the
coolant temperature increases passed the maximum
set point) the pump speed is modulated by coolant
temperature feedback. This keeps the cooler noise
levels to a minimum.

The pump starts operating when any TIG welding
mode has been selected and the welder output is
enabled. The pump is kept on until the coolant tem­perature goes below 175°F (80°C) or for at least 3
minutes after welding has ceased if the cooler was
running while welding.

If a coolant over temperature is detected, welding is
stopped and the cooler is programmed to run at maxi­mum speed in order to recover from the high tempera­ture condition as soon as possible. Welding operation
cannot be re¬started before the coolant temperature
has reached a temperature value below 175°F (80°C).

FIGURE B.1

COOL ARC® 35

B-2

OPERATION

B-2

USER INTERFACE DISPLAY

The 7 segment display shows the coolant temperature during normal operation, but also displays additional cool­er status information.

Status indications:

Display

oo

- -

AA

xx

Meaning

OFF mode. The cooler has been turned off by
the user.

Stand-by mode. The cooler has power and is
ready to function, but the selected weld mode is
not a water cooled operation (STICK modes), or
the unit is initiating at power up.

Alarm mode. The cooler is powered and ready to
start, but operation is prevented due to an alarm
condition being detected. The alarm ID code is
displayed by the power source UI. The alarm
codes displayed on the cooler are:

E43 - coolant stoppage - clogged or broken
hose, torch or bypass hose missing.
E44 - coolant temperature upper limit.

Flashing value during power up - indicates the
cooler software version.

yy

nC







Two digit value during normal operation - dis­plays the coolant temperature (°C).

This message is displayed if no communication
between the cooler and the power source is
detected.

Scrolling dashed line (clockwise) is displayed
during torch priming operation.

COOL ARC® 35

B-3

OPERATION

USER INTERFACE PUSH BUTTON

The push button on the user interface of the cooler
has two different functions:

Holding the push button in for 3 seconds toggles the
cooler ON and OFF. When the cooler is turned OFF,
the display will shown “oo”. In this condition, the
cooler can only be turned ON again by pressing the
push button for 3 seconds again, or by cycling input
power to the power source. The power source has no
control over the cooler when it is OFF. It begins com­municating with the cooler when the cooler is turned
ON again. If the cooler is OFF when the power source
is turned OFF, it will begin operation in the ON condi­tion when the power source is turned on again, and
must be turned OFF if the user does not want the
cooler to operate during welding.

Momentarily pressing the COOL ARC® 35 push but­ton will begin the torch priming procedure and over­ride any current cooler operation. The cooler will ramp
up the pump speed to maximum and hold it for 30
seconds to allow the torch to be filled with coolant.
During the priming procedure the temperature and
flow/pressure sensing are disabled. To stop the prim­ing procedure before the 30 second time limit the
push button must be pressed again - this places the
cooler back into normal operating mode.

B-3

COOL ARC® 35

D-1

SAFETY PRECAUTIONS

MAINTENANCE

RESERVOIR COOLANT LEVEL

D-1

WARNING

ELECTRIC SHOCK can kill.

• Disconnect input power by remov­ing plug from V310-T/V311-T before
working inside Cooler.

• Do not touch electrically “hot” parts
inside Cooler.

• Have qualified personnel do the installation,
maintenance and troubleshooting work.

----------------------------------------------------------------------

ROUTINE MAINTENANCE

Remove accumulated dust and dirt from the internal
components of the cooler by blowing it out with a low­pressure air hose or removing the dust and dirt with a
vacuum hose.

PERIODIC MAINTENANCE

In dirty or dusty environments or if biological growth
occurs in the coolant, it may be necessary to flush the
coolant reservoir. Drain the old coolant, rinse the
inside of the reservoir and circulate rinsing solution
through the coolant system. Add new coolant when
cleaning is finished. It is recommended to flush the
coolant at least once a year. A cooling system free
from debris offers increased cooling efficiency and
longer pump and to r c h life . See the Coolant
Treatment Recommendation in this “Maintenance
Section”.

NOTE: Pure solutions and mixtures of, or materials
(i.e. towels wetted) with ethylene glycol are toxic to
humans and animals. Special precautions should be
taken when discarding toxic material, do not pour this
mixture down any drain. Contact the local EPA office
for responsible disposal methods or for recycling infor­mation.

The reservoir volume should be checked daily before
using the cooler. Remove the reservoir fill cap and
check the coolant level. The reservoir is full when the
coolant level is just below the reservoir fill opening.
Keep the reservoir full, especially after disconnecting
the water lines or changing the accessory being
cooled.

COOLANT TREATMENT
RECOMMENDATION

This procedure is intended to provide a means of
reducing the objectionable amount of fungal and bac­terial contamination that has occurred in COOL ARC®
35 water coolers and cooling systems.

Additive:

The recommended additive can be purchased at local
pool supply stores. An example is "Maintain Pool Pro
30% Non-Foam Algaecide".

Limitations:

• The additive should be used with fresh coolants con­taining only pure water.

• This additive should not be used with coolants con­taining any other substance, including antifreeze
substances.

• No other additives shall be used with the specified
coolant that has been treated with the recommended
additive.

• This procedure is no permanent substitute for a peri­odic maintenance schedule for the specified coolers

• A 1-quart bottle of additive is sufficient to disinfect
and treat about 1000 coolers.

• Check with the manufacturer of your guns or
torches to be sure that this procedure is compat­ible with your equipment.

HEAT EXCHANGER

To maintain maximum cooler efficiency, the heat
exchanger should be kept free of dust and dirt build­up. Clean the heat exchanger periodically using a vac­uum hose or a low-pressure air line. Avoid placing the
unit near a flux hopper or a flux waste container. A
clean heat exchanger offers better cooling perfor­mance and longer product life. In extremely dirty envi­ronments, it may be necessary to remove the heat
exchanger completely from the cooler and clean the
fins with soap and water. Use care to avoid damaging
the fins.

COOL ARC® 35

D-2

Prepare the disinfectant:

Make a quantity of only what is needed to avoid an
excess Bulk preparation (for coolers serviced in quan­tity):

5.7L (1.5 gals.) of pure, fresh water per cooler and

1.0ml of additive per cooler. Example: for 100 coolers,
add 100 ml to 150 gals. of pure fresh water, Pour 5.0L
(1.3 gals.) of disinfectant into the empty reservoir.
Recap the reservoir. Prime the cooling system by
positioning cooler horizontally and circulate disinfec­tant through it for 10 to 15 minutes. Drain disinfectant
from the cooling system. Do not reuse this solution.
Add new, fresh coolant to the cooling system. Add 1L
(0.3 gals.) of fresh disinfectant to the system by pour­ing it into the reservoir, then reduce the concentration
to the nominal 30 ppm:

Add the balance 4.0L (1.0 gals.) of fresh, pure water
to the reservoir to create the treated coolant concen­tration. Prime the cooling system.

MAINTENANCE

D-2

INSPECT CONDITION OF COOLANT

If coolant is contaminated or old:

• Drain the system of coolant and dispose of it in an
environmentally specified manner.

• Flush system of old coolant.

• Fill with fresh tap or distilled water, run for ten min­utes, and drain.

• Proceed to adding coolant.

Check coolant level. Add more fresh, pure water if
required, without adding more than 0.3L (0.1 gal.) of
pure water to prevent diluting the coolant additive.

Procedure and Preparation:

WARNING

• Always disconnect the COOL ARC® 35 machine
from service input power by disconnecting the
V310-T/V311-T from input power.

• Always allow the coolant in the system to cool
enough to avoid burn injuries.

• Avoid contact with contaminated coolant. Wear
waterproof gloves and protective eye wear.

------------------------------------------------------------------------

COOL ARC® 35

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provid es a cours e of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

COOL ARC® 35

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

E43 alarm after initial installation of
power source and cooler, or when
attaching a water cooled torch.

1. Torch water hoses need to be
primed.

2. There is a blockage in the path of
the coolant.

1. Aft e r tu r n ing t h e system O N ,
press the COOL ARC® 35 push
button to begin priming procedure.

2. Ve rify that the cool ant path is
clear – that there are no twists,
kinks, o r p i n ch-points in the
coolant hoses.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

COOL ARC® 35

F-1

WIRING DIAGRAM

Power Supply

360VDC

10k NTC

the rmistor

24VDC brushless

fan

230VAC 3-Phase

Motor Pump

CAN bus

signals

12/13/07

BLUE

RED

BLACK

B

LACK

BROWN

DIAGRAMS

F-1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

COOL ARC® 35

NOTES

COOL ARC® 35

NOTES

COOL ARC® 35

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

●

Não opere com as tampas removidas.

●

Desligue a corrente antes de fazer
serviço.

●

Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com