Lincoln Electric COOL ARC 55 Operator's Manual
Operator’s Manual
COOL ARC ® 55 & COOL ARC ® 55 ALUMINUM
WATER COOLER
For use with machines having Code Numbers:
11859, 12377
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10117-A | Issue D ate Mar-15
© Lincoln Global, Inc. All Rights Reserved.
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
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.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built with
safety in mind. However, your overall safety can be increased by
proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And, most importantly, think before you
act and be careful.
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.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc. Use
corrective lenses if necessary to
stay a reasonable distance away
from the arc.
READ and obey the Material Safety
Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to keep
the fumes and gases from your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away from your
face.
If you de velop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.
WEAR CORRECT EYE, EAR & BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare with
protective screens or barriers.
IN SOME AREAS, protection from noise may be
appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area AT ALL
TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously had
been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release highly
toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat, mechanical
shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline Engines
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
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.
AFETY
S
1.d. Keep all equipment safety guards, covers and
devices in position and in good repair.Keep
hands, hair, clothing and tools away from
-belts, gears, fans and all other moving parts
V
when starting, operating or repairing
equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. 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
verride the governor or idler by pushing on the throttle control
o
rods while the engine is running.
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.
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 current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and welding
machines
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 near 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.
2.b. EMF fields may interfere with some pacemakers, 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. Never coil the electrode lead around your 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.
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.
3
AFETY
S
ELECTRIC SHOCK
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 wet clothing.
Wear dry, hole-free 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 must
be performed under electrically hazardous conditions (in
damp locations or while wearing 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,
electrode reel, welding head, nozzle or semiautomatic 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 simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
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.
between the
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 gases.
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 welding with electrodes
which require special ventilation such as stainless or hard
facing (see instructions on container or MSDS) or on lead or
cadmium plated steel and other metals 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 circumstances, outdoors, a
respirator may be required. 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 vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
3.j. Also see It ems 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employer’s
safety practices. MSDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
4
cause
AFETY
S
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 the welding sparks
from starting a fire. Remember that welding sparks and hot
aterials from welding can easily go through small cracks and
m
openings to adjacent areas. Avoid welding 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 Standard Z49.1)
and the operating information 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 though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 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.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil 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 increase the
possibility of the welding current 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.
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.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
n undercarriage or fixed support.
a
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 follow the instructions on compressed gas 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.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety
for additional safety information.
Welding Safety
Interactive Web Guide
for mobile devices
5
TABLE OF CONTENTSCOOL ARC®55 & COOL ARC®55 ALUMINUM WATER COOLER
Page
Installation...............................................................................................................................Section A
Technical Specifications...............................................................................................................A-1
Safety Precautions .......................................................................................................................A-2
Unpacking the COOL ARC
Installation on Power Source ...............................................................................................A-2
®
55 ..............................................................................................A-2
Location and Mounting .........................................................................................................A-2
Filling the Coolant Reservoir .................................................................................................A-3
Coolant “In” and “out” Connections......................................................................................A-4
Input Power Connection........................................................................................................A-4
Installation of Water Cooled Accessories ......................................................................................A-5
Water Cooled TIG Torch and MIG Gun ...................................................................................A-5
Connection to Wire Feeders..................................................................................................A-5
K529-10 Power Input Cable with Water and Gas Hoses ........................................................A-5
________________________________________________________________________
Operation .................................................................................................................................Section B
Safety Precautions.......................................................................................................................B-1
Product Description
............................................................................................B-1
Recommended Processes and Equipment ............................................................................B-1
Turning the System “On” .....................................................................................................B-1
Cooling Efficiency.................................................................................................................B-2
________________________________________________________________________
Accessories .............................................................................................................................Section C
Optional Equipment (Field Installed) ............................................................................................C-1
________________________________________________________________________
Maintenance............................................................................................................................Section D
Safety Precautions.......................................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Pump Maintenance ..............................................................................................................D-1
Pump Motor .........................................................................................................................D-1
Heat Exchanger....................................................................................................................D-1
Reservoir Coolant Level........................................................................................................D-1
Coolant Treatment Recommendation....................................................................................D-2
Pump Inlet Strainer ..............................................................................................................D-2
Inspect Condition of Coolant.................................................................................................D-2
Service the Pump Inlet Strainer ............................................................................................D-3
Additional Service Notes.......................................................................................................D-3
________________________________________________________________________
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
Dimension Print............................................................................................................................F-2
________________________________________________________________________
Parts List ........................................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.
________________________________________________________________________
6
Product No. / Model
TECHNICAL SPECIFICATIONS – COOL ARC®55
3086-1 ( COOL ARC
K
VIA 3-Prong Plug NEMA Type 5-15P
®
5
INSTALLATIONCOOL ARC®55 & COOL ARC®55 ALUMINUM WATER COOLER
5 )
Input
Current Draw @ 60Hz Input
aximum Operating Pressure and Flow Rate
M
(Open Flow, Without Welding Torch Restriction)
Typical Operating Pressure and Flow Rate
(With Welding Torch Restriction)
Reservoir Size
Recommended Coolant
115VAC 60 Hz 1 Phase
3.8 Amps
60 psi (414 kPa) (4.14 bar) Max.
1.66 gal/min. (6.28 liter/min) Max.
53-57 psi (365-393 kPa)
.45-.60 gal/min. (1.7-2.3 liter/min)
2.375 gal. (9 liters)
For Use Above Freezing: Clean tap, distilled or de-ionized
water.
For Use Below Freezing:
DO NOT USE: Automotive anti-freeze that contains rust inhibitors or leak stoppers. 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: Non-Lincoln branded 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
virtually impossible to purge from the water lines and heat exchanger.
50% water and 50% pure ethylene
glycol (reagent or industrial grade)
mixture.
A Magnum®PRO AL coolant may be
used in aluminum push-pull systems
where high frequency is NOT used.
Lincoln Electric Low Conductivity Coolant
may be used in MIG and TIG systems
(but NOT aluminum push-pull) where
high frequency may be present.
Shipping
Weight
Reservoir
Full (Water)
L
Dimensions W
H (Top Face)
EMC Classification
Temperature Range
Cooling Power
1.33 kW (4540 BTU/hr.) @ 1 L/min.*
62.6 lbs. (28.4 kg)
82.3 lbs. (37.3 kg)
26.5 in. (673.1mm)
13.9 in. (353.0mm)
11.5 in. (292.1mm)
Category 1
14°F to 104°F (-10°C to 40°C)
*Cooling Power is measured at a 1 L/min. flow rate with a 40°C coolant temperature rise in a 25°C (77ºF) environment.
EXPLANATION OF SYMBOLS THAT APPEAR ON THIS EQUIPMENT
ON
I
COOLANT
OUT
OFFOFF
O
COOLANT
IN
A-1
INSTALLATIONCOOL ARC®55 & COOL ARC®55 ALUMINUM WATER COOLER
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
nl y qualified person s should pe rf orm this
• O
installation.
• Turn off the power source at the disconnect
witch before connecting or working inside of
s
the equipment.
• Use only grounded receptacle.
• Do not remove the power cord ground prong.
HOT COOLANT CAN BURN SKIN
• Always be sure coolant is not hot before doing any
work on cooler parts.
ROTATING FAN BLADES ARE
HAZARDOUS
• Do not put your hands near operating fan.
• Keep all equipment safety guards, covers and
devic es i n po sition and in g ood repair.K eep hands, hair,
clothing and tools away from V-belts, gears, fans and all other
moving parts when starting, operating or repairing equipment.
• In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete.
working near moving
------------------------------------------------------------------
UNPACKING THE COOL ARC®55
The packaging of the Cooler is designed to withstand shipping abuse, and
contains a cardboard liner that surrounds the unit. If any shipping damage
has occurred, contact your certified Lincoln distributor or service center.
When unpacking the unit, avoid thrusting sharp objects through the carton
liner, which may puncture the plastic reservoir. Save the instruction manual
and service directory supplied with the
and future maintenance service.
Always use the greatest care when
parts.
COOL ARC®55
for parts orders
LOCATION AND MOUNTING
(See Figure A.1)
To mount the COOL ARC®55 to the bottom of a compatible
Power Wave “S” series power source utilize the quick lock
mechanism as shown.
f using the COOL ARC
I
such as the STT Module, always mount the COOL ARC
the bottom. The COOL ARC®55 will operate in harsh
environments and can be used outdoors. Even so, it is important
that simple preventative measures are followed in order to
assure long life and reliable operation.
• The machine must be located where there is free circulation
of clean air such that movement into and out of the louvers
will not be restricted.
• Dirt and dust that can be drawn into the machine should be
kept to a minimum. The use of air filters on the air intake is
not recommended because normal air flow may be
restricted. Failure to observe these precautions can result in
poor cooling performance.
• Keep the machine dry. Shelter from rain and snow. Do not
place on wet ground or in puddles.
• Always mount the COOL ARC®55 underneath other
machines. Never attach a module underneath the cooler.
• Do not mount the Power Wave “S” series power source and
COOL ARC®55 combination over combustible surfaces.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface shall be
covered with a steel plate at least .060” (1.6mm) thick,
which shall extend not less than 5.90” (150mm) beyond the
equipment on all sides.
• Avoid placing the cooler near areas of extreme heat.
• Avoid placing the cooler near a flux hopper or an area where
dust build-up is extreme.
®
5 in conjuntion with another module
5
FIGURE A.1
®
55 on
Readthis entire installation section before you start installation.
--------------------------------------------------------------------
INSTALLATION ON POWER SOURCE
The COOL ARC®55 can be used as a stand alone unit or
mounted directly to the bottom of the Power Wave “S” series
power source.
Always place the Cool Arc 55 on a level surface to avoid causing
the machine to topple over.
A-2
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