Lincoln Electric IM10117 User Manual

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Operator’s Manual

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COOL ARC ® 55 WATER COOLER

For use with machines having Code Numbers:

11859

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10117 | Issue D ate Oct-13

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

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Page 2

THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

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

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.

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.

Page 3

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

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 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.

SAFETY

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 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 override the governor or idler by pushing on the throttle control 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.

Page 4

SAFETY

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.

cause

Page 5

SAFETY

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 materials from welding can easily go through small cracks and 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.

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 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 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.

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.

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

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety Interactive Web Guide for mobile devices

Page 6

TABLE OF CONTENTS

Page

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

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

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

Unpacking the COOL ARC

Installation on Power Source .........................................................................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

Recommended Processes and Equipment.....................................................B-1

Turning the System “On”.................................................................................B-1

Cooling Efficiency............................................................................................B-2

________________________________________________________________________

55 .......................................................................A-2

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

vi vi

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.................................................................................................................P-695

________________________________________________________________________

Page 7

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – COOL ARC®55

A-1

Product No. / Model

Input

Current Draw @ 60Hz Input

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 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.

Recommended Coolant

Shipping

Weight

Reservoir Full (Water)

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 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.

◊

Magnum Pro AL coolant may be used.

K3086-1 ( COOL ARC®55 )

VIA 3-Prong Plug NEMA Type 5-15P

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)

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

◊

. These coolants may contain

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)

Dimensions

EMC Classification

Temperature Range

Cooling Power

H (Top Face)

1.43 kW (4880 BTU/hr.) @ 1 L/min.

*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

OFFOFF

COOL ARC®55

COOLANT

OUT

COOLANT

Page 8

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

Only qualified persons should perform

•

this installation.

• Turn off the power source at the dis-

connect switch before connecting or working inside of the equipment.

• Use only grounded receptacle.

• Do not remove the power cord ground prong.

LOCATION AND MOUNTING

(See Figure A.1)

To mount the COOL ARC patible Power Wave “S” series power source utilize the quick lock mechanism as shown. If using the COOL ARC module such as the STT Module, always mount the COOL ARC 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

HOT COOLANT CAN BURN SKIN

• Always be sure coolant is not hot before doing any work on cooler parts.

life and reliable operation.

• The machine must be located where there is free circulation of clean air such that movement into

ROTATING FAN BLADES ARE HAZARDOUS

• Do not put your hands near operating fan.

• 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.

• 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 mov-

parts.

ing

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

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 other machines. Never attach a module under-

neath the cooler.

• Do not mount the Power Wave “S” series power source and COOL ARC bustible surfaces. Where there is a combustible surface directly under stationary or fixed electrical

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

COOL ARC®55

for

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.

parts orders and future maintenance service.

55 to the bottom of a com-

55 in conjuntion with another

55 on the bottom. The COOL ARC®55

55 underneath

55 combination over com-

Read

this 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.

COOL ARC®55

Page 9

A-3

INSTALLATION

A-3

FIGURE A.1

FILLING THE COOLANT RESERVOIR:

Recommended Coolant

• For Use Above Freezing: Clean tap, distilled or deionized water.

• For Use Below Freezing: 50% water and 50% pure ethylene glyco (reagent or industrial grade) mixture.

• 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.

• 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 virtually impossible to purge from the water lines and heat exchanger.

To avoid freeze damage and water leakage in shipment, the COOL ARC no coolant in the system. To fill the unit, locate the plastic screw on reservoir fill cap at the front of the unit and remove by turning counter-clockwise.

Clean tap water, distilled water, de-ionized water, a 50/50 mix of pure ethylene glycol and water, or any other coolant specified by the manufacturer of the water cooled product that the Cooler is used with, can be added into the coolant reservoir. The opening of the fill cap mates with most coolant containers but, to avoid spillage of coolant, a funnel should be placed into the reservoir hole when filling the COOL ARC

55 unit is delivered empty with

55.

CAUTION

DO NOT USE OIL BASED COOLANTS OR COOLANTS THAT CONTAIN RUST INHIBITORS OR LEAK STOPPERS.

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

UNPLUG THE COOLER BEFORE FILLING THE COOLANT RESERVOIR:

Carefully add 2.375 gallons (9 liters) of coolant through a funnel into the coolant reservoir fill hole.

The cooler is "FULL" when the coolant lies just below the coolant reservoir opening .

NOTE: DO NOT ADD MORE THAN 2.375 GALLONS (9 LITERS) OF COOLANT INTO THE RESERVOIR. The fill cap contains a pressure release air

hole, which must not be blocked by overfilling the reservoir with coolant.

Be certain to replace the reservoir fill cap when the reservoir is full. Operation of the COOL ARC out the fill cap in place can cause poor cooling efficiency, evaporation loss of coolant and reduced product life.

55 with-

NOTE: Pure solutions and mixtures of, or materials (i.e. towels) wetted with ethylene glycol are toxic to humans and animals. They must not be haphazardly discarded, especially by pouring liquids down the drain. Contact the local EPA office for responsible disposal methods or for recycling information.

For best results when using the COOL ARC

55 with Lincoln guns or torches, use distilled or de-ionized water, although if not available, tap water can be used. If protection from freezing is desired, use a 50% water and 50% pure ethylene glycol (reagent or industrial grade) mixture. An alcohol and water mixture is also acceptable.

When using the COOL ARC

55 with other products, consult the manufacturer's instruction manual for recommended coolants.

COOL ARC®55

Page 10

A-4

FROM HHEAT SO

URCE ((RED)

HEAT

URCE ((BLUE)

INSTALLATION

A-4

COOLANT "IN" AND "OUT" CONNECTIONS

The fittings located on the COOL ARC®55 are two female Quick Disconnect fittings. These mate with water hoses typically used in the welding industry. Two couplers converting from quick disconnect to 5/818 left-hand thread (CGA style) are also included.

Refer to Figure A.2.

Water or Coolant Line Connections

COOL ARC®55

to the

Take the male quick disconnect of the water hose and check if it matches the coupler or the quick disconnect on the front of the unit. When using water hoses with threaded nuts use the supplied couplers to convert from 5/8-18 left hand female thread to male quick disconnect.

(Reference FIG. A.2) Take the accessory "INLET" hose (colored or tagged blue on most hoses) and plug it into the coolant "OUT" fitting located on the front of the cooler. If necessary use the supplied coupler, making sure to secure the connector nut of the hose tightly into the fitting with a wrench so that leaking does not occur. Then take the accessory "OUTLET" hose (colored or tagged red on most hoses) and plug it into the coolant "IN" fitting located on the front of the cooler. Again, if necessary use the coupler, tightly securing the connector nut of the hose into the fitting with a wrench to insure that no leaking occurs.

INPUT POWER CONNECTION

Plug the input power cord on the COOL ARC®55 into a standard 115V NEMA circuit breaker protected receptacle. The receptacle must have overload protection and a grounding conductor pin.

NOTE: BE CERTAIN THAT NO LEAKS EXIST WHEN THE COOLER IS TURNED ON. A LEAK WILL DEPLETE RESERVOIR VOLUME, CAUSING POOR COOLING PERFORMANCE AND REDUCING GUN OR TORCH LIFE.

FIGURE A.2

Inlet and Outlet Hose Connection Diagram

COOLANT

OUT

URC

H URC

COOL ARC®55

Page 11

A-5

INSTALLATION

INSTALLATION OF WATER COOLED ACCESSORIES

After following the installation instructions above, the COOL ARC cooled accessory.

WATER COOLED TIG TORCH AND MIG GUN

Follow Figure A.3 when using the COOL ARC with water-cooled TIG torches. Follow Figure A.5 when using the COOL ARC MIG gun. Consult the manufacturer's instruction manual when using the COOL ARC cooled TIG and MIG accessories.

CONNECTION TO WIRE FEEDERS Follow Figure A.4 when using the COOL ARC

conjunction with a wire feeder. The feeder will need to have pass-through water hoses installed in order to correctly function with the COOL ARC cooler requires continuous flow. DO NOT USE A WATER SOLENOID VALVE with the COOL ARC Water pass-through connection kits are available for wire feeders. Refer to product literature or the wire feeder's instructions manual for kit availability and further connection details. It is not required to run the water lines through the wire feeder, but is does provide a very neat MIG gun connection. If pass-through water hoses are unavailable, connect the MIG gun as

shown in

55 is ready for connection to a water-

55 with water-cooled

55 with other water-

55, since the

Figure A.5.

55 in

55.

A-5

CAUTION

DO NOT USE A WATER SOLENOID VALVE with the COOL ARC the pump would dead-head, causing the pump to heat up excessively leading to premature failure of the pump.

K529-10 POWER INPUT CABLE WITH WATER AND GAS HOSES

This cable assembly includes a (1) power cable, (1) control cable, (1) gas hose and (2) water hoses to connect a power source to a wire feeder. The cable length is 10'. The water hoses have 5/8"-18 left hand male hose fittings and the gas hose has a 5/8"-18 right hand male hose fitting. The cable and hose lengths are designed to connect a wire feeder to a COOL ARC of this connection.

Connection to Wire Feeder (Do Not Use Water Solenoid)

55. When a solenoid valve closes,

55. Refer to Figure A.6 for an illustration

FIGURE A.5

KP504 WATER HOSES AND FEMALE TO FEMALE 5/8" LH CGA ADAPTER COUPLINGS

COOLANT

OUT

COOLANT

= BLUE HOSE

= RED HOSE

GAS

FIGURE A.3

Water Cooled TIG Torch Connection

K1622-4 ADAPTER

FEMALE TO FEMALE CGA FITTING

TO WORK

FIGURE A.4

Water Cooled MIG Gun Connection

COOLANT

GUN CABLE

K1859-1 FOR CONNECTING TO WIRE FEEDERS

COOLANT

OUT

COOLANT

OUT

COOLANT

= BLUE HOSE

= RED HOSE

= BLUE HOSE

= RED HOSE

GUN CABLE

FEMALE TO FEMALE CGA FITTING

COOLANT

FIGURE A.6

Connection to Wire Feeder (Do Not Use Water Solenoid)

TO WORK

NOTE: ORDER K1859-1 FOR WIRE FEEDERS WITH QUICK DISCONNECT FITTINGS.

CONTOL CABLE

OOLA

GAS

ELECTRODE CABLE

GUN CABLE

COOLANT

OUT

COOLANT

= BLUE HOSE

= RED HOSE

COOL ARC®55

Page 12

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not operate with covers removed.

• Do not operate if cables are wet or immersed in water.

• Moving parts can injure. Never place fingers into openings of Cooler.

• Hot coolant can burn skin. Always be sure coolant is NOT HOT before servicing the cooler.

• Do not pour used ethylene glycol coolant down the drain.

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

See additional warning information at

front of this operatorʼs manual.

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

RECOMMENDED PROCESSES AND EQUIPMENT

Recommended Processes, Equipment and

Accessories. The COOL ARC

55 is designed for use with water-cooled TIG, MIG, PAC (Plasma Arc Cutting) and PAW (Plasma Arc Welding) guns and

torches. The COOL ARC

55 can be used with MIG wire feeders and power sources as well as TIG power sources.

TURNING THE SYSTEM "ON"

After connecting the COOL ARC

55 per the installation instructions above, plug the unit into a 115V NEMA electrical receptacle for start-up operation. Be certain that the power input into the unit matches the Cooler's rated input.

The LIGHTED POWER SWITCH is located on the left side of the control panel. The cooler will be "ON" when pressed to " l " and "OFF" when pressed to " O ".

The

switch will also illuminate when in the "ON" position.

You will be able to hear the fan running and feel airflow out of the sides of the unit when the cooler is operating. The cooler will run continuously unless it is plugged into a switched receptacle on the power source.

PRODUCT DESCRIPTION

The COOL ARC®55 is a stand alone re-circulation cooling system designed for use with water-cooled TIG, MIG, PAC (Plasma Arc Cutting) and PAW (Plasma Arc Welding) guns and torches. The coolant "IN" and "OUT" connections are female quick disconnect fittings. The COOL ARC cooler.

The COOL ARC

55 is very easy to use and understand with only one power switch on the control panel. The cooler has a standard 115 V power input receptacle, making it very easy to power up. Adding coolant to the reservoir is simple and connecting to the coolant "IN" and "OUT" connections are easily made by hand with the quick disconnects.

The COOL ARC

55 coolant flow is circulated through a heat exchanger to remove heat energy from the coolant. The coolant flow is then deposited into the coolant reservoir. The pump draws its coolant supply from the coolant reservoir and delivers coolant to the welding torch or gun. Refer to Figure B.1 and B.2.

55 is a continuous duty

COOL ARC

Page 13

B-2

OPERATION

The coolant FLOW INDICATOR is accessed by removal of the fill cap. Actual return flow is directly visible, via the fill opening.

When first starting the unit, check all of the coolant hoses to insure that no water leaks are present. Water leakage causes poor welding performance, poor cooling performance, low welding component life and potential electrical safety hazards.

• The cooler should be turned "OFF" when welding is not taking place for long periods of time.

• Be certain that the cooler is "ON" (power switch in the " l " position) before beginning to weld.

• Never operate the cooler with the reservoir fill cap removed. Unless checking coolant flow.

• Avoid kinking or putting sharp bends in any water lines.

• Keep all water lines clean and free of any blockage.

• Do not operate cooler without coolant in reservoir. Never run pump dry.

FIGURE B.1

Coolant Circulation Diagram

ROOM AIR IN

HOT

AIR

OUT

B-2

COOLING EFFICIENCY

The high cooling efficiency of the COOL ARC cooler, more comfortable weld than conventional air-cooled procedures as well as leading competitors water cooled systems.

The COOL ARC

55 effectively removes the heat of the arc away from the gun or torch handle and places it into the exiting air flow at the sides of the cooler. Ambient air temperature affects the coolant temperature of the COOL ARC

55.

For example: Unlike other water coolers that depend on a bulky reservoir size, the high efficiency components of the COOL ARC allows the reservoir size to be small. The result is a lightweight, portable unit.

55 offers a

HEAT EXCHANGER

FAN

HOT

AIR

OUT

PUMP

RESERVOIR

COOLANT OUT

PUMP

FIGURE B.2

WELD ING

GUN OR

TORCH

HEAT IN

COOLANT IN

FAN

ANT

HEAT

OUT

COOL ARC 55

RESERVOIR

COOL ARC®55

HEAT EXCHANGER

Page 14

C-1

ACCESSORIES

OPTIONAL EQUIPMENT (Field Installed)

K1536-1 Magnum Flow Sensor:

Protects valuable torches, guns and robotic welding systems from damage when loss of coolant flow has occurred for any reason such as a blocked or kinked water line or a ruptured hose.

C-1

KP504 TIG Hook Up Kit:

The Hook-Up Kit includes: (2) water hoses, (1) gas hose, (2) water adapter fittings, male to male 5/8" LH thread, (1) water hose coupler, female to female 5/8" LH thread and (1) power cable adapter. Threads on all hoses and fittings are CGA style.

KP1529-1 Quick Connect Water Adapter:

Converts a male 5/8"-18 left hand hose fitting (CGA Style) to a female quick connect fitting. The female quick connect mates with the male quick connects on water cooled MIG guns or hoses.

K1859-1 Water Cooler to Wire Feeder Hoses:

This kit includes two 25ʼ(7.6m) – 3/16 I.D. water hoses with a 5/8" LH CGA style fitting on one end and a male quick disconnect on the other. Most wire feeders have female quick disconnects and this kit allows direct hook up between the water cooler and the wire feeder.

5/8"-18 Left Hand Male Hose Fitting Parts: (CGA Style)

Fittings that convert a standard 3/16" I.D. hose to a 5/8"-18 left hand male hose fitting. These male hose fittings mate with the fittings on the back of the COOL

55.

ARC

Order the following:

(See Parts Lists for Itemʼs below)

(2) Connector Nuts (2) Nipples for 3/16" I.D. Hose (2) Hose Clamps

CAUTION

DO NOT USE A WATER SOLENOID VALVE with the COOL ARC the pump would dead-head, causing the pump to heat up excessively leading to premature failure of the pump.

Coolant Hoses:

Coolant hoses are readily available from an industrial welding supplier or in various MIG or TIG hook-up kits provided by Lincoln Electric. Refer to Magnum accessory literature sheets.

For lengths of coolant hoses over 25Ft(7.6m). and up to 50Ft.(15.2m), 5/16 I.D. hose is recommended. 5/16 I.D. hose and accommodating fittings are available from an industrial welding supplier.

55. When a solenoid valve closes,

The connector and nipple listed fit tightly onto 5/32” (4.0mm) to 3/16" (4.8mm) inner diameter hose, but if clamped tightly to the hose, can fit up to a .25” (6.4mm) inner diameter hose. These fittings are also readily available from any industrial welding supplier.

K529-10

Power Input Cable with Water and Gas Hoses:

This cable assembly includes the following: (1) power cable, (1) control cable, (1) gas hose and (2) water hoses. The cable assembly connects a power source to a wire feeder for water-cooled MIG applications. The cable length is 10'(3.1m). The water hoses have 5/8"-18 left hand male hose fittings and the gas hose has a 5/8"-18 right hand male hose fitting. The cable and hose lengths are designed to connect a wire feed-

er to a COOL ARC

55 that is vertically mounted at

the rear of a power source on a dual cylinder undercarriage. Refer to Figure A.6 for an illustration of this connection.

COOL ARC

Page 15

D-1

SAFETY PRECAUTIONS

MAINTENANCE

PUMP MAINTENANCE

D-1

WARNING

Have qualified personnel do the maintenance work. 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.

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

ELECTRIC SHOCK can kill.

•

Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Disconnect input power by removing plug from receptacle before working inside Cooler.

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

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

• Unplug the cooler before performing general maintenance.

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

• Always wear dry insulating gloves.

MOVING PARTS can injure.

Do not operate with doors open or guards

• off.

• Keep away from moving parts.

The pump head has a "built in" strainer on the inlet side of the pump. It is recommended to clean or replace the pump's

inlet strainer at least once a year. (See Above):

• Drain the coolant reservoir and all coolant lines. Dispose of the coolant properly as specified above.

• Hold the pump head firmly to apply a counter-torque when loosing the strainer's 7/8" acorn nut located on the bottom. Do not confuse with 3/4" acorn nut. Remove nut and slide inlet strainer down and out from the pump head.

• Gently rinse the strainer under running water to thoroughly clean it.

• Use a mirror to inspect the inside of the pump for contamination. Carefully remove hardened debris with a dental pick if necessary, without scratching the inside of the pump.

• Reinstall the strainer and 7/8 acorn nut, tightening with 75+/15 in-lbs. of torque. Wipe dry all area wetted with coolant. Dispose of coolant soaked towels properly as specified above.

• For a more in depth procedure, See “Maintenace Section”,

“Pump Inlet Strainer”.

PUMP MOTOR

The COOL ARC®55 is rated for continuous operation. It is recommended to re-oil the pump motor bearings once a year as follows:

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

Observe all Safety Guidelines detailed throughout this manual. Be sure to disconnect the Cooler from the Power Source before performing any maintenance procedures.

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

ROUTINE MAINTENANCE

Remove accumulated dust and dirt from the internal components of the cooler by blowing it out with a low pressure air hose or removing it 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 torch life. See the Coolant Treatment Recommendation in this “Maintenace Section”.

NOTE: Pure solutions, mixtures of, or materials (i.e. towels wetted) with ethylene glycol are toxic to humans and animals. They must not be haphazardly discarded, especially by pouring liquids down the drain. Contact the local EPA office for responsible disposal methods or for recycling information.

• Remove the plastic plugs located on the top of both the inboard and outboard bearing end-caps.

• Re-oil each bearing with 30-35 drops of SAE 20 oil then reinstall both plugs.

HEAT EXCHANGER

To maintain maximum cooler efficiency, the heat exchanger should be kept free of dust and dirt build-up. 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.

RESERVOIR COOLANT LEVEL

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.

COOL ARC®55

Page 16

D-2

MAINTENANCE

D-2

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 55 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:

• This 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 500 coolers.

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

Prepare the disinfectant:

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

2.75 gals. (10.41 liters) of pure, fresh water per cooler

1.922 ml of additive per cooler. Example: for 100 coolers,

add 192.2 ml to 275.0 gals. of pure fresh water. Pour

2.375 gals. (9 liters) of disinfectant into the empty reser-

voir. Recap the reservoir, tape over the air vent in the cap, roll disinfectant around the inside the reservoir to thoroughly coat all of its surfaces. Remove the tape from the reservoir cap. 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 0.375 gals. (1.42 liters) of fresh disinfectant to the system by pouring it into the reservoir, then reduce the concentration to the nominal 30 ppm:

Add the balance 2.0 gals. (7.55 liters) of fresh, pure water to the reservoir to create the treated coolant concentration. Prime the cooling system.

Check coolant level. Add more fresh, pure water if required, without adding more than 0.125 gal. (0.475 liters) of pure water to prevent diluting the coolant additive.

COOL ARC

PUMP INLET STRAINER

Poor cooler performance can usually be traced to a partially or completely blocked pump inlet strainer. This is a user-serviceable item and can be cleaned and reused, or replaced. Continued pump operation with a blocked strainer can cause:

• Voiding of cooler service warranty

• Cavitation damage to the pump headʼs inlet areas

• Welding accessory damage from overheating due to insufficient coolant flow rate.

A new or properly cleaned pump inlet strainer should restore the coolerʼs performance.

For additional service and periodic maintenance details and for recommended coolants, follow the recommendations listed below.

Procedure and Preparation:

WARNING

• Always switch off the COOL ARC

power

• Always disconnect the COOL ARC from service 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.

• Do not remove the pump relief valveʼs 3/4 in. acorn hex nut or attempt to adjust the relief valve setting.

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

INSPECT CONDITION OF COOLANT

If coolant is contaminated or old:

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

• Flush system of old coolant.

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

• Proceed to adding coolant..

If coolant is clean and fresh:

• If clean, dedicated coolant handling equipment, including a clean siphon pump and a clean holding tank are available then proceed to servicing the Pump Inlet Strainer.

55 machine

Page 17

D-3

MAINTENANCE

D-3

Removing Coolant:

a. Drain coolant from the reservoir using clean siphon-

ing equipment

b. Coolant level should be drained below the strainerʼs

pressure fitting:

• This prevents coolant from streaming out of unit

when strainer nut is removed

SERVICE THE PUMPʼS INLET STRAINER:

a. Place absorbent towels underneath pump head to

prevent stray coolant from wetting coolerʼs electrical components.

b. See figure D.1. Hold pump head to apply counter-

torque when loosening strainerʼs 7/8 acorn nut. Do not confuse with 3/4 acorn nut. Remove nut and slide inlet strainer down and out from pump head.

c. Inspect strainer for damage or excessive clogging:

• Replace or Gently rinse strainer under running water to thoroughly clean it.

d. Use a mirror to inspect inside of pump for contami-

nation. If hardened debris is present and interferes with filter seating, carefully remove it with dental pick without scratching inside of the pump. Use care not to drop debris into pump.

e. Reinstall strainer and acorn nut, tightening with

75±15 in.-lbs. of torque.

• Hold pump head to apply counter-torque when loosening strainers 7/8 acorn nut.

f. Wipe dry all areas wetted by coolant. Dispose of

towels in an environmentally responsible manner.

FIGURE D.1

Add coolant:

a. Add 2.375 gallons of coolant, either the recommen-

dations off the water cooled accessory or if none, see the design specification summary listed in this manual.

ADDITIONAL SERVICE NOTES:

1. Always use a back-up wrench on pump head when loosening or tightening pump fittings.

2. Never run the pump dry. Always use a recommended coolant, otherwise pump damage may result.

3. Flush coolant from system and replace with fresh, recommended coolant at least once a year. More frequent flushing may be necessary, depending upon the userʼs particular system or its usage, especially if it is prone to clogging from biological growth in the coolant.

COOL ARC

Page 18

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 provides a course 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.

CAUTION

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.

COOL ARC®55

Page 19

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

Cooler does not operate with power switch "ON".

(Switch pushed to "I" position.) Internal water leak.

Torch or gun runs hot.

Fan operates but there is low coolant flow.

1. Input cord unplugged.

2. Power switch faulty

3. Power harness damaged.

4. Water lines blocked or crimped.

5. Leak in gun or water hoses.

6. Coolant reservoir empty.

7. The system needs to be primed

1. Hose clamp loose on one of internal hoses.

2. Internal hose punctured.

3. Heat exchanger leaking.

4. Pump seal is leaking

1. Unit placed by area of extreme heat.

2. Low coolant flow.

3. No coolant flow.

4. Fan not operating.

5. Heat exchanger clogged.

1. Leak in torch/gun or hoses.

2.Torch/gun or hoses partially

obstructed.

3. Reservoir empty or very low.

4. Pump strainer is dirty.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

Fan operates but there is no coolant flow.

Pump operates, but fan does not. Cooler trips outlet circuit breaker.

Cooler trips outlet circuit breaker.

1. Pump or pump motor failure.

2. Pump strainer is blocked.

1. Loose or disconnected fan lead.

2. Obstruction in fan blade.

3. Fan motor failure.

1. Circuit overloaded.

2. Fan or pump motor failure.

CAUTION

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.

COOL ARC®55

Page 20

F-1

DIAGRAM

F-1

COOL ARC®55

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.

Page 21

F-2

DIMENSION PRINT

F-2

L16090

COOL ARC®55

Page 22

NOTES

COOL ARC®55

Page 23

PARTS LIST FOR

Cool Arc® 55

P-695P-695

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs ofﬁcial Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs ofﬁcial Parts Book (BK-34) for the latest pages.

COOL ARC®55

Page 24

ILLUSTRATION OF SUB-ASSEMBLIES

P-695-AP-695-A

COOL ARC

02-02-2012

Page 25

P-695-A.1P-695-A.1

Cool Arc®55

For Code: 11859

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBL Y

PAGE NAME

PAGE NO.

CODE NO.

11859 1 1 1 1

Case Front Asbly & Sides

P-695-C

Top Extrusion Asbly & Roof

P-695-D

Base Extrusion Asbly &

Internal Components

P-695-E

Rear Panel Assembly

P-695-F

COOL ARC

02-02-2012

Page 26

Case Front Assembly & Sides

10B

10A

12A

P-695-CP-695-C

10A

10B

COOL ARC

02-02-2012

Page 27

P-695-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Case Front Assembly, Includes: L16078 1 X 1 Case Front Welded Assembly G5015-2 1 X 2 Nameplate L15996-1 1 X 3A Quick Connect (Female) and Nut S19664-1 2 X 3B Lock Washer (Not Shown) E106A-1 2 X 4A Hose (Not Shown) T10642-326 1 X 4B Hose Clamp S10888-35 1 X 5 Switch T10800-40 1 X 8A Thread Forming Screw (Not Shown) S9225-99 4 X 8B Hose Clamp S10888-35 1 X 10A Right Case Side L12742-1 1 X 10B Thread Forming Screw S9225-99 4 X 11 Logo Decal S11893-13 2 X 12A Left Case Side L12752-1 1 X 12B Thread Forming Screw (Not Shown) S9225-99 4 X 16 Warning Decal (M22880-1) (Part of M22880) NSS 1X 20 Connector (Shipped Loose) (Not Shown) T14557-27 2 X

NSS - Not Sold Separately

COOL ARC

02-02-2012

Page 28

Top Extrusion Assembly & Roof

P-695-DP-695-D

COOL ARC

02-02-2012

Page 29

P-695-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Top Extrusion Assembly, Includes: L12757-1 1 X 1A Base Rail M21251-2 1 X 1B Bracket L15091-1 2 X 1C Thread Forming Screw S9225-99 4 X 1D Thread Forming Screw (Not Shown) S9225-99 8 X 2A Corner Cap L13138 4 X 2B Plain Washer S9262-182 12 X 2C Thread Forming Screw S9225-100 12 X 3A Front Mounting Bracket Assembly S28458 1 X 3B Rear Mounting Bracket Assembly S28459 1 X 3C Lock Washer (Not Shown) E106A-27 8 X 3E Torx Button Head Screw (Not Shown) S25930-3 8 X 5A Locking Bracket S28375 1 X 5B Lock Washer E106A-27 2 X 5C 1/4-20 x .75 HHCS CF000410 2 X 6A Roof L12763-5 1 X 6B Thread Forming Screw S9225-99 2 X 10 Decal, Coolant Level S25103 1 X 11 Wiring Diagram M22842 1 X

NSS - Not Sold Separately

COOL ARC

02-02-2012

Page 30

Base Extrusion Asbly & Internal Components

P-695-EP-695-E

COOL ARC

02-02-2012

Page 31

P-695-E.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Base Extrusion Assembly, Includes: G5144-2 1 X 1A Base Extrusion M21251-2 2 X 2A Base L12785-2 1 X 2B Thread Forming Screw (Not Shown) S9225-99 6 X 3 Quick Lock Foot S28070 4 X 5A Corner Cap L13138 4 X 5B Plain Washer S9262-182 12 X 5B Thread Forming Screw S9225-100 12 X 6 Reservoir Assembly G3904-1 1 X 7A Motor Base L12743-1 1 X 7B Thread Forming Screw (Not Shown) S9225-99 4 X 8A Pump & Motor Assembly L11532-2 1 X 8B 5/16-18 x .75 HHCS CF000040 4 X 8C Plain Washer (Not Shown) S9262-121 4 X 8D Lock Washer (Not Shown) E106A-14 4 X 8E Pump Motor Insulation (Not Shown) S25126 1 X 8F Hose Clamp (Not Shown) S10888-35 1 X 10 Coolant Addition Label S24965 1 X 11 Decal - Coolant Level L15996-2 1 X

NSS - Not Sold Separately

COOL ARC

02-02-2012

Page 32

Rear Panel Assembly

P-695-FP-695-F

COOL ARC

02-02-2012

Page 33

P-695-F.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Rear Panel Assembly (L15801-1), Includes: NSS 1X 1 Rear Panel G5016-2 1 X 2A Input Cord S15254-20 1 X 2B Grommet T9274-2 1 X 3A Cover Plate S25438-3 2 X 3B #10-24 HLN T9187-13 4 X 4 Heat Exchanger M16385-6 1 x 5 Fan Shroud Assembly. Includes: L11536-1 1 X 5A Fan Shroud L11535-1 1 X 5B Fan M19076-4 1 X 5C Socket Head Cap Screw T9447-91 2 X 5D Lock Washer (Not Shown) T9695-3 2 X 5E Earth Ground Connection Decal T13260-4 1 X 5F Thread Forming Screw (Not Shown) S9225-99 4 X 6A Hose (.375 ID x .625 OD) T10642-327 1 X 6B Hose Clamp S10888-35 1 X 7A Hose (.375 ID x .625 OD) T10642-328 1 X 7B Hose Clamp S10888-35 1 X 8A #10-24 HN CF000010 2 X 8B Lock Washer (Not Shown) E106A-1 1 X 8C Ground Reference (Not Shown) S26124 1 X 10 Thread Forming Screw S9225-99 4 X 11 Instruction Tag (Not Shown) T11590-191 1 X 12 Rating Plate M22880-2 1 X 13 Wheeled Bin Decal T13086-201 1 X

NSS - Not Sold Separately 02-02-2012

COOL ARC®55

Page 34

NOTES

COOL ARC®55

Page 35

NOTES

COOL ARC®55

Page 36

CUSTOMER ASSISTANCE POLICY

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.

Lincoln Electric IM10117 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual