Lincoln Electric IM10134 User Manual
Operator’s Manual
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®
COOL ARC
55 S WATER COOLER
For use with machines having Code Numbers:
11949
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10134 | Issue D ate Oct-13
© Lincoln Global, Inc. All Rights Reserved.
Register your machine:
www.lincolnelectric.com/registration
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
THANK YOU FOR SELECTING
AT ALL
TIMES.
SPECIAL SITUATIONS
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
rials 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.
DO NOT WELD OR CUT containers or mate-
Addi t i onal pr ecaut i onar y measur es
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.
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.
3
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.
4
cause
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
5
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
Arclink Connections ........................................................................................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, Power-Up Sequence
Recommended Processes and Equipment, Common Equipment Packages
Turning the System “On”.................................................................................B-1
Cooling Efficiency............................................................................................B-2
Equipment Limitations, Case Front Description ..............................................B-3
Case Back Descriptions ..................................................................................B-4
________________________________________________________________________
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
Using the Status LED to Troubleshoot System .....................................................E-2
Error Codes for COOL ARC
Troubleshooting Guide ..........................................................................................E-4
________________________________________________________________________
Wiring Diagrams ..............................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Dimension Print......................................................................................................F-2
________________________________________________________________________
Parts List.................................................................................................................P-716
________________________________________________________________________
®
55 S...................................................................A-2
.............................................B-1
.......B-1
®
55 S........................................................................E-3
vi vi
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – COOL ARC®55 S
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.
K3086-2 ( COOL ARC®55 S )
VIA 3-Prong Plug NEMA Type 5-15P
115VAC 60 Hz 1 Phase
®
40 VDC (ArcLink
3.8 Amps 115 VAC
.5 Amps 40 VDC
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.
64 lbs (29 kg)
83.7 lbs (38 kg)
)
◊
. These coolants may contain
Dimensions
EMC Classification
Temperature Range
Cooling Power
L
W
H (Top Face)
1.43 kW (4880 BTU/hr.) @ 1 L/min.
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
COOLANT
ArcLink
STATUS
®
OUT
COOLANT
IN
COOL ARC®55 S
A-2
INSTALLATION
A-2
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
Only qualified persons should perform
•
this installation.
LOCATION AND MOUNTING
(See Figure A.1)
To mount the COOL ARC
compatible Power Wave
lize the quick lock mechanism as shown.
• Turn off the power source at the disconnect switch before connecting or
working inside of 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.
If using the COOL ARC
another module such as the STT
mount the COOL ARC
COOL ARC
and can be used outdoors. 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
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
---------------------------------------------------------------------
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
other machines. Never attach a module under-
neath the cooler.
• Do not mount the Power Wave
source and COOL ARC
UNPACKING THE COOL ARC®55 S
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
for parts orders and future maintenance service.
Read
this entire installation section before you
COOL ARC®55 S
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.
start installation.
®
55 S to the bottom of a
®
“S” series power source uti-
®
55 S in conjuntion with
®
Module, always
®
55 S on the bottom. The
®
55 S will operate in harsh environments
®
55 S underneath
®
“S” series power
®
55 S combination over
FIGURE A.1
------------------------------------------------------------------------
INSTALLATION ON POWER SOURCE
The COOL ARC®55 S is designed to mount directly
to the bottom of a Power Wave “S” series power
source.
Always place the COOL ARC
to avoid causing the machine to topple over.
®
55 S on a level surface
COOL ARC®55 S
A-3
INSTALLATION
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 ship-
®
ment, the COOL ARC
with 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
S.
55 S unit is delivered empty
®
55
A-3
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
without the fill cap in place can cause poor cooling
efficiency, evaporation loss of coolant and reduced
product life.
55 S
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
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
ucts, consult the manufacturer's instruction manual for
recommended coolants.
55 S with other prod-
®
55 S
COOL ARC®55 S
A-4
FROM HHEAT
URCE
(RED)
TO
HEAT
SO
URCE
(BLUE)
INSTALLATION
A-4
COOLANT "IN" AND "OUT" CONNECTIONS
The fittings located on the COOL ARC®55 S 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
to the
COOL ARC®55 S
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 male 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 ensure that no leaking occurs.
INPUT POWER CONNECTION
Plug the input power cord on the COOL ARC®55 S
into a standard 115V NEMA circuit breaker protected
receptacle. The receptacle must have overload protection and a grounding conductor pin.
ArcLink®CONNECTIONS
The pigtail connection on the COOL ARC®55 S
includes signal and power lines required for proper
®
operation. With the COOL ARC
tened to the power source, connect the pigtail to its
respective 5 pin receptacle on the back of the power
source. The Arclink receptacle on the back of the
COOL ARC
®
55 S should be used for connection to
compatible wire feeders. Best results will be obtained
when control cables are routed separately from the
welding cables. It is recommended that the total combined length of the Arclink control cable network does
not exceed 200 ft. (61m).
55 S securely fas-
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
SOSOURC
H
URC
COOL ARC®55 S
A-5
C
O
O
L
A
N
T
C
O
O
L
A
N
T
TO WWORK
COOLANTNT
O
UT
COOLA
NT
IN
=
BLUE HHOSE
=
RED HHOSE
G
AS
GAS
K16162222-
4 ADAPTER
FEMALELE TTO FFEMALELE
CGA
FITTING
INSTALLATION
INSTALLATION OF WATER COOLED
ACCESSORIES
After following the installation instructions above, the
®
COOL ARC
55 S is ready for connection to a water-
cooled accessory.
WATER COOLED TIG TORCH AND MIG GUN
®
Follow Figure A.3 when using the COOL ARC
55 S
with water-cooled TIG torches. Follow Figure A.5
when using the COOL ARC
®
55 S with water-cooled
MIG gun. Consult the manufacturer's instruction man-
®
ual when using the COOL ARC
55 S with other
water-cooled TIG and MIG accessories.
CONNECTION TO WIRE FEEDERS
®
Follow Figure A.4 when using the COOL ARC
55 S
in 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
®
55 S, since
the cooler requires continuous flow. DO NOT USE A
WATER SOLENOID VALVE with the COOL ARC
®
55
S. 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
Figure A.5.
FIGURE A.3
Water Cooled TIG Torch Connection
4 A
B
UT
NT
R
A-5
CAUTION
DO NOT USE A WATER SOLENOID VALVE with
the COOL ARC
es, 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
tion of this connection.
Connection to Wire Feeder (Do Not Use Water Solenoid)
FEMALE TO FEMALE
CGA FITTING
®
55 S. When a solenoid valve clos-
®
55 S. Refer to Figure A.6 for an illustra-
FIGURE A.5
KP504 WATER HOSES AND
FEMALE TO FEMALE 5/8" LH
CGA ADAPTER COUPLINGS
GUN CABLE
COOLANT
COOLANT
COOLANT
OUT
COOLANT
IN
= BLUE HOSE
= RED HOSE
FIGURE A.6
Connection to Wire Feeder (Do Not Use Water Solenoid)
F
CONTOL
ELECTRODE CABLE
FIGURE A.4
Water Cooled MIG Gun Connection
COOLANT
COOLANT
GUN CABLE
K1859-1 FOR
CONNECTING TO
WIRE FEEDERS
COOLANT
COOLANT
COOLANT
= BLUE HOSE
OUT
COOLANT
IN
= RED HOSE
TO WORK
COOL ARC®55 S
NOTE:
ORDER K1859-1 FOR WIRE
FEEDERS WITH QUICK
DISCONNECT FITTINGS.
CABLE
T
N
OOLA
C
T
N
A
OOL
C
GAS
GUN CABLE
COOLANT
COOLANT
COOLANT
OUT
COOLANT
IN
= BLUE HOSE
= RED HOSE
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.
-----------------------------------------------------------
PRODUCT DESCRIPTION
POWER-UP SEQUENCE
The
COOL ARC® 55 S
time as the power source. The status light will blink
green for about a minute while the system is configuring.
After this time, the status lights will turn a steady green
indicating the machine is ready.
The pump and fan in the
when welding begins, or while holding the switch on the
front of the unit.
will be powered up at the same
COOL ARC® 55 S
will run only
RECOMMENDED PROCESSES AND
EQUIPMENT
The COOL ARC®55 S is designed for use with watercooled TIG, MIG, PAC (Plasma Arc Cutting) and PAW
(Plasma Arc Welding) guns and torches. The COOL
®
ARC
55 S can be used with MIG wire feeders and S
series power sources.
COMMON EQUIPMENT PACKAGES
K3086-2 COOL ARC®55 S
K2823-3 POWER WAVE
K2230-1 POWER FEED
K1543-XX ArcLink
wire feeder to cooler.
®
®
S350
®
10M
CABLE (5 PIN ) - connects
The COOL ARC®55 S is a 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 COOL ARC
designed for use with S series power sources and
requires 115 VAC power input and an ArcLink
nection. The cooler will communicate via ArcLink
with the wire feeder and power source to automatically turn on when welding is taking place, and off a few
minutes after welding.
The COOL ARC
to only allow welding to occur when coolant is flowing.
When a low or no flow condition is sensed, welding
will be shut down to protect valuable torches and
guns.
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
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 S is equipped with a flow sensor
®
55 S coolant flow is circulated
®
55 S is
®
con-
TURNING THE SYSTEM "ON"
After connecting the COOL ARC®55 S 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.
®
Although the cooler is designed to turn on/off as needed while welding, for initial setup and when installing a
new gun you will first need to fill the system with
coolant. This can be done by using the momentary
switch on the front of the unit. Remove the fill cap and
hold the switch down until you see coolant return into
the tank. The system is now primed and ready for use.
You will be able to hear the fan running and feel airflow out of the sides of the unit when the cooler is
operating.
COOL ARC
®
55 S
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