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Operator’s Manual
COOL ARC ® 55 S WATER COOLER
For use with machines having Code Numbers:
11949
Register your machine:
www.lincolnelectric.com/registration
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10134 | Issue Date Oct-13
© Lincoln Global, Inc. All Rights Reserved.
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
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 develop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.
WEAR CORRECT EYE, EAR & BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area AT ALL TIMES.
SPECIAL SITUATIONSDO 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.
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.
SAFETY
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.
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.
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
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.
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SAFETY
ELECTRIC SHOCK |
ARC RAYS CAN BURN. |
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CAN KILL. |
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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 between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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.
5.d. Shielding gases used for arc welding can displace air and cause 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
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.
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.
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.
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
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TABLE OF CONTENTS |
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Installation ....................................................................................................... |
Section A |
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Technical Specifications ........................................................................................ |
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A-1 |
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Safety Precautions................................................................................................. |
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A-2 |
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Unpacking the COOL ARC® 55 S................................................................... |
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A-2 |
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Installation on Power Source ......................................................................... |
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A-2 |
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Location and Mounting.................................................................................... |
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A-2 |
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Filling the Coolant Reservoir ........................................................................... |
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A-3 |
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Coolant “In” and “out” Connections ................................................................. |
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A-4 |
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Input Power Connection.................................................................................. |
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A-4 |
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Arclink Connections ........................................................................................ |
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A-4 |
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Installation of Water Cooled Accessories .............................................................. |
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A-5 |
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Water Cooled TIG Torch and MIG Gun .......................................................... |
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A-5 |
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Connection to Wire Feeders ........................................................................... |
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A-5 |
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K529-10 Power Input Cable with Water and Gas Hoses ................................ |
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A-5 |
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Operation ......................................................................................................... |
Section B |
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Safety Precautions................................................................................................. |
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B-1 |
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Product Description, Power-Up Sequence............................................. |
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B-1 |
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Recommended Processes and Equipment, Common Equipment Packages |
.......B-1 |
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Turning the System “On”................................................................................. |
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B-1 |
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Cooling Efficiency............................................................................................ |
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B-2 |
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Equipment Limitations, Case Front Description .............................................. |
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B-3 |
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Case Back Descriptions .................................................................................. |
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B-4 |
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Accessories ..................................................................................................... |
Section C |
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Optional Equipment (Field Installed) .................................................................... |
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C-1 |
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Maintenance .................................................................................................... |
Section D |
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Safety Precautions ................................................................................................ |
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D-1 |
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Routine Maintenance ...................................................................................... |
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D-1 |
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Periodic Maintenance ..................................................................................... |
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D-1 |
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Pump Maintenance ......................................................................................... |
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D-1 |
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Pump Motor .................................................................................................... |
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D-1 |
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Heat Exchanger .............................................................................................. |
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D-1 |
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Reservoir Coolant Level.................................................................................. |
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D-1 |
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Coolant Treatment Recommendation ............................................................. |
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D-2 |
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Pump Inlet Strainer ......................................................................................... |
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D-2 |
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Inspect Condition of Coolant........................................................................... |
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D-2 |
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Service the Pump Inlet Strainer ...................................................................... |
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D-3 |
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Additional Service Notes................................................................................. |
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D-3 |
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Troubleshooting .............................................................................................. |
Section E |
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Safety Precautions................................................................................................. |
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E-1 |
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How to Use Troubleshooting Guide ................................................................ |
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E-1 |
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Using the Status LED to Troubleshoot System ..................................................... |
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E-2 |
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Error Codes for COOL ARC® 55 S........................................................................ |
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E-3 |
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Troubleshooting Guide .......................................................................................... |
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E-4 |
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Wiring Diagrams .............................................................................................. |
Section F |
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Wiring Diagram ...................................................................................................... |
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F-1 |
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Dimension Print...................................................................................................... |
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F-2 |
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Parts List................................................................................................................. |
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P -716 |
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A-1 |
INSTALLATION |
A-1 |
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TECHNICAL SPECIFICATIONS – COOL ARC® 55 S |
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Product No. / Model |
K3086-2 ( COOL ARC® 55 S ) |
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VIA 3-Prong Plug NEMA Type 5-15P |
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Input |
115VAC 60 Hz |
1 Phase |
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40 VDC (ArcLink®) |
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Current Draw @ 60Hz Input |
3.8 Amps 115 VAC |
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.5 Amps 40 VDC |
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Maximum Operating Pressure and Flow Rate |
60 psi (414 kPa) (4.14 bar)Max. |
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(Open Flow, Without Welding Torch Restriction) |
1.66 gal/min. (6.28 liter/min) Max. |
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Typical Operating Pressure and Flow Rate |
53-57 psi (365-393 kPa) |
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(With Welding Torch Restriction) |
.45-.60 gal/min. (1.7-2.3 liter/min) |
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Reservoir Size |
2.375 gal. (9 liters) |
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For Use Above Freezing: Clean tap, distilled or de-ionized water. |
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For Use Below Freezing: 50% water and 50% pure ethylene glycol |
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(reagent or industrial grade) mixture. |
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DO NOT USE: Automotive anti-freeze that contains rust inhibitors or leak stoppers. |
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Recommended Coolant |
These coolants will damage the pump and block the small internal passageways of the |
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heat exchanger, affecting cooling performance. To acquire the proper coolant contact |
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a local welding distributor. |
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DO NOT USE: Pre-packaged welding industry coolants◊. These coolants may contain |
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oil-based substances, which attack the plastic components of the cooler. Once added |
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to the cooler, these substances are virtually impossible to purge from the water lines |
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and heat exchanger. |
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◊Magnum Pro AL coolant may be used. |
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Weight |
Shipping |
64 lbs (29 kg) |
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Reservoir |
83.7 lbs (38 kg) |
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Full (Water) |
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L |
26.5 in. (673.1mm) |
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W |
13.9 in. (353.0mm) |
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Dimensions |
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H (Top Face) |
11.5 in. (292.1mm) |
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EMC Classification |
Category 1 |
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Temperature Range |
14°F to 104°F (-10°C to 40°C) |
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Cooling Power |
1.43 kW (4880 BTU/hr.) @ 1 L/min.* |
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*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® |
OUT |
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STATUS |
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COOLANT |
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IN |
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COOL ARC® 55 S
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 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.
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 moving parts.
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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 COOL ARC® 55 S for parts orders and future maintenance service.
Read this entire installation section before you start installation.
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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® 55 S on a level surface to avoid causing the machine to topple over.
LOCATION AND MOUNTING
(See Figure A.1)
To mount the COOL ARC® 55 S to the bottom of a compatible Power Wave® “S” series power source utilize the quick lock mechanism as shown.
If using the COOL ARC® 55 S in conjuntion with another module such as the STT® Module, always mount the COOL ARC® 55 S on the bottom. The COOL ARC® 55 S will operate in harsh environments 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 circulation of clean air such that movement into and out of the louvers will not be restricted.
•Dirt and dust that can be drawn into the machine should be kept to a minimum. The use of air filters on the air intake is not recommended because normal air flow may be restricted. Failure to observe these precautions can result in poor cooling performance.
•Keep the machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles.
•Always mount the COOL ARC® 55 S underneath other machines. Never attach a module underneath the cooler.
•Do not mount the Power Wave® “S” series power source and COOL ARC® 55 S combination over combustible surfaces. Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .060” (1.6mm) thick, which shall extend not less than 5.90” (150mm) beyond the equipment on all sides.
•Avoid placing the cooler near areas of extreme heat.
•Avoid placing the cooler near a flux hopper or an
area where dust build-up is extreme.
FIGURE A.1
COOL ARC® 55 S
A-3 |
INSTALLATION |
A-3 |
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® 55 S unit is delivered empty 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® 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® 55 S with Lincoln guns or torches, use distilled or de-ion- ized 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 S with other products, consult the manufacturer's instruction manual for recommended coolants.
CAUTION
DO NOT USE OIL BASED COOLANTS OR COOLANTS THAT CONTAIN RUST INHIBITORS OR LEAK STOPPERS.
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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® 55 S without the fill cap in place can cause poor cooling efficiency, evaporation loss of coolant and reduced product life.
COOL ARC® 55 S
A-4 INSTALLATION A-4
COOLANT "IN" AND "OUT" CONNECTIONS |
INPUT POWER CONNECTION |
|
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 5/8- 18 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.
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.
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® 55 S securely fastened 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).
FIGURE A.2
Inlet and Outlet Hose Connection Diagram
FROM HEAT |
SOURCE |
(RED) |
TO HEAT |
SOURCE |
(BLUE) |
COOL ARC® 55 S |
A-5 |
INSTALLATION |
A-5 |
INSTALLATION OF WATER COOLED ACCESSORIES
After following the installation instructions above, the COOL ARC® 55 S is ready for connection to a watercooled 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 manual 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
|
K1622-4 ADAPTER |
|
|
COOLANT |
= BLUE HOSE |
|
OUT |
|
|
COOLANT |
= RED HOSE |
|
IN |
|
GAS |
AS |
|
G |
|
|
|
T |
|
|
N |
|
|
A |
|
|
L |
|
|
O |
|
|
O |
|
|
C |
|
|
T |
|
|
N |
|
|
A |
|
|
L |
|
|
O |
|
|
O |
|
|
C |
|
|
FEMALE TO FEMALE |
|
|
CGA FITTING |
|
|
TO WORK |
|
FIGURE A.4
Water Cooled MIG Gun Connection
COOLANT |
|
|
COOLANT |
COOLANT |
= BLUE HOSE |
|
OUT |
|
|
COOLANT |
= RED HOSE |
|
IN |
|
GUN CABLE
COOLANT
K1859-1 FOR
COOLANT
CONNECTING TO
WIRE FEEDERS
CAUTION
DO NOT USE A WATER SOLENOID VALVE with the COOL ARC® 55 S. When a solenoid valve closes, 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® 55 S. Refer to Figure A.6 for an illustration of this connection.
FIGURE A.5
Connection to Wire Feeder (Do Not Use Water Solenoid)
KP504 WATER HOSES AND
FEMALE TO FEMALE 5/8" LH
CGA ADAPTER COUPLINGS
GUN CABLE
COOLANT
FEMALE TO FEMALE
CGA FITTING
COOLANT 
COOLANT = BLUE HOSE
OUT
COOLANT = RED HOSE
IN
FIGURE A.6
Connection to Wire Feeder (Do Not Use Water Solenoid)
|
|
GAS |
|
CONTOL |
COOLANT |
= BLUE HOSE |
|
CABLE |
ELECTRODE CABLE |
OUT |
|
|
|
COOLANT |
= RED HOSE |
|
|
IN |
|
|
NT |
|
|
|
LA |
|
|
|
COO |
|
|
|
NT |
|
|
|
LA |
|
|
|
COO |
|
|
TO WORK
GUN CABLE
NOTE:
ORDER K1859-1 FOR WIRE
FEEDERS WITH QUICK COOLANT
DISCONNECT FITTINGS.
COOLANT
COOL ARC® 55 S
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.
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See additional warning information at front of this operatorʼs manual.
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PRODUCT DESCRIPTION
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® 55 S is designed for use with S series power sources and requires 115 VAC power input and an ArcLink® connection. 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® 55 S is equipped with a flow sensor 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® 55 S 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.
POWER-UP SEQUENCE
The COOL ARC® 55 S will be powered up at the same 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 COOL ARC® 55 S will run only when welding begins, or while holding the switch on the front of the unit.
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® S350
K2230-1 POWER FEED® 10M
K1543-XX ArcLink® CABLE (5 PIN ) - connects wire feeder to cooler.
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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