Lincoln Electric IM645-A User Manual
Power Wave 450 Water Cooler
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Upgrade Kit
UPGRADE INSTALLATION INSTRUCTIONS
Table of Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Recommended Tools for Installation or Service . . . . . .2
G3503-[ ] Installation or Service Tool Usage . . . . . . . . .2
G3503-[ ] Water Cooler Upgrade Kit Contents . . . . . . .2
Recommended Coolants . . . . . . . . . . . . . . . . . . . . . . . .2
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . .3
Replacing a G2725 Cooler with a G3503-[ ] . . . . . . . .3
Removing and Installing the G3503-[ ] Cooler . . . . . .4
G3503-[ ] Cooler Periodic Maintenance . . . . . . . . . . .5
G3503-[ ] Cooler Service . . . . . . . . . . . . . . . . . . . . . .5
Parts List for Cooler (P261-K.2, -K.3) . . . . . . . . . . . . .6,7
Figure 1 (Specified Coolant Level) . . . . . . . . . . . . . . .8
Table 1 (Cooler Electrical Harness Pin-outs) . . . . . . .8
IM645-A
May, 2000
SAFETY
Follow all safety guidelines in your power source operator manual and any additional guidelines covered in this
manual.
GENERAL DESCRIPTION
This upgrade kit is designed to provide all necessary parts and instruction to replace a G2725 water cooler
assembly with an improved design G3503-[ ] water cooler assembly. The G3503-1 and G3503 Coolers are interchangeable as complete units only. These procedures are specified by Lincoln Electric and apply to domestic
Power Wave 450 machines requiring a Lincoln internal water cooler.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• Sales and Service through Subsidiaries and Distributors Worldwide •
RECOMMENDED TOOLS FOR
INSTALLATION OR SERVICE:
S24505 WATER COOLER UPGRADE KIT
CONTENTS:
• absorbent towels
• alcohol wipe
• 3 mm allen wrench (G3503 only)
• socket wrench
• 4 inch long minimum socket extension
• 1/4, 5/16, and 3/8 hex standard depth sockets
• 5/32 allen socket
• medium blade slotted screwdriver
• large blade slotted screwdriver, 8 inches long
minimum
• two 7/16 open or box end wrenches
• one 7/8 open or box end wrench
• needlenose pliers
• two 10 inch long adjustable wrenches
• wire cutter
• molex pin removal tools
• tape measure
• small mechanic’s mirror
• flashlight
• dental pick
• digital multimeter (DMM)
G3503-[ ] INSTALLATION OR SER-
VICE TOOL USAGE
1 Cooler assembly, G3503-[ ]
• Empty Weight: 36 lbs.
• Overall Size: 22.38x14.00x12.50, LxWxH
•
Electrical Input: 230VAC, 2.8A max. steady state
• Coolant Connections:
Welding Industry Standard Quick-Disconnect
(QD) female fittings. Top: Coolant In,
Bottom: Coolant Out
1 Cooler access panel, L9387-2
1 “P4” Electrical power harness (long), S14165-467
1 “P3” Electrical extension harness (short), S14165-466
1 Circuit breaker, T12287-14, spare replacement
2 fasteners, S9225-8, (1/4-20 thread, spares for
cooler mounting)
4 fasteners, S8025-91, (spares for cooler access
panel mounting)
2 Hole plugs, T10397-11
1 Ground Decal, T13260-4
8 cable ties, T13770-2
1 Electrical sleeving, E1159/B-1.00-7.00
1 “B” Stencil, S21212
1 Power Wave machine label: S24503-1
2 Mounting Brackets, S10040-93
2 Fasteners, T9447-42, (#10-24 UNC-3A)
2 Plain washers, S9262-77 (Socket head- cap
screws)
RECOMMENDED COOLANTS
Fastener Usage Qty. Tool
Shroud to cooler base 4 all use 5/16 hex screw and 3/8 hex
Quick Disconnect (QD) bracket 2 nut. Relay may require large blade
Heat exchanger to cooler base 2 slotted screwdriver 8 in. long min.
Relay to cooler base 2
Screw to 4 3 mm allen wrench (G3503 only)
fasten reservoir to cooler base 5/16 Hex Socket (G3503-1 only)
Hose Clamp 10 1/4 hex or medium slotted screwdriver
Fan set screw 1 5/32 allen socket with wrench and 4
in. min. extension
Pump carbonator clamp screw 1 5/16 hex socket with ratchet wrench
Motor mounting bolts 4 two 7/16 open or box end wrenches
Motor access door 2 1/4 hex socket with wrench
Motor harness ground at motor 1 1/4 hex socket with wrench
terminals 2 needlenose pliers
relay terminals 1 and 2 2 large blade slotted screwdriver 8 in.
minimum long.
relay terminals 3 and 4 2 medium slotted screwdriver
All plumbing components N/R two 10 inch adjustable wrenches
1. The following coolants have been determined to be
compatible with the wetted materials used in the
G3503-[ ] cooler assembly:
• Distilled or deionized water
• Potable tap water
• Sediment-free mixtures containing a maxi-
mum of 50% ethylene glycol or automotivegrade antifreeze and the balance of distilled
or deionized water.
2. Ethylene glycol mixtures should be selected if the
cooler may be exposed to a temperature below the
freezing point of water.
3. Consult gun, torch, and wire feeder manuals for
coolant recommendations and select one from the
above list.
4. 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.
5. The cooler’s reservoir has a nominal liquid capacity
of 1.6 gallons.
G3503-[ ] POWER WAVE 450 WATER COOLER UPGRADE KIT
2
INSTALLATION INSTRUCTIONS
WARNING
ELECTRIC SHOCK Can Kill
• Only qualified persons should perform this installation.
HOT COOLANT CAN BURN SKIN
• Always be sure coolant is not hot before doing any
work on cooler parts.
ROTATING FAN BLADES ARE HAZARDOUS
i. Peal off "coolant in / coolant out" decal from
machine’s case back and discard. Remove
residual adhesive from case back with an alcohol wipe.
j. Remove auxiliary transformer #2 (mounted to
Power Wave base, ahead of G2725 cooler) and
set aside. It is no longer needed.
3. Slide electrical sleeving over the non-P4 connector
in the Power Wave’s harness that runs from its terminal strip.
• Fold sleeving over itself and firmly secure it to
the harness with a cable tie.
• Do not put your hands near an operating fan.
• Keep all equipment safety guards, covers and devices in position
and in good repair.Keep hands, hair, clothing and tools away from
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.
near moving
parts.
Always use the greatest care when working
------------------------------------------------------------------------
REPLACING A G2725 COOLER WITH A
G3503-[ ] COOLER
1. Preparation:
• Always switch off the Power Wave machine
power.
• Always disconnect the Power Wave machine
from service input power.
2. Remove the G2725 cooler assembly:
a. Remove gas cylinder(s) from machine’s rear
tray.
b. Remove cooler access panel P/N L9387-1 and
set aside. It is no longer needed.
c. Remove machine’s left side panel (adjacent to
power input cord).
d. Disconnect coolant hoses’ mounting bracket
from machine’s case back.
e. Disconnect all of the coolant hoses’ tie-down
points. These plastic clips may be removed and
discarded if desired.
f. Remove and save both fasteners from Power
Wave base holding cooler in place. Carefully
pull cooler rearward, partially out of the Power
Wave.
g. Disconnect Molex in-line connectors P4 or P5
(cooler power) and P3 (cooler relay and pressure switch) and slide cooler completely from
machine.
h. Optionally remove circuit breaker from case
back and install replacement.
4. Install cooler G3503-[ ]:
a. Install plugs into case back to fill coolant hose
holes. Bend tabs as required to secure plugs in
place.
b. Install new circuit breaker into case back if
replacing the old part.
c. Install new P4 electrical harness into Power
Wave:
• Mate together the labeled P4 connectors.
• Note: H[X]A lead in new harness carries 230
VAC cooler power: (See Table for [X] valve).
[X] Power Wave Wiring
Code Numbers Diagram
2 10406 G2153-5
2 10431 G2153-4
2 10433 G2153-6
3 10106, 10195, 10366 G2153-1
3 10197, SPLC14895 G2153-2
3 10345, 10347 G2153-3
3 10512 G2153-7
3 10514, 10516 G2153-8
3 10520 G3177-1
• Connect insulated terminals to circuit breaker
(order is unimportant).
d. Connect P3 electrical extension harness to the
machine.
e. Apply ground decal to cooler’s base:
• Apply next to mounting screw hole nearest to
circuit breaker.
f. Mate cooler’s connector to the P3 extension
harness.
g. Mate cooler’s power connector to the P4 electri-
cal harness.
h. Carefully slide retrofit cooler G3503-[ ] forward
into Power Wave. Verify that front tabs on cooler base are properly guided into slots in base of
Power Wave (base’s underside may be examined with a mirror and flashlight).
i. Attach ground lead in P4 harness to top of cool-
er’s base or top of mounting bracket, ( if brackets are necessary). Secure cooler to Power
Wave base by installing both fasteners.
j. Install Power Wave machine’s left side panel.
G3503-[ ] POWER WAVE 450 WATER COOLER UPGRADE KIT
3
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