Lincoln Electric IM670 User Manual

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Page 1

Operator’s Manual

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COOL ARC ® 40 STAND ALONE WATER COOLER

For use with machines having Code Numbers:

10928, 11067, 11847

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM670-B | Issue D ate Oct-13

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Page 2

THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

Page 3

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

SAFETY

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Page 4

SAFETY

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

between the

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When welding

with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

cause

Page 5

SAFETY

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

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

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety Interactive Web Guide for mobile devices

Page 6

TABLE OF CONTENTS

Page

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

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

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

Unpacking the COOL ARC

Filling the Coolant Reservoir ...........................................................................A-2

Coolant “In” and “out” Connections .................................................................A-3

Input Power Connection..................................................................................A-4

Installation on Undercarriage or Power Source .............................................A-4

Horizontal Installation on the Top of a Power Source............................................A-4

Vertical Installation on Power Source with a Dual Cylinder Undercarriage. ..........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

RODUCT DESCRIPTION .............................................................................B-1

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

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

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

40.......................................................................A-2

Accessories .....................................................................................................Section C

Optional Equipment (Field Installed) ....................................................................C-1

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

OUTINE MAINTENANCE ......................................................................................D-1

Periodic Maintenance .....................................................................................D-1

UMP MAINTENANCE ..........................................................................................D-1

Pump Motor ....................................................................................................D-1

Heat Exchanger ..............................................................................................D-1

Reservoir Coolant Level..................................................................................D-1

Coolant Treatment Recommendation .............................................................D-2

Pump Inlet Filter..............................................................................................D-2

Inspect Condition of Coolant...........................................................................D-2

Service the Pump Inlet Filter...........................................................................D-3

Additional Service Notes.................................................................................D-3

Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide ................................................................E-1

Troubleshooting Guide ..........................................................................................E-2

Wiring Diagrams ..............................................................................................Section F

Wiring Diagram ......................................................................................................F-1

Dimension Print......................................................................................................F-2

Parts List.................................................................................................................P-385

Page 7

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – COOL ARC®40

A-1

Product No. / Model

Input

Current Draw @ 60Hz Input

Current Draw @ 50Hz 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: Use Clean tap, distilled or de-ionized water.

For Use Below Freezing: Use

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.

K2187-1 ( COOL ARC®40 230V International)

Via Continental European (SCHUKO)- PRONG PLUG

220-240VAC 50/60 Hz 1 Phase

1.3-1.7 Amps

2.0-2.4 Amps

60 psi (414 kPa) (4.14 bar)Max.

1.66 gal/min. (6.28 liter/min) Max.

53-57 psi (365-393 kPa)

.45-.60 gal/min. (1.7-2.3 liter/min)

2.0 ga. (7.6 liters)

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

◊

. These coolants may contain

46.5 lbs. (21.1 kg)

61.2 lbs. (27.8 kg)

Dimensions

H (Top Face)

H Top Handle)

9.03 in. (229.4mm)

9.10 in. (231.1mm)

31.99 in. (812.6mm)

34.26 in. (870.2mm)

EXPLANATION OF SYMBOLS THAT APPEAR ON THIS EQUIPMENT

OFFOFF

COOL ARC®40

N80

IP 21S

Page 8

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

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

• Use only grounded receptacle.

• Do not remove the power cord ground prong.

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

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

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

UNPACKING THE COOL ARC®40

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. Below is the recommended procedure for unpacking the Cooler:

• Open top flap where identification label appears.

• Remove loose items and top insert.

• Open bottom flap.

• Remove bottom insert and slide Cooler, wrapped in inside liner from outer carton.

• Gently remove liner and packaging foam from Cooler.

Save the instruction manual and service directory supplied with the COOL ARC future maintenance service.

FILLING THE COOLANT RESERVOIR

Recommended Coolant

• For Use Above Freezing:

ionized water.

• For Use Below Freezing: 50% water and 50% pure

ethylene glycol (reagent or industrial grade) mixture.

40 for parts orders and

Clean tap, distilled or de-

To avoid freeze damage and water leakage in shipment, the COOL ARC no coolant in the system. To fill the unit, locate the plastic Snap-On reservoir fill cap at the front middle of the unit. Remove the fill cap by pressing the center of the cap inward while pulling at the tab on the outer edge.

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

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 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 consult the manufacturer's instruction manual for recommended coolants.

40 unit is delivered empty with

COOL ARC®40.

40 with

40 with other products,

CAUTION

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

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

The unit can be filled either vertically or horizontally.

UNPLUG THE COOLER BEFORE FILLING THE COOLANT RESERVOIR:

• 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.

COOL ARC®40

UPRIGHT (VERTICAL):

• Tilt the unit backward and pour 2 gallons (7.6 liters)

of coolant into the coolant reservoir fill hole through a funnel. If a 1 gallon (3.8 liters) fill bottle is available, tilt the

• unit forward until the bottle mates with the coolant reservoir fill hole. Then tilt the unit backward until the fill bottle is emptied. Fill the unit with 2 gallons (7.6 liters) of coolant.

Page 9

A-3

INSTALLATION

LYING DOWN (HORIZONTAL):

Carefully add 2 gallons (7.6 liters) of coolant through a funnel into the coolant reservoir fill hole.

AVOID SPILLING COOLANT INTO THE LOUVERS ON THE TOP OF THE COOLER.

A-3

WATER OR COOLANT LINE CONNECTIONS TO THE COOL ARC

Take the connector nut of the water hose and check if the thread of the male connector nut matches the 5/818 left hand female thread in the fitting on the back of the unit.

The cooler is "FULL" when the coolant lies just below the coolant reservoir opening with the cooler in the upright (vertical) position.

NOTE: DO NOT ADD MORE THAN 2 GALLONS (7.6 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. Simply press on the inside center of the fill cap until the cap snaps into place. Operation of

the COOL ARC

40 without the fill cap in place can cause poor cooling efficiency, evaporation loss of coolant and reduced product life.

COOLANT "IN" AND "OUT" CONNECTIONS

The fittings located on the back center of the COOL

40 are two female 5/8-18 left-hand threaded

ARC fittings. (CGA Style) These mate with water hoses typically used in the welding industry.

Refer to Figure 1.

For all Lincoln products and those with a connector nut on the water hose that mate with the fittings on the

back of the COOL ARC

40:

(Reference FIG. 1) Take the accessory "INLET" hose (colored or tagged blue on most hoses) and thread it into the coolant "OUT" fitting located on the right side of the back of the cooler. 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 thread it into the coolant "IN" fitting located on the left side of the back of the cooler. Again, tightly secure the connector nut of the hose into the fitting of the cooler with a wrench to insure 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.

If the connector nut on a water hose does not mate

with the fittings on the back of the COOL ARC

40,

order the following:

(See Parts Lists for Itemʼs below)

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

FIGURE 1

Inlet and Outlet Hose Connection Diagram

COOLANT

FROM HEAT

SOURCE

(RED)

COOL ARC®40

TO

HEAT

SOURCE

(BLUE)

COOLANT

OUT

Page 10

A-4

Remove the connector nut from the INLET hose by making a straight cut 6-12mm(1/4"-1/2") away from the end of the nipple located inside of the hose. Take the nipple and the connector nut ordered above and insert the nipple into the connector nut so that the threaded end of the connector nut points away from the barbed end of the nipple. Twist the barbed end of the nipple into the hose ple is flush with the end of the hose. Secure the hose onto the nipple with the hose clamp to insure that the connection is watertight. No water can leak from the connection if it is properly attached. Repeat the procedure for the OUTLET hose. When complete, follow the connection procedure detailed above for connecting the hoses to the COOL ARC

The connector and nipple listed fit tightly onto 4.0 mm (5/32") to 4.8mm(3/16") inner diameter hose, but if clamped tightly to the hose, can fit up to a

6.4mm(.25”) inner diameter hose.

until the shoulder of the nip-

40 fittings.

INSTALLATION

INPUT POWER CONNECTION

Plug the input power cord on the COOL ARC®40 into a standard 230V circuit breaker protected receptacle.

INSTALLATION ON UNDERCARRIAGE OR POWER SOURCE

The COOL ARC®40 can be mounted either horizontally or vertically on a power source. To mount the cooler horizontally, order the K559-2 Cooler Horizontal Mounting Bracket. To mount the cooler vertically on a power source with a dual cylinder undercarriage, order K559-3 Cooler Vertical Mounting Bracket.

A-4

HORIZONTAL INSTALLATION ON THE TOP OF A POWER SOURCE

For proper installation, follow the instructions provided with the K559-2 Cooler Horizontal Mounting Bracket Kit. The cooler is secured to the power source lift bale. Reference the table below for a list of power sources that allows the COOL ARC zontally on top.

40 to be mounted hori-

VERTICAL INSTALLATION ON POWER SOURCE WITH A DUAL CYLINDER UNDERCARRIAGE.

For proper installation, follow the instructions provided with the K559-3 Cooler Vertical Mounting Bracket Kit. The cooler is securely mounted to the dual cylinder support bracket. Reference the table below for a list of power sources and dual cylinder undercarriages that allows the COOL ARC the rear of the machine on the gas bottle rack.

40 to be mounted vertically at

WARNING

If the COOL ARC izontally on top of a power source or vertically on a dual cylinder undercarriage. THE COOL-ARC 40 MUST BE OPERATED IN THE HORIZONTAL POSITION. This will prevent the cooler from being accidentally tipped over.

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

40 is not securely mounted hor-

Power Source

CV-300 CV-400

CV-655 DC-250 DC-400

DC-600, DC-655 Square Wave TIG 275 Square Wave TIG 355

Power Wave 455

Power MIG 255

K559-3

Cooler Vertical Mounting

Bracket on a Dual

Cylinder Undercarriage

K874 Undercarriage

Not Available Not Available Not Available Not Available Not Available

K932-1 Undercarriage

Not Available

K1570-1 Undercarriage

Not Available

COOL ARC®40

K559-2 Cooler Horizontal Mounting Bracket

Can be used On Top

of a Power Source

Yes Yes Yes Yes Yes Yes

Yes

No No

Page 11

A-5

INSTALLATION

INSTALLATION OF WATER COOLED ACCESSORIES

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

WATER COOLED TIG TORCH AND MIG GUN Follow Figure 2 when using the COOL ARC

water-cooled TIG torches. Follow Figure 4 when using the COOL ARC Consult the manufacturer's instruction manual when using the COOL ARC and MIG accessories.

CONNECTION TO WIRE FEEDERS Follow Figure 3 when using the COOL ARC

conjunction with a wire feeder. The feeder will need to have pass-through water hoses installed in order to correctly function with the COOL ARC cooler requires continuous flow.

WATER SOLENOID VALVE

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

40 is ready for connection to a water-

40 with water-cooled MIG gun.

40 with other water-cooled TIG

40, since the

DO NOT USE A

with the COOL ARC®40.

Figure 4.

40 with

40 in

FIGURE 2

Water Cooled TIG Torch Connection

REGULATOR FLOWMETER

ARGON GAS

CYLINDER

POWER SOURCE

COOLANT

OUT

GAS*

A-5

CAUTION

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

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

K529-10 POWER INPUT CABLE WITH WATER AND GAS HOSES

This cable assembly includes a (1) power cable, (1) control cable, (1) gas hose and (2) water hoses to connect a power source to a wire feeder. The cable length is 3.05m (10Ft.). The water hoses have 5/8"-18 left hand male hose fittings and the gas hose has a 5/8"-18 right hand male hose fitting. The cable and hose lengths are designed to connect a wire feeder to a COOL ARC of a power source on a dual cylinder undercarriage. Refer to Figure 5 for an illustration of this connection.

Connection to Wire Feeder (Do Not Use Water Solenoid)

COOLANT

KP504-WATER HOSES AND

FEMALE TO FEMALE 5/8" LH

CGA ADAPTER COUPLINGS

Connection to Wire Feeder (Do Not Use Water Solenoid)

40. When a solenoid valve closes,

40 that is vertically mounted at the rear

FIGURE 4

FEMALE TO FEMALE 5/8" LH

CGA ADAPTER COUPLINGS

COOLANT

OUT

KP1529-1

(COUPLINGS ONLY)

COOLANT

GUN CABLE

FIGURE 5

GAS

OUT

TO WORK

COOLANT

K1859-1 FOR WIRE

FEEDERS WITH QUICK

DISCONNECT FITTINGS

COOLANT*

GAS



COOLANT*

POWER CABLE ADAPTER*

POWER / COOLANT

COOLANT

GAS

FEMALE TO FEMALE* CGA FITTING

*INCLUDED IN

KP504 HOOK-UP KIT



FIGURE 3

Water Cooled MIG Gun Connection

COOLANT



OUT

COOLANT

KP504 FOR HOOK-UP

TO WIRE FEEDERS

WITH CGA FITTINGS



COOLANT

GUN CABLE

NOTE:

COOLANT

OUT

SHIELDING

OUT

GAS

K529-10

IN OUT

NOTE:

COOLANT

GUN CABLE

COOLANT

OUT

COOLANT

COOLANT

BLUE HOSE

RED HOSE

TIG TORCH

BLUE HOSE

RED HOSE

CONTROL CABLE

TO WORK

COOLANT

COOLANT

ELECTRODE CABLE

NOTE:

ORDER K1859-1 ALONG WITH  K529-10 FOR WIRE FEEDERS  WITH QUICK DISCONNECT FITTINGS.

COOLANT

COOL ARC®40

Page 12

B-1

OPERATION

PRODUCT DESCRIPTION

The COOL ARC®40 is a stand alone re-circulation cooling system designed for use with water-cooled TIG, MIG, PAC (Plasma Arc Cutting) and PAW (Plasma Arc Welding) guns and torches. The coolant "IN" and "OUT" connections are 5/8-18 left-hand female threads which match the standard connector nut of domestic water hoses (CGA style) and watercooled TIG torches. The COOL ARC ous duty cooler.

The overall size and shape of the cooler is identical to the Magnum 20. The COOL ARC either the vertical or horizontal position. The COOL

40 is very easy to use and understand with only

ARC one power switch on the control panel. The cooler has an International 230V power input receptacle, making it very easy to power up. Adding coolant to the reservoir is simple and connecting to the coolant "IN" and "OUT" connections are easily made with an adjustable wrench.

The COOL ARC

40 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 6.

RECOMMENDED PROCESSES AND EQUIPMENT

The COOL ARC

40 is designed for use with watercooled TIG, MIG, PAC (Plasma Arc Cutting) and PAW (Plasma Arc Welding) guns and torches. The COOL

ARC

40 can be used with MIG wire feeders and

power sources as well as TIG power sources.

The following should always be observed when operating the COOL ARC

40:

• High voltage typical of welding operations can kill.

• Immersion in water around electrical lines can cause

electrical shock.

• Moving parts can injure. Never place fingers into

openings of Cooler.

• Never operate the cooler with any case parts off or

removed.

• Unplug the cooler before removing the wraparound

or servicing the unit.

• Unplug the cooler before filling the reservoir.

• 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.

• Do not remove the pump relief valve's 3/4" hex nut

or attempt to adjust the relief valve setting.

• Check the coolant reservoir level daily.

• Keep the reservoir full especially after changing any

water lines.

40 is a continu-

40 can operate in

B-1

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

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

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

• Avoid 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.

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

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

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

TURNING THE SYSTEM "ON"

After connecting the COOL ARC tion instructions above, plug the unit into a International 230V electrical receptacle for start-up operation. Be certain that the power input into the unit matches the Cooler's rated input.

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

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

The coolant FLOW INDICATOR is accessed by removal of the fill cap. Actual return flow is directly visible, via the fill opening with the unit in the vertical or horizontal position.

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

40 per the installa-

COOL ARC

Page 13

B-2

OPERATION

COOLING EFFICIENCY

The high cooling efficiency of the COOL ARC

40 offers a cooler, more comfortable weld than conventional air-cooled procedures as well as leading competitors water cooled systems.

B-2

For example:

Unlike other water coolers that depend on bulky reservoir size, the high efficiency components of the COOL

ARC

40 allows the reservoir size to be small. The

result is a lightweight, portable unit.

The COOL ARC

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

40.

FIGURE 6

Coolant Circulation Diagram

ROOM AIR

FAN

PUMP

COOLANT

RETURN

HEAT

EXCHANGER

COOLANT

INTAKE

HEATED AIR OUT

NOTE:

COOLANT

COOLANT

OUT

COOLANT

BLUE HOSE

RED HOSE

FIGURE 7

COOL ARC® 40 WATER COOLER

COOLANT "OUT"

PUMP

COOL-ARC 40

COOL ARC

HEAT

"IN"

WELDING

TORCH

GUN

COOLANT

RESERVOIR

COOLANT "IN"

AIR

FAN

HEAT

EXCHANGER

FLOW

3-23-2001

M19724

Page 14

C-1

ACCESSORIES

OPTIONAL EQUIPMENT (Field Installed)

K559-2 Cooler Horizontal Mounting Bracket:

Mounts the COOL ARC power source, securing the cooler to the lift bale. The kit includes all necessary mounting hardware.

40 horizontally to the top of a

C-1

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

K529-10

Power Input Cable with Water and Gas Hoses:

K559-3 Cooler Vertical Mounting Bracket:

Mounts the COOL ARC

40 vertically to a power source that has a dual cylinder undercarriage already installed. The bracket securely mounts the cooler to the dual cylinder support bracket. The kit includes all necessary mounting hardware.

K1536-1 Magnum Flow Sensor:

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

KP1529-1 Quick Connect Water Adapter:

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

K1859-1 Water Cooler Hoses

(5/8" LH CGA to QD):

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

K1859-2

Water Cooler Hoses

(5/8" LH CGA to 5/8 LH CGA)

This kit includes two 7.6m(25 Ft.)-4.7mm(3/16”) inside diameter hoses with a 5/8”LH CGA style fitting on both ends. Hoses can be mated with KP1529-1 for a water Cooler to MIG gun application. Ideal for water Cooler to Machines or wire feeders with 5/8”LH CGA style fittings.

Field Installed CGA style hose fittings:

Fittings to convert a standard 4.7mm(3/16") I.D. hose to a 5/8"-18 left hand male hose fitting. These male fittings mate with the fittings on the back of the Cool-Arc

40.

Order the following:

(2) Connector Nuts (T15007-2) (2) Nipples for 3/16" I.D. Hose (T15008) (2) Hose Clamps (S10888-35)

This cable assembly includes the following: (1) power cable, (1) control cable, (1) gas hose and (2) water hoses. The cable assembly connects a power source to a wire feeder for water-cooled MIG applications. The cable length is 10'. 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

40 that is vertically mounted at the rear

of a power source on a dual cylinder undercarriage.

Refer to Figure 5 for an illustration of this connection.

KP504 TIG Hook Up Kit:

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

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.

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

Coolant Hoses:

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

For lengths of coolant hoses over 7.6m(25 Ft.) and up to 15.2m(50 Ft)., 7.9mm(5/16”) I.D. hose is recommended. 7.9mm(5/16”) I.D. hose and accommodating fittings are available from an industrial welding supplier.

40. When a solenoid valve clos-

COOL ARC

Page 15

D-1

SAFETY PRECAUTIONS

WARNING

MAINTENANCE

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

D-1

ELECTRIC SHOCK can kill.

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

• Do not operate with covers

removed.

• Use only grounded receptacle.

• Do not remove the power cord ground prong.

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

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

See additional warning information at the front of this operatorʼs manual.

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

ROUTINE MAINTENANCE

Remove accumulated dust and dirt from the internal components of the cooler by blowing it out with a lowpressure air hose or removing it with a vacuum hose.

PERIODIC MAINTENANCE

In dirty or dusty environments or if biological growth occurs in the coolant, it may be necessary to flush the coolant reservoir. Drain the old coolant, rinse the inside of the reservoir and circulate rinsing solution through the coolant system. Add new coolant when cleaning is finished. It is recommended to flush the coolant at least once a year. A cooling system free from debris offers increased cooling efficiency and longer pump and torch life. See the Coolant Treatment Recommendation in this “Section D-2”.

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

PUMP MAINTENANCE

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

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

• Drain the coolant reservoir and all coolant lines. Dispose

of the coolant properly as specified in NOTE above.

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

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

• For a more in depth procedure, See Section D-2, “Pump Inlet Strainer”.

PUMP MOTOR

The COOL ARC®40 is rated for continuous operation. It is recommended to re-oil the pump motor bearings once a year as follows:

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

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

HEAT EXCHANGER

To maintain maximum cooler efficiency, the heat exchanger should be kept free of dust and dirt buildup. Clean the heat exchanger periodically using a vacuum hose or a low-pressure air line. Avoid placing the unit near a flux hopper or a flux waste container. A clean heat exchanger offers better cooling performance and longer product life. In extremely dirty environments, it may be necessary to remove the heat exchanger completely from the cooler and clean the fins with soap and water. Use care to avoid damaging the fins.

RESERVOIR COOLANT LEVEL

The reservoir volume should be checked daily before using the cooler. Remove the reservoir fill cap and check the coolant level. The reservoir is full when the coolant level is just below the reservoir fill opening with the unit in the upright position. Keep the reservoir full, especially after disconnecting the water lines or changing the accessory being cooled.

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

COOL ARC

Page 16

D-2

MAINTENANCE

D-2

COOLANT TREATMENT

PUMP INLET STRAINER

RECOMMENDATION

This procedure is intended to provide a means of reducing the objectionable amount of fungal and bacterial contamination that has occurred in systems.

Additive:

The recommended additive can be purchased at local pool supply stores. An example is "Maintain Pool Pro 30% Non-Foam Algaecide".

Limitations:

• This additive should be used with fresh coolants containing only pure water.

• This additive should not be used with coolants containing any other substance, including antifreeze substances.

• No other additives shall be used with the specified coolant that has been treated with the recommended additive.

• This procedure is no permanent substitute for a periodic maintenance schedule for the specified coolers

• A 1 quart bottle of additive is sufficient to disinfect and treat about 720 coolers.

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

Prepare the disinfectant:

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

8.775 liters(2.325 gals.) of pure, fresh water per cool-

er 1.625 ml of additive per cooler. Example: for 100 coolers, add 162.5 ml to 232.5 gals. of pure fresh water Pour 7.55 liters(2.0 gals.) of disinfectant into the empty reservoir. Recap the reservoir, tape over the air vent in the cap, roll disinfectant around the inside the reservoir to thoroughly coat all of its surfaces. Remove the tape from the reservoir cap. Prime the cooling system by positioning cooler horizontally and circulate disinfectant through it for 10 to 15 minutes. Drain disinfectant from the cooling system. Do not reuse this solution. Add new, fresh coolant to the cooling system. Add 1.225 liters(0.325 gals.) of fresh disinfectant to the system by pouring it into the reservoir, then reduce the concentration to the nominal 30 ppm:

Add the balance 6.325 liters(1.675 gals.) of fresh, pure water to the reservoir to create the treated coolant concentration. Prime the cooling system. Check coolant level. Add more fresh, pure water if required, without adding more than 0.475 liters(0.125 gal.) of pure water to prevent diluting the coolant additive.

COOL ARC®40

water coolers and cooling

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

• Voiding of cooler service warranty

• Cavitation damage to the pump headʼs inlet areas

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

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

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

Procedure and Preparation:

• Always switch off the COOL ARC power

• Always disconnect the COOL ARC from service input power.

• Always allow the coolant in the system to cool enough to avoid burn injuries.

• Avoid contact with contaminated coolant. Wear waterproof gloves and protective eye wear.

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

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

INSPECT CONDITION OF COOLANT

If coolant is contaminated or old:

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

• Flush system of old coolant.

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

• Proceed to adding coolant..

If coolant is clean and fresh:

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

WARNING

40 machine

COOL ARC

Page 17

D-3

MAINTENANCE

D-3

Removing Coolant:

a. Drain coolant from the reservoir using clean siphon-

ing equipment

b. Coolant level should be drained below the strainer-

pressure fitting:

• This prevents coolant from streaming out of unit when strainer nut is removed

SERVICE THE PUMPS INLET STRAINER:

a. Place absorbent towels underneath pump head to

prevent stray coolant from wetting coolerʼs electrical components.

b. See figure 7. Hold pump head to apply counter

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

c. Inspect strainer for damage or excessive clogging:

• Replace or Gently rinse strainer under running

water to thoroughly clean it.

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

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

e. Reinstall strainer and acorn nut, tightening with

34±15mm-Kilograms( 75±15 in.-lbs.) of torque.

• Hold pump head to apply counter-torque when

loosening strainers 7/8 acorn nut.

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

towels in an environmentally responsible manner.

Add coolant:

a. Add 7.6 ltr. (2 gal.) of coolant, either the recommen-

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

ADDITIONAL SERVICE NOTES:

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

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

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

FIGURE 7

COOL ARC

Page 18

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

COOL ARC®40

Page 19

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

Cooler does not operate with power switch "ON".

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

Torch or gun runs hot.

Fan operates but there is low coolant flow.

1. Input cord unplugged.

2. Power switch faulty

3. Power harness damaged.

4. Water lines blocked or crimped.

5. Leak in gun or water hoses.

6. Coolant reservoir empty.

7. The system needs to be primed

1. Hose clamp loose on one of internal hoses.

2. Internal hose punctured.

3. Heat exchanger leaking.

4. Pump seal is leaking

1. Unit placed by area of extreme heat.

2. Low coolant flow.

3. No coolant flow.

4. Fan not operating.

5. Heat exchanger clogged.

1. Leak in torch/gun or hoses.

2.Torch/gun or hoses partially

obstructed.

3. Reservoir empty or very low.

4. Pump strainer is dirty.

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

your local Lincoln Authorized Field Service Facility.

Fan operates but there is no coolant flow.

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

Cooler trips outlet circuit breaker.

1. Pump or pump motor failure.

2. Pump strainer is blocked.

1. Loose or disconnected fan lead.

2. Obstruction in fan blade.

3. Fan motor failure.

1. Circuit overloaded.

2. Fan or pump motor failure.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

COOL ARC®40

Page 20

F-1

DIAGRAMS

F-1

M20078

0 WATER COOLER

COOL ARC® 4

MTR2

G1 - FAN SHROUD GROUND

CONNECTION(CUSTOMER

GROUND)

G2 - BASE GROUND CONNECTION

G3 - CHASSIS GROUND CONNECTION

(FAN SHROUD)

P1 - INPUT POWER PLUG

SW1 - POWER SWITCH

MTR1 - PUMP MOTOR

MTR2 - FAN MOTOR

MTR1

50/60 HZ

SW1

INPUT: 230 V

COOL ARC®40

ELECTRICAL SYMBOLS PER E1537

COLOR CODE: B - BLACK OR GRAY

W - WHITE

G - GREEN

BR- BROWN

BL- BLUE

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Page 21

F-2

DIMENSION PRINT

34.26

F-2

L11540

FILL CAP

2.27

9.10

9.03

COOL ARC®40

Page 22

NOTES

COOL ARC® 40

Page 23

PARTS LIST FOR

COOL ARC

P-385P-385

This parts list is provided as an informative guide only.

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

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

COOL ARC

Page 24

ILLUSTRATION OF SUB-ASSEMBLIES

P-385-AP-385-A

COOL ARC

10-11-2011

Page 25

P-385-A.1P-385-A.1

COOL ARC®40

For Codes: 10791, 10928, 11066, 11067, 11577, 11845, 11846 & 11847

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

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

Sub Assembly Item

No.

SUB ASSEMBLY

PAGE NAME

Optional Equipment

PAGE NO.

CODE NO.

10791 1 1 1

10928 1 2 2

11066 1 3 1

P-385-B.1

Miscellaneous Items

P-385-B.2

Case Front & Handle Assembly

P-385-C

Reservoir & Fan Assembly

P-385-D

11067 1 4 2

11577 1 5 1

11845 133

11846 153

11847 144

COOL ARC

10-11-2011

Page 26

OPTIONAL EQUIPMENT LISTING

Miscellaneous Options Available for your machine are listed below:

# Indicates a change this printing.

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER

Cooler Horizontal Tig Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K559-2

Cooler Vertical Mig Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K599-3

Magnum Flow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1536-1

Quick Connect Water Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP1529-1

Water Cooler to Wire Feeder Hoses (CGA to Q.D. Fittings) . . . . . . . . . . . . . . . . . . . .Order K1859-1

Power Input Cable with Water and Gas Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K529-10

Water Cooler Hoses ( CGA to GCA Fittings ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1859-2

P-385-B.1P-385-B.1

COOL ARC®40

10-11-2011

Page 27

P-385-B.2

MISCELLANEOUS ITEMS

(THESE ITEMS ARE NOT ILLUSTRATED)

P-385-B.2

# Indicates a change this printing.

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

DESCRIPTION PART NO. QTY. 123456789

Multi-Lead S25127-1 1 X Multi-Lead S25127-2 1 X Lead S25127-3 1 X Flow Diagram M19724 1 X

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Case Front & Handle Assembly

14C

14B

14A

14D

20A

P-385-CP-385-C

14C

14A

14B

14D

20A

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P-385-C.1

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

Case Front & Handle Assembly, Includes: G3885 1 X • X • X

Case Front & Handle Assembly, Includes: G4279 1 • X • X • 1 Case Front & Handle G3905 1 XXXXX 3 Motor Mounting Bracket & Hardware See P-385-D 1 XXXXX 4 Nameplate M19709 1 XXXXX 5 Switch-SPST, Lighted T10800-40 1 X • X • X 5 Switch-DPST T10800-58 1 • X • X • 6 Thread Forming Screw S9225-68 4 XXXX• 6 Thread Forming Screw S9225-92 4 ••••X 7A Wraparound G3888 1 XXXXX 7B Wiring Diagram M19721 1 X • X • X 7B Wiring Diagram M20078 1 • X • X • 7C Self Tapping Screw S8025-91 6 XXXX• 7C Selt Tapping Screw S8025-110 6 ••••X 8 Rating Plate & Warning Decal M19711 1 X •••• 8 Rating Plate & Warning Decal M20079 1 • X • • • 8 Rating Plate & Warning Decal M19711-3 1 • • X • X 8 Rating Plate & Warning Decal M20079-1 1 •••X• 9 Label-Coolant Addition Decal S24965 1 XXXXX 10 Decal-Coolant Level Decal S25103 1 XXXXX 11 Base G3887 1 XXXXX 12 Input Cord S15254-20 1 X • X • X 12 Input Cord S19836-4 1 • X • X • 13 Grommet-Input Cord Strain Relief T9274-2 1 X • X • X 13 Grommet-Input Cord Strain Relief T9274-12 1 • X • X • 14 Connector Assembly, Includes: S24977 1 XXXXX 14A Connector Plate S24978 1 XXXXX 14B Connector T14557-22 2 XXXXX 14C Retaining Ring S9776-7 2 XXXXX 14D Thread Forming Screw S9225-91 1 XXXXX 15 Thread Forming Screw S9225-68 4 XXXX• 15 Thread Forming Screw S9225-92 4 ••••X 16 Decal S25182 1 XXXX•

Ground Screw Assembly, Includes: 20A Thread Forming Screw S9225-88 1 XXXXX 20B #10-24 HN (Not Shown) CF000010 1 XXXXX 20CLock Washer (Not Shown) T9695-1 1 XXXXX

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Reservoir & Fan Assembly

14B

14C

14A

P-385-DP-385-D

14B

14A

14C

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P-385-D.1

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Reservoir Assembly, Includes: G3904 1 XXXX 1A Reservoir Cap (Snap In) S24964 1 X • • • 1A Reservoir Cap (Threaded) S24964-1 1 XXXX 1B Hose Fitting Assembly S24966 1 XXXX 1C Hose Fitting S24967 1 XXXX 1D Rubber Plug S19563 2 XXXX 1E 1/4-20 x .500 Aluminum Insert (Not Shown) S25106 4 XXXX 2 Fan Shroud Assembly (L11536), Includes: NSS 1X•X• 2 Fan Shroud Assembly (L11923), Includes: NSS 1•X•X 2A Fan Shroud (L11535) NSS 1 XX• • 2A Fan Shroud L11535-2 1 • • X X 2B Fan, 115 VAC M19076-1 1 X • X • 2B Fan, 230 VAC M19076-2 1 • X • X 2C Socket Head Cap Screw T9447-91 2 XXXX 2D Lock Washer T9695-3 2 XXXX 2E Ground Screw Assembly S18922-2 1 XXXX 2F Ground Screw Assembly (Customer) S18922 1 XXXX 2G 1/4-20 x 2.00 HHCS T8833-22 4 XXXX 2H Plain Washer S9262-98 4 XXXX 2J 1/4-20 HLN T9187-6 4 XXXX 2K Bottom Bracket S28618 1 • • X X 2L Top Bracket S28619 1 • • X X 3 Pump & Motor Assembly L11532-1 1 XXXX 3A Motor Assembly L11532-1A 1 XXXX 3B Pump Assembly L11532-1B 1 XXXX 3C V-Clamp Assembly (Not Shown) L11532-1C 1 XXXX 3D 3/8 NPT x 3/8 Brass Hose Fitting L11532-1D 2 XXXX 3E Coupling (Not Shown) L11532-1E 1 XXXX 3F Pump Motor Insulation (Not Shown) S25126 1 XXXX 3G 5/16-18 x .75 HHCS CF000040 4 XXXX 3H Plain Washer S9262-121 4 XXXX 3J Lock Washer E106A-14 4 XXXX 3K Pump Inlet Strainer (Not Shown) S24504-7 1 XXXX 4A E3911-.375 I.D. x .625 O.D. Tubing (Cut to Length) T10642-251

1.75Ft.XXXX

4B Hose Clamp S10888-35 2 XXXX 5 Heat Exchanger (M16385-5 1) NSS 1 XX• • 5 Heat Exchanger M16385-6 1 • • X X 6A 1/4-20 x 2.00 HHCS T8833-22 4 XXXX 6B Plain Washer S9262-98 4 XXXX 6C Hex Lock Nut T9187-6 4 XXXX 7 Mounting Bracket M19716 1 XXXX 8A E3911-.375 I.D. x .625 O.D. Tubing (Cut to Length) T10642-250

1.75Ft.XXXX 8B Hose Clamp S10888-35 2 XXXX 9 Earth Ground Connection Decal T13260-4 1 XXXX 12 Fan Guard S25680 1 XXXX 13 Fan Spacer S25681 1 XXXX 14A Socket Head Cap Screw T9447-22 2 XXXX 14B Lock Washer T9695-3 2 XXXX 14C #8-32 HN CF000042 2 XXXX 15A E3911-.375 I.D. x .625 O.D. Tubing (Not Shown) T10642-252 1 XXXX 15B Hose Clamp (Not Shown) S10888-35 2 XXXX

NSS - Not Sold Separately

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P-385-D.2

# Indicates a change this printing.

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

ITEM DESCRIPTION PART NO. QTY. 123456789

16A E3911-.375 I.D. x .625 O.D. Tubing (Not Shown) T10642-253 1 XXXX 16B Hose Clamp (Not Shown) S10888-35 2 XXXX

Note 1: Order S28949 Parts Order Kit for M16385-5 Heat Exchanger

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NOTES

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NOTES

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NOTES

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CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Lincoln Electric IM670 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual