Lincoln Electric IM696 User Manual
Operator’s Manual
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COOL ARC ®40 STAND ALONE WATER COOLER
For use with machines having Code Numbers:
10791, 11066, 11577, 11845,
11846
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM696-C | Issue D ate Oct-13
© Lincoln Global, Inc. All Rights Reserved.
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
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.
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.
3
SAFETY
ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin
or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
between the
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
with electrodes which require special ventilation
such as stainless or hard facing (see instructions
on container or MSDS) or on lead or cadmium
plated steel and other metals or coatings which
produce highly toxic fumes, keep exposure as low
as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or
mechanical ventilation. In confined spaces or in
some circumstances, outdoors, a respirator may
be required. Additional precautions are also
required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
3.j. Also see It ems 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employer’s
safety practices. MSDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
4
cause
SAFETY
WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily go through
small cracks and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures will
not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society (see address
above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in
Cylinders,” available
from the Compressed Gas Association 1235 Jefferson Davis
Highway, Arlington, VA 22202.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Welding Safety
Interactive Web Guide
for mobile devices
5
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions.................................................................................................A-2
Unpacking the COOL ARC
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
Safety Precautions.................................................................................................B-1
RODUCT DESCRIPTION ........................................................................B-1
P
Recommended Processes and Equipment.....................................................B-1
Turning the System “On”.................................................................................B-1
Cooling Efficiency............................................................................................B-2
________________________________________________________________________
®
40.......................................................................A-2
vi vi
Accessories .....................................................................................................Section C
Optional Equipment (Field Installed) ....................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance ......................................................................................D-1
Periodic Maintenance .....................................................................................D-1
P
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,F-2
Dimension Print......................................................................................................F-3
________________________________________________________________________
Parts List.................................................................................................................P-385
________________________________________________________________________
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: Clean tap, distilled or de-ionized water.
For Use Below Freezing:
DO NOT USE: Automotive anti-freeze that contains rust inhibitors or leak stoppers.
Recommended Coolant
Shipping
Weight
Reservoir
Full (Water)
These coolants will damage the pump and block the small internal passageways of the
heat exchanger, affecting cooling performance. To acquire the proper coolant contact
a local welding distributor.
DO NOT USE: Pre-packaged welding industry coolants
oil-based substances, which attack the plastic components of the cooler. Once added
to the cooler, these substances are virtually impossible to purge from the water lines
and heat exchanger.
◊
Magnum Pro AL coolant may be used.
K1813-1, -2 ( COOL ARC®40 115V )
VIA 3-Prong Plug NEMA Type 5-15P
100-120VAC 50/60 Hz 1 Phase
2.8-3.5 Amps
3.5-5.3 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)
L
W
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
ON
I
OFFOFF
O
COOL ARC®40
NTRL/C
IP 21S
o N80
A-2
INSTALLATION
A-2
SAFETY PRECAUTIONS
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
• Do not put your hands near operating fan.
• Keep all equipment safety guards, covers
and devices in position and in good repair.Keep
hands, hair, clothing and tools away from V-belts,
gears, fans and all other moving parts when starting,
operating or repairing equipment.
• In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when
the maintenance requiring their removal is complete.
Always use the greatest care when working near mov-
parts.
ing
---------------------------------------------------------------------
• 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®40
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.
unit is delivered empty with no coolant in the
COOL ARC®40
.
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®40
service.
for parts orders and future maintenance
FILLING THE COOLANT RESERVOIR:
Recommended Coolant
• For Use Above Freezing: Clean tap, distilled or de-ionized
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.
For best results when using the
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
the manufacturer's instruction manual for recommended
coolants.
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:
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.
COOL ARC®40
COOL ARC®40
D
CAUTION
with Lincoln
with other products, consult
COOL ARC®40
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.
The cooler is "FULL" when the coolant lies just below
the coolant reservoir opening with the cooler in the
upright (vertical) position.
A-3
Water or Coolant Line Connections
to the
COOL ARC®40
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.
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.
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.
FIGURE 1
Inlet and Outlet Hose Connection Diagram
(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
COOLANT
IN
FROM
HEAT
SOURCE
(RED)
COOL ARC®40
TO
HEAT
SOURCE
(BLUE)
COOLANT
OUT
A-4
INSTALLATION
A-4
Remove the connector nut from the INLET hose by
making a straight cut 1/4"-1/2" (6-12mm) 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 until the shoulder of the nipple 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 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.
®
40 fittings.
INPUT POWER CONNECTION
Plug the input power cord on the COOL ARC®40 into
a standard 115V NEMA 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.
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
HORIZONTAL POSITION. This will prevent the
cooler from being accidentally tipped over.
®
40 is not securely mounted hor-
®
40 MUST BE OPERATED IN THE
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
No
Yes
No
No
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. DO NOT USE A
WATER SOLENOID VALVE with the COOL ARC
Water pass-through connection kits are available for
wire feeders. Refer to product literature or the wire
feeder's instructions manual for kit availability and further connection details. It is not required to run the
water lines through the wire feeder, but is does provide a very neat MIG gun connection.If pass-through
water hoses are unavailable, connect the MIG gun as
shown in
®
40 is ready for connection to a water-
®
40 with water-cooled MIG gun.
®
40 with other water-cooled TIG
®
40, since the
Figure 4.
®
40 with
®
40 in
®
40.
FIGURE 2
Water Cooled TIG Torch Connection
A-5
CAUTION
DO NOT USE A WATER SOLENOID VALVE with
the COOL ARC
the pump would dead-head, causing the pump to
heat up excessively leading to premature failure of
the pump.
K529-10 POWER INPUT CABLE WITH WATER
AND GAS HOSES
This cable assembly includes a (1) power cable, (1)
control cable, (1) gas hose and (2) water hoses to
connect a power source to a wire feeder. The cable
length is 10'. The water hoses have 5/8"-18 left hand
male hose fittings and the gas hose has a 5/8"-18
right hand male hose fitting. The cable and hose
lengths are designed to connect a wire feeder to a
COOL ARC
of 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
IN
®
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
COOLANT
POWER SOURCE
GAS
OUT
IN
TO WORK
COOLANT
IN
K1859-1 FOR WIRE
FEEDERS WITH QUICK
DISCONNECT FITTINGS
ARGON GAS
CYLINDER
COOLANT
IN
GAS
COOLANT*
POWER CABLE ADAPTER*
POWER / COOLANT
COOLANT
GAS
COOLANT
OUT
COOLANT*
FEMALE TO FEMALE*
CGA FITTING
*INCLUDED IN
KP504 HOOK-UP KIT
FIGURE 3
Water Cooled MIG Gun Connection
COOLANT
OUT
COOLANT
COOLANT
KP504 FOR HOOK-UP
TO WIRE FEEDERS
WITH CGA FITTINGS
COOLANT
COOLANT
GUN CABLE
NOTE:
COOLANT
COOLANT
REGULATOR
FLOWMETER
GAS*
=
OUT
=
IN
BLUE HOSE
RED HOSE
TIG TORCH
KP504-WATER HOSES AND
FEMALE TO FEMALE 5/8" LH
CGA ADAPTER COUPLINGS
GUN CABLE
FIGURE 5
Connection to Wire Feeder (Do Not Use Water Solenoid)
SHIELDING
OUT
GAS
K529-10
IN
OUT
NOTE:
COOLANT
GUN CABLE
COOLANT
OUT
COOLANT
IN
COOLANT
=
BLUE HOSE
=
RED HOSE
CONTROL CABLE
TO WORK
COOLANT
IN
COOLANT
COOLANT
ELECTRODE CABLE
NOTE:
ORDER K1859-1 ALONG WITH
K529-10 FOR WIRE FEEDERS
WITH QUICK DISCONNECT
FITTINGS.
COOLANT
COOL ARC®40
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