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Lincoln Electric IM670-A User's Manual
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1. COOL ARC 40 STAND ALONE 1M670 A WATER COOLER mm For use with machines having Code Numbers 10928 11067 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 thought ful operation on your part DO NOT INSTALL OPERATE OR o REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY A PRECAUTIONS CONTAINED J THROUGHOUT And most O importantly think before you act and be careful LINCOLN E Copyright O Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY 44 WARNING A CALIFORNIA PROPOSITION 65 WARNINGS N Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOU
2. 2 Hose Clamps FIGURE 1 Inlet and Outlet Hose Connection Diagram HEAT RED CN Sa COOLANT SOURCE 5 BLUE COOL ARCO 40 LINCOLN B A 4 INSTALLATION 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 until the shoulder of the nip 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 proce dure for the OUTLET hose When complete follow the connection procedure detailed above for connecting the hoses to the COOL ARCO 40 fittings 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 INPUT POWER CONNECTION Plug the input power cord on the COOL ARCO 40 into a standard 230V circuit breaker protected receptacle INSTALLATION ON UNDERCARRIAGE OR POWER SOURCE The COOL ARCO 40 can be mounted either horizon tally or vertically on a power source To mount the cooler horizo
3. HAY AIR ok US ETS BHE asil aa lal GU dl Catia Llar Jub al gl y g l gal latas al y L LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB S TE www lincolnelectric com
4. WATER SOLENOID VALVE with the COOL ARCO 40 When a solenoid valve clos 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 acces sory 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 recom mended 7 9mm 5 16 LD hose and accommodating fittings are available from an industrial welding suppli er COOL ARCO 40 LINCOLN B D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS 4A WARNING 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 operator s manual ROUTINE MAINTENANCE x Remove accumulated dust and dirt from the internal components of the cooler by blowing it out with a low pressure 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 necessar
5. are unavailable connect the MIG gun as shown in Figure 4 FIGURE 2 Water Cooled TIG Torch Connection REGULATOR FLOWMETER ARGON GAS CYLINDER COOLANT COOLANT G our COOLANT SE TIG TORCH COOLANT _ FEMALE TO FEMALE CGA FITTING POWER CABLE ADAPTER Le POWER COOLANT INCLUDED IN KP504 HOOK UP KIT FIGURE 3 Water Cooled MIG Gun Connection GUN CABLE NOTE COOLANT e QUANT BLUE HOSE RED HOSE KP504 FOR HOOK UP TO VVIRE FEEDERS WITH CGA FITTINGS K1859 1 FOR WIRE FEEDERS WITH QUICK DISCONNECT FITTINGS CAUTION DO NOT USE A WATER SOLENOID VALVE with the COOL ARCO 40 When a solenoid valve clos es the pump would dead head causing the pump to heat up excessively leading to premature failure of the pump K529 10 POWER INPUT CABLE WITH WATER AND GAS HOSES This cable assembly includes a 1 power cable 1 control cable 1 gas hose and 2 water hoses to connect a power source to a wire feeder The cable length is 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 ARCO 40 that is vertically mounted at the rear of a power source on a dual cylinder undercar riage Refer to Figure 5 for an illustration of this connection FIGURE 4 Connection to Wire Feeder Do Not Use Water Soleno
6. hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da e Isole se da peca e terra REPORTED MARHE FPRANERCMNEUYTIE OMLMYT APSSAPHBA NTWSRILTFEU e REA SUR xy ik EE TE RS ER f B ORIIBIERRIT FR e Sea SAHE Ne mc qe Hu Sal OAL e ua HAE HFA AR Juil m os el y oye 31 g li a 2 gl lh El et usa asli DU deg Je Yo e Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos T KE KAN liebe CC OK KEE At ES ZEWE IR EE f ik JL ek HER CH o dem 84758 Belle s xld m 8971 HHPI A4 21247 L 5528 ASSHAR a oe Lenz dal and e TJAN al bia si ac Jaial Les oak Al Ahlat Ge RAN sas lt l Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIE
7. left hand male hose fitting These male fit tings 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 1 Hose T15008 2 Hose Clamps 810888 35 ACCESSORIES 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 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 ARCO 40 that is vertically mounted at the rear of a power source on a dual cylinder undercar riage 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
8. power switch in the 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 reser voir Never run pump dry TURNING THE SYSTEM ON After connecting the COOL ARCO 40 per the installa 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 1 and OFF when pressed to O You will be able to hear the fan running and feel air flow 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 vis ible 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 co
9. properly cleaned pump inlet strainer should restore the cooler s performance For additional service and periodic maintenance details and for recommended coolants follow the rec ommendations listed below Procedure and Preparation 44 WARNING Always switch off the COOL ARCO 40 machine power Always disconnect the COOL ARCO 40 machine 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 valve s 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 min utes 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 COOL ARCO 40 LINCOLN B 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
10. puncture the plastic reservoir Below is the recom mended procedure for unpacking the Cooler Open top flap where identification label appears Remove loose items and top insert Open bottom flap e 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 sup plied with the COOL ARCO 40 for parts orders and future maintenance service 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 glycol 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 pas sageways 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 sub stances are virtually impossible to purge from the water lines and heat exchanger To avoid freeze damage and water leakage in ship ment the COOL ARCO 40 unit is delivered empty with no coolant in the system To fill the unit locate the plastic Snap On reservoir fill cap at the front mid dle of the unit Remove the fill cap by pressing the
11. to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 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 2 d 5 Do not work next to welding power source Mar 95 COOL ARCO 40 LINCOLN B 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
12. 2 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 sys tem by positioning cooler horizontally and circulate dis infectant through it for 10 to 15 minutes Drain disin fectant 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 addi tive PUMP INLET STRAINER 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 head s inlet areas Welding accessory damage from overheating due to insufficient coolant flow rate A new or
13. 8 18 8 H9 N33H9 9 3LIHM M YO 19V 8 4402 4 16513 34 S IOSINAS 1VOIHLO3 13 COOL ARCO 40 LINCOLN E e LL DIMENSION PRINT F 2 Jequunu epoo ueu d nbe ay an 1ueu eosjde e 40 juawuedag 99IAJ9S ay 0 IUM s eu U sjeued einsojoue y jo euo uo euigoeu eui episul p sed s epoo Jejnonted e 10 WeiBelp ouioeds oul jenueuu siy Aq peJeAoo seulyoeu WE 40 ayeunooe eq jou eu y OvSLET V Ajuo e2u84J9j9J 104 SI WeIBeIp 5141 LON 9c ve NN UG Orar A CC CC C r LKR o o dv9 111 COOL ARCO 40 LINCOLN E NOTES COOL ARCO 40 LINCOLN B Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENC O Japanese dam Korean e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e No toque las partes o los electrodos bajo carga con la piel o ropa moja d a e Aislese del trabajo y de la tierra e Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Ber hren Sie keine stromf
14. 90 9101 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged A 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 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 Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in Oylinders 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 Ins
15. ARCO 40 eene A 2 Filling the Coolant Reservoir A 2 Coolant In and out Connections A 3 Input Power Connechon eiciia irn anana da aoei a nekanan aiaa A 4 Installation on Undercarriage or Power Source A 4 Horizontal Installation on the Top of a Power Gource 522 A 4 Vertical Installation on Power Source with a Dual Cylinder Undercarriage A 4 Installation of Water Cooled 5801165 A 5 Water Cooled TIG Torch and MIG Gun ss A 5 Connection to Wire Feeders iid kk kek kek k ke kk kk KAK AKA KAK KA A 5 K529 10 Power Input Cable with Water and Gas Hoses A 5 OPIO M Section B PRODUCT DESCRIPTION 1 Recommended Processes and Equipment B 1 Tumino the System OM a uersu poen ete aia B 1 Cooling E TICIOm Cy dicci n B 2 Jing Section C Optional Equipment Field Installed C 1 Elder I an n Section D Safety rre ian D 1 ROUTINE MAINTENANCE y ka a b AA ER Pe Od adi rk a nada D 1 Periodic Maintenance sise D 1 PUMP mein D 1 PUMP MOTON eI D 1 Heat en Ee D 1 R servoir Coolant LOVE D lcd D 1 Coolant Treatment D 2 Pump Inlet uli ei D 2 Inspect Condition of Coolan
16. Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L 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 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 expo
17. INLET STRAINER a Place absorbent towels underneath pump head to prevent stray coolant from wetting cooler s electrical components b See figure 7 Hold pump head to apply counter torque when loosening strainer s 7 8 acorn nut Do not confuse with 3 4 acorn nut Remove nut and slide inlet strainer down and out from pump head 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 75215 in Ibs 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 o MAINTENANCE D 3 Add coolant a Add 7 6 lir 2 gal of coolant either the recommen dations off the vvater 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 recommend ed coolant otherwise pump damage may result 3 Flush coolant from system and replace
18. NDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN e Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone e Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca e Use ventilac o e exhaust o para remover fumo da zona respirat ria e L1 APDOREMSESIELT Fabs O HH KC TDEHEBU CES R PARER dc EUR Ee fE RUR Hak BE dun 3871248 HUMAL e S XACA E amp S7 E MAS A4 Lait 387E ARSgSHMAIS s oe La duly sui e GAN al ia Ja d aach Serial e E Qad uil A oe gaal sag Lus e Turn power off before servicing e Desconectar el cable de ali
19. Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 COOL ARCO 40 LINCOLN B V V for selecting a QUALITY product by Lincoln Electric We want you Tha OT to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment 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 posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s par
20. S 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 amp 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 of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 h To avoid scalding do not remove the radiator pressure cap when the engine is 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 23 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 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 spille
21. THE COOLANT RESERVOIR UPRIGHT VERTICAL e 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 ARCO 40 LINCOLN B A 3 INSTALLATION A 3 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 NOTE DO NOT ADD MORE THAN 2 GALLONS 7 6 LITERS OF COOLANT INTO THE RESER VOIR 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 ARCO 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 ARCO 40 are two female 5 8 18 left hand threaded fit
22. ary 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 wet ted 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 ARCO 40 is rated for continuous opera tion 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 build up Clean the heat exchanger periodically using a vac uum 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 perfor mance and longer product life In extremely dirty envi ronments 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
23. 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 COOL ARCO 40 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 dis posal methods or for recycling information For best results when using the COOL ARCO 40 with Lincoln guns or torches use distilled or de ionized water although if not available tap water can be used If protection from freezing is desired use a 50 water and 5096 pure ethylene glycol reagent or industrial grade mixture An alcohol and water mix ture is also acceptable When using the COOL ARCO 40 with other products consult the manufacturer s instruction manual for rec ommended coolants CAUTION DO NOT USE OIL BASED COOLANTS OR COOLANTS THAT CONTAIN RUST INHIBITORS OR LEAK STOP PERS The unit can be filled either vertically or horizontally UNPLUG THE COOLER BEFORE FILLING
24. d fuel from vaporiz ing 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 lt Q moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known 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 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 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 Do not put your hands near the engine fan Do not attempt
25. e is low coolant 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 Fan operates but there is no coolant 1 Pump or pump motor failure flow 2 Pump strainer is blocked Pump operates but fan does not 1 Loose or disconnected fan lead Cooler trips outlet circuit breaker 2 Obstruction in fan blade 3 Fan motor failure Cooler trips outlet circuit breaker 1 Circuit overloaded 2 Fan or pump motor failure 44 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 ARCO 40 LINCOLN B Vi Jequunu epoo 1ueuidinbe y SAME jueueoe dai e Jo juauuedag 291S v o 9 lJM eidelt 51 ureiSeip ay j Si ued einsoj oue y jo euo uo y LL p sul p sed s po Jejnonued e 104 wesbelp 2uede ay penueuu siy Ag p 4 AO saulyoeuu je 40 e1e4n99e eq jou eu y AjUO e2u949J8J 40 SI WIBABEIp SIUL ALON 81002 NV4 ZALIN YOLOW dd HLN HOLIMS H3MOd LMS 9N1d YIMOd LNANI Ld ZH 09 08 INOYHS NV VI NOLLO3NNOO UNNOYOI SISSVHO 9 A 0 Z LN NOILOZNNO9 3SV8 Z GNTOM H43INOLSTO NOLLO4NNO GNTOM GNOYHS NV4 LO DIAGRAMS 431002 OIAV 1009 F 1 301
26. g Bracket Mounts the COOL ARCO 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 25 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 feed er 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 fit tings Field Installed CGA style hose fittings Fittings to convert a standard 4 7mm 3 16 I D hose to a 5 8 18
27. gas and other irritating prod ucts 5 d Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 5f AUG 06 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 Also see item 1 b COOL ARC 40 LINCOLN B 6 j SAFETY 3 7 WELDING and CUTTING SPARKS 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 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 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 Do not heat cut
28. id KP1529 1 j FEMALE TO FEMALE 5 8 LH CGA ADAPTER COUPLINGS COUPLINGS ONLY COOLANT COOLANT COOLANT 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 TO WORK ORDER K1859 1 ALONG WITH K529 10 FOR WIRE FEEDERS WITH QUICK DISCONNECT FITTINGS BLUE HOSE RED HOSE COOL ARC 40 LINCOLN B B 1 OPERATION B 1 PRODUCT DESCRIPTION The COOL ARCO 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 water cooled TIG torches The COOL ARCO 40 is a continu ous duty cooler The overall size and shape of the cooler is identical to the Magnum 20 The COOL ARCO 40 can operate in either the vertical or horizontal position The COOL ARCO 40 is very easy to use and understand with only one power switch on the control panel The cool er 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 ARCO 40 coolant flow is circulated through a heat exchanger to remove heat e
29. identally tipped over K559 2 Cooler Horizontal Mounting Bracket Can be used On Top of a Power Source K874 Undercarriage Not Available Not Available Not Available Not Available Not Available K932 1 Undercarriage Not Available K1570 1 Undercarriage Not Available COOL ARCO 40 LINCOLN B A 5 INSTALLATION A 5 INSTALLATION OF WATER COOLED ACCESSORIES After following the installation instructions above the COOL ARCO 40 is ready for connection to a water cooled accessory WATER COOLED TIG TORCH AND MIG GUN Follow Figure 2 when using the COOL ARCO 40 with water cooled TIG torches Follow Figure 4 when using the COOL ARCO 40 with water cooled MIG gun Consult the manufacturer s instruction manual when using the COOL ARCO 40 with other water cooled TIG and MIG accessories CONNECTION TO WIRE FEEDERS Follow Figure 3 when using the COOL ARCO 40 in conjunction with a wire feeder The feeder will need to have pass through water hoses installed in order to correctly function with the COOL ARCO 40 since the cooler requires continuous flow DO NOT USE A WATER SOLENOID VALVE with the COOL ARCO 40 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 fur ther connection details It is not required to run the water lines through the wire feeder but is does pro vide a very neat MIG gun connection lf pass through water hoses
30. mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarheiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas XLFFYA F EACRUP PSR TER F4 d l CT e MER BEEN eS HO AAS datz Ala Ay dai J 0 46 juil e e Do not operate with panel open or guards off No operar con panel abierto guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos 0u guardas removidas NEVRPAN ERYALEEE dalar CARITA SAR ARTS Ko ego del Yala Ss THAS h Yi cuts ll Ha gaii Y e ae cud Ail dl ayaat AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O tie SIR Chinese Korean LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR ESMERO x 2 DETEE LORA TEMUCEF U CUCRHEOE EME Ni CF We ah ET AN DE HA l HE AZ BNI XES RR HE Ut 19 BI BA D OR RE EK fE A 19 18 55 F ian GE US HAM 55 f BERTE o Alo AAAS oot Axe
31. nergy from the coolant The coolant flow is then deposited into the coolant reservoir The pump draws its coolant sup ply from the coolant reservoir and delivers coolant to the welding torch or gun Refer to Figure 6 RECOMMENDED PROCESSES AND EQUIPMENT The COOL ARCO 40 is designed for use with water cooled TIG MIG PAC Plasma Arc Cutting and PAW Plasma Arc Welding guns and torches The COOL ARCO 40 can be used with MIG wire feeders and power sources as well as TIG power sources The following should always be observed when oper ating the COOL ARCO 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 The cooler should be turned OFF when welding is not taking place for long periods of time Be certain that the cooler is ON
32. ntally order the K559 2 Cooler Horizontal Mounting Bracket To mount the cooler ver tically on a power source with a dual cylinder under carriage order K559 3 Cooler Vertical Mounting Bracket K559 3 Cooler Vertical Mounting Bracket on a Dual Cylinder Undercarriage 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 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 ARCO 40 to be mounted hori zontally on top 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 ARCO 40 to be mounted vertically at the rear of the machine on the gas bottle rack 44 WARNING If the COOL ARCO 40 is not securely mounted horizontally 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 acc
33. oling performance low welding component life and potential electrical safety hazards COOL ARCO 40 LINCOLN B B 2 COOLING EFFICIENCY The high cooling efficiency of the COOL ARCO 40 offers a cooler more comfortable weld than conven tional air cooled procedures as well as leading com OPERATION B 2 For example Unlike other water coolers that depend on bulky reser voir size the high efficiency components of the COOL ARCO 40 allows the reservoir size to be small The petitors water cooled systems result is a lightweight portable unit The COOL ARCO 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 tempera ture of the COOL ARCO 40 FIGURE 6 Coolant Circulation Diagram HEATED AIR OUT TT COOLANT OUT COOLANT IN BLUE HOSE REDHOSE COOLANT RETURN COOLANT OUT COOLANT IN VVELDING OR GUN EXCHANGER O FAN COOLANT RESERVOIR 3 23 2001 M19724 COOL ARCO 40 LINCOLN B C 1 OPTIONAL EQUIPMENT Field Installed K559 2 Cooler Horizontal Mounting Bracket Mounts the COOL ARCO 40 horizontally to the top of a power source securing the cooler to the lift bale The kit includes all necessary mounting hardware K559 3 Cooler Vertical Mountin
34. 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c 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 0226
35. position Keep the reservoir full especially after disconnecting the water lines or changing the accessory being cooled COOL ARCO 40 LINCOLN B D 2 MAINTENANCE D 2 COOLANT TREATMENT RECOMMENDATION This procedure is intended to provide a means of reducing the objectionable amount of fungal and bacterial contamination that has occurred in COOL ARCO 40 water coolers and cooling systems Additive The recommended additive can be purchased at local pool supply stores An example is Maintain Pool Pro 3096 Non Foam Algaecide Limitations This additive should be used with fresh coolants con taining only pure water This additive should not be used with coolants con taining any other substance including antifreeze sub stances 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 peri odic 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 compati ble with your equipment Prepare the disinfectant Make a quantity of only what is needed to avoid an excess Bulk preparation for coolers serviced in quan tity 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 16
36. r affecting cooling performance To acquire the proper coolant contact a local welding distributor 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 Shipping 46 5 Ibs 21 1 kg Weight Reservoir 61 2 Ibs 27 8 kg Full Water L 9 03 in 229 4mm W 9 10 in 231 1mm Dimensions H Top Face 31 99 in 812 6mm H Top Handle 34 26 in 870 2mm EXPLANATION OF SYMBOLS THAT APPEAR ON THIS EQUIPMENT ON O COOL ARCO 40 LINCOLN B A 2 INSTALLATION A 2 SAFETY PRECAUTIONS 44 WARNING ELECTRIC SHOCK can kill 5 9 Disconnect input power by remov ing 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 main tenance 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 thrust ing sharp objects through the carton liner which may
37. r le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER 3 Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes
38. se 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 below Threshold Limit Values TLV 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 spe cific 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
39. ssible 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 44 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 LINCOLN B E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION Cooler does not operate with power 1 Input cord unplugged switch ON Power switch faulty Power harness damaged Water lines blocked or crimped Leak in gun or water hoses Coolant reservoir empty The system needs to be primed Switch pushed to I position Hose clamp loose on one of inter Internal water leak nal hoses Internal hose punctured Heat exchanger leaking Pump seal is leaking If all recommended possible areas of misadjustment have been checked Torch or gun runs hot Unit placed by area of extremeland the problem persists Contact heat your local Lincoln Authorized Low coolant flow Field Service Facility No coolant flow Fan not operating Heat exchanger clogged Fan operates but ther
40. t oii ciar irc rca D 2 Service the Pump Inlet Filter D 3 Additional Service Notes D 3 AAPP AA Section E Safety Precautions C d a E 1 How to Use Troubleshooting Guide E 1 Troubleshooting Guide du cak nak d n di tri es fenetres E 2 Wiring HRC LE Section F A RD F 1 DIMENSION Priscila DEL F 2 Parts BR CC O E E EWE WES DERE a KWE SE TOK DEWA RESA WISE VAR case P 385 INSTALLATION TECHNICAL SPECIFICATIONS COOLARC 40 Product No Model K2187 1 COOL ARCO 40 230V International Via Continental European SCHUKO PRONG PLUG Input 220 240VAC 50 60 Hz 1 Phase Current Draw 60Hz Input 1 3 1 7 Amps Current Draw 9 50Hz Input 2 0 2 4 Amps Maximum Operating Pressure and Flow Rate 60 psi 414 kPa 4 14 bar Max Open Flow Without Welding Torch Restriction 1 66 gal min 6 28 liter min Max Typical Operating Pressure and Flow Rate 53 57 psi 365 393 kPa With Welding Torch Restriction 45 60 gal min 1 7 2 3 liter min Reservoir Size 2 0 ga 7 6 liters For Use Above Freezing Use Clean tap distilled or de ionized water For Use Below Freezing Use 50 water and 50 pure ethylene glycol reagent or industrial grade mixture DO NOT USE Automotive anti freeze that contains rust inhibitors or leak stoppers Recommended Coolant These coolants will damage the pump and block the small internal passageways of the heat exchange
41. tall equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations COOL ARCO 40 LINCOLN B i SAFETY S PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simul
42. tan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pou
43. ticular 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 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 Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever
44. tings CGA Style These mate with water hoses typically used in the welding industry Refer to Figure 1 Water or Coolant Line Connections to the COOL ARCO 40 Take the connector nut of the water hose and check if the thread of the male connector nut matches the 5 8 18 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 ARCO 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 ARCO 40 order the following See Parts Lists for Item s below 2 Connector Nuts 2 Nipples for 3 16 1 D hose
45. with fresh recommended coolant at least once a year More frequent flushing may be necessary depending upon the user s particular system or its usage especially if it is prone to clogging from biological growth in the coolant FIGURE 7 A e Loos LN EL Ld Endi EN b Ve h i or i ji 4 COOL ARCO 40 LINCOLN B E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A 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 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 SYMP TOMS 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 Po
46. y 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 dis posal 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 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 Gently rinse the strainer under running water to thor oughly clean it Use a mirror to inspect the inside of the pump for contamination Carefully remove hardened debris with a dental pick if necess
47. you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below Ai WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page WAS tA ATION MEE Section A Technical Specifications sisirin kalak hekat s wak dakae kek d ke Hd k se adan kad A 1 Safety PDrecauttons arrancan rca A 2 Unpacking the COOL
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