RETURN TO MAIN MENU ® COOL ARC 40 STAND ALONE WATER COOLER For use with machines having Code Numbers: IM670-A December, 2008 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 thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING 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 Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. 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.
iii iii 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.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: iv 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you 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 equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions.................................................................................................A-2 Unpacking the COOL ARC® 40......................................................................
A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS – COOL ARC® 40 Product No. / Model K2187-1 ( COOL ARC® 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 @ 50Hz Input 2.0-2.4 Amps Maximum Operating Pressure and Flow Rate (Open Flow, Without Welding Torch Restriction) 60 psi (414 kPa) (4.14 bar)Max. 1.66 gal/min. (6.28 liter/min) Max.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside Cooler. • Use only grounded receptacle. • Do not remove the power cord ground prong. • Do not touch electrically “hot” parts inside Cooler. • Have qualified personnel do the installation, maintenance and troubleshooting work.
A-3 INSTALLATION LYING DOWN (HORIZONTAL): A-3 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. 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.
A-4 A-4 INSTALLATION 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 nipple is flush with the end of the hose.
A-5 A-5 INSTALLATION INSTALLATION OF WATER COOLED ACCESSORIES CAUTION After following the installation instructions above, the COOL ARC® 40 is ready for connection to a watercooled accessory. WATER COOLED TIG TORCH AND MIG GUN Follow Figure 2 when using the COOL ARC® 40 with water-cooled TIG torches. Follow Figure 4 when using the COOL ARC® 40 with water-cooled MIG gun. Consult the manufacturer's instruction manual when using the COOL ARC® 40 with other water-cooled TIG and MIG accessories.
B-1 OPERATION PRODUCT DESCRIPTION The COOL ARC® 40 is a stand alone re-circulation cooling system designed for use with water-cooled TIG, MIG, PAC (Plasma Arc Cutting) and PAW (Plasma Arc Welding) guns and torches. The coolant "IN" and "OUT" connections are 5/8-18 left-hand female threads which match the standard connector nut of domestic water hoses (CGA style) and watercooled TIG torches. The COOL ARC® 40 is a continuous duty cooler.
B-2 B-2 OPERATION COOLING EFFICIENCY The high cooling efficiency of the COOL ARC® 40 offers a cooler, more comfortable weld than conventional air-cooled procedures as well as leading competitors water cooled systems. For example: Unlike other water coolers that depend on bulky reservoir size, the high efficiency components of the COOL ARC® 40 allows the reservoir size to be small. The result is a lightweight, portable unit.
C-1 C-1 ACCESSORIES OPTIONAL EQUIPMENT (Field Installed) K559-2 Cooler Horizontal Mounting Bracket: Mounts the COOL ARC® 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 Mounting Bracket: Mounts the COOL ARC® 40 vertically to a power source that has a dual cylinder undercarriage already installed. The bracket securely mounts the cooler to the dual cylinder support bracket.
D-1 MAINTENANCE SAFETY PRECAUTIONS D-1 • Gently rinse the strainer under running water to thoroughly clean it. 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.
D-2 D-2 MAINTENANCE COOLANT TREATMENT RECOMMENDATION PUMP INLET STRAINER This procedure is intended to provide a means of reducing the objectionable amount of fungal and bacterial contamination that has occurred in COOL ARC® 40 water coolers and cooling systems. 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.
D-3 MAINTENANCE D-3 Removing Coolant: Add coolant: a. Drain coolant from the reservoir using clean siphoning equipment b. Coolant level should be drained below the strainerpressure fitting: • This prevents coolant from streaming out of unit when strainer nut is removed a. Add 7.6 ltr. (2 gal.) of coolant, either the recommendations off the water cooled accessory or if none, see the design specification summary listed in this manual. SERVICE THE PUMPS INLET STRAINER: 1.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION Cooler does not operate with power 1. Input cord unplugged. switch "ON". 2. Power switch faulty 3. Power harness damaged. 4. Water lines blocked or crimped. 5. Leak in gun or water hoses. 6. Coolant reservoir empty. 7. The system needs to be primed (Switch pushed to "I" position.) Internal water leak. Torch or gun runs hot. 1.
COOL ARC® 40 BL G2 G3 W B B W 1 MTR1 4 50/60 HZ INPUT: 230 V W G SW1 M20078 G1 - FAN SHROUD GROUND CONNECTION(CUSTOMER GROUND) G2 - BASE GROUND CONNECTION G3 - CHASSIS GROUND CONNECTION (FAN SHROUD) P1 - INPUT POWER PLUG SW1 - POWER SWITCH MTR1 - PUMP MOTOR A.03 MTR2 - FAN MOTOR W MTR2 B DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
9.10 34.26 COOL ARC® 40 L11540 A DIMENSION PRINT NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.. 9.03 2.
NOTES COOL ARC® 40
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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