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COOL ARC® 40 STAND ALONE
WATER COOLER
IM911
December, 2008
11373
For use with machines having Code Numbers:
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
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
N80
IP 21S
OPERATOR’S MANUAL
Copyright © 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
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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.
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.
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.
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.
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:
FUMES AND GASES
can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.
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.
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.
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
between the two can be the total of the open circuit voltage
of both welders.
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 prod-
ucts.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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 manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
COOL ARC® 40
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SAFETY
WELDING and CUTTING
CYLINDER may explode
SPARKS can
if damaged.
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
If this is not possible, cover them to prevent
process used and properly operating
the welding sparks from starting a fire.
regulators designed for the gas and
Remember that welding spark sand 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.
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.
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.
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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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).
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.
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.h. Also see item 1.c.
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.
Jan, 07
6.j. Do not use a welding power source for pipe thawing.
COOL ARC® 40
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SAFETY
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.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instruc-
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler 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 couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte-
ment toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de nʼimporte quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du
rayonnement de lʼarc et des projections quand on soude
ou quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
1. Relier à la terre le chassis du poste conformement au code
de lʼélectricité et aux recommendations du fabricant. Le dis-
positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflamma-
bles.
2. Autant que possible, Iʼinstallation et lʼentretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la
debrancher à lʼinterrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection
libres de lʼhuile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ʻ93
COOL ARC® 40
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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!
Thank 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 customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
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 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:
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.
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TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions.................................................................................................A-2
Unpacking the COOL ARC® 40......................................................................A-2
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
PRODUCT DESCRIPTION .............................................................................B-1
Recommended Processes and Equipment.....................................................B-1
Turning the System “On”.................................................................................B-1
Cooling Efficiency............................................................................................B-2
Accessories.....................................................................................................Section C
Optional Equipment (Field Installed) ....................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
ROUTINE MAINTENANCE......................................................................................D-1
Periodic Maintenance .....................................................................................D-1
PUMP 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 Strainer ......................................................................D-3
Additional Service Notes.................................................................................D-3
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide ................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams..............................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Dimension Print......................................................................................................F-2
Parts List.................................................................................................................P-545
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – COOL ARC® 40
Product No. / Model
K2187-2 (COOL ARC® 40 230V International)
Via Continental European (SCHUKO)- PRONG PLUG
Input
220-240VAC 50/60 Hz 1 Phase
Current Draw @ 60Hz Input
Current Draw @ 50Hz Input
1.3-1.7 Amps
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.
Typical Operating Pressure and Flow Rate
(With Welding Torch Restriction)
53-57 psi (365-393 kPa)
.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.
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.
Recommended Coolant
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 impossible to purge from the water lines and heat
exchanger.
Shipping
Weight
46.5 lbs. (21.1 kg)
61.2 lbs. (27.8 kg)
Reservoir
Full (Water)
9.03 in. (229.4mm)
9.10 in. (231.1mm)
31.99 in. (812.6mm)
34.26 in. (870.2mm)
L
W
Dimensions
H (Top Face)
H Top Handle)
EXPLANATION OF SYMBOLS THAT APPEAR ON THIS EQUIPMENT
ON
OFF
O
COOL ARC® 40
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A-2
A-2
INSTALLATION
SAFETY PRECAUTIONS
To avoid freeze damage and water leakage in ship-
ment, the COOL ARC® 40 unit is delivered empty with
no coolant in the system. To fill the unit, locate the
plastic 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.
WARNING
ELECTRIC SHOCK can kill.
• Disconnect input power by remov-
ing plug from receptacle before
working inside Cooler.
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-Arc 40.
• 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
puncture the plastic reservoir. The following is the rec-
ommended procedure for unpacking the Cooler:
NOTE: Pure solutions and mixtures of, or materials
(i.e. towels) wetted with ethylene glycol are toxic to
humans and animals. Special precautions should be
taken when discarding toxic material, do not pour this-
mixture down any drain. Contact the local EPA office
for responsible disposal methods or for recycling infor-
mation.
For best results when using the COOL ARC® 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 50% pure ethylene glycol (reagent or indus-
trial grade) mixture. An alcohol and water mixture is
also acceptable.
• Open top flap where the identification label appears.
• Remove loose items and the top insert.
• Open the bottom flap.
• Remove the bottom insert and then slide the Cooler,
wrapped in inside liner, from the outer carton.
• Gently remove the liner and packaging foam from
the Cooler.
Save the instruction manual and the service directory
supplied with the COOL ARC® 40 for parts orders and
future maintenance service.
When using the COOL ARC® 40 with other products,
consult the manufacturer's instruction manual for rec-
ommended coolants. DO NOT USE OIL BASED
COOLANTS OR COOLANTS THAT CONTAIN RUST
INHIBITORS OR LEAK STOPPERS.
FILLING THE COOLANT RESERVOIR
Recommended Coolant
• For Use Above Freezing: Clean tap, distilled or de-
ionized water.
The unit can be filled either vertically or horizontally.
CAUTION
• For Use Below Freezing: 50% water and 50% pure
ethylene glycol (reagent or industrial grade) mixture.
UNPLUG THE COOLER BEFORE FILLING THE
COOLANT RESERVOIR:
• DO NOT USE: Automotive anti-freeze that contains
rust inhibitors or leak stoppers. These coolants will
damage the pump and block the small internal pas-
sageways of the heat exchanger, affecting cooling
performance.
------------------------------------------------------------------------
UPRIGHT (VERTICAL):
• Tilt the unit backward and pour 2 gallons (7.6 liters)
of coolant into the coolant reservoir fill hole through a
funnel.
• 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.
• 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
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A-3
A-3
INSTALLATION
LYING DOWN (HORIZONTAL):
Water or Coolant Line Connections to the COOL ARC®
40
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.
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.
The cooler is "FULL" when the coolant lies just below
the coolant reservoir opening with the cooler in the
upright (vertical) position.
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 RESER-
VOIR. The fill cap contains a pressure release air
hole, which must not be blocked by overfilling the
reservoir with coolant.
(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.
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.
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.
COOLANT "IN" AND "OUT" CONNECTIONS
The fittings located on the back center of the COOL
ARC® 40 are two female 5/8-18 left-hand threaded fit-
tings. (CGA Style) These mate with water hoses typi-
cally used in the welding industry. Refer to Figure 1.
If the connector nut on a water hose does not mate
with the fittings on the back of the COOL ARC® 40,
order the following:
(See Parts Lists for Itemʼs below)
(2) Connector Nuts
(2) Nipples for 3/16" I.D. hose
(2) Hose Clamps
FIGURE 1
Inlet and Outlet Hose Connection Diagram
COOLANT
IN
COOLANT
OUT
FROM
HEAT
TO
HEAT
SOURCE
(RED)
SOURCE
(BLUE)
COOL ARC® 40
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A-4
A-4
INSTALLATION
Remove the connector nut from the INLET hose by
making a straight cut 6-12 mm (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 ARC® 40 fittings.
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® 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 ARC® 40 to be mounted vertically at
the rear of the machine on the gas bottle rack.
The connector and nipple listed fit tightly onto 4.0 mm
( 5/32") to 4.8 mm (3/16") inner diameter hose, but if
clamped tightly to the hose, can fit up to a 6.4 mm
(.25”) inner diameter hose.
INPUT POWER CONNECTION
Plug the input power cord on the COOL ARC® 40 into
a standard 230V circuit breaker protected receptacle.
WARNING
®
INSTALLATION ON UNDERCARRIAGE OR
POWER SOURCE
If the COOL ARC 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 HORIZON-
TAL POSITION. This will prevent the cooler from
being accidentally tipped over.
The COOL ARC® 40 can be mounted either horizon-
tally or vertically on a power source. To mount the
cooler horizontally, 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
K559-2
Cooler Vertical Mounting
Bracket on a Dual
Cooler Horizontal
Power Source
Mounting Bracket
Cylinder Undercarriage
Can be used On Top
of a Power Source
CV-300
CV-400
K874 Undercarriage
Not Available
Yes
Yes
Yes
Yes
Yes
Yes
No
CV-655
Not Available
DC-250
Not Available
DC-400
Not Available
DC-600, DC-655
Square Wave TIG 275
Square Wave TIG 355
Power Wave 455
Power MIG 255
Not Available
K932-1 Undercarriage
Not Available
Yes
No
K1570-1 Undercarriage
Not Available
No
COOL ARC® 40
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A-5
A-5
INSTALLATION
INSTALLATION OF WATER COOLED
CAUTION
ACCESSORIES
After following the installation instructions above, the
COOL ARC® 40 is ready for connection to a water-
cooled accessory.
DO NOT USE A WATER SOLENOID VALVE with
the COOL ARC® 40. When a solenoid valve clos-
es, the pump dead-head, causing the pump to
heat up and will lead to premature failure of the
pump.
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.
------------------------------------------------------------------------
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 3.05 m (10 Ft.). The water hoses have 5/8"-
18 left hand male hose fittings and the gas hose has a
5/8"-18 right hand male hose fitting. The cable and
hose lengths are designed to connect a wire feeder to
a COOL ARC® 40 that is vertically mounted at the
rear of a power source on a dual cylinder undercar-
riage.
CONNECTION TO WIRE FEEDERS
Follow Figure 3 when using the COOL ARC® 40 in
conjunction with a wire feeder. Because the COOL
ARC® 40 requires continuos flow the feeder will need
to have pass-through water hoses installed in order to
operate with the COOL ARC® 40. DO NOT USE A
WATER SOLENOID VALVE with the COOL ARC®
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. If pass-through
water hoses are unavailable, connect the MIG gun as
shown in Figure 4.
Refer to Figure 5 for an illustration of this connection.
FIGURE 4
Connection to Wire Feeder (Do Not Use Water Solenoid)
KP1529-1
FEMALE TO FEMALE 5/8" LH
CGA ADAPTER COUPLINGS
(COUPLINGS ONLY)
FIGURE 2
Water Cooled TIG Torch Connection
COOLANT
IN
COOLANT
OUT
COOLANT
COOLANT
REGULATOR
FLOWMETER
ARGON GAS
CYLINDER
COOLANT
OUT
COOLANT
IN
KP504-WATER HOSES AND
FEMALE TO FEMALE 5/8" LH
CGA ADAPTER COUPLINGS
POWER SOURCE
GAS*
GUN CABLE
GAS
IN
COOLANT*
OUT
FIGURE 5
Connection to Wire Feeder (Do Not Use Water Solenoid)
COOLANT*
FEMALE TO FEMALE*
CGA FITTING
TIG TORCH
POWER CABLE ADAPTER*
POWER / COOLANT
COOLANT
GAS
SHIELDING
GAS
TO WORK
*INCLUDED IN
KP504 HOOK-UP KIT
COOLANT
IN
FIGURE 3
COOLANT
OUT
Water Cooled MIG Gun Connection
CONTROL CABLE
COOLANT
IN
OUT
COOLANT
COOLANT
COOLANT
ELECTRODE CABLE
TO WORK
K529-10
GUN CABLE
COOLANT
COOLANT
IN
COOLANT
COOLANT
OUT
NOTE:
COOLANT
NOTE:
COOLANT
OUT
ORDER K1859-1 ALONG WITH
K529-10 FOR WIRE FEEDERS
WITH QUICK DISCONNECT
FITTINGS.
=
=
BLUE HOSE
RED HOSE
COOLANT
COOLANT
IN
GUN CABLE
NOTE:
COOLANT
OUT
=
=
BLUE HOSE
RED HOSE
KP504 FOR HOOK-UP
TO WIRE FEEDERS
WITH CGA FITTINGS
K1859-1 FOR WIRE
FEEDERS WITH QUICK
DISCONNECT FITTINGS
COOLANT
IN
COOL ARC® 40
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B-1
B-1
OPERATION
• Keep the reservoir full especially after changing any
PRODUCT DESCRIPTION
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" (power switch in
the " l " position) before beginning to weld.
• Unless checking coolant flow, never operate the
cooler with the reservoir fill cap removed.
• 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.
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 water-
cooled TIG torches. The COOL ARC® 40 is a continu-
ous duty cooler.
• Avoid kinking or putting sharp bends in any water
lines.
The overall size and shape of the cooler is identical to
the Magnum 20. The COOL ARC® 40 can operate in
either the vertical or horizontal position. The COOL
ARC® 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.
• 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 ARC® 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 COOL ARC® 40 coolant flow circulates through a
heat exchanger to remove heat energy from the
coolant. The coolant flow is then deposited into the
coolant reservoir. The pump draws its coolant supply
from the coolant reservoir and delivers coolant to the
welding torch or gun. Refer to Figure 6.
The POWER SWITCH is located on the right side of
the control panel. The cooler will be "ON" when
pressed to " l " and "OFF" when pressed to " O ".
RECOMMENDED PROCESSES AND EQUIPMENT
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.
Recommended Processes, Equipment and
Accessories. The COOL ARC® 40 is designed for use
with water-cooled TIG, MIG, PAC (Plasma Arc
Cutting) and PAW (Plasma Arc Welding) guns and
torches. The COOL ARC® 40 can be used with MIG
wire feeders and power sources as well as TIG power
sources.
The 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.
Observe the following when operating the COOL
ARC® 40:
• High voltage typical of welding operations can kill.
• Immersion in water around electrical lines can cause
electrical shock.
When first starting the unit, check all of the coolant
hoses to insure that no water leaks are present.
Water leakage may causes poor welding perfor-
mance, poor cooling performance, low welding com-
ponent life and may cause electrical safety hazards.
• Moving parts can injure. Never place fingers into the
openings of the Cooler.
• Never operate the cooler with any case parts off or
removed.
• Unplug the cooler before removing the external case
when 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.
COOL ARC® 40
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B-2
B-2
OPERATION
COOLING EFFICIENCY
For example:
The high cooling efficiency of the COOL ARC® 40
offers a cooler, more comfortable Torch than a con-
ventional air-cooled Torch.
Unlike other water coolers that depend on bulky reser-
voir size, the high efficiency components of the COOL
ARC® 40 allows the reservoir to be small. The result
is a lightweight, portable unit.
The COOL ARC® 40 effectively removes the heat
produced by the welding arc 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 effective coolant temperature of the COOL ARC®
40.
FIGURE 6
Coolant Circulation Diagram
ROOM AIR
IN
HEATED
AIR OUT
HEAT
EXCHANGER
FAN
COOLANT
OUT
=
=
BLUE HOSE
RED HOSE
NOTE:
COOLANT
IN
PUMP
COOLANT
RETURN
COOLANT
INTAKE
FIGURE 7
COOL ARC 40® W ATER COOLER
HEAT
"IN"
COOLANT "OUT"
COOLANT "IN"
WELDING
TORCH
OR
GUN
AIR
HEAT
EXCHANGER
FAN
FLOW
PUMP
COOLANT
RESERVOIR
COOL-ARC 40
3-23-2001
M19724
COOL ARC® 40
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C-1
C-1
ACCESSORIES
OPTIONAL EQUIPMENT (Field Installed)
“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.
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.
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 ARC® 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 con-
nection.
K559-3 Cooler Vertical Mounting Bracket:
Mounts the COOL ARC® 40 vertically to a power
source that has a dual cylinder undercarriage already
installed. The bracket securely mounts the cooler to
the dual cylinder support bracket. The kit includes all
necessary mounting hardware.
K1536-1 Magnum Flow Sensor:
Protects valuable torches, guns and robotic welding
systems from damage when loss of coolant flow has
occurred for any reason such as a blocked or kinked
water line or a ruptured hose.
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.
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.
CAUTION
K1859-1 Water Cooler Hoses (5/8" LH CGA to QD):
DO NOT USE A WATER SOLENOID VALVE with
the COOL ARC® 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.
This kit includes two 25ʼ – 3/16 I.D. water hoses with a
5/8" LH CGA style fitting on one end and a male quick
disconnect on the other. Most wire feeders have
female quick disconnects and this kit allows direct
hook up between the water cooler and the wire feed-
er.
------------------------------------------------------------------------
Coolant Hoses:
K1859-2 Water Cooler Hoses (5/8" LH CGA to 5/8 LH CGA)
Coolant hoses are readily available from an industrial
welding supplier or in MIG or TIG hook-up kits provid-
ed by Lincoln Electric. Refer to Magnum accessory lit-
erature sheets.
This kit includes two 7.6 m (25 Ft.)-4.7 mm (3/16”)
inside diameter hoses with a 5/8” LH CGA style fitting
on both ends. Hoses can be mated with KP1529-1 for
a water Cooler to MIG gun application. Ideal for water
Cooler to Machines or wire feeders with 5/8” LH CGA
style fittings.
For lengths of coolant hoses over 7.6 m (25 Ft.) and
up to 15.2 m (50 Ft)., 7.9 mm (5/16”) I.D. hose is rec-
ommended. 7.9 mm (5/16”) I.D. hose and accommo-
dating fittings are available from an industrial welding
supplier.
Field Installed CGA style hose fittings:
Fittings to convert a standard 4.7 mm (3/16") I.D. hose
to a 5/8"-18 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" I.D. Hose (T15008)
(2) Hose Clamps (S10888-35)
COOL ARC® 40
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D-1
D-1
MAINTENANCE
• Hold the pump head firmly to apply a counter-torque when
loosing the strainer's 7/8" (22 mm) acorn nut located on the
bottom. Do not confuse with 3/4" (19 mm) 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.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Disconnect input power by
removing plug from receptacle
before working inside Cooler.
• Do not operate with covers
removed.
• Use a mirror to inspect the inside of the pump for
contamination. Carefully remove hardened debris
with a dental pick if necessary, without scratching
the inside of the pump.
• Use only grounded receptacle.
• Do not remove the power cord ground prong.
• Do not touch electrically “hot” parts inside
Cooler.
• Reinstall the strainer and 7/8 (22 mm) acorn nut, tight-
ening with 75 +/- 15 in-lbs. of torque. Wipe dry all
area wetted with coolant. Dispose of coolant soaked
towels properly as specified above.
• Have qualified personnel do the installation,
maintenance and troubleshooting work.
See additional warning information at the
• For a more in depth procedure, See Section D-2,
“Pump Inlet Strainer”.
front of this operatorʼs manual.
------------------------------------------------------------
ROUTINE MAINTENANCE
PUMP MOTOR
Remove accumulated dust and dirt from the internal
components of the cooler by blowing it out with a low-
pressure air hose or removing the dust and dirt with a
vacuum hose.
The COOL ARC® 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.
PERIODIC MAINTENANCE
In dirty or dusty environments or if biological growth
occurs in the coolant, it may be necessary to flush the
coolant reservoir. Drain the old coolant, rinse the
inside of the reservoir and circulate rinsing solution
through the coolant system. Add new coolant when
cleaning is finished. It is recommended to flush the
coolant at least once a year. A cooling system free
from debris offers increased cooling efficiency and
longer pump and torch life. See the Coolant
Treatment Recommendation in this “Maintenance
Section”.
• 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.
NOTE: Pure solutions and mixtures of, or materials
(i.e. towels wetted) with ethylene glycol are toxic to
humans and animals. Special precautions should be
taken when discarding toxic material, do not pour this-
mixture down any drain. Contact the local EPA office
for responsible disposal methods or for recycling infor-
mation
RESERVOIR COOLANT LEVEL
The reservoir volume should be checked daily before
using the cooler. Remove the reservoir fill cap and
check the coolant level. The reservoir is full when the
coolant level is just below the reservoir fill opening
with the unit in the upright position. Keep the reservoir
full, especially after disconnecting the water lines or
changing the accessory being cooled.
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.
COOL ARC® 40
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D-2
D-2
MAINTENANCE
COOLANT TREATMENT
Check coolant level. Add more fresh, pure water if
required, without adding more than 0.475 L (0.125
gal.) of pure water to prevent diluting the coolant addi-
tive.
RECOMMENDATION
This procedure is intended to provide a means of
reducing the objectionable amount of fungal and bac-
terial contamination that has occurred in COOL ARC®
40 water coolers and cooling systems.
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 filter can cause:
Additive
The recommended additive can be purchased at local
pool supply stores. An example is "Maintain Pool Pro
30% Non-Foam Algaecide".
• Voiding of cooler service warranty
• Cavitation damage to the pump headʼs inlet areas
• Welding accessory damage from overheating due to
insufficient coolant flow rate.
Limitations
• The additive should be used with fresh coolants con-
taining only pure water.
A new or properly cleaned pump inlet strainer should
restore the coolerʼs performance.
• This additive should not be used with coolants con-
taining any other substance, including antifreeze
substances.
For additional service and periodic maintenance
details and for recommended coolants, follow the rec-
ommendations listed below.
• 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.
Procedure and Preparation:
WARNING
• Check with the manufacturer of your guns or
torches to be sure that this procedure is compat-
ible with your equipment.
• Always switch off the COOL ARC® 40 machine
power
• Always disconnect the COOL ARC® 40 machine
from service input power.
Prepare the disinfectant:
• Always allow the coolant in the system to cool
enough to avoid burn injuries.
Make a quantity of only what is needed to avoid an
excess Bulk preparation (for coolers serviced in quan-
tity):
• Avoid contact with contaminated coolant. Wear
waterproof gloves and protective eye wear.
• Do not remove the pump relief valveʼs 3/4 in.
acorn hex nut or attempt to adjust the relief valve
setting.
8.775 L (2.325 gals.) of pure, fresh water per cooler
1.625 ml of additive per cooler. Example: for 100 cool-
ers, add 162.5 ml to 232.5 gals. of pure fresh water
Pour 7.55 L (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 reser-
voir to thoroughly coat all of its surfaces. Remove the
tape from the reservoir cap. Prime the cooling system
by positioning cooler horizontally and circulate disin-
fectant through it for 10 to 15 minutes. Drain disinfec-
tant from the cooling system. Do not reuse this solu-
tion. Add new, fresh coolant to the cooling system.
Add 1.225 L (0.325 gals.) of fresh disinfectant to the
system by pouring it into the reservoir, then reduce
the concentration to the nominal 30 ppm:
------------------------------------------------------------------------
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 new:
• 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.
Add the balance 6.325 L (1.675 gals.) of fresh, pure
water to the reservoir to create the treated coolant
concentration. Prime the cooling system.
COOL ARC® 40
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D-3
D-3
MAINTENANCE
Removing Coolant:
Add coolant:
a. Drain coolant from the reservoir using clean siphon-
ing equipment
a. Add 7.6 L (2 gal.) of coolant, either the recommen-
dations off the water cooled accessory or if none,
see the design specification summary listed in this
manual.
b. Coolant level should be drained below the strainerʼs
pressure fitting:
• This prevents coolant from streaming out of unit
when strainer nut is removed
ADDITIONAL SERVICE NOTES:
SERVICE THE PUMPS INLET STRAINER:
1. Always use a back-up wrench on pump head when
loosening or tightening pump fittings.
a. Place absorbent towels underneath pump head to
prevent stray coolant from wetting coolerʼs electrical
components.
2. Never run the pump dry. Always use a recommend-
ed coolant, otherwise pump damage may result.
b. See figure 7. Hold pump head to apply counter
torque when loosening strainerʼs 7/8 acorn nut. Do
not confuse with 3/4 acorn nut. Remove nut and
slide inlet strainer down and out from pump head.
c. Inspect strainer for damage or excessive clogging:
• Replace or Gently rinse strainer under running
water to thoroughly clean it.
3. Flush coolant from system and replace with
fresh, recommended coolant at least once a
year. More frequent flushing may be necessary,
depending upon the userʼs particular system or
its usage, especially if it is prone to clogging
from biological growth in the coolant.
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
15 mm-Kilograms ( 75 15 in.-lbs.) of torque.
• Hold pump head to apply counter-torque when
loosening strainers 7/8 acorn nut.
f. Wipe dry all areas wetted by coolant. Dispose of
towels in an environmentally responsible manner.
FIGURE 7
COOL ARC® 40
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E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
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.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
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
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
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.
1. Hose clamp loose on one of inter-
nal hoses.
2. Internal hose punctured.
3. Heat exchanger leaking.
4. Pump seal is leaking
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
Torch or gun runs hot.
1. Unit placed by area of extreme
heat.
2. Low coolant flow.
3. No coolant flow.
4. Fan not operating.
5. Heat exchanger clogged.
Fan operates but there is low coolant 1. Leak in torch/gun or hoses.
flow.
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.
Cooler trips outlet circuit breaker.
1. Loose or disconnected fan lead.
2. Obstruction in fan blade.
3. Fan motor failure.
Cooler trips outlet circuit breaker.
1. Circuit overloaded.
2. Fan or pump motor failure.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
COOL ARC® 40
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F-1
F-1
DIAGRAMS
R
E
L
O
O
C
TER
A
W
0
4
C®
AR
OL
C
COOL ARC® 40
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F-2
F-2
DIMENSION PRINT
COOL ARC® 40
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NOTES
COOL ARC® 40
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● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
cuerpo.
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• 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
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