Lincoln Electric Cool Arc 40 Operating instructions
- Category
- Welding System
- Type
- Operating instructions
Operator’s Manual
COOL ARC 40 STAND ALONE WATER COOLER
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM911-A | Issue D ate Feb-15
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
11373, 11848
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
!
"
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.
""
Lincoln arc welding and cutting equipment is designed and built with
safety in mind. However, your overall safety can be increased by
proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And, most importantly, think before you
act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to
avoid minor personal injury or damage to this equipment.
"
DON’T get too close to the arc. Use
corrective lenses if necessary to
s
tay a reasonable distance away
from the arc.
READ and obey the Material Safety
Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to keep
the fumes and gases from your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away from your
face.
If you de velop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.
""
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare with
protective screens or barriers.
IN SOME AREAS, protection from noise may be
appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL
TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously had
been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release highly
toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat, mechanical
shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines
D
iesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline Engines
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
#
"
" "
Read and understand the following safety highlights. For additional
safety information, it is strongly recommended that you purchase a
copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the
American Welding Society, P.O. Box 351040, Miami, Florida 33135 or
CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety”
booklet E205 is available from the Lincoln Electric Company, 22801
St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers and
devices in position and in good repair.Keep
hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving parts
when starting, operating or repairing
equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
w
orking near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is
5<A
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
2.b. EMF fields may interfere with some pacemakers, and welders
having a pacemaker should consult their physician before
welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
3
S
AFETY
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.
0$'',6,10616+(014/$.5$)(6;24(&$76,105,)
9(.',0*/756%(2(4)14/('70'(4(.(&64,&$..;
+$<$4'175&10',6,105,0'$/2.1&$6,105149+,.(
9($4,0*9(6&.16+,0*10/(6$.5647&674(557&+$5
).1145*4$6,0*5145&$))1.'59+(0,0&4$/2('
215,6,10557&+$55,66,0*-0((.,0*14.;,0*,)6+(4(
,5$+,*+4,5-1)70$81,'$%.(14$&&,'(06$.&106$&6
9,6+6+(914-2,(&(14*4170'75(6+()1..19,0*
(37,2/(06
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see It ems 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
t
hemselves 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. +(09(.',0*
9,6+(.(&641'(59+,&+4(37,4(52(&,$.8(06,.$6,10
57&+$556$,0.(5514+$4')$&,0*5((,05647&6,105
10&106$,0(4141410.($'14&$'/,7/
2.$6('56((.$0'16+(4/(6$.514&1$6,0*59+,&+
241'7&(+,*+.;61:,&)7/(5-((2(:21574($5.19
$52155,%.($0'9,6+,0$22.,&$%.($0'
.,/,6575,0*.1&$.(:+$75614
/(&+$0,&$.8(06,.$6,100&10),0('52$&(514,0
51/(&,4&7/56$0&(5176'1145$4(52,4$614/$;
%(4(37,4(''',6,10$.24(&$76,105$4($.51
4(37,4('9+(09(.',0*10*$.8$0,<('56((.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
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
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employer’s
safety practices. MSDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
4
S
AFETY
WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily go through
small cracks and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures will
not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society (see address
above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7
.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in
Cylinders,” available
from the Compressed Gas Association 1235 Jefferson Davis
Highway, Arlington, VA 22202.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
()(461
+662999.,0&1.0(.(&64,&&1/5$)(6;
)14$'',6,10$.5$)(6;,0)14/$6,10
5
S
AFETY
Welding Safety
Interactive Web Guide
for mobile devices
R
ELECTROMAGNETIC COMPATIBILITY (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professi
onal u
se.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio tran
smitter. When emissions are
received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of
electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines,
telephone systems, computers, etc.
Warning: This Class A equipment
is not intended for use in residential locations where the electrical power is
provided by the public low-voltage supply system. There may be potential difficulties in ensuring electro-
magnetic
compatibility in those locations, due to conducted as well as radiated disturbances.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions.
If electromagnetic disturbances are d
etected then it shall be the responsibility of the user of the welding equipment
to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may
be as simple as earthing (grounding) the welding circuit, s
ee Note. In other cases it could involve constructing an
electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases
electromagnetic disturbances must be reduced to the point where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons
. Follow your local and national
standards for installation and use. Changing the earthing arrangements should only be authorized by
a
person who is competent to assess whether the changes will increase the risk of injury, e.g.,
by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of area
Before installing welding equipment the user shall make an assessment o
f potential electromagnetic problems in
the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; ab
ove, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement;
g) the immunity of other equipment in the environment. The user shall ens
ure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out
.
CLEVELAND, OHIO U.S.A.
C
L10093PRINT
The size of the surrounding area to be considered will depend on the structure of the building and other activities
that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Public Supply System
Welding equipment should be connected to the public supply system
according to the manufacturer’s
recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
system. Consideration should be
given to shielding the supply cable of permanently installed welding equipment,
in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding
should be connected to the welding power source so that g
ood electrical contact is maintained between the conduit
and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All
access and ser
vice doors and covers should be closed and properly fastened when the welding equipment is in
operation. The welding equipment should not be modified in any way except for those changes and adjustments
covered in the manufacturer’s instructions. In parti
cular, the spark gaps of arc striking and stabilizing devices
should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together,
running at or close
to the floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered. However,
metallic components bonded to the work piece will increase the risk that the o
perator could receive a shock by
touching these metallic components and the electrode at the same time. The operator should be insulated from all
such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, nor
connected to earth because of its size and
position, e.g., ship’
s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions
in some, but not all instances. Care should be taken to prevent the earthin
g of the workpiece increasing the risk of
injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth
should be made by a direct connection to the workpiece, but in some countries where direct connec
tion is not
permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate proble
ms of
interference. Screening of the entire welding installation may be considered for special applications.
1
1
Portions of the preceding text are contained in EN 60974-
10: “Electromagnetic Compatibility (EMC) product standard for arc
welding equipment.”
TABLE OF CONTENTS
%.42
Product Description
Installation .......................................................................................................Section A
(205;60.9'=206360.A6<;@
'.32AF%?20.BA6<;@
);=.086;4A52$$!&
I
6996;4A52<<9.;A&2@2?C<6?
<<9.;AL;M.;1L<BAM<;;20A6<;@
;=BA%<D2?<;;20A6<;
;@A.99.A6<;<;);12?0.??6.42<?%<D2?'<B?02
<?6G<;A.9;@A.99.A6<;<;A52(<=<3.%<D2?'<B?02
*2?A60.9;@A.99.A6<;<;%<D2?'<B?02D6A5.B.9F96;12?);12?0.??6.42
;@A.99.A6<;<3+.A2?<<921002@@<?62@
+.A2?<<921((<?05.;1"B;
<;;20A6<;A<+6?22212?@
%<D2?;=BA./92D6A5+.A2?.;1.@<@2@
Operation .........................................................................................................Section B
&20<::2;121%?<02@@2@.;1>B6=:2;A
(B?;6;4A52'F@A2:L$;M
<<96;4336062;0F
Accessories .....................................................................................................Section C
$=A6<;.9>B6=:2;A6291;@A.9921
Maintenance ....................................................................................................Section D
'.32AF%?20.BA6<;@
&$)(# "#(##
%2?6<160".6;A2;.;02
%)"% "#(##
%B:="<A<?
2.AE05.;42?
&2@2?C<6?<<9.;A!2C29
<<9.;A(?2.A:2;A&20<::2;1.A6<;
%B:=;92A69A2?
;@=20A<;16A6<;<3<<9.;A
'2?C602A52%B:=;92A'A?.6;2?
116A6<;.9'2?C602#<A2@
Troubleshooting ..............................................................................................Section E
'.32AF%?20.BA6<;@
<DA<)@2(?<B/92@5<<A6;4B612
(?<B/92@5<<A6;4B612
Wiring Diagrams ..............................................................................................Section F
+6?6;46.4?.:
6:2;@6<;%?6;A
Parts List.................................................................................................................P-545
8
9
PRODUCT DESCRIPTION
PRODUCT DESCRIPTION
(52 $$! &
I
6@ . @A.;1 .9<;2 ?206?0B9.A6<;
0<<96;4 @F@A2: 12@64;21 3<? B@2 D6A5 D.A2?0<<921
( " % %9.@:. ?0 BAA6;4 .;1 %+
%9.@:.?0 +2916;44B;@.;1A<?052@(520<<9.;A
# .;1 $)( 0<;;20A6<;@ .?2 923A5.;1
32:.92 A5?2.1@ D5605 :.A05 A52 @A.;1.?1 0<;;20A<?
;BA <3 1<:2@A60 D.A2? 5<@2@ @AF92 .;1 D.A2?
0<<921(A<?052@(52$$!&
I
6@.0<;A6;B
<B@1BAF0<<92?
(52<C2?.99@6G2.;1@5.=2<3A520<<92?6@612;A60.9A<
A52".4;B:(52$$! &
I
0.;<=2?.A26;
26A52? A52 C2?A60.9 <? 5<?6G<;A.9 =<@6A6<; (52 $$!
&
I
6@C2?F2.@FA<B@2.;1B;12?@A.;1D6A5<;9F
<;2=<D2?@D6A05<;A520<;A?<9=.;29(520<<92?5.@
.;;A2?;.A6<;.9*=<D2?6;=BA?202=A.092:.86;4
6AC2?F2.@FA<=<D2?B=116;40<<9.;AA<A52?2@2?
C<6?6@@6:=92.;10<;;20A6;4A< A52 0<<9.;A # .;1
$)(0<;;20A6<;@.?22.@69F:.12D6A5.;.17B@A./92
D?2;05
(52$$!&
I
0<<9.;A39<D06?0B9.A2@A5?<B45.
52.A 2E05.;42? A< ?2:<C2 52.A 2;2?4F 3?<: A52
0<<9.;A (52 0<<9.;A 39<D 6@ A52; 12=<@6A21 6;A< A52
0<<9.;A?2@2?C<6?(52 =B:=1?.D@6A@0<<9.;A @B==9F
3?<:A520<<9.;A?2@2?C<6?.;11296C2?@0<<9.;A A<A52
D2916;4 A<?05 <? 4B; Refer to Figure 6 (Operation
Section).
$$!&
I
*;A2?;.A6<;.9
*6.<;A6;2;A.9B?<=2.;') $%&$#%!)
*G%5.@2
:=@
:=@
=@68%./.?".E
4.9:6;96A2?:6;".E
=@68%.
4.9:6;96A2?:6;
4.96A2?@
For Use Above Freezing: )@2 92.;A.=16@A69921<?126<;6G21D.A2?
For Use Below Freezing: )@2
D.A2?.;1=B?22A5F92;249F0<9
?2.42;A<?6;1B@A?6.94?.12:6EAB?2
DO NOT USE: BA<:<A6C2 .;A63?22G2 A5.A 0<;A.6;@ ?B@A 6;56/6A<?@ <? 92.8 @A<==2?@
(52@20<<9.;A@D6991.:.42A52=B:=.;1/9<08A52@:.996;A2?;.9=.@@.42D.F@<3A52
52.A2E05.;42?.3320A6;40<<96;4=2?3<?:.;02(<.0>B6?2A52=?<=2?0<<9.;A0<;A.0A
.9<0.9D2916;416@A?6/BA<?
DO NOT USE: %?2=.08.421D2916;46;1B@A?F0<<9.;A@
◊
(52@20<<9.;A@:.F0<;A.6;
<69/.@21@B/@A.;02@D5605.AA.08A52=9.@A600<:=<;2;A@<3A520<<92?$;02.1121
A<A520<<92?A52@2@B/@A.;02@.?2 C6?AB.99F6:=<@@6/92A<=B?423?<:A52D.A2?96;2@
.;152.A2E05.;42?
◊
".4;B:%?<!0<<9.;A:.F/2B@21
9/@84
9/@84
6;::
6;::
6;::
6;::
A-1
INSTALLATION
COOL ARC
I
40
A-1
%?<1B0A#<"<129
;=BA
B??2;A?.DG;=BA
B??2;A?.DG;=BA
".E6:B:$=2?.A6;4%?2@@B?2.;19<D&.A2
$=2;9<D+6A5<BA+2916;4(<?05&2@A?60A6<;
(F=60.9$=2?.A6;4%?2@@B?2.;19<D&.A2
+6A5+2916;4(<?05&2@A?60A6<;
&2@2?C<6?'6G2
&20<::2;121<<9.;A
'56==6;4
+2645A
&2@2?C<6?
B99+.A2?
!
+
6:2;@6<;@
(<=.02
(<=.;192
TECHNICAL SPECIFICATIONS – COOL ARC
I
40
EXPLANATION OF SYMBOLS THAT APPEAR ON THIS EQUIPMENT
OFFOFF
O
ON
IP 21S
A-2
INSTALLATION
COOL ARC
I
40
A-2
SAFETY PRECAUTIONS
UNPACKING THE COOL-ARC
I
40
(52=.08.46;4<3A52<<92?6@12@64;21A<D6A5@A.;1
@56==6;4 ./B@2 .;1 0<;A.6;@ . 0.?1/<.?1 96;2? A5.A
@B??<B;1@ A52 B;6A 3 .;F @56==6;4 1.:.42 5.@
<00B??21 0<;A.0A F<B? 02?A63621 !6;0<9; 16@A?6/BA<? <?
@2?C60202;A2?+52;B;=.086;4A52B;6A.C<61A5?B@A
6;4@5.?=</720A@A5?<B45A520.?A<;96;2?D5605:.F
=B;0AB?2A52=9.@A60?2@2?C<6?(523<99<D6;46@A52?20
<::2;121=?<021B?23<?B;=.086;4A52<<92?
H$=2;A<=39.=D52?2A52612;A6360.A6<;9./29.==2.?@
H&2:<C29<<@26A2:@.;1A52A<=6;@2?A
H$=2;A52/<AA<:39.=
H&2:<C2A52/<AA<:6;@2?A.;1A52;@9612A52<<92?
D?.==216;6;@61296;2?3?<:A52<BA2?0.?A<;
H2;A9F ?2:<C2 A52 96;2? .;1 =.08.46;4 3<.: 3?<:
A52<<92?
'.C2A526;@A?B0A6<;:.;B.9.;1A52@2?C60216?20A<?F
@B==9621D6A5A52$$!&
I
3<?=.?A@<?12?@.;1
3BAB?2:.6;A2;.;02@2?C602
FILLING THE COOLANT RESERVOIR
Recommended CoolanA
H<? )@2 /<C2 ?22G6;4
92.; A.= 16@A69921 <? 12
6<;6G21D.A2?
H<?)@229<D?22G6;4D.A2?.;1=B?2
2A5F92;249F0<9?2.42;A<?6;1B@A?6.94?.12:6EAB?2
H$#$()'BA<:<A6C2.;A63?22G2A5.A0<;A.6;@
?B@A 6;56/6A<?@ <? 92.8 @A<==2?@ (52@2 0<<9.;A@ D699
1.:.42A52=B:=.;1/9<08A52@:.996;A2?;.9=.@
@.42D.F@ <3 A52 52.A 2E05.;42? .3320A6;4 0<<96;4
=2?3<?:.;02
H$ #$( )' %?2=.08.421 D2916;4 6;1B@A?F
0<<9.;A@ (52@2 0<<9.;A@ :.F 0<;A.6; <69/.@21
@B/@A.;02@D5605.AA.08A52=9.@A600<:=<;2;A@<3
A52 0<<92? $;02 .1121 A< A52 0<<92? A52@2 @B/
@A.;02@ .?2 C6?AB.99F 6:=<@@6/92 A< =B?42 3?<: A52
D.A2?96;2@.;152.A2E05.;42?
(< .C<61 3?22G2 1.:.42 .;1 D.A2? 92.8.42 6; @56=
:2;AA52$$!&
I
B;6A6@1296C2?212:=AFD6A5
;< 0<<9.;A 6; A52 @F@A2: (< 3699 A52 B;6A 9<0.A2 A52
=9.@A6036990.=.AA523?<;A:61192<3A52B;6A&2:<C2
A52 3699 0.= /F =?2@@6;4 A52 02;A2? <3 A52 0.= 6;D.?1
D5692=B996;4.AA52A./<;A52<BA2?2142
92.; A.= D.A2? 16@A69921 D.A2? 126<;6G21 D.A2? .
:6E <3 =B?2 2A5F92;2 49F0<9 .;1 D.A2? <? .;F
<A52? 0<<9.;A @=2063621 /F A52 :.;B3.0AB?2? <3 A52
D.A2?0<<921=?<1B0AA5.AA52<<92?6@B@21D6A50.;
/2 .1121 6;A< A52 0<<9.;A ?2@2?C<6? (52 <=2;6;4 <3
A5236990.=:.A2@D6A5:<@A0<<9.;A0<;A.6;2?@/BAA<
.C<61 @=699.42 <3 0<<9.;A . 3B;;29 @5<B91 /2 =9.021
6;A<A52?2@2?C<6?5<92D52;36996;4A52<<9?0
NOTE: %B?2 @<9BA6<;@ .;1 :6EAB?2@ <3 <? :.A2?6.9@
62 A<D29@ D2AA21 D6A5 2A5F92;2 49F0<9 .?2 A<E60 A<
5B:.;@ .;1 .;6:.9@ '=206.9 =?20.BA6<;@ @5<B91 /2
A.82;D52;16@0.?16;4A<E60:.A2?6.91<;<A=<B?A56@
:6EAB?21<D;.;F1?.6;<;A.0AA529<0.9 %<33602
3<??2@=<;@6/9216@=<@.9:2A5<1@<?3<??20F096;46;3<?
:.A6<;
<?/2@A?2@B9A@D52;B@6;4A52$$!&
I
D6A5
!6;0<9; 4B;@ <? A<?052@ B@2 16@A69921 <? 126<;6G21
D.A2? .9A5<B45 63 ;<A .C.69./92 A.= D.A2? 0.; /2
B@213=?<A20A6<;3?<:3?22G6;46@12@6?21B@2.
D.A2?.;1=B?22A5F92;249F0<9?2.42;A<?6;1B@
A?6.9 4?.12 :6EAB?2 ; .90<5<9 .;1 D.A2? :6EAB?2 6@
.9@<.002=A./92
+52;B@6;4A52$$!&
I
D6A5<A52?=?<1B0A@
0<;@B9AA52:.;B3.0AB?2?@6;@A?B0A6<;:.;B.93<??20
<::2;121 0<<9.;A@ $ #$( )' $! '
$$!#('$&$$!#('(($#(#&)'(
#($&'$&! '($%%&'
(52B;6A0.;/236992126A52?C2?A60.99F<?5<?6G<;A.99F
UNPLUG THE COOLER BEFORE FILLING THE
COOLANT RESERVOIR:
UPRIGHT (VERTICAL):
• (69AA52B;6A/.08D.?1.;1=<B?4.99<;@96A2?@
<30<<9.;A6;A<A520<<9.;A?2@2?C<6?36995<92A5?<B45.
3B;;29
H3. 4.99<;96A2?@ 3699 /<AA926@.C.69./92 A69AA52
B;6A 3<?D.?1 B;A69 A52 /<AA92 :.A2@ D6A5 A52 0<<9.;A
?2@2?C<6?36995<92(52;A69AA52B;6A/.08D.?1B;A69A52
3699 /<AA92 6@ 2:=A621 699 A52 B;6A D6A5 4.99<;@
96A2?@<30<<9.;A
ELECTRIC SHOCK 0.;8699
H6@0<;;20A6;=BA=<D2?/F?2:<C
6;4 =9B4 3?<: ?202=A.092 /23<?2
D<?86;46;@612<<92?
H)@2<;9F4?<B;121?202=A.092
H<;<A?2:<C2A52=<D2?0<?1
4?<B;1=?<;4
H<;<AA<B052920A?60.99FL5<AM=.?A@6;@612<<92?
H.C2>B.963621=2?@<;;291<A526;@A.99.A6<;:.6;
A2;.;02.;1A?<B/92@5<<A6;4D<?8
WARNING
CAUTION
A-3
INSTALLATION
COOL ARC
I
40
A-3
LYING DOWN (HORIZONTAL):
.?23B99F.114.99<;@96A2?@<30<<9.;AA5?<B45.
3
B;;29 6;A< A52 0<<9.;A ?2@2?C<6? 3699 5<92 AVOID
SPILLING COOLANT INTO THE LOUVERS ON THE
TOP OF THE COOLER.
(
520<<92?6@)!!D52;A520<<9.;A962@7B@A/29<D
A52 0<<9.;A ?2@2?C<6? <=2;6;4 D6A5 A52 0<<92? 6; A52
B=?645AC2?A60.9=<@6A6<;
NOTE: DO NOT ADD MORE THAN 2 GALLONS
(7.6 LITERS) OF COOLANT INTO THE RESER-
VOIR. (52 3699 0.= 0<;A.6;@ . =?2@@B?2 ?292.@2 .6?
5<92 D5605 :B@A ;<A /2 /9<0821 /F <C2?36996;4 A52
?2@2?C<6?D6A50<<9.;A
2 02?A.6; A< ?2=9.02 A52 ?2@2?C<6? 3699 0.= D52; A52
?2@2?C<6? 6@ 3B99 '6:=9F =?2@@ <; A52 6;@612 02;A2? <3
A5236990.=B;A69A520.=@;.=@6;A<=9.02$=2?.A6<;<3
A52 $$! &
I
D6A5<BA A52 3699 0.= 6; =9.02 0.;
0.B@2 =<<? 0<<96;4 2336062;0F 2C.=<?.A6<; 9<@@ <3
0<<9.;A.;1?21B021=?<1B0A9632
COOLANT "IN" AND "OUT" CONNECTIONS
(52 36AA6;4@ 9<0.A21 <; A52 /.08 02;A2? <3 A52 $$!
&
I
.?2AD<32:.92923A5.;1A5?2.12136A
A6;4@'AF92(52@2:.A2D6A5D.A2?5<@2@AF=6
0.99FB@216;A52D2916;46;1B@A?FRefer to Figure 1
W
ater or Coolant Line Connections to the
C
OOL ARC
I
40
(.82A520<;;20A<?;BA<3A52D.A2?5<@2.;10520863
A
52A5?2.1<3A52:.920<;;20A<?;BA:.A052@A52
923A5.;132:.92A5?2.16;A5236AA6;4<;A52/.08<3
A
52B;6A
<? .99 !6;0<9; =?<1B0A@ .;1 A5<@2 D6A5 . 0<;;20A<?
;BA<;A52D.A2?5<@2A5.A:.A2D6A5A5236AA6;4@<;A52
/.08<3A52$$!&
I
(Reference FIG. 1) (.82A52.002@@<?F#!(5<@2
0<9<?21<?A.4421/9B2<;:<@A5<@2@.;1A5?2.1 6A
6;A<A520<<9.;A$)(36AA6;49<0.A21<;A52?645A@612
<3A52/.08<3A520<<92?'20B?2A520<;;20A<?;BA<3
A52 5<@2 A645A9F 6;A< A52 36AA6;4 D6A5 . D?2;05 @< A5.A
92.86;4 1<2@ ;<A <00B? (52; A.82 A52 .002@@<?F
$)(!( 5<@2 0<9<?21 <? A.4421 ?21 <; :<@A
5<@2@.;1A5?2.16A6;A<A520<<9.;A#36AA6;49<0.A21
<;A52923A@612<3A52/.08<3A520<<92?4.6;A645A9F
@20B?2A520<;;20A<?;BA<3A525<@26;A<A5236AA6;4<3
A52 0<<92? D6A5 . D?2;05 A< 6;@B?2 A5.A ;< 92.86;4
<00B?@
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.
3 A52 0<;;20A<? ;BA <; . D.A2? 5<@2 1<2@ ;<A :.A2
D6A5 A52 36AA6;4@ <; A52 /.08 <3 A52 $$! &
I
<?12?A523<99<D6;4
(See Parts Lists for Item’s below)
<;;20A<?#BA@
#6==92@3<?5<@2
<@29.:=@
FIGURE 1
;92A.;1$BA92A<@2<;;20A6<;6.4?.:
COOLANT
IN
COOLANT
OUT
FROM
HEAT
SOURCE
(RED)
TO
HEAT
SOURCE
(BLUE)
A-4
INSTALLATION
COOL ARC
I
40
A-4
HORIZONTAL INSTALLATION ON THE
TOP OF A POWER SOURCE
<?=?<=2?6;@A.99.A6<;3<99<DA526;@A?B0A6<;@=?<C6121
D6A5 A52 <<92? <?6G<;A.9 "<B;A6;4 ?.082A
6A(520<<92?6@@20B?21A<A52=<D2?@<B?02963A/.92
&232?2;02A52A./92/29<D3<?.96@A<3=<D2?@<B?02@
A5.A .99<D@ A52 $$! &
I
A< /2 :<B;A21 5<?6
G<;A.99F<;A<=
VERTICAL INSTALLATION ON POWER
SOURCE WITH A DUAL CYLINDER
UNDERCARRIAGE.
<?=?<=2?6;@A.99.A6<;3<99<DA526;@A?B0A6<;@=?<C6121
D6A5A52 <<92?*2?A60.9"<B;A6;4?.082A 6A
(52 0<<92? 6@ @20B?29F :<B;A21 A< A52 1B.9 0F96;12?
@B==<?A/?.082A&232?2;02A52A./92/29<D3<?.96@A<3
=<D2? @<B?02@ .;1 1B.9 0F96;12? B;12?0.??6.42@ A5.A
.99<D@A52$$!&
I
A</2:<B;A21C2?A60.99F.A
A52?2.?<3A52:.056;2<;A524.@/<AA92?.08
If the COOL ARC
I
40 is not securely mounted hor-
izontally on top of a power source or vertically on
a dual cylinder undercarriage, THE COOL ARC
I
40
MUST BE OPERATED IN THE HORIZONTAL POSI-
TION. This will prevent the cooler from being acci-
dentally tipped over.
&2:<C2 A52 0<;;20A<? ;BA 3?<: A52 #!( 5<@2 /F
:.86;4 . @A?.645A 0BA :: .D.F 3?<:
A522;1<3A52;6==929<0.A216;@612<3A525<@2(.82
A
52 ;6==92 .;1 A52 0<;;20A<? ;BA <?12?21 ./<C2 .;1
6;@2?A A52 ;6==92 6;A< A52 0<;;20A<? ;BA @< A5.A A52
A5?2.121 2;1 <3 A52 0<;;20A<? ;BA =<6;A@ .D.F 3?<:
A52/.?/212;1<3A52;6==92(D6@AA52/.?/212;1<3
A
52;6==926;A<A525<@2 B;A69 A52 @5<B912? <3 A52 ;6=
=926@39B@5D6A5A522;1<3A525<@2'20B?2A525<@2
<
;A<A52;6==92D6A5A525<@209.:=A<6;@B?2A5.AA52
0<;;20A6<; 6@ D.A2?A645A #< D.A2? 0.; 92.8 3?<: A52
0<;;20A6<;636A6@=?<=2?9F.AA.0521&2=2.AA52=?<02
1B?23<?A52$)(!(5<@2+52;0<:=92A23<99<DA52
0<;;20A6<; =?<021B?2 12A.6921 ./<C2 3<? 0<;;20A6;4
A525<@2@A<A52$$!&
I
36AA6;4@
(520<;;20A<?.;1;6==9296@A2136AA645A9F<;A<::
A<:: 6;;2?16.:2A2? 5<@2/BA63
09.:=21 A645A9F A< A52 5<@2 0.; 36A B= A< . ::
M6;;2?16.:2A2?5<@2
INPUT POWER CONNECTION
%9B4A526;=BA=<D2?0<?1<;A52$$!&
I
6;A<
.@A.;1.?1*06?0B6A/?2.82?=?<A20A21?202=A.092
INSTALLATION ON UNDERCARRIAGE OR
POWER SOURCE
(52$$!&
I
0.;/2:<B;A2126A52? 5<?6G<;
A.99F <? C2?A60.99F <; . =<D2? @<B?02 (< :<B;A A52
0<<92? 5<?6G<;A.99F <?12? A52 <<92?
<?6G<;A.9"<B;A6;4?.082A(<:<B;AA520<<92?C2?
A60.99F <; . =<D2? @<B?02 D6A5 . 1B.9 0F96;12? B;12?
0.??6.42 <?12? <<92? *2?A60.9 "<B;A6;4
?.082A
WARNING
Power Source
CV-300
CV-400
CV-655
DC-250
DC-400
DC-600, DC-655
Square Wave TIG 275
Square Wave TIG 355
Power Wave 455
Power MIG 255
K559-3
Cooler Vertical Mounting
Bracket on a Dual
Cylinder Undercarriage
K874 Undercarriage
Not Available
Not Available
Not Available
Not Available
Not Available
K932-1 Undercarriage
Not Available
K1570-1 Undercarriage
Not Available
K559-2
Cooler Horizontal
Mounting Bracket
Can be used On Top
of a Power Source
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
No
A-5
INSTALLATION
COOL ARC
I
40
A-5
INSTALLATION OF WATER COOLED
ACCESSORIES
3A2? 3<99<D6;4 A52 6;@A.99.A6<; 6;@A?B0A6<;@ ./<C2 A52
$$! &
I
6@ ?2.1F 3<? 0<;;20A6<; A< . D.A2?
0
<<921.002@@<?F
WATER COOLED TIG TORCH AND MIG GUN
<99<D Figure 2 D52;B@6;4A52$$!&
I
D6A5
D.A2?0<<921 ( A<?052@ <99<D Figure 4 D52;
B@6;4A52$$!&
I
D6A5D.A2?0<<921"4B;
<;@B9A A52 :.;B3.0AB?2?@ 6;@A?B0A6<; :.;B.9 D52;
B@6;4A52$$!&
I
D6A5<A52?D.A2?0<<921(
.;1".002@@<?62@
CONNECTION TO WIRE FEEDERS
<99<D Figure 3 D52; B@6;4 A52 $$! &
I
6;
0<;7B;0A6<; D6A5 . D6?2 32212? 20.B@2 A52 $$!
&
I
?2>B6?2@0<;A6;B<@39<DA5232212?D699;221
A<5.C2=.@@A5?<B45D.A2?5<@2@6;@A.99216;<?12?A<
<=2?.A2 D6A5 A52 $$! &
I
$ #$( )'
+(&'$!#$*!*D6A5A52$$!&
I
+.A2? =.@@A5?<B45 0<;;20A6<; 86A@ .?2 .C.69./92 3<?
D6?2 32212?@ &232? A< =?<1B0A 96A2?.AB?2 <? A52 D6?2
32212?@6;@A?B0A6<;@:.;B.93<?86A.C.69./696AF.;13B?
A52? 0<;;20A6<; 12A.69@ A 6@ ;<A ?2>B6?21 A< ?B; A52
D.A2? 96;2@ A5?<B45 A52 D6?2 32212? 3 =.@@A5?<B45
D.A2?5<@2@.?2B;.C.69./920<;;20AA52"4B;.@
@5<D;6;
Figure 4.
DO NOT USE A WATER SOLENOID VALVE with
the COOL ARC
®
40. When a solenoid valve closes,
t
he pump dead-head, causing the pump to heat up
and will lead to premature failure of the pump.
K529-10 POWER INPUT CABLE WITH WATER
AND GAS HOSES
(56@ 0./92 .@@2:/9F 6;09B12@ . =<D2? 0./92
0<;A?<9 0./92 4.@ 5<@2 .;1 D.A2? 5<@2@ A<
0<;;20A . =<D2? @<B?02 A< . D6?2 32212? (52 0./92
92;4A56@:A(52D.A2?5<@2@5.C2
923A5.;1:.925<@236AA6;4@.;1A524.@5<@25.@.
?645A 5.;1 :.92 5<@2 36AA6;4 (52 0./92 .;1
5<@292;4A5@.?212@64;21A<0<;;20A.D6?232212?A<
.$$!&
I
A5.A6@C2?A60.99F:<B;A21.AA52?2.?
<3.=<D2?@<B?02<;.1B.90F96;12?B;12?0.??6.42
&232?A<Figure 5 3<?.;699B@A?.A6<;<3A56@0<;;20A6<;
CAUTION
REGULATOR
FLOWMETER
GAS*
ARGON GAS
CYLINDER
COOLANT
OUT
COOLANT
IN
COOLANT*
GAS
COOLANT*
GAS
IN
OUT
COOLANT
GAS
TO WORK
POWER / COOLANT
POWER CABLE ADAPTER*
TIG TORCH
*INCLUDED IN
FEMALE TO FEMALE*
C
GA FITTING
KP504 HOOK-UP KIT
POWER SOURCE
COOLANT
IN
COOLANT
O
UT
COOLANT
COOLANT
GUN CABLE
KP504-WATER HOSES AND
FEMALE TO FEMALE 5/8" LH
CGA ADAPTER COUPLINGS
K
P1529-1
FEMALE TO FEMALE 5/8" LH
CGA ADAPTER COUPLINGS
(COUPLINGS ONLY)
SHIELDING
GAS
COOLANT
OUT
NOTE:
ORDER K1859-1 ALONG WITH
K529-10 FOR WIRE FEEDERS
WITH QUICK DISCONNECT
FITTINGS.
COOLANT
COOLANT
GUN CABLE
IN
OUT
K529-10
COOLANT
COOLANT
ELECTRODE CABLE
TO WORK
CONTROL CABLE
COOLANT
IN
NOTE:
BLUE HOSE
RED HOSE
=
COOLANT
OUT
COOLANT
IN
=
COOLANT
IN
COOLANT
OUT
COOLANT
COOLANT
COOLANT
COOLANT
GUN CABLE
NOTE:
COOLANT
OUT
K1859-1 FOR WIRE
FEEDERS WITH QUICK
DISCONNECT FITTINGS
KP504 FOR HOOK-UP
TO WIRE FEEDERS
WITH CGA FITTINGS
COOLANT
IN
=
=
BLUE HOSE
RED HOSE
FIGURE 2
+.A2?<<921((<?05<;;20A6<;
FIGURE 3
+.A2?<<921"B;<;;20A6<;
FIGURE 4
<;;20A6<;A<+6?22212?<#<A)@2+.A2?'<92;<61
FIGURE 5
<;;20A6<;A<+6?22212?<#<A)@2+.A2?'<92;<61
B-1
OPERATION
B-1
H
22=A52?2@2?C<6?3B992@=206.99F.3A2?05.;46;4.;F
D.A2?96;2@
H
(520<<92?@5<B91/2AB?;21$D52;D2916;46@
;<AA.86;4=9.023<?9<;4=2?6<1@<3A6:2
H 2 02?A.6; A5.A A52 0<<92? 6@ $# =<D2? @D6A05 6;
A529=<@6A6<;/23<?2/246;;6;4A<D291
H
);92@@ 052086;4 0<<9.;A 39<D ;2C2? <=2?.A2 A52
0<<92?D6A5A52?2@2?C<6?36990.=?2:<C21
HC<61=9.06;4A520<<92?;2.?.?2.@<32EA?2:252.A
H C<61 =9.06;4 A52 0<<92? ;2.? . 39BE 5<==2? <? .;
.?2.D52?21B@A/B691B=6@2EA?2:2
HC<61 86;86;4 <? =BAA6;4 @5.?= /2;1@ 6; .;F D.A2?
96;2@
H 22=.99D.A2?96;2@092.;.;13?22<3.;F/9<08.42
• Do not operate cooler without coolant in reser-
voir. Never run pump dry.
TURNING THE SYSTEM "ON"
3A2?0<;;20A6;4A52$$!&
I
=2?A526;@A.99.
A6<; 6;@A?B0A6<;@ ./<C2 =9B4 A52 B;6A 6;A< .
;A2?;.A6<;.9 * 2920A?60.9 ?202=A.092 3<? @A.?AB=
<=2?.A6<;202?A.6;A5.AA52=<D2?6;=BA6;A<A52B;6A
:.A052@A520<<92?@?.A216;=BA
(52 %$+& '+( 6@ 9<0.A21 <; A52 ?645A @612 <3
A52 0<;A?<9 =.;29 (52 0<<92? D699 /2 $# D52;
=?2@@21A<9.;1$D52;=?2@@21A<$
,<BD699/2 ./92A<52.?A52 3.;?B;;6;4.;13229 .6?
39<D <BA <3 A52 /.08 <3 A52 B;6A D52; A52 0<<92? 6@
<=2?.A6;4(520<<92?D699?B;0<;A6;B<B@9FB;92@@6A6@
=9B4421 6;A< . @D6A0521 ?202=A.092 <; A52 =<D2?
@<B?02
(52 0<<9.;A !$+ #($& 6@ .002@@21 /F
?2:<C.9<3A5236990.=0AB.9?2AB?;39<D6@16?20A9FC6@
6/92C6.A523699<=2;6;4D6A5A52B;6A6;A52C2?A60.9<?
5<?6G<;A.9=<@6A6<;
+52; 36?@A @A.?A6;4 A52 B;6A 05208 .99 <3 A52 0<<9.;A
5<@2@ A< 6;@B?2 A5.A ;< D.A2? 92.8@ .?2 =?2@2;A
+.A2? 92.8.42 :.F 0.B@2@ =<<? D2916;4 =2?3<?
:.;02 =<<? 0<<96;4 =2?3<?:.;02 9<D D2916;4 0<:
=<;2;A9632.;1:.F0.B@22920A?60.9@.32AF5.G.?1@
COOL ARC
I
40
PRODUCT DESCRIPTION
(52 $$! &
I
6@ . @A.;1 .9<;2 ?206?0B9.A6<;
0<<96;4 @F@A2: 12@64;21 3<? B@2 D6A5 D.A2?0<<921
( " % %9.@:. ?0 BAA6;4 .;1 %+
%9.@:.?0 +2916;44B;@.;1A<?052@(520<<9.;A
# .;1 $)( 0<;;20A6<;@ .?2 923A5.;1
32:.92 A5?2.1@ D5605 :.A05 A52 @A.;1.?1 0<;;20A<?
;BA <3 1<:2@A60 D.A2? 5<@2@ @AF92 .;1 D.A2?
0<<921(A<?052@(52$$!&
I
6@.0<;A6;B
<B@1BAF0<<92?
(52<C2?.99@6G2.;1@5.=2<3A520<<92?6@612;A60.9A<
A52".4;B:(52$$!&
I
0.;<=2?.A26;
26A52? A52 C2?A60.9 <? 5<?6G<;A.9 =<@6A6<; (52 $$!
&
I
6@C2?F2.@FA<B@2.;1B;12?@A.;1D6A5<;9F
<;2=<D2?@D6A05<;A520<;A?<9=.;29(520<<92?5.@
.;;A2?;.A6<;.9*=<D2?6;=BA?202=A.092:.86;4
6AC2?F2.@FA<=<D2?B=116;40<<9.;AA<A52?2@2?
C<6?6@@6:=92.;10<;;20A6;4A< A52 0<<9.;A # .;1
$)(0<;;20A6<;@.?22.@69F:.12D6A5.;.17B@A./92
D?2;05
(52$$!&
I
0<<9.;A39<D06?0B9.A2@A5?<B45.
52.A 2E05.;42? A< ?2:<C2 52.A 2;2?4F 3?<: A52
0<<9.;A (52 0<<9.;A 39<D 6@ A52; 12=<@6A21 6;A< A52
0<<9.;A?2@2?C<6?(52 =B:=1?.D@6A@0<<9.;A @B==9F
3?<:A52 0<<9.;A?2@2?C<6?.;11296C2?@0<<9.;AA<A52
D2916;4A<?05<?4B;Refer to Figure 6
RECOMMENDED PROCESSES AND EQUIPMENT
&20<::2;121 %?<02@@2@ >B6=:2;A .;1
002@@<?62@(52$$!&
I
6@12@64;213<?B@2
D6A5 D.A2?0<<921 ( " % %9.@:. ?0
BAA6;4 .;1 %+ %9.@:. ?0 +2916;4 4B;@ .;1
A<?052@ (52 $$! &
I
0.; /2 B@21 D6A5 "
D6?232212?@.;1=<D2?@<B?02@.@D299.@(=<D2?
@<B?02@
$/@2?C2 A52 3<99<D6;4 D52; <=2?.A6;4 A52 $$!
&
I
H645C<9A.42AF=60.9<3D2916;4<=2?.A6<;@0.;8699
H::2?@6<;6;D.A2?.?<B;12920A?60.996;2@0.;0.B@2
2920A?60.9@5<08
H"<C6;4=.?A@0.;6;7B?2#2C2?=9.0236;42?@6;A<A52
<=2;6;4@<3A52<<92?
H#2C2?<=2?.A2A520<<92?D6A5.;F0.@2=.?A@<33<?
?2:<C21
H);=9B4A520<<92?/23<?2?2:<C6;4A522EA2?;.90.@2
D52;@2?C606;4A52B;6A
H);=9B4A520<<92?/23<?236996;4A52?2@2?C<6?
H<A0<<9.;A0.;/B?;@86;9D.F@/2@B?20<<9.;A6@
#$($(/23<?2@2?C606;4A520<<92?
H< ;<A =<B? B@21 2A5F92;2 49F0<9 0<<9.;A 1<D; A52
1?.6;
H< ;<A ?2:<C2 A52 =B:= ?29623 C.9C2@ 52E ;BA
<?.AA2:=AA<.17B@AA52?29623C.9C2@2AA6;4
H5208A520<<9.;A?2@2?C<6?92C291.69F
B-2
OPERATION
B-2
COOLING EFFICIENCY
(52 5645 0<<96;4 2336062;0F <3 A52 $$! &
I
<332?@ . 0<<92? :<?2 0<:3<?A./92 (<?05 A5.; . 0<;
C2;A6<;.9.6?0<<921(<?05
(52$$!&
I
23320A6C29F?2:<C2@A5252.A=?<
1B021/FA52D2916;4.?03?<:A524B;<?A<?055.;192
.;1=9.02@6A6;A<A522E6A6;4.6?39<D.AA52/.08<3A52
<<92? :/62;A .6? A2:=2?.AB?2 .3320A@ A52 23320A6C2
0<<9.;AA2:=2?.AB?2<3A52$$!&
I
For example:
);9682<A52?D.A2?0<<92?@A5.A12=2;1<;/B98F?2@2?
C<6?@6G2A5256452336062;0F0<:=<;2;A@<3A52$$!
&
I
.99<D@A52?2@2?C<6?A</2@:.99(52?2@B9A6@
.
9645AD2645A=<?A./92B;6A
COOL ARC
I
40
CO
OL
ARC 40® W ATER COOLER
M19724
3-23-2001
COOLANT
RESERVOIR
PUMP
HEAT
EXCHANGER
FAN
AIR
FLOW
WELDING
TORCH
OR
GUN
HEAT
"IN"
COOL-ARC 40
COOLANT "OUT"
COOLANT "IN"
ROOM AIR
IN
HEATED
AIR OUT
HEAT
EXCHANGER
FAN
PUMP
COOLANT
RETURN
COOLANT
INTAKE
C
OOLA
N
T
C
OOLA
N
T
NOTE:
COOLANT
O
UT
COOLANT
IN
=
=
B
LUE HOSE
RED HOSE
FIGURE 6
<<9.;A6?0B9.A6<;6.4?.:
FIGURE 7
C-1
ACCESSORIES
C-1
OPTIONAL EQUIPMENT (Field Installed)
K559-2 Cooler Horizontal Mounting Bracket:
"<B;A@A52$$!&
I
5<?6G<;A.99FA<A52A<=<3.
=
<D2?@<B?02@20B?6;4A520<<92?A<A52963A/.92(52
86A6;09B12@.99;202@@.?F:<B;A6;45.?1D.?2
K559-3 Cooler Vertical Mounting Bracket:
"<B;A@ A52 $$! &
I
C2?A60.99F A< . =<D2?
@<B?02A5.A5.@.1B.90F96;12?B;12?0.??6.42.9?2.1F
6;@A.9921 (52 /?.082A @20B?29F :<B;A@ A52 0<<92? A<
A521B.90F96;12? @B==<?A/?.082A(5286A 6;09B12@.99
;202@@.?F:<B;A6;45.?1D.?2
K1536-1 Magnum Flow Sensor:
%?<A20A@ C.9B./92 A<?052@ 4B;@ .;1 ?</<A60 D2916;4
@F@A2:@ 3?<: 1.:.42 D52; 9<@@ <3 0<<9.;A 39<D 5.@
<00B??213<?.;F?2.@<;@B05.@. /9<0821<?86;821
D.A2?96;2<?.?B=AB?215<@2
KP1529-1 Quick Connect Water Adapter:
<;C2?A@.:.925/8"-18 left hand 5<@2 36AA6;4
'AF92 A< . 32:.92 >B608 0<;;20A 36AA6;4 (52 32:.92
>B6080<;;20A:.A2@D6A5A52:.92>B6080<;;20A@<;
D.A2?0<<921"4B;@<?5<@2@
K1859-1 Water Cooler Hoses (5/8" LH CGA to QD):
(56@86A6;09B12@AD<OKD.A2?5<@2@D6A5.
!@AF9236AA6;4<;<;22;1.;1.:.92>B608
16@0<;;20A <; A52 <A52? "<@A D6?2 32212?@ 5.C2
32:.92 >B608 16@0<;;20A@ .;1 A56@ 86A .99<D@ 16?20A
5<<8B=/2AD22;A52D.A2?0<<92?.;1A52D6?23221
2?
K1859-2
Water Cooler Hoses (5/8" LH CGA to 5/8 LH CGA)
(56@ 86A 6;09B12@ AD< : A :: M
6;@61216.:2A2?5<@2@D6A5.M!@AF9236AA6;4
<;/<A52;1@<@2@0.;/2:.A21D6A5 %3<?
.D.A2?<<92?A<"4B;.==960.A6<;12.93<?D.A2?
<<92?A<".056;2@<?D6?232212?@D6A5M!
@AF9236AA6;4@
Field Installed CGA style hose fittings:
6AA6;4@A<0<;C2?A.@A.;1.?1::5<@2
A<.923A5.;1:.925<@236AA6;4(52@2:.9236A
A6;4@ :.A2 D6A5 A52 36AA6;4@ <; A52 /.08 <3 A52 $$!
&
I
Order the following:
<;;20A<?#BA@(
#6==92@3<?<@2(
<@29.:=@'
COOL ARC
I
40
L(52 0<;;20A<? .;1 ;6==92 96@A21 36A A645A9F <;A<
::A< ::6;;2?16.:2A2? 5<@2/BA63
09.:=21 A645A9F A< A52 5<@2 0.; 36A B= A< .
:: 6;;2? 16.:2A2? 5<@2 (52@2 36AA6;4@ .?2 .9@<
?2.169F.C.69./923?<:.;F6;1B@A?6.9D2916;4@B==962?
K529-10
Power Input Cable with Water and Gas Hoses:
(56@0./92.@@2:/9F6;09B12@A523<99<D6;4=<D2?
0./92 0<;A?<9 0./92 4.@ 5<@2 .;1 D.A2?
5<@2@(520./92.@@2:/9F0<;;20A@.=<D2?@<B?02
A< . D6?2 32212? 3<? D.A2?0<<921 " .==960.A6<;@
(520./9292;4A5 6@ (52 D.A2? 5<@2@5.C2
923A5.;1:.925<@236AA6;4@.;1A524.@5<@25.@.
?645A 5.;1 :.92 5<@2 36AA6;4 (52 0./92 .;1
5<@292;4A5@.?212@64;21A<0<;;20A.D6?232212?A<
.$$!&
I
A5.A6@C2?A60.99F:<B;A21.AA52?2.?
<3 . =<D2? @<B?02 <; . 1B.9 0F96;12? B;12?0.??6.42
Refer to Figure 5 3<? .; 699B@A?.A6<; <3 A56@ 0<;;20
A6<;
KP504 TIG Hook Up Kit:
(52 <<8)= 6A 6;09B12@ D.A2? 5<@2@ 4.@
5<@2D.A2?.1.=A2?36AA6;4@:.92A<:.92!
A5?2.1 D.A2?5<@2 0<B=92?32:.92 A<32:.92
!A5?2.1.;1=<D2?0./92.1.=A2?(5?2.1@<;.99
5<@2@.;136AA6;4@.?2@AF92
DO NOT USE A WATER SOLENOID VALVE with
the COOL ARC
I
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:
<<9.;A5<@2@.?2?2.169F.C.69./923?<:.;6;1B@A?6.9
D2916;4@B==962?<?6;"<?(5<<8B=86A@=?<C61
21/F!6;0<9;920A?60&232?A<".4;B:.002@@<?F96A
2?.AB?2@522A@
<?92;4A5@<3 0<<9.;A5<@2@<C2? :A.;1
B=A<:A::M5<@26@?20
<::2;121::M5<@2 .;1 .00<::<
1.A6;436AA6;4@.?2.C.69./923?<:.;6;1B@A?6.9D2916;4
@B==962?
CAUTION
D
-1
MAINTENANCE
D
-1
ROUTINE MAINTENANCE
&2:<C2 .00B:B9.A21 1B@A .;1 16?A 3?<: A52 6;A2?;.9
0<:=<;2;A@<3A520<<92?/F/9<D6;46A<BAD6A5.9<D
=?2@@B?2.6?5<@2<??2:<C6;4A521B@A.;116?AD6A5.
C.0BB:5<@2
PERIODIC MAINTENANCE
; 16?AF <? 1B@AF 2;C6?<;:2;A@ <? 63 /6<9<460.9 4?<DA5
<00B?@6;A520<<9.;A6A:.F/2;202@@.?FA<39B@5A52
0<<9.;A ?2@2?C<6? ?.6; A52 <91 0<<9.;A ?6;@2 A52
6;@612 <3 A52 ?2@2?C<6? .;1 06?0B9.A2 ?6;@6;4 @<9BA6<;
A5?<B45 A52 0<<9.;A @F@A2: 11 ;2D 0<<9.;A D52;
092.;6;46@36;6@521It is recommended to flush the
coolant at least once a year. 0<<96;4@F@A2:3?22
3?<: 12/?6@ <332?@ 6;0?2.@21 0<<96;4 2336062;0F .;1
9<;42? =B:= .;1 A<?05 9632 '22 A52 Coolant
Treatment Recommendation 6; A56@ L".6;A2;.;02
'20A6<;M
NOTE: %B?2 @<9BA6<;@ .;1 :6EAB?2@ <3 <? :.A2?6.9@
62 A<D29@ D2AA21 D6A5 2A5F92;2 49F0<9 .?2 A<E60 A<
5B:.;@ .;1 .;6:.9@ '=206.9 =?20.BA6<;@ @5<B91 /2
A.82;D52;16@0.?16;4A<E60:.A2?6.91<;<A=<B?A56@
:6EAB?21<D; .;F1?.6;<;A.0AA529<0.9%<33602
3<??2@=<;@6/9216@=<@.9:2A5<1@<?3<??20F096;46;3<?
:.A6<;
PUMP MAINTENANCE
(52=B:=52.15.@./B69A6;@A?.6;2?<;A526;92A@612<3
A52 =B:= It is recommended to clean or replace the
pumps inlet strainer at least once a year. (See Above):
H?.6;A52 0<<9.;A?2@2?C<6?.;1.990<<9.;A 96;2@6@=<@2
<3A520<<9.;A=?<=2?9F.@@=20636216;NOTE ./<C2
H
<91 A52 =B:= 52.1 36?:9F A< .==9F . 0<B;A2?A<?>B2 D52;
9<<@6;4 A52 @A?.6;2?@ :: .0<?; ;BA 9<0.A21 <; A52
/<AA<:<;<A0<;3B@2D6A5::.0<?;;BA&2:<C2
;BA.;1@96126;92A@A?.6;2?1<D;.;1<BA3?<:A52=B:=52.1
H
2;A9F?6;@2A52@A?.6;2?B;12??B;;6;4D.A2?A<A5<?
<B459F092.;6A
H)@2 . :6??<? A< 6;@=20A A52 6;@612 <3 A52 =B:= 3<?
0<;A.:6;.A6<; .?23B99F ?2:<C2 5.?12;21 12/?6@
D6A5 . 12;A.9 =608 63 ;202@@.?F D6A5<BA @0?.A056;4
A526;@612<3A52=B:=
H&26;@A.99A52@A?.6;2?.;1
::
.0<?;;BAA645A
2;6;4 D6A5 6;9/@ <3 A<?>B2 +6=2 1?F .99
.?2.D2AA21D6A50<<9.;A6@=<@2<30<<9.;A@<.821
A<D29@=?<=2?9F.@@=2063621./<C2
H<? . :<?2 6; 12=A5 =?<021B?2 '22 '20A6<;
L%B:=;92A'A?.6;2?M
PUMP MOTOR
(52$$!&
I
6@?.A213<?0<;A6;B<B@<=2?.A6<;
A6@?20<::2;121 A<?2<69A52=B:= :<A<?/2.?6;4@
<;02.F2.?.@3<99<D@
H&2:<C2A52=9.@A60=9B4@9<0.A21<;A52A<=<3/<A5
A526;/<.?1.;1<BA/<.?1/2.?6;42;10.=@
H&2<692.05/2.?6;4D6A51?<=@<3'<69
A52;?26;@A.99/<A5=9B4@
HEAT EXCHANGER
(< :.6;A.6; :.E6:B: 0<<92? 2336062;0F A52 52.A
2E05.;42?@5<B91/282=A3?22 <3 1B@A .;116?A/B691
B=92.;A5252.A2E05.;42?=2?6<160.99FB@6;4.C.0
BB:5<@2<?.9<D=?2@@B?2.6?96;2C<61=9.06;4A52
B;6A ;2.? . 39BE 5<==2? <? . 39BE D.@A2 0<;A.6;2?
092.; 52.A 2E05.;42? <332?@ /2AA2? 0<<96;4 =2?3<?
:.;02.;19<;42?=?<1B0A9632;2EA?2:29F16?AF2;C6
?<;:2;A@ 6A :.F /2 ;202@@.?F A< ?2:<C2 A52 52.A
2E05.;42? 0<:=92A29F 3?<: A52 0<<92? .;1 092.; A52
36;@D6A5@<.=.;1D.A2?)@20.?2A<.C<611.:.46;4
A5236;@
RESERVOIR COOLANT LEVEL
(52?2@2?C<6?C<9B:2@5<B91/205208211.69F/23<?2
B@6;4 A52 0<<92? &2:<C2 A52 ?2@2?C<6? 3699 0.= .;1
05208A520<<9.;A92C29(52?2@2?C<6?6@3B99D52;A52
0<<9.;A 92C29 6@ 7B@A /29<D A52 ?2@2?C<6? 3699 <=2;6;4
D6A5A52B;6A6;A52B=?645A=<@6A6<; 22=A52?2@2?C<6?
3B99 2@=206.99F .3A2? 16@0<;;20A6;4 A52 D.A2? 96;2@ <?
05.;46;4A52.002@@<?F/26;40<<921
COOL ARC
I
40
ELECTRIC SHOCK can kill.
• Disconnect input power by
removing plug from receptacle
b
efore working inside Cooler.
• Do not operate with covers
r
emoved.
• Use only grounded receptacle.
• Do not remove the power cord ground prong.
• Do not touch electrically “hot” parts inside
Cooler.
• Have qualified personnel do the installation,
maintenance and troubleshooting work.
See additional warning information at the
front of this operator’s manual.
WARNING
SAFETY PRECAUTIONS
D
-2
MAINTENANCE
D
-2
COOLANT TREATMENT
RECOMMENDATION
(56@ =?<021B?2 6@ 6;A2;121 A< =?<C612 . :2.;@ <3
?21B06;4A52</720A6<;./92.:<B;A<33B;4.9.;1/.0
A
2?6.90<;A.:6;.A6<;A5.A5.@<00B??216;$$!&
I
D.A2?0<<92?@.;10<<96;4@F@A2:@
Additive
(52?20<::2;121.116A6C20.;/2=B?05.@21.A9<0.9
=<<9@B==9F@A<?2@;2E.:=926@".6;A.6;%<<9%?<
#<;<.:94.20612
Limitations
H(52.116A6C2@5<B91/2B@21D6A53?2@50<<9.;A@0<;
A.6;6;4<;9F=B?2D.A2?
H(56@.116A6C2@5<B91;<A/2B@21 D6A50<<9.;A@0<;
A.6;6;4 .;F <A52? @B/@A.;02 6;09B16;4 .;A63?22G2
@B/@A.;02@
H#< <A52? .116A6C2@ @5.99 /2 B@21 D6A5 A52 @=2063621
0<<9.;AA5.A5.@/22;A?2.A21D6A5A52?20<::2;121
.116A6C2
H(56@=?<021B?26@;<=2?:.;2;A@B/@A6ABA23<?.=2?6
<160:.6;A2;.;02@0521B923<?A52@=20636210<<92?@
H >B.?A /<AA92 <3 .116A6C2 6@ @B336062;A A< 16@6;320A
.;1A?2.A./<BA0<<92?@
• Check with the manufacturer of your guns or
torches to be sure that this procedure is compat-
ible with your equipment.
Prepare the disinfectant:
".82 . >B.;A6AF <3 <;9F D5.A 6@ ;22121 A< .C<61 .;
2E02@@B98=?2=.?.A6<;3<?0<<92?@@2?C60216;>B.;
A6AF
!4.9@ <3=B?23?2@5D.A2?=2? 0<<92?
:9<3.116A6C2=2?0<<92?E.:=923<?0<<9
2?@ .11 :9 A< 4.9@ <3 =B?2 3?2@5 D.A2?
%<B? ! 4.9@ <3 16@6;320A.;A 6;A< A52 2:=AF
?2@2?C<6? &20.= A52 ?2@2?C<6? A.=2 <C2? A52 .6? C2;A
6;A520.=?<9916@6;320A.;A.?<B;1A526;@612A52?2@2?
C<6?A<A5<?<B459F0<.A.99<36A@@B?3.02@&2:<C2A52
A.=23?<:A52?2@2?C<6?0.=%?6:2A520<<96;4@F@A2:
/F =<@6A6<;6;4 0<<92? 5<?6G<;A.99F .;1 06?0B9.A2 16@6;
320A.;AA5?<B456A3<?A<:6;BA2@?.6;16@6;320
A.;A3?<:A520<<96;4@F@A2: < ;<A ?2B@2A56@@<9B
A6<; 11 ;2D 3?2@5 0<<9.;A A< A52 0<<96;4 @F@A2:
11 ! 4.9@ <3 3?2@5 16@6;320A.;A A< A52
@F@A2: /F =<B?6;4 6A 6;A< A52 ?2@2?C<6? A52; ?21B02
A520<;02;A?.A6<;A<A52;<:6;.9==:
11 A52 /.9.;02 ! 4.9@ <3 3?2@5 =B?2
D.A2? A< A52 ?2@2?C<6? A< 0?2.A2 A52 A?2.A21 0<<9.;A
0<;02;A?.A6<;%?6:2A520<<96;4@F@A2:
PUMP INLET STRAINER
%
<<? 0<<92? =2?3<?:.;02 0.; B@B.99F /2 A?.021 A< .
=.?A6.99F <? 0<:=92A29F /9<0821 =B:= 6;92A @A?.6;2?
(56@ 6@ . B@2?@2?C602./92 6A2: .;1 0.; /2 092.;21
.;1 ?2B@21 <? ?2=9.021 <;A6;B21 =B:= <=2?.A6<;
D6A5./9<0821369A2?0.;0.B@2
H*<616;4<30<<92?@2?C602D.??.;AF
H.C6A.A6<;1.:.42A<A52=B:=52.1O@6;92A.?2.@
H+2916;4.002@@<?F1.:.423?<:<C2?52.A6;41B2A<
6;@B336062;A0<<9.;A39<D?.A2
;2D<?=?<=2?9F092.;21=B:=6;92A@A?.6;2?@5<B91
?2@A<?2A520<<92?O@=2?3<?:.;02
<? .116A6<;.9 @2?C602 .;1 =2?6<160 :.6;A2;.;02
12A.69@.;13<??20<::2;1210<<9.;A@3<99<DA52?20
<::2;1.A6<;@96@A21/29<D
Procedure and Preparation:
• Always switch off the COOL ARC
I
40 machine
power
• Always disconnect the COOL ARC
I
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
30<<9.;A6@0<;A.:6;.A21<?<91
H?.6; A52 @F@A2: <3 0<<9.;A .;1 16@=<@2 <3 6A 6; .;
2;C6?<;:2;A.99F?2@=<;@6/92:.;;2?
H9B@5@F@A2:<3<910<<9.;A
H699D6A53?2@5A.= <? 16@A69921D.A2??B;3<?A2; :6;
BA2@.;11?.6;
H%?<0221A<.116;40<<9.;A
30<<9.;A6@;2D
H3 092.; 12160.A21 0<<9.;A 5.;196;4 2>B6=:2;A
6;09B16;4 . 092.; @6=5<; =B:= .;1 . 092.; 5<916;4
A.;8 .?2 .C.69./92 A52; =?<0221 A< @2?C606;4 A52
%B:=;92A'A?.6;2?
COOL ARC
I
40
WARNING
5208 0<<9.;A 92C29 11 :<?2 3?2@5 =B?2 D.A2? 63
?
2>B6?21 D6A5<BA .116;4 :<?2 A5.; !
4.9<3=B?2D.A2?A<=?2C2;A169BA6;4A520<<9.;A.116
A6C2
D
-3
MAINTENANCE
D
-3
Removing Coolant:
.?.6;0<<9.;A3?<:A52?2@2?C<6?B@6;4092.;@6=5<;
6
;42>B6=:2;A
/<<9.;A92C29@5<B91/21?.6;21/29<DA52@A?.6;2?O@
=
?2@@B?236AA6;4
H(56@ =?2C2;A@ 0<<9.;A 3?<: @A?2.:6;4 <BA <3 B;6A
D52;@A?.6;2?;BA6@?2:<C21
SERVICE THE PUMPS INLET STRAINER:
.%9.02 ./@<?/2;A A<D29@ B;12?;2.A5 =B:= 52.1 A<
=?2C2;A@A?.F0<<9.;A3?<:D2AA6;40<<92?O@2920A?60.9
0<:=<;2;A@
/'22 364B?2 <91 =B:= 52.1 A< .==9F 0<B;A2?
A<?>B2D52;9<<@2;6;4@A?.6;2?O@.0<?;;BA<
;<A 0<;3B@2 D6A5 .0<?; ;BA &2:<C2 ;BA .;1
@96126;92A@A?.6;2?1<D;.;1<BA3?<:=B:=52.1
0;@=20A@A?.6;2?3<?1.:.42<?2E02@@6C209<446;4
H&2=9.02 <? 2;A9F ?6;@2 @A?.6;2? B;12? ?B;;6;4
D.A2?A<A5<?<B459F092.;6A
1)@2.:6??<?A<6;@=20A6;@612<3=B:=3<?0<;A.:6
;.A6<;35.?12;2112/?6@6@=?2@2;A.;16;A2?32?2@
D6A5 369A2? @2.A6;4 0.?23B99F ?2:<C2 6A D6A5 12;A.9
=608 D6A5<BA @0?.A056;4 6;@612 <3 A52 =B:= )@2
0.?2;<AA<1?<=12/?6@6;A<=B:=
2&26;@A.99@A?.6;2?.;1.0<?;;BAA645A2;6;4D6A5J
:: 69<4?.:@J6;9/@<3A<?>B2
H<91 =B:= 52.1 A< .==9F 0<B;A2?A<?>B2 D52;
9<<@2;6;4@A?.6;2?@.0<?;;BA
3+6=2 1?F .99 .?2.@ D2AA21 /F 0<<9.;A 6@=<@2 <3
A<D29@6;.;2;C6?<;:2;A.99F?2@=<;@6/92:.;;2?
Add coolant:
.11!4.9<30<<9.;A26A52?A52?20<::2;
1
.A6<;@ <33 A52 D.A2? 0<<921 .002@@<?F <? 63 ;<;2
@22A5212@64;@=206360.A6<;@B::.?F96@A216;A56@
:
.;B.9
ADDITIONAL SERVICE NOTES:
9D.F@B@2./.08B=D?2;05<;=B:=52.1D52;
9<<@2;6;4<?A645A2;6;4=B:=36AA6;4@
#2C2??B;A52=B:=1?F9D.F@B@2.?20<::2;1
210<<9.;A<A52?D6@2=B:=1.:.42:.F?2@B9A
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 user’s particular system or
its usage, especially if it is prone to clogging
from biological growth in the coolant.
COOL ARC
I
40
FIGURE 7
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
-
20
-
21
-
22
-
23
-
24
-
25
-
26
Lincoln Electric Cool Arc 40 Operating instructions
- Category
- Welding System
- Type
- Operating instructions
Ask a question and I''ll find the answer in the document
Finding information in a document is now easier with AI
Related papers
-
Lincoln Electric Power Wave C300 Operating instructions
-
Lincoln Electric Cool Arc 35 Operating instructions
-
-
Lincoln Electric COOL ARC 27 User manual
-
Lincoln Electric Cool Arc 40 Operating instructions
-
-
-
-
-
Other documents
-
Flame King YSN100 User guide
-
G.F. Garden GF80545073 Installation guide
-
Air Vent Inc. IM10065 User manual
-
Hessaire 6020050 Installation guide
-
A&F Machine Products BPF-2 1/2 Installation guide
-
Miller RADIATOR 2A Owner's manual
-
-
Miller Coolmate 4 Owner's manual
-
-
Hessaire FP12000 Operating instructions
