RETURN TO MAIN MENU
IM438-B
MAGNUM™COOLERS 10-I AND 20-I
March, 1999
For use with machines having Code Number 9743, 9745, 9984, 9986,10266 and 10268
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.
OPERATOR’S MANUAL
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• 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
Download from Www.Somanuals.com. All Manuals Search And Download.
ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
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.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.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
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.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
3.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.
5.c. 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.
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.d. 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.
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.e. Also see item 1.b.
Mar ‘95
Download from Www.Somanuals.com. All Manuals Search And Download.
iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
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.
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.
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.
•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.
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 manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
Download from Www.Somanuals.com. All Manuals Search And Download.
iv
iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on 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 d’incendie 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 d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode 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 s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits 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 d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils 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.
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 l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte-
ment toxique) ou autres produits irritants.
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 s’applicuent aussi au pistolet de
soudage.
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 n’importe quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
1. Relier à la terre le chassis du poste conformement au code
de l’électricité 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 l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma-
bles.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, 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. ‘93
Download from Www.Somanuals.com. All Manuals Search And Download.
v
v
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
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.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
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.
EXPLANATION OF SYMBOLS THAT APPEAR ON THIS EQUIPMENT
OFF
O
ON
Download from Www.Somanuals.com. All Manuals Search And Download.
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Product Description ...............................................................................................A-2
Warranty ................................................................................................................A-2
Safety Precautions.................................................................................................A-3
Product Overview. .................................................................................................A-3
Filling the Reservoir ..............................................................................................A-4
Water Line Connection ..........................................................................................A-4
Horizontally Mounting Magnum Coolers to Lincoln TIG Power Sources...............A-5
Vertically Mounting Magnum Coolers to Lincoln Undercarriages..........................A-5
Water Cooled Equipment Installation ....................................................................A-8
K440-1 LN-7 GMA Wire Feeder with Gas and Water Solenoid Valve.................A-10
K527 Water Solenoid Kit for LN-7........................................................................A-10
K529-10 Power Input Cable with Water and Gas Lines ......................................A-11
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
Operating Precautions...........................................................................................B-1
Lighted Power Switch ............................................................................................B-1
Turning the System On..........................................................................................B-1
Magnum System Monitor.......................................................................................B-2
Demand System with Water Valve or Solenoid.....................................................B-2
Surge Protection....................................................................................................B-2
Fan Motor and Fan Blade......................................................................................B-2
Pump and Pump Pressure.....................................................................................B-2
Pump Failure .........................................................................................................B-3
Cooling Efficiency ..................................................................................................B-3
Accessories.....................................................................................................Section C
Accessories ...........................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Heat Exchanger Maintenance ...............................................................................D-1
Reservoir Maintenance..........................................................................................D-1
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams..............................................................................................Section F
Wiring Diagrams..............................................................................................F-1,F-2
Parts List..........................................................................................................Appendix
Download from Www.Somanuals.com. All Manuals Search And Download.
A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – MAGNUM COOLERS 10-I AND 20-I
Model
Cooler 10-I
Cooler 20-I
Product No.
K873-1
K879-1
Input
220V 50/60 Hz 1 Phase
.75 Amps
220V 50/60 Hz 1 Phase
1.25 Amps
Current Draw at Input
Rated Current Draw
Operating Pressure
1.0 Amps
1.6 Amps
45 psi (310 kPa) (3.0 bar)
60 psi (410 kPa) (4.0 bar)
Shutdown Pressure
(No delay after flow is
stopped)
60-65 psi (414-446 kPa)
(4.0-4.4 bar)
Flow Range
0.1 to 0.8 gal/min (0.4 to 3.0 liters/min)
Typical
Operating
Flow
MIG
with Magnum 15’ (4.5m) gun 0.55-0.60 gal/min (2.1-2.3 liters/min)
with Magnum 12.5’ (3.8m) torch 0.25-0.30 gal/min (1.0-1.2 liters/min)
0.8 (3.0 liters/min)
TIG
Open Flow
Reservoir Size
2.0 ga. (8.0 liters)
Coolant Requirement
For Use Above Freezing: Tap, distilled, de-ionized, mineral water or well water.
For Use Below Freezing: 50% water and 50% automotive antifreeze mixture
such as Prestone, Peak or Zerex or 50% water and 50% pure ethylene glycol
mixture or any water alcohol mixture.
DO NOT USE: Prepackaged welding industry coolants. These coolants may
contain oil-based substances which attack the plastic components in the pump
of the Magnum Cooler and severely reduce pump life.
Weight
Shipping
30 lbs. (13.6 kg)
34 lbs. (15.4 kg)
47 lbs. (21.3 kg)
Reservoir
Full
43 lbs. (19.5 kg)
Dimensions
L
9.0 in. (229mm)
9.0 in. (229mm)
26.5 in. (673mm)
28.75 in. (730mm)
9.0 in. (229mm)
9.0 in. (229mm)
32.00 in. (815mm)
34.25 in. (870mm)
W
H Top Face
H Top
Handle
Undercarriage Use
K874
K840-1*, K841-1*, K842-1*,
K874
* Not available at the time of printing.
MAGNUM COOLER 10-I & 20-I
MAR97
Download from Www.Somanuals.com. All Manuals Search And Download.
A-2
A-2
INSTALLATION
PRODUCT DESCRIPTION
The unique “On-Demand” system (when used with a
water valve or solenoid in the system) only pumps
coolant when it is needed, saves energy, reduces
noise and increases pump and fan motor life by turn-
ing off the system between welds.
Magnum Coolers 10-I and 20-I are stand alone recir-
culating cooling systems designed for use with water
cooled TIG, MIG, PAC (Plasma Arc Cutting) and PAW
(Plasma Arc Welding) guns and torches. Additional
applications include resistance welding, induction
heating and water cooled fixtures such as EDM’s and
small Verti-Shield dams. The connection block located
at the back of the Cooler contains 5/8-18 left hand
female thread. A 5/8-18 left hand nut and matching
nipple are supplied with each Magnum Cooler 10-Iand
Cooler 20-I unit to convert hoses that may have differ-
ent connectors. The international Cooler 10-I and 20-I
are also furnished with a bracket so that the Cooler
can be anchored at the back of a Lincoln K874 double
cylinder undercarriage.
The Magnum Cooler is capable of operating continu-
ously; however, the "on-demand" feature is strongly
recommended in ALL APPLICATIONS TO ASSURE
GOOD PUMP AND MOTOR LIFE.
Magnum Cooler are easy to service. Removal of the
front case provides access to all internal components.
The Phillips head fasteners used to anchor the casing
of the unit match those of the pump and other internal
component connections. In this manner, an operator
can repair all major components using just a Phillips
head screwdriver.
With lower 45 psi (310 kPa) (3.0 bar) output pressure
delivery to increase TIG torch component life,
Magnum Cooler 10-I is made for all water cooled TIG
applications and low to medium duty MIG applica-
tions. The higher 60 psi (410 kPa) (4.0 bar) output
pressure delivery of Magnum Cooler 20-I supports
higher demand water cooled applications without
decreasing component life.
WARRANTY
Warranty for this product is one year after the date of
purchase. For any warranty claim, contact a certified
Lincoln service center.
The Magnum Coolers bring new technology in the
areas of pump, heat exchanger and reservoir designs
to the water cooler market. These technologies allow
the Magnum Coolers to be lighter in weight, lower in
energy consumption, mounted either vertically or hori-
zontally, and operated even in the case of a “soft”
pump failure. The unique “soft” pump failure feature
allows some pump stages to continue to pump coolant
even if one or two stages have failed.
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
A-3
A-3
INSTALLATION
INSTALLATION
The FILL CAP is at the front of the unit (C).
WARNING
Cap removal: While pressing the bulls-eye
inward, grip the tab and remove the cap with
a peeling motion.
ELECTRIC SHOCK can kill.
• Disconnect input power by removing
plug from receptacle before working
inside Cooler.
Cap replacement: Install by pressing inward on the
bulls-eye; the cap will “snap” into position.
• 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.
The coolant FLOW INDICATOR is accessed by
removal of the fill cap. Actual return flow is directly vis-
ible, via the fill opening (D) with the unit in vertical or
horizontal position.
---------------------------------------------------------------------
Air flow vents (E).
PRODUCT OVERVIEW
The LIGHTED POWER SWITCH is located at the left
side of the control panel (A). Cooler will be “ON” when
pressed to “ | “.
Coolant INLET and OUTLET fittings are found at the
rear of the unit (B). They are welding industry stan-
dard English left-hand fittings for water coolant lines.
The right side fitting is marked “coolant out” (coolant
supply to the welding equipment); the left side fitting is
marked “coolant in” (coolant returning from the weld-
ing equipment).
FIGURE 1
A
E
E
B
C
D
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
A-4
A-4
INSTALLATION
The case front sheet metal design allows for ease of
access to repair all internal components. The Phillips
head fasteners used to secure the casing match the
style of fasteners used in the pump head and other
major components. In this manner, an operator can
repair all major components in the unit using just a
Phillips head screwdriver. The case back trapezoidal
shape eliminates the possibility of the exit airflow of
the Cooler being choked when the Cooler is operated
lying horizontally. The exiting airflow is also pushed
back away from the unit so that hot air does not recir-
culate through the louvers in the case front.
When using the Magnum Cooler with other products,
consult the manufacturer’s recommendations for
coolant. Do not use oil based coolants.
The unit can be filled either vertically or horizontally.
UNPLUG THE COOLER BEFORE FILLING THE
RESERVOIR.
Upright: Tilt the unit backward and pour 2 gallons (8.0
liters) of coolant into the reservoir fill hole through a
funnel.
or
A blow molded, high density one piece polyethylene
housing serves as both the reservoir and support
frame for the Coolers. The use of polyethylene plastic
gives a design that is lightweight and durable.
If 1 gallon (4 liters) antifreeze or fill bottle is available,
tilt the unit forward until the bottle mates with the
reservoir fill hole. Then tilt the unit backward until the
fill bottle is emptied. Fill the unit with 2 gallons (8
liters) of coolant.
FILLING THE RESERVOIR
Lying down: Carefully add 2 gallons (8.0 liters) of
coolant through a funnel into the reservoir fill hole.
AVOID SPILLING COOLANT INTO THE FRONT
CASING OF THE UNIT.
Unit will be full when coolant lies just below the reser-
voir opening with the unit in its upright position.
PROPER COOLANT ADDITION
FOR USE ABOVE FREEZING: Tap, distilled,
deionized, mineral water, or well water.
FOR USE BELOW FREEZING: 50% water and
50% automotive antifreeze mixture such as
Prestone, Peak or Zerex or 50% water and 50%
pure ethylene glycol mixture or any water alcohol
mixture.
NOTE: DO NOT ADD MORE THAN 2 GALLONS
(8 LITERS) OF COOLANT INTO THE RESERVOIR.
The fill cap contains a pressure release air hole
which must not be blocked by overfilling the reser-
voir with coolant.
DO NOT USE: Prepackaged welding industry
coolants. These coolants may contain oil-based
substances which attack the plastic components in
the pump of the Magnum Cooler and severely
reduce pump life. Once added to the Cooler, the
substances are virtually impossible to purge from
the water lines and heat exchanger.
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 Magnum Cooler without the fill cap in place can
cause poor cooling efficiency, evaporation loss of
coolant, and low product life.
WATER LINE CONNECTION
To avoid freeze damage and water leakage in ship-
ment, every Cooler 10-I and 20-I unit is delivered
empty with no coolant in the system. To fill the unit,
locate the plastic snap-on reservoir fill cap at the front
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.
Two connector nuts and mating nipples are supplied
in each Cooler 10-I and 20-I model. The connector
and nipple fit tightly onto 4.0mm (5/32”) to 4.0mm
(3/16”) inner diameter hose, but if clamped tightly to
the hose can fit up to 6.4mm (.250”) inner diameter
hose.
To install water lines onto the Cooler, check if your
coolant hose mates with the 5/8-18 left hand female
thread in the connector block at the back of the unit.
NOTE: The unit can be filled either vertically or hori-
zontally. UNPLUG THE COOLER BEFORE FILLING
THE RESERVOIR.
If the connector nut on your water hose does not mate
with the connector block at the back of the Magnum
Cooler:
For best results when using the Magnum Cooler with
Lincoln guns or torches, use distilled, deionized or
demineralized water, although if not available, tap
water can be used. If protection from freezing is
desired, use a 1 gallon (4 liter) automotive antifreeze
and 1 gallon (4 liter) tap water mixture. An alcohol or
glycol mixture with water is also acceptable.
Remove the connector nut from the INLET hose by
making a straight cut 6-12mm (1/4-1/2”) away from
the end of the nipple located inside of the hose. Take
the nipple and the connector nut supplied with the
MAGNUM COOLER 10-I & 20-I
MAR97
Download from Www.Somanuals.com. All Manuals Search And Download.
A-5
A-5
INSTALLATION
Cooler and insert the nipple into the connector nut so that the
threaded end of the connector nut points away from the barbed
end of the nipple. Twist the barbed end of the nipple into the
hose until the shoulder of the nipple is flush with the end of the
hose. Secure the hose onto the nipple with a hose clamp to
insure that the connection is water tight. No water can leak from
the connection if it is properly attached. Repeat the procedure for
the OUTLET hose. When complete, reference Figure 2 and fol-
low the connection procedure detailed below for connector nuts
that mate to the Magnum Cooler connector block.
HORIZONTALLY MOUNTING MAGNUM COOLERS
ON LINCOLN TIG POWER SOURCES
Magnum Coolers can be mounted either upright or
horizontally. For a complete compact system,
Magnum 10-I or 20-I Cooler can be mounted horizon-
tally on the roof of Lincoln TIG Power Sources using
the optional K559-2 Horizontal TIG Mounting Bracket.
For proper installation, follow the instructions provided
with the kit. (See Figures 3a and 3b)
For additional water lines that do not mate with Magnum Cooler
connections, order:
VERTICALLY MOUNTING MAGNUM COOLERS TO
LINCOLN UNDERCARRIAGES K874, K840-1*, K841-
1*, or K842-1*
Order:
(2) T15007-2 Connector Nuts*
(2) T15008 Nipples*
(2) S10888-35 Hose Clamps*
When placing the Cooler 10-I or 20-I at the back of a
Lincoln Undercarriage used in tandem with a Lincoln
MIG power source, order K559-3 Magnum Cooler
MIG Mounting Bracket.
For all Lincoln products and those with a connector nut on the
water hose which mates with the connector block at the back of
a Magnum Cooler:
Save the two connector nuts and nipples provided with the unit
for future use. (Reference Figure 2). Take the water INLET hose
(colored or tagged blue on most hoses) and thread it into the
coolant OUT line located on the right hand side of the connector
block at the back of the Cooler. Secure the connector nut of the
hose tightly into the connector block with a wrench so that leak-
ing does not occur. Then take the OUTLET hose (colored or
tagged red on most hoses) and thread it into the coolant IN line
located on the left hand side of the connector block. Again, tight-
ly secure the connector nut of the hose into the connector block
of the Cooler with a wrench to insure that no leaking occurs. BE
CERTAIN THAT NO LEAKS EXIST WHEN COOLER IS
TURNED ON. A LEAK WILL DEPLETE RESERVOIR VOLUME,
CAUSE POOR OR COOLING PERFORMANCE AND REDUCE
GUN OR TORCH LIFE.
Reference Figure 3c and Table 2 for proper connec-
tion of the bracket to the back bolt pattern of the
Cooler. With the four Phillips head screws supplied,
align the bracket onto the back of the Cooler at the
proper holes displayed in Figure 3c. Do not fully tight-
en the bracket allowing the bracket to slightly move up
and down. Place the Cooler at the back right of the
undercarriage so that the lip of the Cooler bracket
rests on the top of the undercarriage upper cylinder
support. Align the holes of the Cooler bracket with the
holes on the undercarriage upper cylinder support.
Fasten the Cooler bracket with the holes on the
undercarriage upper cylinder support. Fasten the
Cooler bracket onto the undercarriage support with
both 1/4-20 bolts, 1/4-20 hex nuts, plain washers and
lock washers provided. Be certain to tighten all the
fasteners when the installation is complete.
NOTE: Be certain that only 5/8-18 left hand male nuts with
clean and smooth threads are used on your water hoses. Poor
connections cause water to leak at connector block, down
hose lines, and eventually out the case sides of the unit.
* The connector and nipples listed fit tightly onto 4mm (5/32”) to
4.8mm (3/16”) inner diameter hose, but if clamped tightly to the
hose, can fit up to 6.4mm (1/4” inner diameter hose.
* Not available at time of printing.
FIGURE 2
Inlet and Outlet Hose Connection Diagram
COOLANT
IN
COOLANT
OUT
FROM
HEAT
SOURCE
(RED)
TO
HEAT
SOURCE
(BLUE)
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
A-6
A-6
INSTALLATION
FIGURE 3a
FIGURE 3b
NOTE: FOR PROPER INSTALLATION WHEN USED WITH LINCOLN K835, K840,
K841 OR K842 UNDERCARRIAGES, THE RUBBER FEET MAY NEED TO BE
REMOVED FROM THE BOTTOM OF THE MOUNTING BRACKET.
C O O L E R H O L E " A "
C O O L E R H O L E " B "
C O O L E R H O L E " C "
B R A C K E T H O L E " A "
B R A C K E T H O L E " B "
B R A C K E T H O L E " C "
D o o r B u m p e r
( F a c t o r y I n s t a l l e d )
( 6 r e q ' d )
S E E N O T E
W
ARNIN
G
O p t i o n a l
U n d e r c a r r i a g e A r m
M o u n t i n g B r a c k e t
( s h o w n d e t a t c h e d
f r o m C o o l e r b a c k
f o r c l a r i t y )
S e l f T a p p i n g S c r e w
( 4 r e q ' d )
P l a i n W a s h e r
L o c k W a s h e r
1 / 2 - 1 3 H e x N u t
1. ON COOLERS 10 & 10-I :
Align holes A & C of mounting bracket with holes B & C of Magnum Cooler. Secure bracket to the back
of Cooler with 4 self tapping screws provided.
ON COOLERS 20 & 20-I :
Align holes A & B of mounting bracket with holes A & B of Magnum Cooler. Secure bracket to the back
of Cooler with 4 self tapping screws provided.
POWER SOURCE
FRONT
1 / 2 - 1 3 x 1 . 5 0 H H C S
2. Route all water line connections onto connection block at back of Cooler as outlined in the IM manual
provided with the Magnum Cooler.
L a r g e P l a i n W a s h e r
* N O T R E Q ' D W H E N U S I N G
U N D E R C A R R I A G E O P T I O N
TABLE 2
Recommended Magnum Cooler Use with Lincoln
Power Source / Undercarriage Combination
Figure 3c
Mtg. Bkt.
Scheme
Power Source
Cooler
Undercarriage
CV-200-I
CV-300-I
CV-400-I
CV-500-I
R3R-375-I
R3R-500-I
R3R-600-I
Cooler 10-I
Cooler 10-I or 20-I**
Cooler 10-I or 20-I**
Cooler 20-I
K874
K874
A
A or C
K874
B or D
K841-1*
K841-1*
K841-1*
K841-1*
E
E
E
E
Cooler 20-I
Cooler 20-I
Cooler 20-I
** Use 20-I model for demanding welding applications.
* Not available at the time of printing.
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
A-7
A-7
INSTALLATION
FIGURE 3c
Undercarriage Mounting Bracket Layout
A
B
POWER SOURCE HEIGHT
POWER SOURCE HEIGHT
16.44" (417.6mm)
21.50" (546.1mm)
Cooler 10-I Mounting Scheme
C
D
E
POWER SOURCE HEIGHT
POWER SOURCE HEIGHT
POWER SOURCE HEIGHT
16.44" (417.6mm)
21.50" (546.1mm)
27.50" (698.5mm)
Cooler 20-I Mounting Scheme
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
A-8
A-8
INSTALLATION
WATER COOLED EQUIPMENT INSTALLATION
NOTE: Magnum Coolers operate at 45 psi (3.0 bar)
(310 kPa) of pressure for Cooler 10-I and 60 psi (4.0
bar) (414 kPa) of pressure for Cooler 20-I. When used
in the demand system, the pressure in the supply
hose to the water solenoid or valve can surge to 20
psi (1.4 bar) (138 kPa) above holding pressure just
before shutdown. The holding pressure will be 60-65
psi (4.0-4.4 bar) (414-448 kPa). When using the
Magnum Cooler with other water cooled TIG, MIG and
plasma systems, consult the manufacturer’s instruc-
tion manual.
FIGURE 4
Water Cooled TIG Torch Connection
REGULATOR
FLOWMETER
ARGON GAS
CYLINDER
COOLANT
OUT
COOLANT
IN
POWER SOURCE
GAS*
COOLANT
GAS
IN
IN
OUT
OUT
COOLANT*
GAS
COOLANT*
TIG TORCH
POWER CABLE ADAPTER*
POWER / COOLANT
COOLANT
GAS
TO WORK
*INCLUDED IN
KP504 HOOK-UP KIT
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
A-9
A-9
INSTALLATION
FIGURE 5
Water Cooled MIG Gun Connection
COOLANT
IN
COOLANT
OUT
COOLANT
COOLANT
GUN CABLE
FIGURE 6
Water Cooled Plasma System Connection
COOLANT
OUT
COOLANT
IN
COOLANT
PLASMA
CUTTING
POWER
ELECTRODE
CABLE & AIR
SOURCE
AIR
COOLANT
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
A-10
A-10
INSTALLATION
K440-1 LN-7 GMA WIRE FEEDER WITH GAS AND
WATER SOLENOID VALVE
K527 WATER SOLENOID KIT FOR LN-7 2-ROLL
AND LN-7 2-ROLL AND 4-ROLL GMA WIRE FEED-
ERS
The K440-1 LN-7 GMA wire feeder is equipped with
internal water lines and external connectors for attach-
ment to a water cooled MIG gun and a Magnum
Cooler. The water solenoid control of the K440-1 LN-7
GMA enables the feeder to trigger the demand system
of a Magnum Cooler. (Reference Operation Section
for an explanation of the Magnum Cooler demand
system). Follow the instruction manual supplied with
the wire feeder and Figure 7 for proper connection of
the K440-1 LN-7 GMA wire feeder to a Magnum
Cooler and a water cooled MIG gun.
For LN-7 2-Roll Model Above Code 9484
For LN-7 GMA 2-Roll and 4-Roll Models Above Code
9100
The K527 water solenoid kit can be added to an LN-7
or LN-7 GMA wire feeder for conversion from an air
cooled to a water cooled MIG system. The added
solenoid control enables the feeder to trigger the
demand system of a Magnum Cooler. Follow the kit
instructions provided for proper installation of the
K527 water solenoid kit to an LN-7 or LN-7 GMA wire
feeder and Figure 7 for proper connection of the con-
verted wire feeder to a Magnum Cooler and a water
cooled MIG gun. Reference Operation Section for an
explanation of the Magnum Cooler demand system.
FIGURE 7
Connection to Wire Feeder Equipped with Solenoid Control
COOLANT
COOLANT
IN
COOLANT
COOLANT
OUT
COOLANT
COOLANT
GUN CABLE
NOTE:
COOLANT
OUT
=
=
BLUE HOSE
RED HOSE
COOLANT
IN
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
A-11
A-11
INSTALLATION
K529-10 POWER INPUT CABLE WITH WATER AND
GAS LINES
The K529 power input cable connects from the front of
a Lincoln power source to the back of LN-7 and LN-7
GMA wire feeders equipped with a water solenoid
control. K529-10 is 10 ft. (3.0m) long and includes two
water hoses and a gas line. The lengths of the two
water hoses and gas line are designed for proper con-
nection to a Magnum Cooler and a gas cylinder locat-
ed on the back of a Lincoln K874, K840-1*, K841-1* or
K842-1* double cylinder undercarriage. The water
connections are 5/8-18 left hand thread while the gas
connection is 5/8-18 right hand thread. Reference
Figure 8 when using the K529 power input cable.
* Not available at time of printing.
Figure 8
K529-10 POWER INPUT CABLE CONNECTION
SHIELDING
GAS
COOLANT
IN
CONTROL CABLE
TO WORK
WITHOUT
SOLENOID CONNECTIONS
COOLANT
OUT
COOLANT
COOLANT
IN
COOLANT
COOLANT
OUT
ELECTRODE CABLE
GUN CABLE
K529-XX
NOTE:
COOLANT
OUT
=
=
BLUE HOSE
RED HOSE
COOLANT
IN
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
B-1
B-1
OPERATION
SAFETY PRECAUTIONS
- Even when using the Magnum Cooler in an “on-
demand” application, the power to the Cooler should
be turned off when welding is not taking place for a
long period of time.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground.
- Be certain that the Cooler is on (power switch in the
“|” position) before beginning to weld, especially
when using the Cooler in the demand system.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
FUMES AND GASES can be danger-
ous.
- Never operate the Cooler with the reservoir fill cap
removed.
- Avoid placing the Cooler near areas of extreme
heat.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
- Avoid placing the Cooler near a flux hopper or an
area where dust build-up is extreme.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or
explosion.
- Avoid kinking or putting sharp bends in any water
lines.
• Keep flammable material away.
• Do not weld on closed containers.
- Keep all water lines clean.
LIGHTED POWER SWITCH
------------------------------------------------------------------------
ARC RAYS can burn eyes and skin.
• Wear eye, ear and body
A long life, lighted power switch is located at the left
side on the control panel. When switched “ON”, the
switch will be pressed toward the “|” symbol.
protection.
------------------------------------------------------------
Because it will only light when the Cooler is pumping
coolant, the switch serves as an indicator for the
Magnum system monitor. For proper operation, the
switch should beam steadily when coolant is pumping
and remain unlit when flow is stopped. Reference the
Magnum system monitor sections for an explanation.
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
The following should always be observed when oper-
ating any Magnum Cooler:
TURNING THE SYSTEM ON
- Never operate the Cooler with case off.
After filling the reservoir and connecting the coolant
hoses to the Magnum Cooler per the Installation
Sections, plug the unit into an electrical receptacle for
start-up operation. Be certain that the power input into
the unit matches the Cooler’s rated input. Both Cooler
10-I and 20-I cordsets contain a 90 angled CEE 7/4,
7/7 Schuko compatible plug. The plug mates with an
auxiliary receptacle located at the back of many inter-
national Lincoln power sources for power supply to a
Magnum Cooler 10-I and 20-I when placed at the
back of a Lincoln K874, K840-1*, K841-1*, and K842-
1* undercarriage.
- Immersion in water around electrical lines can
cause electrical shock.
- Never place fingers into openings of Cooler. Moving
parts can injure.
- Unplug the Cooler before filling the reservoir.
-
Never operate the Cooler with the reservoir fill cap off.
OPERATING PRECAUTIONS
The following should always be observed when oper-
ating any Magnum Cooler:
* Not available at time of printing.
- Check the Magnum system monitor to verify ade-
quate flow for the applicationr.
- Check the reservoir daily.
- Keep the reservoir full especially after changing any
water lines.
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
B-2
B-2
OPERATION
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 when
operated without a water solenoid or valve. If a water
solenoid or valve is used, the Cooler will run for a
short period of time until the demand system is acti-
vated and the unit shuts off.
and the internal components of the Cooler turn off.
When the arc is started and the trigger and the sole-
noid are enabled, the system pressure is relieved and
the Cooler immediately begins to run. When a water
valve or solenoid is not used, the pump does not
sense any build up of pressure and the Cooler runs
continuously.
When first starting the unit, check all of the water lines
to insure that no water leaks are present. Water leak-
age causes poor welding performance, poor cooling
performance, low welding component life and poten-
tial electrical safety hazards.
CAUTION
NEVER BYPASS THE COOLER POWER SWITCH.
MAGNUM SYSTEM MONITOR
When using a water valve or solenoid, be certain to
turn the Magnum Cooler off (“O” position) when not in
use. Cooler will appear to be off in the demand system
Always check the Magnum System Monitor before
beginning to weld. The power switch light located at
the top of the unit functions as the system monitor.
The light will beam steadily when coolant is flowing
and remain unlit when flow is stopped. The light will
flicker if there is inadequate flow through the sys-
tem. Be sure to check the operation periodically
and each time your welding setup is changed.
but will be supplied as long as the switch is on (“|
”
position). Leaving the Cooler on can eventually cause
the system to turn on and off when not in use (light will
turn on and off) and, over time, decrease the demand
system performance.
------------------------------------------------------------------------
SURGE PROTECTION
Coolers are factory set to deliver coolant for the most
common welding setups.
To protect components from voltage spikes in power
lines, an MOV-Capacitor suppressor assembly attach-
es across the AC input of the rectifier bridge. The sup-
pressor blocks spikes up to 3000V for 1 ms.
IF COOLANT STILL FLOWS, BUT THE LIGHT
FLICKERS:
FAN MOTOR AND FAN BLADE
1. The System Monitor light indicates if there is a
restriction somewhere downstream from the
Cooler. Be certain that water lines and welding
apparatus are not crimped, partially blocked or
obstructed.
The smaller Cooler 10-I model contains one fan while
the larger Cooler 20-I model contains two fans. All
Cooler 10-I and 20-I units use the same fan blade
capable of moving a large volume of air in a small
area of space. Each fan blade is independently driven
by a high torque, AC, small industrial fan motor. A
one-time blow fuse prevents a failed fan motor from
overheating and further damaging the Cooler or caus-
ing a safety problem. The fan motor is capable of
operating both vertically or horizontally although verti-
cal operation offers longer fan motor life.
2. Uncoil the water lines to remove any kinks from the
lines.
3. Unhook the input and output lines from the Cooler.
Blow out the welding apparatus lines and/or con-
nection lines to remove any particulate. Reattach
and check flow again.
PUMP AND PUMP PRESSURE
NOTE: If the system uses a water valve, check to
make sure that the valve is working properly.
All Cooler 10-I and 20-I units contain a DC motored
diaphragm pump manufactured with an integral pres-
sure sensing control switch. The positive displace-
ment self-priming pump consists of 3 separate, self-
regulating, parallel pumping stages. If one stage fails,
the other two continue pumping with a slight decrease
in flow. This “soft” failure protects the water cooled
gun or torch from meltdown and allows the operator to
continue welding until a repair can be made. The
pump’s plastic design resists the common causes of
water cooler pump failure such as:
DEMAND SYSTEM WITH WATER VALVE OR SOLE-
NOID
When linked to a water solenoid or valve, the demand
system works as follows:
When the weld is complete and the trigger circuit
opened, the solenoid stops water flow into the torch or
the gun. The pump senses the buildup of pressure
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
B-3
B-3
OPERATION
- Abrasion failure due to particulate in coolant.
The Magnum Cooler effectively removes the heat of
the arc away from the gun or torch handle and places
it into the exiting air flow at the back of the Cooler.
Outside temperature can affect the cooling perfor-
mance of a Magnum Cooler.
- Corrosion failure due to deionized water and pure
glycol mixtures.
- Cavitation failure due to air bubbles introduced by
an intake screen ( or any other source).
For example:
- Dry operation failure due to the reservoir being emp-
tied.
A. COOL day (50°F, 10°C): More HEAT is trans-
ferred from the water in the heat exchanger to the
air. The water is COOLER and more HEAT is
transferred from the gun or torch to the water.
RESULT: THE GUN OR TORCH FEELS COOL-
ER
- Over pressure failure due to crimping or blocking of
water hoses.
- Catastrophic sudden failure due to wear of carbon
vanes in turbine pumps.
B. HOT day (100°F, 38°C): Less HEAT is transferred
from the water in the heat exchanger to the air.
The water is HOTTER and less HEAT is trans-
ferred from the gun or torch to the water.
RESULT: THE GUN OR TORCH FEELS HOT-
TER.
The spring actuated normally closed pressure switch
is located at the top of the pump head. The springs
sense a pressure buildup in the pump head and, with
a buildup of pressure above the operating pressure,
enable the switch which shuts off power to the fan
motor and pump motor. The pressure switch allows
the Cooler to run intermittently “On Demand” when
connected to a water valve or solenoid only providing
cooling water when it is needed. This feature saves
energy, but more importantly, drastically increases
pump and fan motor life. For best operation, no delay
time should exist from the time flow stops and when
the pump is turned off. (Refer to “Magnum System
Monitor” Section).
Unlike other water coolers that depend on bulky reser-
voir size, the high efficiency components of Magnum
Coolers allows the reservoir size to be small. The
result is a lightweight, portable unit.
PUMP FAILURE
Magnum Cooler pumps are designed to fail “soft” so
that welding can continue until a repair is made. In the
unlikely event of a “soft” pump failure, water will slowly
leak from the pump head and drip out the case sides
of the unit. The internal electrical components are iso-
lated away from the pump and are in no danger from
the leak. S20095-1 and S20095-3 Pump Replacement
Kits and S20095-2 Pump Rebuild Kit are available for
repair of the pump. The only tool required is a Phillips
head screwdriver.
COOLING EFFICIENCY
The high cooling efficiency of Magnum Coolers offers
a cooler, more comfortable gun or torch than conven-
tional air cooled procedures as well as leading com-
petitors water cooled systems. The heat exchanger’s
corrugated fin improves heat convection transfer while
minimizing air flow restriction. This design offers a
durable construction capable of withstanding impact of
objects through air slots. Table 3 states the recom-
mended use and cooling rate for 10-I and 20-I Cooler
models. Refer to Figure 9 for a description of how
Magnum Coolers perform.
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
B-4
B-4
OPERATION
FIGURE 9
Circulation of Magnum Cooler
ROOM AIR
IN
HEATED
AIR OUT
HEAT
EXCHANGER
FAN
COOLANT
=
=
BLUE HOSE
RED HOSE
OUT
NOTE:
COOLANT
IN
PUMP
COOLANT
RETURN
COOLANT
INTAKE
TABLE 3
(1)
Approximate Cooling Rate and Recommended Use
Model
Cooler 10-I
Cooler 20-I
Product No.
K873-1
K879-1
Max. Welding Current
TIG
350A
100% duty cycle
550A
100% duty cycle
Max. Welding Current
MIG
350A
100% duty cycle
550A
100% duty cycle
Max. Arc Current
PAW
Test each application
for cooling requirements
PAC
Misc. Applications
(1)
The values listed are based on lab test results. Some applications may vary.
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
C-1
C-1
ACCESSORIES
PARTS DESCRIPTION FOR MAGNUM COOLER
ACCESSORIES
S20095-1 Pump Replacement Kit (60 psi) (4.0 bar)
(414 kPa) for Magnum Cooler 20-I Models
Includes:
* (1) Complete 40-60 psi (3.0-4.0 bar) (310-414)
kPa) Pressure switch assembly.
* (1) Complete 60 psi (4.0 bar) (414 kPa) Pump
with all internal components and hose connec
tions.
* (1) Drive assembly
(1) Installation instructions
* All of the above assembled together with three short
screws and retaining hex nuts.
S20095-2 Pump Rebuild Kit for Magnum Cooler
10-I and 20-I Models
Includes:
(1) Teflon shim
(1) Diaphragm
(2) 45 psi (3.0 bar) (310 kPa) spring
(1) 60 psi (4.0 bar) (414 kPa) spring
(1) 80 psi (5.4 bar) (551 kPa) spring
(3) Conical spring seats
(1) Installation instructions
S20095-3 Pump Replacement Kit (45 psi) (3.0 bar)
(310 kPa) for Magnum Cooler 10-I Models
Includes:
* (1) Complete 40-60 psi (3.0-4.0 bar) (310-414 kPa)
Pressure switch assembly.
* (1) Complete 45 psi (3.0 bar) (310 kPa) Pump with
all internal components and hose connections.
* (1) Drive assembly
(1) Installation instructions
* All of the above assembled together with three short
screws and retaining hex nuts.
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
D-1
D-1
MAINTENANCE
Both the S20095-1 and S20095-3 Pump Replacement
Kits consist of a molded pump head equipped with all
internal pump components to replace a failed pump or
cracked pump head of a Magnum Cooler. The Pump
Replacement Kit includes a complete pre-assembled
pressure switch assembly and pump assembly.
Although the Pump Replacement Kit costs more than
the Pump Rebuild Kit, the time to install it is less and
saves money when down time is costly. When repair-
ing the Cooler pump, follow the instructions supplied
with the kit. The only tool needed for installing the
S20095-1 or S20095-3 Pump Replacement Kit is a
Phillips head screw driver. Reference Parts Section
for a parts list of the Pump Replacement Kit.
WARNING
ELECTRIC SHOCK can kill.
• Disconnect input power by removing
plug from receptacle before working
inside Cooler.
• Do not operate with covers removed.
• Use only grounded receptacle.
• Do not remove the power cord ground prong.
• Do not touch electrically “hot” parts inside Cooler.
• Have qualified personnel do the installation, main-
tenance and troubleshooting work.
---------------------------------------------------------------------
S20095-2 Pump Rebuild Kit for Magnum Cooler 10-I
and 20-I Units:
The S20095-2 Rebuild Kit consists of a all the neces-
sary internal components to rebuild the most common
“soft” pump failure that occurs in a Magnum Cooler.
Water will slowly drip from the pump head when the
pump experiences a “soft” failure. The rebuild proce-
dure is more involved than the pump replacement pro-
cedure but is more cost efficient when labor rates are
low or when down time is not critical. The only tool
needed for rebuilding the pump is a Phillips head
screw driver. Follow the instructions supplied with the
kit when rebuilding the pump head. Reference Parts
Section for the S20095-2 Magnum Cooler Pump
Rebuild Kit.
HEAT EXCHANGER MAINTENANCE
To maintain maximum efficiency, the heat exchanger
should be kept clean from dust and dirt buildup. Clean
the heat exchanger periodically using a vacuum hose
or low pressure air line. Avoid placing the unit near a
flux hopper or a flux waste container. A clean heat
exchanger offers better cooling performance and
longer product life. If extremely dirty conditions exist, it
may be necessary to remove the heat exchanger
completely from the Cooler for a thorough soap and
water cleaning of the cooling fins. Use care to avoid
damaging the fins.
RESERVOIR MAINTENANCE
The reservoir volume should be checked daily before
using the Cooler. Remove the reservoir fill cap and
check the coolant level. Unit is full when the coolant
lies just below the reservoir fill opening with the unit in
an upright position. Keep the reservoir full especially
after changing the water lines.
The Cooler should always be operated with the reser-
voir fill cap on. In areas where dust can be introduced
into the reservoir through water lines or reservoir fill
cap removal, periodically flush the unit out. Dump the
old coolant and rinse the inside of the reservoir. Add
new coolant when finished. A reservoir free from parti-
cle buildup and dirt offers better cooling efficiency and
longer pump, gun and torch life.
S20095-1 Pump Replacement Kit (60 psi) for Magnum
Cooler 20-I Units:
S20095-3 Pump Replacement Kit (45 psi) for Magnum
Cooler 10-I Units:
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
E-1
E-1
TROUBLESHOOTING
TROUBLESHOOTING GUIDE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as internal wiring.
• Turn OFF input power at welding power
source and accessory power source
before installation or service.
• Cooler must be connected to system
ground per any National Electrical Code
or any applicable local codes.
• Only qualified personnel should
perform installation or service.
Observe all additional Safety Guidelines detailed
throughout this manual.
WARNING
This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per-
formed on this equipment may result in danger to the technician and machine operator and will invalidate your
factory warranty. For your safety, please observe all safety notes and precautions detailed in the Safety Section
of this manual to avoid electrical shock or danger while troubleshooting this equipment.
_________________________________________________________________________________________
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Cooler does not operate with power
switch on.
(Switch pushed to
"1" position.)
a. Power cord unplugged.
b. No power at outlet.
a. Plug in power cord.
b. Check outlet circuit breaker.
c. Repair damaged cord or order
new cordset.
c. Power cordset damaged.
d. Unit too hot. Thermal protector
tripped.
e. Water lines blocked or crimped.
d. Allow unit to cool. Relocate unit
away from source of heat.
e. Clear blockage in hose. Avoid
kinking or putting sharp bends in
water lines.
f. Repair water valve or solenoid.
f. Unit is used in a demand system
and water valve or solenoid dam-
aged.
g. Leak in gun or water hoses.
h. Reservoir empty.
I. Power switch faulty.
j. Solenoid valve is closed.
g. Repair leak.
h. Fill reservoir.
I. Replace power switch.
j. Pull trigger on welding gun to open
solenoid valve.
k. Female quick-connect fittings are
not connected to male fittings.
k. Connect all quick connect fittings
to their mating parts.
Power switch blinks or flickers while
coolant is flowing. (Continuous use,
NO Water Valve or Solenoid in the
system.)
a. Water lines partially blocked or
obstructed.
a. Clear blockage in hose. Avoid
kinking or putting sharp bends in
water lines.
b. Internal hose or heat exchanger is
blocked.
c. Restriction is too high for the
Cooler being used.
b. Carefully clear blockage. Clean all
hoses and the reservoir.
c. Use the Cooler 20-I for MIG appli-
cations. Cooler 10-I can be used
for either MIG or TIG applications.
Using a water valve or solenoid and
power switch blinks or flickers while
coolant is flowing or when flow is
stopped.
a. Water lines partially blocked or
obstructed.
a. Clear blockage in hose. Avoid
kinking or putting sharp bends in
water lines.
b. Water valve or solenoid failure.
b. Repair or replace water valve or
solenoid.
c. Internal hose or heat exchanger is
blocked.
d. Restriction is too high for the
Cooler being used.
c. Carefully clear blockage. Clean all
hoses and the reservoir.
d. Use the Cooler 20-I for MIG appli-
cations. Cooler 10-I can be used
for either MIG or TIG applications.
Using water valve or solenoid and
power switch light turns on and off
when not in use.
a. Leak in gun or water hoses.
b. Demand system stress. System
not used for long period of time
with Cooler left on. (Power switch
pushed to “|”).
a. Repair leak.
b. Turn power switch off when not in
use. (Power switch pushed to
“O”). DO NOT LEAVE POWER
ON WHEN COOLER IS NOT IN
USE FOR A LONG PERIOD OF
TIME.
Internal water leak.
a. Hose clamp loose on one of inter-
nal hoses.
b. Internal hose punctured.
a. Tighten or replace hose clamp.
b. Replace punctured hose with new
hose.
c. Heat exchanger leaking.
d. Pump experiencing “soft” failure
and leaking around plastic hous-
ing of pump head.
c. Replace heat exchanger.
d. Repair pump with S20095-1 or
S20095-3 Pump Replacement Kit
or S20095-2 Pump Rebuild Kit.
e. Replace pump head with S20095-
1 or S20095-3 Pump
e. Pump head cracked.
Replacement Kit.
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Leak at inlet/outlet connector
block.
a. Loose connector fitting.
a. Tighten connector nut. (5/8-18
left hand thread).
b. Tighten hose clamp onto hose.
b. Hose clamp loose.
Torch or gun runs hot.
a. Unit placed by area of extreme
heat.
a. Move unit away from hot air.
b. Low coolant flow.
b. See Low Coolant Flow
Section.
c. See No Coolant Flow Section.
d. Reference fan section.
e. Clean heat exchanger.
c. No coolant flow.
d. Fan not operating.
e. Heat exchanger clogged.
Fan operates but there is low
coolant flow.
a. Leak in torch/gun or hoses.
b. Torch/gun or hoses partially
obstructed.
c. Reservoir empty or very low.
d. DC+ or DC- connection loose
on rectifier bridge.
e. Pressure low (pump motor fail-
ing).
f. One or more pump stages
have failed.
a. Repair leak.
b. Clear obstruction.
c. Refill reservoir.
d. Secure DC+ or DC- connec-
tors on rectifier bridge.
e. Replace pump motor.
f. Repair the pump with S20095-
1 or S20095-3 Pump
Replacement Kit or S20095-2
Pump Rebuild Kit.
Fan operates but there is no
coolant flow.
a. Pump motor failure.
b. Pump head seized (bearing
failure).
a. Replace pump motor.
b. Replace pump head with
S20095-1 or S20095-3 Pump
Replacement Kit.
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.
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Pump operates, but fan does not.
a. Internal AC circuit open.
a. Secure AC connectors on rec-
tifier bridge.
b. If fan blades are plastic,
replace. Reset fan clearance
and secure fan to motor shaft.
c. Replace fan motor with Fan
Motor and Mount Assembly.
b. Fan blade contacting heat
exchanger.
c. Fan motor failure
Cooler trips outlet circuit breaker.
a. Circuit overloaded.
b. Cooler electrical component
failure.
a. Check outlet circuit breaker.
b. Replace suppressor assembly
and rectifier bridge inside of
Cooler.
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.
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
F-1
F-1
DIAGRAMS
ꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ ꢆꢇꢈꢉ ꢀꢊꢋꢋꢌꢍꢎꢁꢀꢊꢋꢏꢍꢁꢀꢐꢑꢂꢒꢒꢀꢓꢔꢎꢉꢀꢐꢑꢂꢒꢕꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀꢀ
ꢐꢑꢈꢐꢒꢐꢋꢓꢔꢔꢑꢋꢓ
ꢔꢌꢕꢊꢖꢎ
ꢕꢇꢊꢓꢋꢇ
ꢊꢉ
ꢘ
ꢍ
ꢍ
ꢇ
ꢚꢄ
ꢐꢑꢈꢐ
ꢄꢀ
ꢃꢀ
ꢈꢉꢊꢉꢋ
ꢐ
ꢀ
ꢍ
ꢐꢑꢈꢐ
ꢈꢉꢊꢉꢋ
ꢎꢅ
ꢎꢄ
ꢎꢃ
ꢅꢀ
ꢌ
ꢁ
ꢂ
ꢃ
ꢃꢛꢜ
ꢏ
ꢃ
ꢃ
ꢆ
ꢇ
ꢈꢉꢊꢉꢋ
ꢌ
ꢚꢃ
ꢌ
ꢌ
ꢖꢉꢇꢇꢓꢖꢊꢓꢗꢒꢊꢉꢒꢎꢄꢒꢆꢉꢋ
ꢔꢓꢖꢉꢇꢗꢒꢆ ꢇꢒꢉꢇ
ꢖꢉꢉꢘꢓꢋꢒꢄꢙꢒ ꢇꢗꢒꢄꢙꢂꢕ
ꢈꢉꢗꢓꢘꢔ
ꢖꢉꢉꢘꢓꢋꢒꢃꢙꢒ ꢇꢗꢒꢄꢙꢒꢈꢉꢗꢓꢘꢔ
ꢖꢉꢇꢇꢓꢖꢊꢓꢗꢒꢊꢉꢒꢎꢅꢒꢆꢉꢋ
ꢖꢉꢉꢘꢓꢋꢒꢃꢙꢂꢕꢒ ꢇꢗꢒꢄꢙꢂꢕꢒꢈꢉꢗꢓꢘꢔ
ꢁꢂꢃꢄꢅꢆ ꢀꢅꢃꢄꢇ
ꢇꢁꢀ ꢉꢊꢋꢌꢍꢀꢍꢇꢂ ꢊꢁꢎ
ꢅꢈ
ꢌꢇꢇꢐꢅꢆꢀꢕꢚꢏꢊ
ꢑꢁꢈ
ꢛꢛꢚ
ꢜ
ꢊꢁꢔꢂꢋꢙ
ꢌꢇꢇꢐꢅꢆꢀꢕꢚ
ꢑꢁꢈ
ꢕꢕꢖ
"ꢚ
ꢜ
ꢀ
ꢅꢐꢅꢌꢋꢆꢊꢌꢑꢐꢀ ꢓꢃꢄꢇꢐ ꢀꢔꢅꢆꢀꢅꢕꢖꢗꢘ
ꢌꢇꢐꢇꢆꢀꢌꢇꢈꢅꢙ
ꢖꢚ!"ꢚ ꢍ
ꢌꢇꢇꢐꢅꢆꢀꢛꢚꢏꢕ
ꢌꢇꢇꢐꢅꢆꢀꢛꢚ
ꢍ
ꢀꢀꢄ
ꢀꢀꢉ
ꢀꢀꢎ
ꢏꢀꢄꢐꢑꢌꢒ
ꢏꢀꢉꢍꢊꢋꢅ
ꢏꢀꢎꢆꢅꢅꢁ
ꢁꢀꢏꢀꢄꢆꢇꢉꢁ
ꢀꢀꢀꢀꢀꢆꢀꢀꢀꢀꢀ
ꢀꢀꢀꢁꢂꢂꢃꢄꢅꢀꢀꢀ
MAGNUM COOLER 10-I & 20-I
Download from Www.Somanuals.com. All Manuals Search And Download.
F-2
F-2
DIAGRAMS
MAGNUM COOLERS CODES 9743 THRU 9746
B L A C K
1
B R O W N
I N T E R N A L
T O
2
P U M P
115
60
V
W H I T E
COOLER 10
3
*
Hz
+
-
P U M P
M O T O R
5
L
M
220
V
F A N
M O T O R
L E A D S
M
COOLER 10-I
E X T E R N A L
50/60 Hz
F O R C O D E S 9 7 4 3 T H R U 9 7 4 6
C O O L E R 1 0 1 0 - I W I R I N G D I A G R A M
NUMBERS EMBOSSED
ON SWITCH HOUSING
*
&
B R O W N
2
B L A C K
1
I N T E R N A L
T O
P U M P
115
60
V
COOLER 20
3
W H I T E
*
Hz
+
-
P U M P
L
M
M O T O R
5
220
V
F A N
L E A D S
M
M
M O T O R
E X T E R N A L
COOLER 20-I
50/60 Hz
F O R C O D E S 9 7 4 3 T H R U 9 7 4 6
C O O L E R 2 0 2 0 - I W I R I N G D I A G R A M
NUMBERS EMBOSSED
ON SWITCH HOUSING
&
*
1 0 - 2 2 - 9 3
S20690
MAGNUM COOLERS CODES 9984 THRU 9987
B L A C K
B R O W N
2 *
I N T E R N A L
T O
1 *
P U M P
M O T O R
115
60
V
*
3 *
W H I T E
COOLER 10
Hz
+
-
P U M P
L
M
M O T O R
3
220
V
F A N
M O T O R
L E A D S
M
COOLER 10-I
50/60 Hz
NUMBERS EMBOSSED
ON SWITCH HOUSING
F O R C O D E S 9 9 8 4 T H R U 9 9 8 7
C O O L E R 1 0 1 0 - I W I R I N G D I A G R A M
*
&
I N T E R N A L
T O
B R O W N
B L A C K
1 *
2 *
P U M P
M O T O R
115
60
V
*
3 *
COOLER 20
W H I T E
Hz
+
-
P U M P
M O T O R
3
L
M
220
V
F A N
L E A D S
M
M
M O T O R
COOLER 20-I
50/60 Hz
F O R C O D E S 9 9 8 4 T H R U 9 9 8 7
C O O L E R 2 0 2 0 - I W I R I N G D I A G R A M
NUMBERS EMBOSSED
ON SWITCH HOUSING
&
*
1 0 - 2 2 - 9 3
S20691
Download from Www.Somanuals.com. All Manuals Search And Download.
● 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
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
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.
Download from Www.Somanuals.com. All Manuals Search And Download.
● 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.
Download from Www.Somanuals.com. All Manuals Search And Download.
|