Lincoln Electric Water Dispenser IM670 A User Manual

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COOL ARC®40 STAND ALONE  
WATER COOLER  
IM670-A  
December, 2008  
For use with machines having Code Numbers:  
10928, 11067  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However, your  
overall safety can be increased by  
proper installation ... and thought-  
ful operation on your part. DO  
NOT INSTALL, OPERATE OR  
REPAIR THIS EQUIPMENT  
WITHOUT READING THIS  
MANUAL AND THE SAFETY  
PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
N80  
IP 21S  
OPERATOR’S MANUAL  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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SAFETY  
ELECTRIC SHOCK can  
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.  
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.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
• AC Welder with Reduced Voltage Control.  
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. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of  
the equipment, maintenance of the equipment and the spe-  
cific welding procedure and application involved. Worker  
exposure level should be checked upon installation and  
periodically thereafter to be certain it is within applicable  
OSHA PEL and ACGIH TLV limits.  
3.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.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
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.  
3.j. Also see Items 6.c. and 8.  
5.e. Read and understand the manufacturerʼs instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employerʼs safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
AUG 06  
COOL ARC® 40  
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SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
6.a. Remove fire hazards from the welding area.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
If this is not possible, cover them to prevent  
process used and properly operating  
the welding sparks from starting a fire.  
regulators designed for the gas and  
Remember that welding 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.  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
Away from areas where they may be struck or subjected to  
physical damage.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturerʼs  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturerʼs recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma  
022690-9101.  
Jan, 07  
6.j. Do not use a welding power source for pipe thawing.  
COOL ARC® 40  
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SAFETY  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où lʼon pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
Pour votre propre protection lire et observer toutes les instruc-  
tions et les précautions de sûreté specifiques qui parraissent  
dans ce manuel aussi bien que les précautions de sûreté  
générales suivantes:  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque dʼincendie dû aux étincelles.  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque dʼincendie.  
Sûreté Pour Soudage A LʼArc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à lʼélectrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien sʼisoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une  
grande partie du corps peut être en contact avec la  
masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
d.Ne jamais plonger le porte-électrode dans lʼeau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode sʼapplicuent aussi au pistolet de  
soudage.  
8. Sʼassurer que la masse est connectée le plus prés possible  
de la zone de travail quʼil est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou dʼautres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques dʼincendie ou dʼechauffement des chaines et des  
câbles jusquʼà ce quʼils se rompent.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
dʼopérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de lʼarc peuvent réagir avec les  
vapeurs du solvant pour produire du phosgéne (gas forte-  
ment toxique) ou autres produits irritants.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
2. Dans le cas de travail au dessus du niveau du sol, se pro-  
téger contre les chutes dans le cas ou on recoit un choc. Ne  
jamais enrouler le câble-électrode autour de nʼimporte quelle  
partie du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi quʼun verre blanc afin de se protéger les yeux du  
rayonnement de lʼarc et des projections quand on soude  
ou quand on regarde lʼarc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
lʻarc.  
1. Relier à la terre le chassis du poste conformement au code  
de lʼélectricité et aux recommendations du fabricant. Le dis-  
positif de montage ou la piece à souder doit être branché à  
une bonne mise à la terre.  
c. Protéger lʼautre personnel travaillant à proximité au  
soudage à lʼaide dʼécrans appropriés et non-inflamma-  
bles.  
2. Autant que possible, Iʼinstallation et lʼentretien du poste  
seront effectués par un électricien qualifié.  
3. Avant de faires des travaux à lʼinterieur de poste, la  
debrancher à lʼinterrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de lʼarc de  
soudage. Se protéger avec des vêtements de protection  
libres de lʼhuile, tels que les gants en cuir, chemise épaisse,  
pantalons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
Mar. ʻ93  
COOL ARC® 40  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln  
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,  
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or  
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any  
warranty with respect to the sale of our products.  
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control  
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in  
applying these types of fabrication methods and service requirements.  
for any updated information.  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Product _________________________________________________________________________________  
Model Number ___________________________________________________________________________  
Code Number or Date Code_________________________________________________________________  
Serial Number____________________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.  
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TABLE OF CONTENTS  
Page  
Installation .......................................................................................................Section A  
Technical Specifications ........................................................................................A-1  
Safety Precautions.................................................................................................A-2  
Unpacking the COOL ARC® 40......................................................................A-2  
Filling the Coolant Reservoir...........................................................................A-2  
Coolant “In” and “out” Connections.................................................................A-3  
Input Power Connection..................................................................................A-4  
Installation on Undercarriage or Power Source .............................................A-4  
Horizontal Installation on the Top of a Power Source............................................A-4  
Vertical Installation on Power Source with a Dual Cylinder Undercarriage. ..........A-4  
Installation of Water Cooled Accessories ..............................................................A-5  
Water Cooled TIG Torch and MIG Gun ..........................................................A-5  
Connection to Wire Feeders ...........................................................................A-5  
K529-10 Power Input Cable with Water and Gas Hoses ................................A-5  
Operation .........................................................................................................Section B  
PRODUCT DESCRIPTION .............................................................................B-1  
Recommended Processes and Equipment.....................................................B-1  
Turning the System “On.................................................................................B-1  
Cooling Efficiency............................................................................................B-2  
Accessories.....................................................................................................Section C  
Optional Equipment (Field Installed) ....................................................................C-1  
Maintenance ....................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
ROUTINE MAINTENANCE......................................................................................D-1  
Periodic Maintenance .....................................................................................D-1  
PUMP MAINTENANCE ..........................................................................................D-1  
Pump Motor ....................................................................................................D-1  
Heat Exchanger ..............................................................................................D-1  
Reservoir Coolant Level..................................................................................D-1  
Coolant Treatment Recommendation.............................................................D-2  
Pump Inlet Filter..............................................................................................D-2  
Inspect Condition of Coolant...........................................................................D-2  
Service the Pump Inlet Filter...........................................................................D-3  
Additional Service Notes.................................................................................D-3  
Troubleshooting..............................................................................................Section E  
Safety Precautions.................................................................................................E-1  
How to Use Troubleshooting Guide ................................................................E-1  
Troubleshooting Guide ..........................................................................................E-2  
Wiring Diagrams..............................................................................................Section F  
Wiring Diagram ......................................................................................................F-1  
Dimension Print......................................................................................................F-2  
Parts List.................................................................................................................P-385  
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A-1  
A-1  
INSTALLATION  
®
TECHNICAL SPECIFICATIONS – COOL ARC 40  
Product No. / Model  
K2187-1 ( COOL ARC® 40 230V International)  
Via Continental European (SCHUKO)- PRONG PLUG  
Input  
220-240VAC 50/60 Hz 1 Phase  
Current Draw @ 60Hz Input  
Current Draw @ 50Hz Input  
1.3-1.7 Amps  
2.0-2.4 Amps  
Maximum Operating Pressure and Flow Rate  
(Open Flow, Without Welding Torch Restriction)  
60 psi (414 kPa) (4.14 bar)Max.  
1.66 gal/min. (6.28 liter/min) Max.  
Typical Operating Pressure and Flow Rate  
(With Welding Torch Restriction)  
53-57 psi (365-393 kPa)  
.45-.60 gal/min. (1.7-2.3 liter/min)  
Reservoir Size  
2.0 ga. (7.6 liters)  
For Use Above Freezing: Use Clean tap, distilled or de-ionized water.  
For Use Below Freezing: Use 50% water and 50% pure ethylene glycol  
(reagent or industrial grade) mixture.  
DO NOT USE: Automotive anti-freeze that contains rust inhibitors or leak stoppers.  
These coolants will damage the pump and block the small internal passageways of the  
heat exchanger, affecting cooling performance. To acquire the proper coolant contact  
a local welding distributor.  
Recommended Coolant  
DO NOT USE: Pre-packaged welding industry coolants. These coolants may contain  
oil-based substances, which attack the plastic components of the cooler. Once added  
to the cooler, these substances are virtually impossible to purge from the water lines  
and heat exchanger.  
Shipping  
Weight  
46.5 lbs. (21.1 kg)  
61.2 lbs. (27.8 kg)  
Reservoir  
Full (Water)  
9.03 in. (229.4mm)  
9.10 in. (231.1mm)  
31.99 in. (812.6mm)  
34.26 in. (870.2mm)  
L
W
Dimensions  
H (Top Face)  
H Top Handle)  
EXPLANATION OF SYMBOLS THAT APPEAR ON THIS EQUIPMENT  
ON  
OFF  
O
COOL ARC® 40  
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A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS  
WARNING  
To avoid freeze damage and water leakage in ship-  
ment, the COOL ARC® 40 unit is delivered empty  
with no coolant in the system. To fill the unit, locate  
the plastic Snap-On reservoir fill cap at the front mid-  
dle of the unit. Remove the fill cap by pressing the  
center of the cap inward while pulling at the tab on the  
outer edge.  
ELECTRIC SHOCK can kill.  
• Disconnect input power by remov-  
ing plug from receptacle before  
working inside Cooler.  
• Use only grounded receptacle.  
Clean tap water, distilled water, de-ionized water, a  
50/50 mix of pure ethylene glycol and water, or any  
other coolant specified by the manufacturer of the  
water cooled product that the Cooler is used with, can  
be added into the coolant reservoir. The opening of  
the fill cap mates with most coolant containers but, to  
avoid spillage of coolant, a funnel should be placed  
into the reservoir hole when filling the COOL ARC®  
40.  
• Do not remove the power cord ground prong.  
• Do not touch electrically “hot” parts inside Cooler.  
• Have qualified personnel do the installation, main-  
tenance and troubleshooting work.  
----------------------------------------------------------------------  
®
UNPACKING THE COOL ARC 40  
The packaging of the Cooler is designed to withstand  
shipping abuse, and contains a cardboard liner that  
surrounds the unit. If any shipping damage has  
occurred, contact your certified Lincoln distributor or  
service center. When unpacking the unit, avoid thrust-  
ing sharp objects through the carton liner, which may  
puncture the plastic reservoir. Below is the recom-  
mended procedure for unpacking the Cooler:  
NOTE: Pure solutions and mixtures of, or materials  
(i.e. towels) wetted with ethylene glycol are toxic to  
humans and animals. They must not be haphazardly  
discarded, especially by pouring liquids down the  
drain. Contact the local EPA office for responsible dis-  
posal methods or for recycling information.  
For best results when using the COOL ARC® 40 with  
Lincoln guns or torches, use distilled or de-ionized  
water, although if not available, tap water can be  
used. If protection from freezing is desired, use a 50%  
water and 50% pure ethylene glycol (reagent or  
industrial grade) mixture. An alcohol and water mix-  
ture is also acceptable.  
• Open top flap where identification label appears.  
• Remove loose items and top insert.  
• Open bottom flap.  
• Remove bottom insert and slide Cooler, wrapped in  
inside liner from outer carton.  
• Gently remove liner and packaging foam from  
Cooler.  
When using the COOL ARC® 40 with other products,  
consult the manufacturer's instruction manual for rec-  
ommended coolants.  
Save the instruction manual and service directory sup-  
plied with the COOL ARC® 40 for parts orders and  
future maintenance service.  
CAUTION  
FILLING THE COOLANT RESERVOIR  
DO NOT USE OIL BASED COOLANTS OR COOLANTS  
THAT CONTAIN RUST INHIBITORS OR LEAK STOP-  
PERS.  
Recommended Coolant  
• For Use Above Freezing: Clean tap, distilled or de-  
ionized water.  
---------------------------------------------------------------------------  
The unit can be filled either vertically or horizontally.  
UNPLUG THE COOLER BEFORE FILLING THE  
COOLANT RESERVOIR:  
• For Use Below Freezing: 50% water and 50% pure  
ethylene glycol (reagent or industrial grade) mixture.  
DO NOT USE: Automotive anti-freeze that contains  
rust inhibitors or leak stoppers. These coolants will  
damage the pump and block the small internal pas-  
sageways of the heat exchanger, affecting cooling  
performance.  
UPRIGHT (VERTICAL):  
Tilt the unit backward and pour 2 gallons (7.6 liters)  
of coolant into the coolant reservoir fill hole through  
a funnel.  
• If a 1 gallon (3.8 liters) fill bottle is available, tilt the  
unit forward until the bottle mates with the coolant  
reservoir fill hole. Then tilt the unit backward until the  
fill bottle is emptied. Fill the unit with 2 gallons (7.6  
liters) of coolant.  
DO NOT USE: Pre-packaged welding industry  
coolants. These coolants may contain oil-based  
substances, which attack the plastic components of  
the cooler. Once added to the cooler, these sub-  
stances are virtually impossible to purge from the  
water lines and heat exchanger.  
COOL ARC® 40  
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A-3  
A-3  
INSTALLATION  
LYING DOWN (HORIZONTAL):  
Water or Coolant Line Connections to the  
COOL ARC® 40  
Carefully add 2 gallons (7.6 liters) of coolant through a  
funnel into the coolant reservoir fill hole.  
Take the connector nut of the water hose and check if  
the thread of the male connector nut matches the 5/8-  
18 left hand female thread in the fitting on the back of  
the unit.  
AVOID SPILLING COOLANT INTO THE LOUVERS  
ON THE TOP OF THE COOLER.  
The cooler is "FULL" when the coolant lies just below  
the coolant reservoir opening with the cooler in the  
upright (vertical) position.  
For all Lincoln products and those with a connector  
nut on the water hose that mate with the fittings on the  
back of the COOL ARC® 40:  
(Reference FIG. 1) Take the accessory "INLET" hose  
(colored or tagged blue on most hoses) and thread it  
into the coolant "OUT" fitting located on the right side  
of the back of the cooler. Secure the connector nut of  
the hose tightly into the fitting with a wrench so that  
leaking does not occur. Then take the accessory  
"OUTLET" hose (colored or tagged red on most  
hoses) and thread it into the coolant "IN" fitting located  
on the left side of the back of the cooler. Again, tightly  
secure the connector nut of the hose into the fitting of  
the cooler with a wrench to insure that no leaking  
occurs.  
NOTE: DO NOT ADD MORE THAN 2 GALLONS  
(7.6 LITERS) OF COOLANT INTO THE RESER-  
VOIR. The fill cap contains a pressure release air  
hole, which must not be blocked by overfilling the  
reservoir with coolant.  
Be certain to replace the reservoir fill cap when the  
reservoir is full. Simply press on the inside center of  
the fill cap until the cap snaps into place. Operation of  
the COOL ARC® 40 without the fill cap in place can  
cause poor cooling efficiency, evaporation loss of  
coolant and reduced product life.  
NOTE: BE CERTAIN THAT NO LEAKS EXIST  
WHEN THE COOLER IS TURNED ON. A LEAK  
WILL DEPLETE RESERVOIR VOLUME, CAUSING  
POOR COOLING PERFORMANCE AND REDUCING  
GUN OR TORCH LIFE.  
COOLANT "IN" AND "OUT" CONNECTIONS  
The fittings located on the back center of the COOL  
ARC® 40 are two female 5/8-18 left-hand threaded  
fittings. (CGA Style) These mate with water hoses  
typically used in the welding industry.  
If the connector nut on a water hose does not mate  
with the fittings on the back of the COOL ARC® 40,  
order the following:  
Refer to Figure 1.  
(See Parts Lists for Itemʼs below)  
(2) Connector Nuts  
(2) Nipples for 3/16" I.D. hose  
(2) Hose Clamps  
FIGURE 1  
Inlet and Outlet Hose Connection Diagram  
COOLANT  
IN  
COOLANT  
OUT  
FROM  
HEAT  
TO  
HEAT  
SOURCE  
(RED)  
SOURCE  
(BLUE)  
COOL ARC® 40  
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A-4  
A-4  
INSTALLATION  
Remove the connector nut from the INLET hose by  
making a straight cut 6-12mm(1/4"-1/2") away from  
the end of the nipple located inside of the hose. Take  
the nipple and the connector nut ordered above and  
insert the nipple into the connector nut so that the  
threaded end of the connector nut points away from  
the barbed end of the nipple. Twist the barbed end of  
the nipple into the hose until the shoulder of the nip-  
ple is flush with the end of the hose. Secure the hose  
onto the nipple with the hose clamp to insure that the  
connection is watertight. No water can leak from the  
connection if it is properly attached. Repeat the proce-  
dure for the OUTLET hose. When complete, follow the  
connection procedure detailed above for connecting  
the hoses to the COOL ARC® 40 fittings.  
HORIZONTAL INSTALLATION ON THE  
TOP OF A POWER SOURCE  
For proper installation, follow the instructions provided  
with the K559-2 Cooler Horizontal Mounting Bracket  
Kit. The cooler is secured to the power source lift bale.  
Reference the table below for a list of power sources  
that allows the COOL ARC® 40 to be mounted hori-  
zontally on top.  
VERTICAL INSTALLATION ON POWER  
SOURCE WITH A DUAL CYLINDER  
UNDERCARRIAGE.  
For proper installation, follow the instructions provided  
with the K559-3 Cooler Vertical Mounting Bracket Kit.  
The cooler is securely mounted to the dual cylinder  
support bracket. Reference the table below for a list of  
power sources and dual cylinder undercarriages that  
allows the COOL ARC® 40 to be mounted vertically at  
the rear of the machine on the gas bottle rack.  
The connector and nipple listed fit tightly onto 4.0 mm  
(5/32") to 4.8mm(3/16") inner diameter hose, but if  
clamped tightly to the hose, can fit up to a  
6.4mm(.25”) inner diameter hose.  
INPUT POWER CONNECTION  
Plug the input power cord on the COOL ARC® 40 into  
a standard 230V circuit breaker protected receptacle.  
WARNING  
INSTALLATION ON UNDERCARRIAGE OR  
POWER SOURCE  
If the COOL ARC® 40 is not securely mounted  
horizontally on top of a power source or vertically  
on a dual cylinder undercarriage.  
The COOL ARC® 40 can be mounted either horizon-  
tally or vertically on a power source. To mount the  
cooler horizontally, order the K559-2 Cooler  
Horizontal Mounting Bracket. To mount the cooler ver-  
tically on a power source with a dual cylinder under-  
carriage, order K559-3 Cooler Vertical Mounting  
Bracket.  
THE COOL-ARC 40 MUST BE OPERATED IN THE  
HORIZONTAL POSITION. This will prevent the  
cooler from being accidentally tipped over.  
------------------------------------------------------------------------  
K559-3  
K559-2  
Cooler Vertical Mounting  
Bracket on a Dual  
Cooler Horizontal  
Power Source  
Mounting Bracket  
Cylinder Undercarriage  
Can be used On Top  
of a Power Source  
CV-300  
CV-400  
K874 Undercarriage  
Not Available  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
No  
CV-655  
Not Available  
DC-250  
Not Available  
DC-400  
Not Available  
DC-600, DC-655  
Square Wave TIG 275  
Square Wave TIG 355  
Power Wave 455  
Power MIG 255  
Not Available  
K932-1 Undercarriage  
Not Available  
Yes  
No  
K1570-1 Undercarriage  
Not Available  
No  
COOL ARC® 40  
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A-5  
A-5  
INSTALLATION  
INSTALLATION OF WATER COOLED  
CAUTION  
ACCESSORIES  
After following the installation instructions above, the  
COOL ARC® 40 is ready for connection to a water-  
cooled accessory.  
DO NOT USE A WATER SOLENOID VALVE with  
the COOL ARC® 40. When a solenoid valve clos-  
es, the pump would dead-head, causing the pump  
to heat up excessively leading to premature failure  
of the pump.  
WATER COOLED TIG TORCH AND MIG GUN  
Follow Figure 2 when using the COOL ARC® 40 with  
water-cooled TIG torches. Follow Figure 4 when using  
the COOL ARC® 40 with water-cooled MIG gun.  
Consult the manufacturer's instruction manual when  
using the COOL ARC® 40 with other water-cooled  
TIG and MIG accessories.  
------------------------------------------------------------------------  
K529-10 POWER INPUT CABLE WITH WATER  
AND GAS HOSES  
This cable assembly includes a (1) power cable, (1)  
control cable, (1) gas hose and (2) water hoses to  
connect a power source to a wire feeder. The cable  
length is 3.05m (10Ft.). The water hoses have 5/8"-18  
left hand male hose fittings and the gas hose has a  
5/8"-18 right hand male hose fitting. The cable and  
hose lengths are designed to connect a wire feeder to  
a COOL ARC® 40 that is vertically mounted at the  
rear of a power source on a dual cylinder undercar-  
riage.  
CONNECTION TO WIRE FEEDERS  
Follow Figure 3 when using the COOL ARC® 40 in  
conjunction with a wire feeder. The feeder will need to  
have pass-through water hoses installed in order to  
correctly function with the COOL ARC® 40, since the  
cooler requires continuous flow. DO NOT USE A  
WATER SOLENOID VALVE with the COOL ARC® 40.  
Water pass-through connection kits are available for  
wire feeders. Refer to product literature or the wire  
feeder's instructions manual for kit availability and fur-  
ther connection details. It is not required to run the  
water lines through the wire feeder, but is does pro-  
vide a very neat MIG gun connection.If pass-through  
water hoses are unavailable, connect the MIG gun as  
shown in Figure 4.  
Refer to Figure 5 for an illustration of this connection.  
FIGURE 4  
Connection to Wire Feeder (Do Not Use Water Solenoid)  
KP1529-1  
FEMALE TO FEMALE 5/8" LH  
CGA ADAPTER COUPLINGS  
(COUPLINGS ONLY)  
COOLANT  
IN  
COOLANT  
OUT  
COOLANT  
COOLANT  
FIGURE 2  
Water Cooled TIG Torch Connection  
KP504-WATER HOSES AND  
FEMALE TO FEMALE 5/8" LH  
CGA ADAPTER COUPLINGS  
REGULATOR  
FLOWMETER  
ARGON GAS  
CYLINDER  
GUN CABLE  
COOLANT  
OUT  
COOLANT  
IN  
FIGURE 5  
POWER SOURCE  
GAS*  
Connection to Wire Feeder (Do Not Use Water Solenoid)  
GAS  
IN  
COOLANT*  
OUT  
SHIELDING  
GAS  
COOLANT*  
FEMALE TO FEMALE*  
CGA FITTING  
TIG TORCH  
COOLANT  
IN  
POWER CABLE ADAPTER*  
POWER / COOLANT  
COOLANT  
OUT  
COOLANT  
GAS  
TO WORK  
*INCLUDED IN  
KP504 HOOK-UP KIT  
CONTROL CABLE  
COOLANT  
IN  
OUT  
COOLANT  
FIGURE 3  
COOLANT  
COOLANT  
ELECTRODE CABLE  
TO WORK  
Water Cooled MIG Gun Connection  
K529-10  
GUN CABLE  
NOTE:  
NOTE:  
COOLANT  
OUT  
ORDER K1859-1 ALONG WITH  
K529-10 FOR WIRE FEEDERS  
WITH QUICK DISCONNECT  
FITTINGS.  
=
=
BLUE HOSE  
RED HOSE  
COOLANT  
IN  
COOLANT  
COOLANT  
IN  
COOLANT  
COOLANT  
OUT  
COOLANT  
COOLANT  
GUN CABLE  
NOTE:  
COOLANT  
OUT  
=
=
BLUE HOSE  
RED HOSE  
KP504 FOR HOOK-UP  
TO WIRE FEEDERS  
WITH CGA FITTINGS  
K1859-1 FOR WIRE  
FEEDERS WITH QUICK  
DISCONNECT FITTINGS  
COOLANT  
IN  
COOL ARC® 40  
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B-1  
B-1  
OPERATION  
• The cooler should be turned "OFF" when welding is  
PRODUCT DESCRIPTION  
not taking place for long periods of time.  
• Be certain that the cooler is "ON" (power switch in  
the " l " position) before beginning to weld.  
• Never operate the cooler with the reservoir fill cap  
removed. Unless checking coolant flow.  
The COOL ARC® 40 is a stand alone re-circulation  
cooling system designed for use with water-cooled  
TIG, MIG, PAC (Plasma Arc Cutting) and PAW  
(Plasma Arc Welding) guns and torches. The coolant  
"IN" and "OUT" connections are 5/8-18 left-hand  
female threads which match the standard connector  
nut of domestic water hoses (CGA style) and water-  
cooled TIG torches. The COOL ARC® 40 is a continu-  
ous duty cooler.  
• Avoid placing the cooler near areas of extreme heat.  
• Avoid placing the cooler near a flux hopper or an  
area where dust build-up is extreme.  
• Avoid kinking or putting sharp bends in any water  
lines.  
• Keep all water lines clean and free of any blockage.  
• Do not operate cooler without coolant in reser-  
voir. Never run pump dry.  
The overall size and shape of the cooler is identical to  
the Magnum 20. The COOL ARC® 40 can operate in  
either the vertical or horizontal position. The COOL  
ARC® 40 is very easy to use and understand with  
only one power switch on the control panel. The cool-  
er has an International 230V power input receptacle,  
making it very easy to power up. Adding coolant to the  
reservoir is simple and connecting to the coolant "IN"  
and "OUT" connections are easily made with an  
adjustable wrench.  
TURNING THE SYSTEM "ON"  
After connecting the COOL ARC® 40 per the installa-  
tion instructions above, plug the unit into a  
International 230V electrical receptacle for start-up  
operation. Be certain that the power input into the unit  
matches the Cooler's rated input.  
The COOL ARC® 40 coolant flow is circulated  
through a heat exchanger to remove heat energy from  
the coolant. The coolant flow is then deposited into  
the coolant reservoir. The pump draws its coolant sup-  
ply from the coolant reservoir and delivers coolant to  
the welding torch or gun. Refer to Figure 6.  
The POWER SWITCH is located on the right side of  
the control panel. The cooler will be "ON" when  
pressed to " l " and "OFF" when pressed to " O ".  
You will be able to hear the fan running and feel air-  
flow out of the back of the unit when the cooler is  
operating. The cooler will run continuously unless it is  
plugged into a switched receptacle on the power  
source.  
RECOMMENDED PROCESSES AND EQUIPMENT  
The COOL ARC® 40 is designed for use with water-  
cooled TIG, MIG, PAC (Plasma Arc Cutting) and PAW  
(Plasma Arc Welding) guns and torches. The COOL  
ARC® 40 can be used with MIG wire feeders and  
power sources as well as TIG power sources.  
The coolant FLOW INDICATOR is accessed by  
removal of the fill cap. Actual return flow is directly vis-  
ible, via the fill opening with the unit in the vertical or  
horizontal position.  
The following should always be observed when oper-  
ating the COOL ARC® 40:  
When first starting the unit, check all of the coolant  
hoses to insure that no water leaks are present.  
Water leakage causes poor welding performance,  
poor cooling performance, low welding component life  
and potential electrical safety hazards.  
• High voltage typical of welding operations can kill.  
• Immersion in water around electrical lines can cause  
electrical shock.  
• Moving parts can injure. Never place fingers into  
openings of Cooler.  
• Never operate the cooler with any case parts off or  
removed.  
• Unplug the cooler before removing the wraparound  
or servicing the unit.  
• Unplug the cooler before filling the reservoir.  
• Hot coolant can burn skin. Always be sure coolant is  
NOT HOT before servicing the cooler.  
• Do not pour used ethylene glycol coolant down the  
drain.  
• Do not remove the pump relief valve's 3/4" hex nut  
or attempt to adjust the relief valve setting.  
• Check the coolant reservoir level daily.  
• Keep the reservoir full especially after changing any  
water lines.  
COOL ARC® 40  
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B-2  
B-2  
OPERATION  
COOLING EFFICIENCY  
For example:  
The high cooling efficiency of the COOL ARC® 40  
offers a cooler, more comfortable weld than conven-  
tional air-cooled procedures as well as leading com-  
petitors water cooled systems.  
Unlike other water coolers that depend on bulky reser-  
voir size, the high efficiency components of the COOL  
ARC® 40 allows the reservoir size to be small. The  
result is a lightweight, portable unit.  
The COOL ARC® 40 effectively removes the heat of  
the arc away from the gun or torch handle and places  
it into the exiting air flow at the back of the Cooler.  
Ambient air temperature affects the coolant tempera-  
ture of the COOL ARC® 40.  
FIGURE 6  
Coolant Circulation Diagram  
ROOM AIR  
IN  
HEATED  
AIR OUT  
HEAT  
EXCHANGER  
FAN  
COOLANT  
OUT  
=
=
BLUE HOSE  
RED HOSE  
NOTE:  
COOLANT  
IN  
PUMP  
COOLANT  
RETURN  
COOLANT  
INTAKE  
FIGURE 7  
COOL ARC® 40 WATER COOLER  
HEAT  
"IN"  
COOLANT "OUT"  
COOLANT "IN"  
WELDING  
TORCH  
OR  
GUN  
AIR  
HEAT  
EXCHANGER  
FAN  
FLOW  
PUMP  
COOLANT  
RESERVOIR  
COOL-ARC 40  
3-23-2001  
M19724  
COOL ARC® 40  
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C-1  
C-1  
ACCESSORIES  
“The connector and nipple listed fit tightly onto 5/32"  
(4.0mm) to 3/16" (4.8mm) inner diameter hose, but if  
clamped tightly to the hose, can fit up to a .25  
(6.4mm) inner diameter hose. These fittings are also  
readily available from any industrial welding supplier.  
OPTIONAL EQUIPMENT (Field Installed)  
K559-2 Cooler Horizontal Mounting Bracket:  
Mounts the COOL ARC® 40 horizontally to the top of  
a power source, securing the cooler to the lift bale.  
The kit includes all necessary mounting hardware.  
K529-10 Power Input Cable with Water and Gas Hoses:  
This cable assembly includes the following: (1) power  
cable, (1) control cable, (1) gas hose and (2) water  
hoses. The cable assembly connects a power source  
to a wire feeder for water-cooled MIG applications.  
The cable length is 10'. The water hoses have 5/8"-  
18 left hand male hose fittings and the gas hose has a  
5/8"-18 right hand male hose fitting. The cable and  
hose lengths are designed to connect a wire feeder to  
a COOL ARC® 40 that is vertically mounted at the  
rear of a power source on a dual cylinder undercar-  
riage.  
K559-3 Cooler Vertical Mounting Bracket:  
Mounts the COOL ARC® 40 vertically to a power  
source that has a dual cylinder undercarriage already  
installed. The bracket securely mounts the cooler to  
the dual cylinder support bracket. The kit includes all  
necessary mounting hardware.  
K1536-1 Magnum Flow Sensor:  
Protects valuable torches, guns and robotic welding  
systems from damage when loss of coolant flow has  
occurred for any reason such as a blocked or kinked  
water line or a ruptured hose.  
Refer to Figure 5 for an illustration of this connection.  
KP504 TIG Hook Up Kit:  
The Hook-Up Kit includes: (2) water hoses, (1) gas  
hose, (2) water adapter fittings, male to male 5/8" LH  
thread, (1) water hose coupler, female to female 5/8"  
LH thread and (1) power cable adapter. Threads on all  
hoses and fittings are CGA style.  
KP1529-1 Quick Connect Water Adapter:  
Converts a male 5/8"-18 left hand hose fitting (CGA  
Style) to a female quick connect fitting. The female  
quick connect mates with the male quick connects on  
water cooled MIG guns or hoses.  
CAUTION  
K1859-1 Water Cooler Hoses (5/8" LH CGA to QD):  
DO NOT USE A WATER SOLENOID VALVE with  
the COOL ARC® 40. When a solenoid valve clos-  
es, the pump would dead-head, causing the pump  
to heat up excessively leading to premature failure  
of the pump.  
This kit includes two 25ʼ – 3/16 I.D. water hoses with a  
5/8" LH CGA style fitting on one end and a male quick  
disconnect on the other. Most wire feeders have  
female quick disconnects and this kit allows direct  
hook up between the water cooler and the wire feed-  
er.  
------------------------------------------------------------------------  
Coolant Hoses:  
K1859-2 Water Cooler Hoses (5/8" LH CGA to 5/8 LH CGA)  
Coolant hoses are readily available from an industrial  
welding supplier or in various MIG or TIG hook-up kits  
provided by Lincoln Electric. Refer to Magnum acces-  
sory literature sheets.  
This kit includes two 7.6m(25 Ft.)-4.7mm(3/16”) inside  
diameter hoses with a 5/8”LH CGA style fitting on both  
ends. Hoses can be mated with KP1529-1 for a water  
Cooler to MIG gun application. Ideal for water Cooler  
to Machines or wire feeders with 5/8”LH CGA style fit-  
tings.  
For lengths of coolant hoses over 7.6m(25 Ft.) and up  
to 15.2m(50 Ft)., 7.9mm(5/16”) I.D. hose is recom-  
mended. 7.9mm(5/16”) I.D. hose and accommodating  
fittings are available from an industrial welding suppli-  
er.  
Field Installed CGA style hose fittings:  
Fittings to convert a standard 4.7mm(3/16") I.D. hose  
to a 5/8"-18 left hand male hose fitting. These male fit-  
tings mate with the fittings on the back of the Cool-Arc  
40.  
Order the following:  
(2) Connector Nuts (T15007-2)  
(2) Nipples for 3/16" I.D. Hose (T15008)  
(2) Hose Clamps (S10888-35)  
COOL ARC® 40  
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D-1  
D-1  
MAINTENANCE  
• Gently rinse the strainer under running water to thor-  
oughly clean it.  
SAFETY PRECAUTIONS  
WARNING  
• Use a mirror to inspect the inside of the pump for  
contamination. Carefully remove hardened debris  
with a dental pick if necessary, without scratching  
the inside of the pump.  
ELECTRIC SHOCK can kill.  
• Disconnect input power by  
removing plug from receptacle  
before working inside Cooler.  
• Do not operate with covers  
removed.  
• Reinstall the strainer and 7/8 acorn nut, tightening  
with 75+/-15 in-lbs. of torque. Wipe dry all area wet-  
ted with coolant. Dispose of coolant soaked towels  
properly as specified above.  
• Use only grounded receptacle.  
• Do not remove the power cord ground prong.  
• Do not touch electrically “hot” parts inside  
Cooler.  
• For a more in depth procedure, See Section D-2,  
“Pump Inlet Strainer”.  
• Have qualified personnel do the installation,  
maintenance and troubleshooting work.  
See additional warning information at the  
PUMP MOTOR  
front of this operatorʼs manual.  
------------------------------------------------------------  
ROUTINE MAINTENANCE  
The COOL ARC® 40 is rated for continuous opera-  
tion. It is recommended to re-oil the pump motor  
bearings once a year as follows:  
Remove accumulated dust and dirt from the internal  
components of the cooler by blowing it out with a low-  
pressure air hose or removing it with a vacuum hose.  
• Remove the plastic plugs located on the top of both  
the inboard and outboard bearing end-caps.  
• Re-oil each bearing with 30-35 drops of SAE 20 oil  
then reinstall both plugs.  
PERIODIC MAINTENANCE  
In dirty or dusty environments or if biological growth  
occurs in the coolant, it may be necessary to flush the  
coolant reservoir. Drain the old coolant, rinse the  
inside of the reservoir and circulate rinsing solution  
through the coolant system. Add new coolant when  
cleaning is finished. It is recommended to flush the  
coolant at least once a year. A cooling system free  
from debris offers increased cooling efficiency and  
longer pump and torch life. See the Coolant  
Treatment Recommendation in this “Section D-2”.  
HEAT EXCHANGER  
To maintain maximum cooler efficiency, the heat  
exchanger should be kept free of dust and dirt build-  
up. Clean the heat exchanger periodically using a vac-  
uum hose or a low-pressure air line. Avoid placing the  
unit near a flux hopper or a flux waste container. A  
clean heat exchanger offers better cooling perfor-  
mance and longer product life. In extremely dirty envi-  
ronments, it may be necessary to remove the heat  
exchanger completely from the cooler and clean the  
fins with soap and water. Use care to avoid damaging  
the fins.  
NOTE: Pure solutions and mixtures of, or materials  
(i.e. towels wetted) with ethylene glycol are toxic to  
humans and animals. They must not be haphazardly  
discarded, especially by pouring liquids down the  
drain. Contact the local EPA office for responsible dis-  
posal methods or for recycling information  
RESERVOIR COOLANT LEVEL  
The reservoir volume should be checked daily before  
using the cooler. Remove the reservoir fill cap and  
check the coolant level. The reservoir is full when the  
coolant level is just below the reservoir fill opening  
with the unit in the upright position. Keep the reservoir  
full, especially after disconnecting the water lines or  
changing the accessory being cooled.  
PUMP MAINTENANCE  
The pump head has a "built in" strainer on the inlet side of  
the pump. It is recommended to clean or replace the  
pumps inlet strainer at least once a year. (See Above):  
Drain the coolant reservoir and all coolant lines. Dispose  
of the coolant properly as specified in NOTE above.  
• Hold the pump head firmly to apply a counter-torque when  
loosing the strainer's 7/8" acorn nut located on the bottom. Do  
not confuse with 3/4" acorn nut. Remove nut and slide inlet  
strainer down and out from the pump head.  
COOL ARC® 40  
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D-2  
D-2  
MAINTENANCE  
COOLANT TREATMENT  
PUMP INLET STRAINER  
RECOMMENDATION  
Poor cooler performance can usually be traced to a  
partially or completely blocked pump inlet strainer.  
This is a user-serviceable item and can be cleaned  
and reused, or replaced. Continued pump operation  
with a blocked strainer can cause:  
This procedure is intended to provide a means of reducing the  
objectionable amount of fungal and bacterial contamination that  
has occurred in COOL ARC® 40 water coolers and cooling  
systems.  
• Voiding of cooler service warranty  
Additive:  
• Cavitation damage to the pump headʼs inlet areas  
• Welding accessory damage from overheating due to  
insufficient coolant flow rate.  
The recommended additive can be purchased at local  
pool supply stores. An example is "Maintain Pool Pro  
30% Non-Foam Algaecide".  
A new or properly cleaned pump inlet strainer should  
restore the coolerʼs performance.  
Limitations:  
• This additive should be used with fresh coolants con-  
taining only pure water.  
For additional service and periodic maintenance  
details and for recommended coolants, follow the rec-  
ommendations listed below.  
• This additive should not be used with coolants con-  
taining any other substance, including antifreeze sub-  
stances.  
• No other additives shall be used with the specified  
coolant that has been treated with the recommended  
additive.  
Procedure and Preparation:  
WARNING  
• This procedure is no permanent substitute for a peri-  
odic maintenance schedule for the specified coolers  
• A 1 quart bottle of additive is sufficient to disinfect  
and treat about 720 coolers.  
• Always switch off the COOL ARC® 40 machine  
power  
• Always disconnect the COOL ARC® 40 machine  
from service input power.  
• Check with the manufacturer of your guns or  
torches to be sure that this procedure is compati-  
ble with your equipment.  
• 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 valveʼs 3/4 in.  
acorn hex nut or attempt to adjust the relief valve  
setting.  
Prepare the disinfectant:  
Make a quantity of only what is needed to avoid an  
excess Bulk preparation (for coolers serviced in quan-  
tity):  
------------------------------------------------------------------------  
INSPECT CONDITION OF COOLANT  
8.775 liters(2.325 gals.) of pure, fresh water per cool-  
er 1.625 ml of additive per cooler. Example: for 100  
coolers, add 162.5 ml to 232.5 gals. of pure fresh  
water Pour 7.55 liters(2.0 gals.) of disinfectant into the  
empty reservoir. Recap the reservoir, tape over the air  
vent in the cap, roll disinfectant around the inside the  
reservoir to thoroughly coat all of its surfaces. Remove  
the tape from the reservoir cap. Prime the cooling sys-  
tem by positioning cooler horizontally and circulate dis-  
infectant through it for 10 to 15 minutes. Drain disin-  
fectant from the cooling system. Do not reuse this  
solution. Add new, fresh coolant to the cooling system.  
Add 1.225 liters(0.325 gals.) of fresh disinfectant to the  
system by pouring it into the reservoir, then reduce the  
concentration to the nominal 30 ppm:  
If coolant is contaminated or old:  
• Drain the system of coolant and dispose of it in an  
environmentally responsible manner.  
• Flush system of old coolant.  
• Fill with fresh tap or distilled water, run for ten min-  
utes, and drain.  
• Proceed to adding coolant..  
If coolant is clean and fresh:  
• If clean, dedicated coolant handling equipment,  
including a clean siphon pump and a clean holding  
tank are available then proceed to servicing the  
Pump Inlet Strainer.  
Add the balance 6.325 liters(1.675 gals.) of fresh, pure  
water to the reservoir to create the treated coolant  
concentration. Prime the cooling system.  
Check coolant level. Add more fresh, pure water if  
required, without adding more than 0.475 liters(0.125  
gal.) of pure water to prevent diluting the coolant addi-  
tive.  
COOL ARC® 40  
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D-3  
D-3  
MAINTENANCE  
Removing Coolant:  
Add coolant:  
a. Drain coolant from the reservoir using clean siphon-  
ing equipment  
a. Add 7.6 ltr. (2 gal.) of coolant, either the recommen-  
dations off the water cooled accessory or if none,  
see the design specification summary listed in this  
manual.  
b. Coolant level should be drained below the strainer-  
pressure fitting:  
• This prevents coolant from streaming out of unit  
when strainer nut is removed  
ADDITIONAL SERVICE NOTES:  
SERVICE THE PUMPS INLET STRAINER:  
1. Always use a back-up wrench on pump head when  
loosening or tightening pump fittings.  
a. Place absorbent towels underneath pump head to  
prevent stray coolant from wetting coolerʼs electrical  
components.  
2. Never run the pump dry. Always use a recommend-  
ed coolant, otherwise pump damage may result.  
b. See figure 7. Hold pump head to apply counter  
torque when loosening strainerʼs 7/8 acorn nut. Do  
not confuse with 3/4 acorn nut. Remove nut and  
slide inlet strainer down and out from pump head.  
c. Inspect strainer for damage or excessive clogging:  
• Replace or Gently rinse strainer under running  
water to thoroughly clean it.  
3. Flush coolant from system and replace with  
fresh, recommended coolant at least once a  
year. More frequent flushing may be necessary,  
depending upon the userʼs particular system or  
its usage, especially if it is prone to clogging  
from biological growth in the coolant.  
d. Use a mirror to inspect inside of pump for contami-  
nation. If hardened debris is present and interferes  
with filter seating, carefully remove it with dental  
pick without scratching inside of the pump. Use  
care not to drop debris into pump.  
e. Reinstall strainer and acorn nut, tightening with  
34 15mm-Kilograms( 75 15 in.-lbs.) of torque.  
• Hold pump head to apply counter-torque when  
loosening strainers 7/8 acorn nut.  
f. Wipe dry all areas wetted by coolant. Dispose of  
towels in an environmentally responsible manner.  
FIGURE 7  
COOL ARC® 40  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and  
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
COOL ARC® 40  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENTS(S)  
COURSE OF ACTION  
Cooler does not operate with power 1. Input cord unplugged.  
switch "ON".  
2. Power switch faulty  
3. Power harness damaged.  
4. Water lines blocked or crimped.  
5. Leak in gun or water hoses.  
6. Coolant reservoir empty.  
7. The system needs to be primed  
(Switch pushed to "I" position.)  
Internal water leak.  
1. Hose clamp loose on one of inter-  
nal hoses.  
2. Internal hose punctured.  
3. Heat exchanger leaking.  
4. Pump seal is leaking  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
Torch or gun runs hot.  
1. Unit placed by area of extreme  
heat.  
2. Low coolant flow.  
3. No coolant flow.  
4. Fan not operating.  
5. Heat exchanger clogged.  
Fan operates but there is low coolant 1. Leak in torch/gun or hoses.  
flow.  
2.Torch/gun or hoses partially  
obstructed.  
3. Reservoir empty or very low.  
4. Pump strainer is dirty.  
Fan operates but there is no coolant 1. Pump or pump motor failure.  
flow.  
2. Pump strainer is blocked.  
Pump operates, but fan does not.  
Cooler trips outlet circuit breaker.  
1. Loose or disconnected fan lead.  
2. Obstruction in fan blade.  
3. Fan motor failure.  
Cooler trips outlet circuit breaker.  
1. Circuit overloaded.  
2. Fan or pump motor failure.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
COOL ARC® 40  
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F-1  
F-1  
DIAGRAMS  
ER  
L
O
O
C
TER  
A
0W  
4
ARC®  
L
O
CO  
COOL ARC® 40  
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F-2  
F-2  
DIMENSION PRINT  
COOL ARC® 40  
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NOTES  
COOL ARC® 40  
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Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
Keep flammable materials away.  
Wear eye, ear and body protection.  
WARNING  
Spanish  
No toque las partes o los electrodos Mantenga el material combustible  
Protéjase los ojos, los oídos y el  
cuerpo.  
bajo carga con la piel o ropa moja-  
da.  
Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
AVISO DE  
PRECAUCION  
French  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Gardez à l’écart de tout matériel  
inflammable.  
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
Isolez-vous du travail et de la terre.  
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
Turn power off before servicing.  
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
Débranchez le courant avant l’entre- N’opérez pas avec les panneaux  
tien.  
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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