Lincoln Electric IM645-A User's Manual
Contents
1. RETURN TO MAIN MENU Power Wave 450 Water Cooler 434 May 2000 Upgrade Kit UPGRADE INSTALLATION INSTRUCTIONS SSS SSS o Table of Contents Safety sisne a s eee 1 General Description 000 0c eee eae 1 Recommended Tools for Installation or Service 2 G3503 Installation or Service Tool Usage 2 G3503 Water Cooler Upgrade Kit Contents 2 Recommended Coolants 0000 eee eae 2 Installation Instructions 00000e eee 3 Replacing a G2725 Cooler with a G3503 3 Removing and Installing the G3503 Cooler 4 G3503 Cooler Periodic Maintenance 5 G3503 Cooler Service 0 02 ee eee 5 Parts List for Cooler P261 K 2 K 3 6 7 Figure 1 Specified Coolant Level 8 Table 1 Cooler Electrical Harness Pin outs 8 SAFETY Follow all safety guidelines in your power source operator manual and any additional guidelines covered in this manual GENERAL DESCRIPTION This upgrade kit is designed to provide all necessary parts and instruction to replace a G2725 water cooler assembly with an improved design G3503 water cooler assembly The G3503 1 and G3503 Coolers are inter changeable as complete units only These procedures are specified by Lincoln Electric and apply to domestic Power Wave 450 machines requiring a Lincoln internal water cooler Date of Purchase ISO 9002 Seria2. 7 16 open or box end wrenches 1 4 hex socket with wrench terminals 2 needlenose pliers relay terminals 1 and 2 2 large blade slotted screwdriver 8 in minimum long relay terminals 3 and 4 medium slotted screwdriver All plumbing components N R two 10 inch adjustable wrenches 1 4 hex socket with wrench S24505 WATER COOLER UPGRADE KIT CONTENTS 1 Cooler assembly G3503 e Empty Weight 36 Ibs e Overall Size 22 38x14 00x12 50 LxWxH e Electrical Input 230VAC 2 8A max steady state e Coolant Connections Welding Industry Standard Quick Disconnect QD female fittings Top Coolant In Bottom Coolant Out Cooler access panel L9387 2 P4 Electrical power harness long S14165 467 P3 Electrical extension harness short S14165 466 Circuit breaker T12287 14 spare replacement fasteners S9225 8 1 4 20 thread spares for cooler mounting fasteners S8025 91 spares for cooler access panel mounting Hole plugs T10397 11 Ground Decal T13260 4 cable ties T13770 2 Electrical sleeving E1159 B 1 00 7 00 B Stencil S21212 Power Wave machine label S24503 1 Mounting Brackets S10040 93 Fasteners T9447 42 10 24 UNC 3A Plain washers S9262 77 Socket head cap screws RECOMMENDED COOLANTS mats A NNNWH4H1 HADDEONW 1 The following coolants have been determined to be compatible with the wetted materials used in the G3503 cooler assembly e Distilled or deionized water e Po
3. is no longer needed Slide electrical sleeving over the non P4 connector in the Power Wave s harness that runs from its ter minal strip e Fold sleeving over itself and firmly secure it to the harness with a cable tie Install cooler G3503 I a Install plugs into case back to fill coolant hose holes Bend tabs as required to secure plugs in place b Install new circuit breaker into case back if replacing the old part c Install new P4 electrical harness into Power Wave e Mate together the labeled P4 connectors e Note HIXJA lead in new harness carries 230 VAC cooler power See Table for X valve Power Wave Wiring Code Numbers Diagram 10406 10431 10433 10106 10195 10366 10197 SPLC14895 10345 10347 10512 10514 10516 10520 3 2 3 3 3 3 3 3 e Connect insulated terminals to circuit breaker order is unimportant Connect P3 electrical extension harness to the machine Apply ground decal to cooler s base e Apply next to mounting screw hole nearest to circuit breaker Mate cooler s connector to the P3 extension harness Mate cooler s power connector to the P4 electri cal harness Carefully slide retrofit cooler G3503 forward into Power Wave Verify that front tabs on cool er base are properly guided into slots in base of Power Wave base s underside may be exam ined with a mirror and flashlight Attach ground lead in P4 harness to top of cool er s ba
4. kinking or damage cut abrasion swelling etc Replace if necessary 5 Remove accumulated dust from cooler especially from the motor and heat exchanger by blowing it off with shop air or vacuuming it out e The heat exchanger fins are sharp but can be easily bent Treat them with care to avoid personal injury and damaging them e Remove the cooler from the machine for a more thorough cleaning job 6 Motor lubrication is recommended once a year e Remove plug over lube port at top of motor near fan end e Add 20 drops of electric motor or SAE 10 oil then reinstall plug 7 Flush coolant from the system and replace with fresh recommended coolant at least once a year More fre quent flushing may be necessary depending upon a user s particular system or its usage NOTE Never run the pump dry Always use a recommend ed coolant otherwise pump damage may result 8 Reinstall the G3503 cooler into the Power Wave machine G3503 COOLER SERVICE 1 Preparation e Always switch off the Power Wave machine power e Always disconnect the Power Wave machine from service input power e Do not remove the pump relief valve s 3 4 in acorn hex nut or attempt to adjust the relief valve setting 2 Remove the G3503 cooler from the Power Wave machine whenever e replacing major cooler components i e pump motor heat exchanger etc e replacing hoses and electrical harnesses that are kinked or damaged cut abrad
5. Switch amp Relay 24504 12 1 X 13 Fan Shroud G3503 Only 24504 13 1 X 13 Fan Shroud G3503 1 Only S24504 37 14 Quick Disconnect Fitting S24504 14 2 X 15 Quick Disconnect Bracket with Label 24504 15 1 X 16 Reservoir G3503 Only 24504 16 1 X 16 Reservoir G3503 1 Only 24504 38 1 X 16 Replacement Reservoir amp Fan Shroud G3503 Only 24504 39 1 X 17 Reservoir Inlet Strainer G3503 Only 22067 3 1 X 17 Reservoir Inlet Strainer G3503 1 Only S24504 40 1 X 18 Reservoir Cap G3503 Only S22067 2 1 X 18 Reservoir Cap G3503 1 Only S24504 41 1 X 19 Reservoir Elbow Fitting 24504 34 2 X 20 Reservoir Sealing Bushing 24504 35 2 X 21 Hose Pump Inlet S24504 17 1 X 22 Hose Pump Outlet 24504 18 1 X 23 Hose Heat Exchanger Inlet G3503 Only S24504 19 1 X 23 Hose Heat Exchanger Inlet G3503 1 Only S24504 42 1 X 24 Hose Heat Exchanger Outlet S24504 20 1 X 25 Hose Reservoir Inlet G3503 Only 24504 21 1 X 25 Hose Reservoir Inlet G3503 1 Only S24504 43 1 X 26 Hose Clamp 24504 22 10 X 27 Hydraulic Manifold 24504 23 1 X 28 Manifold Inlet Fitting 1 4 NPT to 3 8 ID Hose Barb S24504 24 1 X 29 Orifice Fitting 1 89 NPT to 3 8 ID Hose Barb 24504 25 1 x 30 Pump Elbow Fitting S24504 26 2 X 31 Screw Reservoir G3503 Only S24504 27 4 X 31 Screw Reservoir G3503 1 Only 24504 45 1 X 32 Internal tooth Star Washer Motor Not Shown 24504 28 4 X 33 Warranty Label Not Shown S24504 29 2 X 34 Data Plate G3503 Onl
6. ck coolant level Add more if required G3503 POWER WAVE 450 WATER COOLER UPGRADE KIT G3503 COOLER PERIODIC MAINTENANCE 1 Preparation e Always switch off the Power Wave machine power e Always disconnect the Power Wave machine from service input power e Do not remove the pump relief valve s 3 4 in acorn hex nut or attempt to adjust the relief valve setting 2 Remove the G3503 cooler from the Power Wave machine 3 Clean or replace the pump s inlet strainer Clogged or partially blocked strainer is the most common cause for unacceptal coolant flow e Drain the reservoir of coolant and dispose of it in an environmentally responsible manner see Recommended Coolants e Place absorbent towels underneath pump head e Hold pump head to apply countertorque when loos ening strainer s 7 8 acorn nut Do not confuse with 3 4 acorn nut Remove nut and slide inlet strainer down and out from pump head e Replace or gently rinse strainer under running water to thouroughly clean it e Use the mirror to inspect inside of pump for contam ination Carefully remove hardened debris with den tal pick if necessary without scratching inside of the pump e Reinstall strainer and acorn nut tightening with 75 15 in lbs of torque Wipe dry all areas wetted by coolant Dispose of towels in an environmentally responsible manner see Recommended Coolants 4 Remove fan shroud and inspect hoses and electrical har nesses for
7. e Tighten set screw with 65 to 75 in lbs of torque against motor shaft s flat e Fan rotation is counterclockwise as viewed from fan end of motor s shaft e Fan pulls air through the heat exchanger blows it over the motor then exhausts it through the reser voir G3503 POWER WAVE 450 WATER COOLER UPGRADE KIT COOLER ASSEMBLY PARTS P 261 K 2 P 261 K 2 ADOD RO We je FAFA fF L NCE KL 10 2 98 G3503 POWER WAVE 450 WATER COOLER UPGRADE KIT 6 P 261 K 3 Indicates a change this printing Recommended Spare Parts are Highlighted in Bold P 261 K 3 Use oniv the parts marked x in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO QTY 1 2 31415161718 19 Powerwave 450 Water Cooler Upgrade Assembly G3503 amp 1 1 X Includes 1 Base Assembly G3503 Only 24504 1 1 X 1 Base Assembly G3503 1 Only S24504 36 1 X 2 Motor S24504 2 1 X 3 Fan Blade 824504 3 1 X 4 Pump with Torque Coupling 24504 4 1 X 5 V Clamp Pump 824504 5 1 X 6 Torque Coupling Pump S24504 6 1 X 7 Pump Inlet Strainer S24504 7 1 X 8 Heat Exchanger 824504 8 1 X 9 Pressure Switch 824504 9 1 X 10 Solid State Relay S24504 10 1 X 11 Electrical Harness Motor 24504 11 1 X 12 Electrical Harness Pressure
8. ed deteriorated or swollen etc e investigating suspect coolant leakage 3 Pump replacement a Drain the reservoir of coolant and dispose of it in an environmentally responsible manner see Recommended Coolants b Remove fan shroud c Place absorbent towels underneath pump head and wherever coolant system is opened d Carefully pull pump inlet hose and its elbow from reservoir bottom e Loosen pump outlet hose clamp at QD then carefully remove from fitting f Disconnect v band clamp from motor and remove pump e Do not drop or lose drive coupling between pump and motor e Do not discard old pump Remove both fittings Keep v clamp Seal old pump in a waterproof bag Package into protective container and Return to nearest Lincoln Electric FSS center g Install new pump and v band clamp e Do not apply any lubricant to pump s drive coupling e Pump body is properly oriented with its strainer at the 6 00 position e Tighten v clamp with 15 to 30 in lbs of torque h Attach coolant lines to QD and reservoir i Wipe dry all areas wetted by coolant Dispose of tow els in an environmentally responsible manner see Recommended Coolants j Reinstall cooler into machine 4 Motor removal or replacement e Do not reuse the 4 internal tooth star washers Replace with new parts 5 Installing the fan e Slide onto motor shaft until the fan is located between 0 25 to 0 50 inches from the heat exchang er
9. l Number SN Na e Code Number Model Where Purchased LINCOLN amp e Sales and Service through Subsidiaries and Distributors Worldwide 9 Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com RECOMMENDED TOOLS FOR INSTALLATION OR SERVICE e absorbent towels e alcohol wipe e 3 mm allen wrench G3503 only e socket wrench e 4 inch long minimum socket extension e 1 4 5 16 and 3 8 hex standard depth sockets e 5 32 allen socket e medium blade slotted screwdriver e large blade slotted screwdriver 8 inches long minimum e two 7 16 open or box end wrenches e one 7 8 open or box end wrench e needlenose pliers e two 10 inch long adjustable wrenches e wire cutter e molex pin removal tools e tape measure e small mechanic s mirror e flashlight e dental pick e digital multimeter DMM G3503 INSTALLATION OR SER VICE TOOL USAGE Shroud to cooler base 4 all use 5 16 hex screw and 3 8 hex Quick Disconnect QD bracket 2 nut Relay may require large blade 2 2 4 1 Heat exchanger to cooler base Relay to cooler base slotted screwdriver 8 in long min Screw to 3 mm allen wrench G3503 only fasten reservoir to cooler base 5 16 Hex Socket G3503 1 only Hose Clamp 1 4 hex or medium slotted screwdriver Fan set screw 1 5 32 allen socket with wrench and 4 in min extension Pump carbonator clamp screw 5 16 hex socket with ratchet wrench two
10. nnect the Power Wave machine from service input power 2 Remove cooler assembly G3503 I a remove gas cylinder s from tray b remove cooler access panel c Remove both fasteners from base that hold cooler and mounting brackets if equipped in place Remove ground lead if present Carefully pull cooler assembly rearward until cooler s Molex connectors are visible d disconnect cooler s connectors from the P3 and P4 harnesses Continue pulling the cooler out of the Power Wave 3 If necessary perform periodic maintenance or ser vice on the cooler 4 Reinstall cooler by reversing tasks in step 2 Be sure to reattach ground lead if previously removed 5 If necessary fill cooler with selected coolant to specified level see Fig 1 6 Attach desired water cooled accessory gun and wire feeder or TIG torch to cooler s QDs 7 Reconnect service input power to the Power Wave e verify that the reconnect panel setting and lead placement match the service voltage 8 Prime the cooler a Install the Set up overlay b Keep accessories hose lengths horizontal either coiled or straight and no higher than 4 feet of the specified coolant level Fig 1 c Switch on the Power Wave machine d Press the WATER COOLER ENABLE button so that the WATER COOLER ENABLED light is illuminated e Press the PRIME WATER COOLER button until the WATER COOLER PRESSURE light is steadily illuminated 9 Che
11. required maintenance Remove guards only when neces sary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts REPLACING A G2725 COOLER WITH A G3503 COOLER 1 Preparation e Always switch off the Power Wave machine power e Always disconnect the Power Wave machine from service input power 2 Remove the G2725 cooler assembly a Remove gas cylinder s from machine s rear tray b Remove cooler access panel P N L9387 1 and set aside It is no longer needed c Remove machine s left side panel adjacent to power input cord d Disconnect coolant hoses mounting bracket from machine s case back e Disconnect all of the coolant hoses tie down points These plastic clips may be removed and discarded if desired f Remove and save both fasteners from Power Wave base holding cooler in place Carefully pull cooler rearward partially out of the Power Wave g Disconnect Molex in line connectors P4 or P5 cooler power and P3 cooler relay and pres sure switch and slide cooler completely from machine h Optionally remove circuit breaker from case back and install replacement i Peal off coolant in coolant out decal from machine s case back and discard Remove residual adhesive from case back with an alco hol wipe j Remove auxiliary transformer 2 mounted to Power Wave base ahead of G2725 cooler and set aside It
12. se or top of mounting bracket if brack ets are necessarv Secure cooler to Power Wave base by installing both fasteners j Install Power Wave machine s left side panel Qa o hn F7 a G3503 POWER WAVE 450 WATER COOLER UPGRADE KIT 3 Attach Power Wave machine label from retrofit kit to its case back m Stamp or etch B as the suffix of Power Wave s code number located on its rating plate Include this suffix for all future parts orders n Install gas cylinder s onto tray 5 Select a recommended coolant and fill cooler to specified level see Figure 1 6 Attach desired water cooled accessory gun and wire feeder or TIG torch to cooler s QDs 7 Reconnect service input power to the Power Wave e Verify that the reconnect panel setting and lead placement match the service voltage 8 Prime the cooler a Install the Set up overlay b Keep accessories hose lengths horizontal either coiled or straight and no higher than 4 feet of the specified coolant level Fig 1 c Switch on the Power Wave machine d Press the WATER COOLER ENABLE button so that the WATER COOLER ENABLED light is illuminated e Press the PRIME WATER COOLER button until the WATER COOLER PRESSURE light is steadily illuminated 9 Check coolant level Add more if required REMOVING AND INSTALLING THE G3503 COOLER 1 Preparation e Always switch off the Power Wave machine power e Always disco
13. table tap water e Sediment free mixtures containing a maxi mum of 50 ethylene glycol or automotive grade antifreeze and the balance of distilled or deionized water 2 Ethylene glycol mixtures should be selected if the cooler may be exposed to a temperature below the freezing point of water 3 Consult gun torch and wire feeder manuals for coolant recommendations and select one from the above list 4 Pure solutions and mixtures of or materials i e towels wetted with ethylene glycol are toxic to humans and animals They must not be haphaz ardly discarded especially by pouring liquids down the drain Contact the local EPA office for responsi ble disposal methods or for recycling information 5 The cooler s reservoir has a nominal liquid capacity of 1 6 gallons G3503 POWER WAVE 450 WATER COOLER UPGRADE KIT NSTALLATION INSTRUCTIONS A WARNING ELECTRIC SHOCK Can Kill e Only qualified persons should perform this installa tion T o HOT COOLANT CAN BURN SKIN e Always be sure coolant is not hot before doing any work on cooler parts ROTATING FAN BLADES ARE HAZARDOUS is Wx e Do not put your hands near an operating fan Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from fans and all other moving parts when starting operating or repair ing equipment In some cases it may be necessary to remove safety guards to perform
14. y 24504 30 1 X 34 Data Plate G3503 1 Only S24504 44 1 x 35 Cable Holder Push Mount 24504 31 2 X 36 Grommet Edging Heat Exchanger 24504 32 1 75in X 37 Trim Motor Mount 24504 33 15in X 39 Platform Not used on 450 w stand G2391 1 X 40 Axle M8809 129 1 X 41 Wheel S13127 3 2 X 42 Push Nut T12570 2 2 X 43 Base Assembly L8860 1 X 44 Caster 11124 4 2 X 44A Thread Forming Screw 9225 28 8 X 7 26 99 G3503 POWER WAVE 450 WATER COOLER UPGRADE KIT 7 Rear Panel of Power Wave Reservoir Screen Visible Coolant Level i 0 25 to 0 50 inches Figure 1 Specified coolant level TABLE 1 COOLER ELECTRICAL HARNESS PIN OUTS Molex Molex Description Connector Pin No Ground Motor Common Unused Unused Motor 230 VAC PW 450 only Motor 230 Vac PW 455 only Unused Unused Relay coil Relay coil Pressure Switch NO contact Pressure Switch common contact LINCOLN amp e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
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