Lincoln Electric IM959 User's Manual
Contents
1. Q Io Eh sl 875 zr n get m L v fs t c A el ee d IL 21 VI GI or SNI eo 9 S A ddns um LE INVH9VIG SNIHIM COOL ARC 35 LINCOLN E NOTES COOL ARC 35 LINCOLN 5 NOTES COOL ARC 35 LINCOLN 5 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG 2 Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 105 electrodos bajo carga con la piel ropa da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra CBEPORABRR XIRBE 7 5 ATUBSHRIELTFEL ACID 2j ERE RR AER 4 Ej C B8 Jb IH obg HER ATAH S2538358 RE Jy FE uu YA ous e z3j9 AXE HER AIA l A pay uil el jal Gaal Y O J amed A8 ON d Al gS elle All usu2. COOL ARC 35 For use with machines having Code Numbers 11427 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 thoughtful operation on your part DO NOT INSTALL OPER ATE OR REPAIR THIS EQUIP MENT WITHOUT READING THIS MANUAL AND THE SAFE TY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful ff S ri ri Ed A IN80 IP 21S IEC 60974 2 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 SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACE
3. Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone 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 within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 limits 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 Shielding gases used for arc welding can displa
4. A 2 jor end entente ete ea en H Section B Product Description zoe osos ewan PR Re Cu Eee DIN P EP REC Seege B 1 em E B 1 User Interface Display cei cete er yada a kn ai ean weka nada Akan dakan B 2 User Interface Push Button B 3 Maintenance ce K k Ak Section D Safety IT EE D 1 Routine Maintenance sise D 1 PerodicMaintenarce cuoc reote street D 1 Heat Exchariger ecrit Erie tacet iac ro i ete EEN D 1 Reservoir Coolant eret teet dira y k za ay A ena ERR Ea Lad D 1 Coolant Treatment Recommendation sse D 1 Inspect Condition of Coolamt eene eene D 2 Troubleshooting ss kk nnne nennen kaka kawe annt nn Section E Safety Precautions ii E 1 How to Use Troubleshooting Guide uEE keke kk kk kek E 1 Troubleshooting Guide sis E 2 Wiring AE Le Section F A E F 1 Parts Li EE P 573 vi 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS COOL 35 Product No Model K2630 1 COOL ARC 35 Input 350VDC From V310 T AC DC amp V311 T AC DC Current Draw 0 35 Amps Maximum Operating Pressure and Flow Rate 50 psi 345 kPa 3 5 bar Max Open Flow Without Welding Torch Restriction 1 2 gal min 4 6 liter min Max Typical Operating Pressure and Flow Rate 53
5. Fill the reservoir with coolant per the Recommended Coolant section on the TECH NICAL SPECIFICATIONS page The reservoir is full when the coolant reaches a level just below the cap 10 The system is now ready for water cooled torch applications Connecting a water cooled torch 1 Disconnect all power to the power source 2 Assemble the torch per the instructions included with the torch and Twist mate Adapter 3 Connect the HOT water return hose normally RED to the Coolant Inlet on the front of the cooler Depending on the type of hose connectors on the torch it may be necessary to use brass couplers that are included with the cooler 4 Connect the COLD water to the torch hose normal ly BLUE to the Coolant Outlet on the front of the cooler 5 Attach the twist mate from the torch to the DC neg ative Electrode Gas output terminal on the power source 6 Turn the power ON to the power source 7 The cooler Display will illuminate and go through initialization The cooler will enter into standby mode if a Stick welding mode is selected 8 Press the push button on the cooler to begin the priming procedure The cooler display will show dashed lines moving in a circular motion 9 The torch is now ready for water cooled welding applications Note If E43 alarm codes are encountered the torch has not been properly primed Run the priming procedure again by pressing the cooler push button COOL ARC 35 L
6. aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et
7. aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN 8 V V for selecting a QUALITY product by Lincoln Electric We want you You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to 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 customer s particular purpose with respect to such information or advice As a matter of practical considera
8. empty reservoir Recap the reservoir Prime the cooling system by positioning cooler horizontally and circulate disinfec tant through it for 10 to 15 minutes Drain disinfectant from the cooling system Do not reuse this solution Add new fresh coolant to the cooling system Add 1L 0 3 gals of fresh disinfectant to the system by pour ing it into the reservoir then reduce the concentration to the nominal 30 ppm Add the balance 4 0L 1 0 gals of fresh pure water to the reservoir to create the treated coolant concen tration Prime the cooling system Check coolant level Add more fresh pure water if required without adding more than 0 3L 0 1 gal of pure water to prevent diluting the coolant additive Procedure and Preparation A WARNING e Always disconnect the COOL ARC 35 machine from service input power by disconnecting the V310 T V311 T from input power Always allow the coolant in the system to cool enough to avoid burn injuries Avoid contact with contaminated coolant Wear waterproof gloves and protective eye wear INSPECT CONDITION OF COOLANT If coolant is contaminated or old Drain the system of coolant and dispose of it in an environmentally specified manner Flush system of old coolant Fill with fresh tap or distilled water run for ten min utes and drain Proceed to adding coolant COOL ARC 35 LINCOLN 1 TROUBLESHOOTING 1 HOW TO USE TROUBLESHOOTING GUIDE WARN
9. pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps 3 Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d
10. the unit is initiating at power up Alarm mode The cooler is powered and ready to start but operation is prevented due to an alarm condition being detected The alarm 10 code is displayed by the power source UI The alarm codes displayed on the cooler are E43 coolant stoppage clogged or broken hose torch or bypass hose missing E44 coolant temperature upper limit Flashing value during power up indicates the cooler software version Two digit value during normal operation dis plays the coolant temperature C This message is displayed if no communication between the cooler and the power source is detected Scrolling dashed line clockwise is displayed during torch priming operation a AA XX yy nC COOL ARC 35 LINCOLN 8 ET OPERATION USER INTERFACE PUSH BUTTON The push button on the user interface of the cooler has two different functions Holding the push button in for 3 seconds toggles the cooler ON and OFF When the cooler is turned OFF the display will shown oo In this condition the cooler can only be turned ON again by pressing the push button for 3 seconds again or by cycling input power to the power source The power source has no control over the cooler when it is OFF It begins com municating with the cooler when the cooler is turned ON again If the cooler is OFF when the power source is turned OFF it will begin operation in the ON condi tion when the power s
11. 57 psi 865 393 kPa With Welding Torch Restriction 45 60 gal min 1 7 2 3 liter min Reservoir Size 1 3 gal 5 liters For Use Above Freezing Clean tap distilled or de ionized water 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 Recommended Coolant 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 DO NOT USE Pre packaged welding industry coolants These coolants may contain oil based substances which attack the plastic components of the cooler Once added to the cooler these substances are impossible to purge from the water lines and heat exchanger Shipping 29 8 Ibs 13 5 kg Weight Reservoir 42 0 lbs 19 0 kg Full Water L 24 5 in 622 mm W 11 0 in 280 mm Dimensions 10 0 in 256 mm Temperature Conversion Chart COOL ARC 35 LINCOLN 5 A 2 INSTALLATION A 2 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Disconnect input power by remov ing plug from V310 T V311 T before working inside Cooler Do not touch electrically hot parts inside Cooler Have qualified personnel do the installation maintenance and troubleshooting work Connectin
12. INCOLN 5 B 1 OPERATION B 1 PRODUCT DESCRIPTION The new COOL ARC 35 is an intelligent cooling unit equipped with a variable speed three phase rotary pump and an embedded microprocessor PC board which controls the pump operation fan operation and the overall functioning of the unit The cooler operation is enabled by the power source and utilizes a cool as needed approach so the pump and fan speed vary based on real coolant tempera ture Furthermore error signals and related codes are managed by the power source The COOL ARC 35 manages both the coolant tem perature and pressure in order to maximize the cool ing of the torch while using as little energy as possi ble If the coolant temperature goes above the maxi mum limit 185 F 85 C or the coolant flow is stopped or the coolant is missing an alarm is generated and an error code is sent to the power source The power source consequently displays the alarm ID code on the user interface and places the power source and cooler in a safe condition in order to avoid any dam age being done to the cooling components or to the welding torch Any alarm condition must be reset by the user by clearing the alarm code at the power source user interface before restarting operation oth erwise the overall welding system is kept in a standby condition safety mode If a coolant over temperature is detected welding is stopped and the cooler is programmed to run at maxi m
13. ING 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 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 Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom 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 If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility 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 te
14. MAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a of Safety in Welding A Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE i A 1 h To avoid scalding do not remove the T P radiator pressure cap when the engine is powered equipment xil eege 1 a Turn the engine off before troubleshooting and maintenance Ws work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes 3 outdoors O X 49 ELECTRIC AND E MAGNETIC FIELDS 1 c Do not add the fuel near an open flame may be dangerous welding arc or when the engine is running Stop the engine and allow it to cool before 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from vaporiz localized Electric and Magnetic Fields EMF Welding ing on contact with hot engine parts and current creates EMF fields around welding cables and igniti
15. N Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a Use ventilac o e exhaust o para remover fumo da zona respirat ria 57 KEE 1c UR Ez fE FE MX BEM SR ER TR e e sst 247 5 2 247 S 82 Ash 7 57471 58718 Asse n lu y ade bus js d usin al hill e GA usi Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico e toque as partes el tricas nuas e X7TTLZA V U AILINUPD DORI EF BRA YF CES e HEA BIER SHA AHS hy ail AN ui
16. al das DE dan ule Y jo ua Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos COREE CIE EVA e i18 9 D PA Wj els 222 Sc AI He Aa dan ALU Aal ala e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo H EROS SICIRBEREUCEF Ue f RIR 1855 ox 119 Sol Soars ASS AIS due de Lily fan la pus Al daa 9 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTE
17. ce air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 Also see item 1 b Jan 09 SAFETY Z WELDING and CUTTING gt SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 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 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 fro
18. chnical troubleshooting assistance before you proceed COOL ARC 35 LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION E43 alarm after initial installation off 1 Torch water hoses need to bel1 After turning the system ON power source and cooler or when press the COOL ARC 35 push attaching a water cooled torch button to begin priming procedure 2 There is a blockage in the path of 2 Verify that the coolant path is the coolant clear that there are no twists kinks or pinch points in the coolant hoses 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 35 LINCOLN Jequinu epoo ueu d nbe y e JO jueumnredeg eui O yum s eui sjaued y JO euo uo eui 20 81 21 a uej Jo1ol ssejusn q 3aAvz eseud e S E BE Qs 2 m 10 SIU OU E 21 401 Li EE e ro Q C SE ve er INO 9NI lt Se ae Y us sjeubis 11
19. corded 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page Installati n i s y ee eessen Section A Bel Eelere 1 Safety Precautions iii A 2 Connecting the COOL ARC 35 to a power source A 2 Connecting a water cooled torch iu Eke kek kk kk kk k kk
20. g the COOL ARC 35 to a power source 1 Disconnect all power to the power source 2 Turn the power source on its side revealing the Cooler Access Panel on the bottom 3 Loosen the fasteners and remove the Panel Keep the fas teners to reattach the Panel 4 Place the COOL ARC 35 near the V310 T V31 1 T and push the lead harness from the cooler through the grommet in the Access Panel that was just removed from the power source making sure that the direction of the leads going through the panel is correct 5 Attach the two plugs from the COOL ARC 35 harness into the mating receptacles inside the power source where the Cooler Access Panel was removed making sure that these connectors lock into the mating receptacles 6 Slide the Access Panel up the harness toward the power source and reattach using the fasteners that were removed NOTE Make sure that the grommet or the harness itself does not put any stress on the connectors when closing up the Panel 7 Place the power source on top of the cooler locating the feet of the power source into the mating foot prints in the cooler case front and back 8 Secure the power source to the cooler with the four fasteners that were included with the cooler 9 Unscrew the coolant reservoir cap and remove the clear plug keep for transporting the cooler when filled with coolant The clear plug should never be installed when operating the cooler it will prevent proper venting
21. m 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 Also see item 1 c 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 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode if damaged 7 a Use only compressed ga
22. n your right side lt A Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while d 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN 8 SAFETY u ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground 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 Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle o
23. ng Do not spill fuel when filling tank If welding machines fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving i si Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety mb P minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible parts 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or 2 d 3 Do not place your body between the electrode and idler by pushing on the throttle control rods work cables If the electrode cable is on your right while the engine is running side the work cable should also be o
24. nt when cleaning is finished It is recommended to flush the coolant at least once a year A cooling system free from debris offers increased cooling efficiency and longer pump and torch life See the Coolant Treatment Recommendation in this Maintenance Section NOTE Pure solutions and mixtures of or materials i e towels wetted with ethylene glycol are toxic to humans and animals Special precautions should be taken when discarding toxic material do not pour this mixture down any drain Contact the local EPA office for responsible disposal methods or for recycling infor mation 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 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 Keep the reservoir full especially after disconnecting the water lines
25. or changing the accessory being cooled COOLANT TREATMENT RECOMMENDATION This procedure is intended to provide a means of reducing the objectionable amount of fungal and bac terial contamination that has occurred in COOL ARC 35 water coolers and cooling systems Additive The recommended additive can be purchased at local pool supply stores An example is Maintain Pool Pro 30 Non Foam Algaecide Limitations The additive should be used with fresh coolants con taining only pure water This additive should not be used with coolants con taining any other substance including antifreeze substances No other additives shall be used with the specified coolant that has been treated with the recommended additive This procedure is no permanent substitute for a peri odic maintenance schedule for the specified coolers A 1 quart bottle of additive is sufficient to disinfect and treat about 1000 coolers Check with the manufacturer of your guns or torches to be sure that this procedure is compat ible with your equipment COOL ARC 35 LINCOLN 8 D 2 MAINTENANCE D 2 Prepare the disinfectant Make a quantity of only what is needed to avoid an excess Bulk preparation for coolers serviced in quan tity 5 7L 1 5 gals of pure fresh water per cooler and 1 0ml of additive per cooler Example for 100 coolers add 100 ml to 150 gals of pure fresh water Pour 5 0L 1 3 gals of disinfectant into the
26. ound the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information Jan 09 SAFETY M PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux
27. ource is turned on again and must be turned OFF if the user does not want the cooler to operate during welding Momentarily pressing the COOL ARC 35 push but ton will begin the torch priming procedure and over ride any current cooler operation The cooler will ramp up the pump speed to maximum and hold it for 30 seconds to allow the torch to be filled with coolant During the priming procedure the temperature and flow pressure sensing are disabled To stop the prim ing procedure before the 30 second time limit the push button must be pressed again this places the cooler back into normal operating mode COOL ARC 35 LINCOLN 8 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill e Disconnect input power by remov ing plug from V310 T V311 T before working inside Cooler Do not touch electrically hot parts inside Cooler Have qualified personnel do the installation maintenance and troubleshooting work ROUTINE MAINTENANCE 0 Remove accumulated dust and dirt from the internal components of the cooler by blowing it out with a low pressure air hose or removing the dust and dirt with a vacuum hose 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 coola
28. r semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 5 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 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 FUMES AND GASES can be dangerous 5 a
29. s cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders 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 Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Gr
30. t gS Jl alal e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e opere com os paineis abertos ou guardas removidas e XJ JI amp JIR VJ 20 Ze EE CRRATEE f CT Lie RE BI RT EVE Ro edo Sel Sele Ss 452 1 Aal la dik y e Aale veel Al dl Aaya Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG JIR LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR GK MHRC HOX H DIH R E CA BIB CT LTRHOR MEI ED TFE RA ET ER b HE RR JE RU BA DL Re RE EX fE A AO SR A LAR ST RR D fii A BI gt OR SESI SE o 0 SSE HAR axjspAbn HA AUX eua AS EFEM BECH Jali a al gl baled asl y d AA oig ql gal alala agil L LINCOLN 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 216 486 1751 WEB SITE www lincolnelectric com
31. tion 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 Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com 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 re
32. um speed in order to recover from the high tempera ture condition as soon as possible Welding operation cannot be re started before the coolant temperature has reached a temperature value below 175 F 80 C FRONT PANEL See Figure B 1 The COOL ARC 35 is enabled only when DC TIG or AC TIG modes are selected The cooler does not operate when STICK modes are selected Due to the cool as needed functionality when the coolant temperature increases passed the maximum set point the pump speed is modulated by coolant temperature feedback This keeps the cooler noise levels to a minimum The pump starts operating when any TIG welding mode has been selected and the welder output is enabled The pump is kept on until the coolant tem perature goes below 175 F 80 C or for at least 3 minutes after welding has ceased if the cooler was running while welding FIGURE B 1 COOLANT OUTLET COOLANT INLET www lincolnelectric com LINCOLN ELECTRIC COOL Arc 35 DISPLAY PUSH BUTTON COOL ARC 35 LINCOLN 5 ES OPERATION B 2 USER INTERFACE DISPLAY The 7 segment display shows the coolant temperature during normal operation but also displays additional cool er status information Status indications Display Meaning OFF mode The cooler has been turned off by the user Stand by mode The cooler has power and is ready to function but the selected weld mode is not a water cooled operation STICK modes or
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