Lincoln Electric COOLARC-45 Manual de usuario

IM3025

01/2011

Rev. 2a

COOLARC-45

OPERATOR’S MANUAL

MANUALE OPERATIVO

BEDIENUNGSANLEITUNG

MANUAL DE INSTRUCCIONES

BRUKSANVISNING OG DELELISTE

GEBRUIKSAANWIJZING

INSTRUKCJA OBSŁUGI

KÄYTTÖOHJE

ИНСТРУКЦИЯ ПО ЭКСПЛУАТАЦИИ

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

www.lincolnelectric.eu

English EnglishI

Declaration of conformity

Lincoln Electric Bester Sp. z o.o.

Declares that the welding machine:

COOLARC-45

conforms to the following directives:

2006/95/CEE, 2004/108/CEE

and has been designed in compliance with the

following standards:

EN 60974-2, EN 60974-1, EN 60974-10

(2009)

PawełLipiński

Operations Director

Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland 12/05

English EnglishII

12/05

THANKS! For having choosen the QUALITY of the Lincoln Electric products.

•Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

•For future reference record in the table below your equipment identification information. Model Name, Code &

Serial Number can be found on the machine rating plate.

Model Name:

………………...…………………………….…………………………………………………………………………………………..

Code & Serial number:

………………….……………………………………………….. …………………………………………………….……………..

Date & Where Purchased:

…………………………………………………………………... ……………………….…………………………………………..

ENGLISH INDEX

Safety ..............................................................................................................................................................................1

Installation and Operator Instructions..............................................................................................................................2

Electromagnetic Compatibility (EMC)..............................................................................................................................5

Technical Specifications..................................................................................................................................................5

WEEE..............................................................................................................................................................................6

Spare Parts......................................................................................................................................................................6

Electrical Schematic ........................................................................................................................................................6

Accessories.....................................................................................................................................................................6

English English1

Safety 11/04

WARNING

This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair

procedures are performed only by qualified person. Read and understand this manual before operating this equipment.

Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this

equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible

for damages caused by improper installation, improper care or abnormal operation.

WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,

loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or

death.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating

this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could

cause serious personal injury, loss of life, or damage to this equipment.

ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the

electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from

the electrode, work clamp, and connected work pieces.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the

fuse box before working on this equipment. Ground this equipment in accordance with local electrical

regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp

cables. If any insulation damage exists replace the cable immediately. Do not place the electrode

holder directly on the welding table or any other surface in contact with the work clamp to avoid the

risk of accidental arc ignition.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any

conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some

pacemakers, and welders having a pacemaker shall consult their physician before operating this

equipment.

CE COMPLIANCE: This equipment complies with the European Community Directives.

FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to

health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use

enough ventilation or exhaust to keep fumes and gases away from the breathing zone.

ARC RAYS CAN BURN: 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. Use suitable clothing made from durable

flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel

with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to

the arc.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding

area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding

process can easily go through small cracks and openings to adjacent areas. Do not weld on any

tanks, drums, containers, or material until the proper steps have been taken to insure that no

flammable or toxic vapors will be present. Never operate this equipment when flammable gases,

vapors or liquid combustibles are present.

WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and

materials in work area can cause serious burns. Use gloves and pliers when touching or moving

materials in the work area.

SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in

an environment with increased hazard of electric shock.

English English2

CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the

correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. Always keep cylinders in an upright position securely chained to a fixed support. Do

not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,

electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders

must be located away from areas where they may be subjected to physical damage or the welding

process including sparks and heat sources.

Installation and Operator Instructions

Read this entire section before installation or operation

of the machine.

Product Description

COOLARC-45 is the cooler for semi automatic welding

with water cooled TIG, MIG.

COOLARC-45 cooler is designed for use with all water-

cooled gun’s up to 500A, TIG and MIG torches and

guns.

The COOLARC-45 coolers bring new technology in the

areas of pump, heat exchanger and reservoir designs to

the water cooler market. These technologies allow the

COOLARC-45 coolers to be lighter in weight, lower in

energy consumption.

Warranty

Warranty for this product is 3 year after the date of

purchase. For any warranty claim, contact a certified

Lincoln service center.

Installation

FIGURE 1

Coolant INLET and OUTLET fittings (A) type

21KATS09MPX are placed at the front of the unit. The

blue fitting is marked (supplies coolant to the welding

equipment); the red ones is marked (takes warm

coolant from the welding equipment).

The FILL CAP of the coolant reservoir is on the top of

the unit (B). Fill Cap can be removed by twisting it off.

Air flow louvers (C): Air flow louvers secure adequate air

circulation. The side louvers allow sucking in cold air

from bottom of the unit. Hot air is removed by the front

louvers.

For convenience you can press and hold the FLOW

SENSOR OFF switch (D) and the torch button to fill the

water system on first usage.

WARNING

INCORPORATED INTO THE COOLER IS AN

AUTOMATIC FLOW SENSOR TO DETECT LOW OR

NO COOLANT FLOW. A LOW OR NO FLOW

CONDITION WILL CAUSE WELDING OUTPUT TO

AUTOMATICALLY STOP TO PROTECT THE TORCH.

Filling The Reservoir

Proper Coolant Addition

Acorox is recommended coolant for COOLARC-45.

For use above freezing: Tap, distilled, deionized, mineral

water. For use below freezing: water and pure ethylene

glycol mixture (10% glycol between at 0°C and 30% at -

15°C).

WARNING

DO NOT USE PREPACKAGED WELDING INDUSTRY

COOLANTS. These coolants may contain oil-based

substances which attack the plastic components in the

pump of the COOLARC-45 cooler and severely reduce

pump life. Once added to the cooler, the substances are

virtually impossible to purge from the water lines and

heat exchanger.

To avoid freeze damage and water leakage in shipment,

every COOLARC-45 unit is delivered empty with no

coolant in the system. To fill the unit, locate the plastic

reservoir fill cap (B).

NOTE: The unit can be filled only horizontal.

WARNING

UNPLUG THE COOLER BEFORE FILLING THE

RESERVOIR.

Filling:

Pour 4 liters at least of coolant into the reservoir.

WARNING

DO NOT START COOLER WITH COOLANT LESS

THEN 4 LITERS.

TOO LESS VOLUME OF COOLANT CAN NOT BE

ENOUGH TO FULL PRIMING OF THE SYSTEM AND

MAY DAMAGE THE PUMP.

English English3

WARNING

AVOID SPILLING COOLANT INTO THE BACK CASING

OF THE UNIT.

NOTE: DO NOT ADD MORE THAN 6 LITERS OF

COOLANT INTO THE RESERVOIR.

WARNING

AT FIRST STARTING OF THE COOLARC-45

RESERVOIR FILL CAP MUST BE REMOVED FOR A

MOMENT TO AVOID GENERATE PARTIAL VACUUM

IN COOLING SYSTEM DURING FILLING (THE PUMP

MUST BE FLOODING).

Be certain to replace the reservoir fill cap when the

reservoir is full. Operation of the COOLARC-45 cooler

without the fill cap in place can cause poor cooling

efficiency, evaporation loss of coolant, and low product

life.

Water Hoses Connection

A FROM HEAT SOURCE (RED)

B TO HEAT SOURCE (BLUE)

FIGURE 2:

Water Hoses Connection Diagram

Water hoses connection is made with quick water fittings

(type 21KATS09MPX) which are equipped with the

automatic outflow blockade.

Before water hoses installing to the cooler, you should

check if the water hose connectors matches to the quick

water connectors placed in the connector block on the

front of the unit. You should:

•Take INLET hose (colored or tagged blue on most

hoses) and attach it into the coolant OUT line

marked . Then take the OUTLET hose (colored

or tagged red on most hoses) and attach it into the

coolant IN line marked .

WARNING

BE CERTAIN THAT NO LEAKS EXIST WHEN COOLER

IS TURNED ON. A LEAK WILL DEPLETE RESERVOIR

VOLUME, CAUSE POOR OR COOLING

PERFORMANCE AND REDUCE GUN, TORCH OR

PUMP LIFE.

The following should always be observed when

operating the COOLARC-45:

•Never operate the cooler with case off.

•Immersion in water around electrical lines can

cause electrical shock.

•Never place fingers into openings of cooler. Moving

parts can injure.

•Unplug the cooler before filling the reservoir.

•Never operate the cooler with the reservoir fill cap

off.

•Never operate the cooler with the reservoir empty.

Operating Precautions

The following should always be observed when

operating any COOLARC-45 cooler:

•Check the reservoir daily.

•Keep the reservoir full especially after changing any

water lines.

•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.

Turning The System ON

After filling the reservoir and connecting the coolant

hoses to the COOLARC-45 cooler per the Installation

Sections, be certain that the power input into the unit

matches the cooler’s rated input. Plug the unit into an

electrical receptacle for start-up operation.

You will be able to hear the fan running and feel air flow

out of the back of the unit when the cooler is operating.

When first starting the unit, check all of the water lines to

insure that no water leaks are present. Water leakage

causes poor welding performance, poor cooling

performance, low welding component and pump life and

potential electrical safety hazards.

Cooling Efficiency

1. COOLANT RETURN

2. COOLANT IN TAKE

3. PUMP

4. FAN

5. HEAT EXCHANGER

6. HEATED AIR OUT

7. COOLANT OUT

8. COOLANT IN

9. RESERVOIR FIGURE 3

Circulation of COOLARC-45

The high cooling efficiency COOLARC-45 offers a

cooler, more comfortable weld than conventional air-

cooled procedures as well as leading competitors water

cooled systems. Radiator improves heat convection with

minimal air flow restriction.

English English4

The COOLARC-45 cooler effectively removes the heat

of the arc away from the torch handle and places it into

the exiting air flow at the back of the cooler. Ambient air

temperature can affect the cooling parameters of the

COOLARC-45.

For example:

•COOL day (50°F, 10°C): More HEAT is transferred

from the water into the heat exchanger to the air.

The water is COOLER and more HEAT is

transferred from the torch to the water.

RESULT: THE TORCH FEELS COOLER

•HOT day (100°F, 38°C): Less HEAT is transferred

from the water into the heat exchanger to the air.

The water is HOTTER and less HEAT is transferred

from the torch to the water.

RESULT: THE TORCH FEELS HOTTER.

Unlike other water coolers that depend on bulky

reservoir size, the high efficiency components of

COOLARC-45 cooler allows the reservoir size to be

small. The result is a lightweight, portable unit.

Cooling Efficiency - Recommended Values

COOLARC-45 ref: K14067-1

Max welding current TIG 100% duty cycle 500A

Max welding current MIG 100% duty cycle 500A

Maintenance

WARNING

For any maintenance or repair operations it is

recommended to contact the nearest Technical Service

Center or Lincoln Electric. Maintenance or repairs

performed by unauthorized service centers or personnel

will null and void the manufacturer's warranty.

Heat Exchanger Maintenance

To maintain maximum efficiency, the heat exchanger

should be kept clean from dust and dirt buildup. Clean

the heat exchanger periodically using a vacuum hose or

low pressure air line. Avoid placing the unit near a flux

hopper or a flux waste container. A clean heat

exchanger offers better cooling performance and longer

product life. If extremely dirty conditions exist, it may be

necessary to remove the heat exchanger completely

from the cooler for a through soap and water cleaning of

the cooling fins. Use care to avoid damaging the fins.

Reservoir Maintenance

The reservoir volume should be checked daily before

using the cooler. You can do it by observation the level

of the coolant in the front panel. The unit is full when the

coolant level reaches upper part of reservoir. Keep the

reservoir full especially after changing the water lines.

The cooler should always be operated with the reservoir

fill cap on. In areas where dust can be introduced into

the reservoir through water lines or reservoir fill cap

removal, periodically flush the unit out. Dump the old

coolant and rinse the inside of the reservoir. Add new

coolant when finished. A reservoir free from particle

buildup and dirt offers better cooling efficiency and

longer pump, gun and torch life.

Troubleshooting

This Troubleshooting Guide is designed to be used by the machine Owner/Operator. 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, please observe all safety notes and precautions detailed in the Safety Section of this manual to avoid

electrical shock or danger while troubleshooting this equipment.

WARNING

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact

your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

Cooler does not operate. •Power cord unplugged.

•No power at outlet.

•Power cordset damaged.

•Water lines blocked or crimped.

•Leak in gun or water hoses.

•Reservoir empty.

•Plug in power cord.

•Check outlet circuit breaker.

•Repair damaged cord or order new cordset.

•Clear blockage in hose. Avoid kinking or

putting sharp bends in water lines.

•Repair leak.

•Fill reservoir.

Internal water leak. •Hose clamp loose on one of internal hoses.

•Internal hose punctured.

•Heat exchanger leaking.

•Tighten or replace hose clamp.

•Replace punctured hose with new hose.

•Replace heat exchanger.

Leak at inlet/outlet

connector block. •Hose clamp loose. •Tighten hose clamp onto hose.

Torch or gun runs hot. •Unit placed by area of extreme heat.

•Low coolant flow.

•No coolant flow.

•Fan not operating.

•Move unit away from hot air.

•See Low Coolant FlowSection.

•See No Coolant Flow Section.

•Reference fan section.

Fan operates but there is

low coolant flow. •Leak in torch/gun or hoses.

•Torch/gun or hoses partially obstructed.

•Reservoir empty or very low.

•Repair leak.

•Clear obstruction.

•Refill reservoir.

English English5

Fan operates but there is

no coolant flow. •Pump failure.

•Pump seized. •Replace pump.

•Replace pump.

Pump operates, but fan

does not. •Fan blade contacting heat exchanger.

•Fan motor failure. •Replace fan.

•Replace fan.

Cooler trips outlet circuit

breaker. •Circuit overloaded.

•Cooler electrical component failure. •Check outlet circuit breaker.

•Replace suppressor assembly and rectifier

bridge inside of cooler.

Electromagnetic Compatibility (EMC) 11/04

This machine has been designed in accordance with all relevant directives and standards. However, it may still generate

electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or

other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand

this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.

This machine has been designed to operate in an industrial area. To operate in a domestic area it is

necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The

operator must install and operate this equipment as described in this manual. If any electromagnetic

disturbances are detected the operator must put in place corrective actions to eliminate these disturbances

with, if necessary, assistance from Lincoln Electric.

Before installing the machine, the operator must check the work area for any devices that may malfunction because of

electromagnetic disturbances. Consider the following.

•Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the

machine.

•Radio and/or television transmitters and receivers. Computers or computer controlled equipment.

•Safety and control equipment for industrial processes. Equipment for calibration and measurement.

•Personal medical devices like pacemakers and hearing aids.

•Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure

that all equipment in the area is compatible. This may require additional protection measures.

•The dimensions of the work area to consider will depend on the construction of the area and other activities that are

taking place.

Consider the following guidelines to reduce electromagnetic emissions from the machine.

•Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take

additional precautions such as filtering the input supply.

•The output cables should be kept as short as possible and should be positioned together. If possible connect the

work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting

the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.

•Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special

applications.

Technical Specifications

INPUT

Input Voltage

400 V ±10%

single phase

Rated current

0,8 A Frequency

50/60 Hz

RATED OUTPUT AT 40°C

Flow range

MIG

TIG

Open flow

0,5 to 3,3 l/min

with torch 4,5m: 1,7 ÷1,8 l/min

with torch 3,8m: 1,3 ÷1,4 l/min

3,3 l/min

Reservoir size 6 l

Coolant requirement:

Do not use prepackaged welding industry coolants. These

coolants may contain oil-based substances which attack

the plastic components in the pump.

Recommended coolant for COOLARC-45: Acorox

Water or water and pure ethylene glycol mixture can be

used interchangeably.

The glycol % must not exceed 30%.

PHYSICAL DIMENSIONS

Height

245 mm Width

305 mm Length

710 mm Weight

22 Kg

Operating Temperature

–10°C to +40°C Storage Temperature

-25°C to +55°C

English English6

WEEE 07/06

English

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE)

and its implementation in accordance with national law, electrical equipment that has reached the end of its

life must be collected separately and returned to an environmentally compatible recycling facility. As the

owner of the equipment, you should get information on approved collection systems from our local

representative.

By applying this European Directive you will protect the environment and human health!

Spare Parts 12/05

Part List reading instructions

•Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service

Department for any code number not listed.

•Use the illustration of assembly page and the table below to determine where the part is located for your particular

code machine.

•Use only the parts marked "X" in the column under the heading number called for in the assembly page (# indicate

a change in this printing).

First, read the Part List reading instructions above, then refer to the "Spare Part" manual supplied with the machine, that

contains a picture-descriptive part number cross-reference.

Electrical Schematic

Refer to the "Spare Part" manual supplied with the machine.

Accessories

K14075-1 Assembly Kit: SPEEDTEC-COOLARC45 (brackets)

Italiano ItalianoI

Dichiarazione di conformità

Lincoln Electric Bester Sp. z o.o.

Dichiara che il generatore per saldatura tipo:

COOLARC-45

è conforme alle seguenti direttive:

2006/95/CEE, 2004/108/CEE

ed è stato progettato in conformità alle seguenti

norme:

EN 60974-2, EN 60974-1, EN 60974-10

(2009)

PawełLipiński

Operations Director

Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland 12/05

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