Lincoln Electric Cool Arc Im670 A Users Manual

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COOL ARC 40 STAND ALONE
WATER COOLER
For use with machines having Code Numbers:

IM670-A
December, 2008

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 thoughtful 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

• 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

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER 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 copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” 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
powered equipment.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

1.a. Turn the engine off before troubleshooting and maintenance
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
outdoors.

____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt
to override the governor or idler by pushing on the throttle
control rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.

Mar ʻ95
COOL ARC® 40

SAFETY
ARC RAYS can burn.

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.
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.
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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.

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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.

FUMES AND GASES
can be dangerous.
5.a. 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 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.
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 specific 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.
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 products.
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.
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

iii

SAFETY
WELDING and CUTTING
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.

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.
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.
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).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

CYLINDER may explode
if damaged.
7.a. 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. 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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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.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.
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 circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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

SAFETY
PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:

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.
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 souder 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.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de nʼimporte quelle
partie du corps.
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.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
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.

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 levage, 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 fortement 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.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
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. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ʻ93
COOL ARC® 40

Thank You

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!

CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. 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 possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information 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.
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 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.

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

A-1

INSTALLATION

A-1

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

1.3-1.7 Amps

Current Draw @ 50Hz Input

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.
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.

Recommended Coolant

Shipping

46.5 lbs. (21.1 kg)

Reservoir
Full (Water)

61.2 lbs. (27.8 kg)

9.03 in. (229.4mm)

9.10 in. (231.1mm)

H (Top Face)

31.99 in. (812.6mm)

H Top Handle)

34.26 in. (870.2mm)

Weight

Dimensions

EXPLANATION OF SYMBOLS THAT APPEAR ON THIS EQUIPMENT

OFF
COOL ARC® 40

A-2

INSTALLATION

SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Disconnect input power by removing plug from receptacle before
working inside Cooler.
• Use only grounded receptacle.
• Do not remove the power cord ground prong.
• Do not touch electrically “hot” parts inside Cooler.
• Have qualified personnel do the installation, maintenance 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 thrusting sharp objects through the carton liner, which may
puncture the plastic reservoir. Below is the recommended procedure for unpacking the Cooler:
• 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.
Save the instruction manual and service directory supplied with the COOL ARC® 40 for parts orders and
future maintenance service.

To avoid freeze damage and water leakage in shipment, 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 middle of the unit. Remove the fill cap by pressing the
center of the cap inward while pulling at the tab on the
outer edge.
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.
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 disposal 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 mixture is also acceptable.
When using the COOL ARC® 40 with other products,
consult the manufacturer's instruction manual for recommended coolants.

CAUTION

FILLING THE COOLANT RESERVOIR
Recommended Coolant
• For Use Above Freezing: Clean tap, distilled or deionized 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. These coolants will
damage the pump and block the small internal passageways of the heat exchanger, affecting cooling
performance.
• 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.

DO NOT USE OIL BASED COOLANTS OR COOLANTS
THAT CONTAIN RUST INHIBITORS OR LEAK STOPPERS.
---------------------------------------------------------------------------

The unit can be filled either vertically or horizontally.
UNPLUG THE COOLER BEFORE FILLING THE
COOLANT RESERVOIR:
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.

COOL ARC® 40

A-3

INSTALLATION

LYING DOWN (HORIZONTAL):

A-3

Carefully add 2 gallons (7.6 liters) of coolant through a
funnel into the coolant reservoir fill hole.
AVOID SPILLING COOLANT INTO THE LOUVERS
ON THE TOP OF THE COOLER.

Water or Coolant Line Connections to the
COOL ARC® 40
Take the connector nut of the water hose and check if
the thread of the male connector nut matches the 5/818 left hand female thread in the fitting on the back of
the unit.

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:

NOTE: DO NOT ADD MORE THAN 2 GALLONS
(7.6 LITERS) OF COOLANT INTO THE RESERVOIR. 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.

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.
Refer to Figure 1.

(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: 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.
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:
(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
SOURCE
(RED)

TO
HEAT
SOURCE
(BLUE)

COOL ARC® 40

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 nipple 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 procedure for the OUTLET hose. When complete, follow the
connection procedure detailed above for connecting
the hoses to the COOL ARC® 40 fittings.
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

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 horizontally 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.

Plug the input power cord on the COOL ARC® 40 into
a standard 230V circuit breaker protected receptacle.

INSTALLATION ON UNDERCARRIAGE OR
POWER SOURCE
The COOL ARC® 40 can be mounted either horizontally or vertically on a power source. To mount the
cooler horizontally, order the K559-2 Cooler
Horizontal Mounting Bracket. To mount the cooler vertically on a power source with a dual cylinder undercarriage, order K559-3 Cooler Vertical Mounting
Bracket.

Power Source

CV-300
CV-400
CV-655
DC-250
DC-400
DC-600, DC-655
Square Wave TIG 275
Square Wave TIG 355
Power Wave 455
Power MIG 255

WARNING
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 MUST BE OPERATED IN THE
HORIZONTAL POSITION. This will prevent the
cooler from being accidentally tipped over.
------------------------------------------------------------------------

K559-3
Cooler Vertical Mounting
Bracket on a Dual
Cylinder Undercarriage
K874 Undercarriage
Not Available
Not Available
Not Available
Not Available
Not Available
K932-1 Undercarriage
Not Available
K1570-1 Undercarriage
Not Available
COOL ARC® 40

K559-2
Cooler Horizontal
Mounting Bracket
Can be used On Top
of a Power Source
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
No

A-5

INSTALLATION

INSTALLATION OF WATER COOLED
ACCESSORIES

CAUTION

After following the installation instructions above, the
COOL ARC® 40 is ready for connection to a watercooled accessory.
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.
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 further connection details. It is not required to run the
water lines through the wire feeder, but is does provide a very neat MIG gun connection.If pass-through
water hoses are unavailable, connect the MIG gun as
shown in Figure 4.

DO NOT USE A WATER SOLENOID VALVE with
the COOL ARC® 40. When a solenoid valve closes, the pump would dead-head, causing the pump
to heat up excessively leading to premature failure
of the pump.
-----------------------------------------------------------------------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 undercarriage.
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

FIGURE 2

COOLANT
COOLANT

Water Cooled TIG Torch Connection
KP504-WATER HOSES AND
FEMALE TO FEMALE 5/8" LH
CGA ADAPTER COUPLINGS

REGULATOR
FLOWMETER

GUN CABLE

ARGON GAS
CYLINDER

POWER SOURCE

COOLANT
IN

COOLANT
OUT

FIGURE 5

GAS*

Connection to Wire Feeder (Do Not Use Water Solenoid)
GAS
IN OUT

COOLANT*
GAS
COOLANT*

SHIELDING
GAS

FEMALE TO FEMALE*
CGA FITTING

TIG TORCH

COOLANT
IN

POWER CABLE ADAPTER*

POWER / COOLANT

COOLANT
OUT

COOLANT
TO WORK

*INCLUDED IN
KP504 HOOK-UP KIT

GAS

CONTROL CABLE

FIGURE 3

COOLANT

COOLANT
OUT
COOLANT

COOLANT
COOLANT
GUN CABLE
NOTE:

KP504 FOR HOOK-UP
TO WIRE FEEDERS
WITH CGA FITTINGS

COOLANT

ELECTRODE CABLE
TO WORK

COOLANT

K1859-1 FOR WIRE
FEEDERS WITH QUICK
DISCONNECT FITTINGS

IN
OUT

COOLANT

Water Cooled MIG Gun Connection

COOLANT
IN

COOLANT

COOLANT =
BLUE HOSE
OUT
COOLANT =
RED HOSE
IN

COOL ARC® 40

K529-10
NOTE:
ORDER K1859-1 ALONG WITH
K529-10 FOR WIRE FEEDERS
WITH QUICK DISCONNECT
FITTINGS.

GUN CABLE
NOTE:
COOLANT
OUT
COOLANT
IN

= BLUE HOSE
= RED HOSE

B-1

OPERATION

PRODUCT DESCRIPTION
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 watercooled TIG torches. The COOL ARC® 40 is a continuous duty cooler.
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 cooler 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.
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 supply from the coolant reservoir and delivers coolant to
the welding torch or gun. Refer to Figure 6.
RECOMMENDED PROCESSES AND EQUIPMENT
The COOL ARC® 40 is designed for use with watercooled 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 following should always be observed when operating the COOL ARC® 40:
• 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.

B-1

• The cooler should be turned "OFF" when welding is
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.
• 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 reservoir. Never run pump dry.
TURNING THE SYSTEM "ON"
After connecting the COOL ARC® 40 per the installation 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 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 airflow 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.
The coolant FLOW INDICATOR is accessed by
removal of the fill cap. Actual return flow is directly visible, via the fill opening with the unit in the vertical or
horizontal position.
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.

COOL ARC® 40

B-2

OPERATION

COOLING EFFICIENCY
The high cooling efficiency of the COOL ARC® 40
offers a cooler, more comfortable weld than conventional air-cooled procedures as well as leading competitors water cooled systems.

For example:
Unlike other water coolers that depend on bulky reservoir 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 temperature of the COOL ARC® 40.

FIGURE 6
Coolant Circulation Diagram

ROOM AIR
IN
HEATED
AIR OUT
HEAT
EXCHANGER

FAN

NOTE:

COOLANT
OUT

= BLUE HOSE

COOLANT
IN

PUMP

COOLA

COOLANT
RETURN

COOLA
COOLANT
INTAKE

FIGURE 7
COOL ARC® 40 WATER COOLER
HEAT
"IN"
COOLANT "OUT"

COOLANT "IN"

WELDING
TORCH
OR
GUN

FAN

HEAT
EXCHANGER

AIR
FLOW

PUMP

COOLANT
RESERVOIR

COOL-ARC 40
3-23-2001
M19724

COOL ARC® 40

RED HOSE

C-1

ACCESSORIES

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.
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.
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.

“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.
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 undercarriage.
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.

CAUTION

K1859-1 Water Cooler Hoses (5/8" LH CGA to QD):
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 feeder.

K1859-2 Water Cooler Hoses (5/8" LH CGA to 5/8 LH CGA)

Coolant Hoses:

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 fittings.

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 accessory literature sheets.

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 fittings 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)

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 recommended. 7.9mm(5/16”) I.D. hose and accommodating
fittings are available from an industrial welding supplier.

COOL ARC® 40

D-1

MAINTENANCE

SAFETY PRECAUTIONS

D-1

• Gently rinse the strainer under running water to thoroughly clean it.

WARNING
ELECTRIC SHOCK can kill.
• Disconnect input power by
removing plug from receptacle
before working inside Cooler.
• Do not operate with covers
removed.
• Use only grounded receptacle.
• Do not remove the power cord ground prong.
• Do not touch electrically “hot” parts inside
Cooler.
• Have qualified personnel do the installation,
maintenance and troubleshooting work.

• 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.
• Reinstall the strainer and 7/8 acorn nut, tightening
with 75+/-15 in-lbs. of torque. Wipe dry all area wetted with coolant. Dispose of coolant soaked towels
properly as specified above.
• For a more in depth procedure, See Section D-2,
“Pump Inlet Strainer”.

See additional warning information at the
front of this operatorʼs manual.
-----------------------------------------------------------ROUTINE MAINTENANCE

PUMP MOTOR

Remove accumulated dust and dirt from the internal
components of the cooler by blowing it out with a lowpressure 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.

PERIODIC MAINTENANCE

• Re-oil each bearing with 30-35 drops of SAE 20 oil
then reinstall both plugs.

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”.
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 disposal methods or for recycling information

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.

The COOL ARC® 40 is rated for continuous operation. It is recommended to re-oil the pump motor
bearings once a year as follows:

HEAT EXCHANGER
To maintain maximum cooler efficiency, the heat
exchanger should be kept free of dust and dirt buildup. Clean the heat exchanger periodically using a vacuum 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 performance and longer product life. In extremely dirty environments, 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
with the unit in the upright position. Keep the reservoir
full, especially after disconnecting the water lines or
changing the accessory being cooled.

• 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

D-2

MAINTENANCE

COOLANT TREATMENT
RECOMMENDATION

PUMP INLET STRAINER

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.

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:
• Voiding of cooler service warranty
• Cavitation damage to the pump headʼs inlet areas
• Welding accessory damage from overheating due to
insufficient coolant flow rate.

Additive:
The recommended additive can be purchased at local
pool supply stores. An example is "Maintain Pool Pro
30% Non-Foam Algaecide".
Limitations:
• This additive should be used with fresh coolants containing only pure water.
• This additive should not be used with coolants containing 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 periodic maintenance schedule for the specified coolers
• A 1 quart bottle of additive is sufficient to disinfect
and treat about 720 coolers.
• Check with the manufacturer of your guns or
torches to be sure that this procedure is compatible with your equipment.
Prepare the disinfectant:
Make a quantity of only what is needed to avoid an
excess Bulk preparation (for coolers serviced in quantity):
8.775 liters(2.325 gals.) of pure, fresh water per cooler 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 system by positioning cooler horizontally and circulate disinfectant 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 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:

A new or properly cleaned pump inlet strainer should
restore the coolerʼs performance.
For additional service and periodic maintenance
details and for recommended coolants, follow the recommendations listed below.
Procedure and Preparation:

WARNING
• Always switch off the COOL ARC® 40 machine
power
• Always disconnect the COOL ARC® 40 machine
from service 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.
• Do not remove the pump relief valveʼs 3/4 in.
acorn hex nut or attempt to adjust the relief valve
setting.
------------------------------------------------------------------------

INSPECT CONDITION OF COOLANT
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 minutes, 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 additive.
COOL ARC® 40

D-3

MAINTENANCE

D-3

Removing Coolant:

Add coolant:

a. Drain coolant from the reservoir using clean siphoning equipment
b. Coolant level should be drained below the strainerpressure fitting:
• This prevents coolant from streaming out of unit
when strainer nut is removed

a. Add 7.6 ltr. (2 gal.) of coolant, either the recommendations off the water cooled accessory or if none,
see the design specification summary listed in this
manual.

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.
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.
d. Use a mirror to inspect inside of pump for contamination. 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.

ADDITIONAL SERVICE NOTES:

2. Never run the pump dry. Always use a recommended coolant, otherwise pump damage may result.
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.

FIGURE 7

COOL ARC® 40

E-1

TROUBLESHOOTING

E-1

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 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

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.

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

E-2

TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

RECOMMENDED
COURSE OF ACTION

Cooler does not operate with power 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.

Torch or gun runs hot.

1. Hose clamp loose on one of internal hoses.
2. Internal hose punctured.
3. Heat exchanger leaking.
4. Pump seal is leaking
If all recommended possible areas of
misadjustment have been checked
1. Unit placed by area of extreme and the problem persists, Contact
heat.
your local Lincoln Authorized
2. Low coolant flow.
Field Service Facility.
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.

COOL ARC® 40

1
MTR1
4

50/60 HZ

INPUT: 230 V

SW1

M20078

G1 - FAN SHROUD GROUND
CONNECTION(CUSTOMER
GROUND)
G2 - BASE GROUND CONNECTION
G3 - CHASSIS GROUND CONNECTION
(FAN SHROUD)
P1 - INPUT POWER PLUG
SW1 - POWER SWITCH
MTR1 - PUMP MOTOR
A.03
MTR2 - FAN MOTOR

MTR2

DIAGRAMS

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

ELECTRICAL SYMBOLS PER E1537
COLOR CODE: B - BLACK OR GRAY
W - WHITE
G - GREEN
BR- BROWN
BL- BLUE

COOL ARC® 4 0 WATER COOLER

F-1
F-1

9.10

34.26

COOL ARC® 40

L11540

DIMENSION PRINT

9.03

2.27

FILL CAP

F-2
F-2

NOTES

COOL ARC® 40

● Do not touch electrically live parts or

WARNING
Spanish

AVISO DE
PRECAUCION
French

ATTENTION
German

WARNUNG
Portuguese

ATENÇÃO

● Keep flammable materials away.

● Wear eye, ear and body protection.

● Mantenga el material combustible

● Protéjase los ojos, los oídos y el

electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.

fuera del área de trabajo.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

cuerpo.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Mantenha inflamáveis bem guarda-

dos.

● Use proteção para a vista, ouvido e

corpo.

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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.
● Use ventilation or exhaust to

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

remove fumes from breathing zone.
● Los humos fuera de la zona de res-

piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von

Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Strom vor Wartungsarbeiten

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

oder Innenschutzverkleidung in
Betrieb setzen!

● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer

● Mantenha-se afastado das partes

serviço.
● Não toque as partes elétricas nuas.

● Não opere com os paineis abertos

moventes.

WARNING
Spanish

AVISO DE
PRECAUCION
French

ATTENTION
German

WARNUNG
Portuguese

ATENÇÃO

ou guardas removidas.
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.

• 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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