Lincoln Electric IM438-B manual

MA GNUM COOLERS 1 0 -I AND 20-I OPERA TOR’S MANUAL IM438-B March, 1999 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT[...]

FOR ENGINE powered equipment. 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. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y 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 manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

v v EXPLANA TION OF SYMBOLS THA T APPEAR ON THIS EQUIPMENT OFF ON O 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! Read this Operators Manual completely before attempting to use this equipm[...]

vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Product Description ............................................................[...]

A-1 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-1 TECHNICAL SPECIFICA TIONS – MA GNUM COOLERS 10-I AND 20-I Model Cooler 10-I Cooler 20-I Product No. K873-1 K879-1 Input 220V 50/60 Hz 1 Phase 220V 50/60 Hz 1 Phase Current Draw at Input .75 Amps 1.25 Amps Rated Current Draw 1.0 Amps 1.6 Amps Operating Pressure 45 psi (310 kPa) (3.0 bar) 60 psi [...]

A-2 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-2 PRODUCT DESCRIPTION Magnum Coolers 10-I and 20-I are stand alone recir- culating cooling systems designed for use with water cooled TIG, MIG, PAC (Plasma Arc Cutting) and PAW (Plasma Arc Welding) guns and torches. Additional applications include resistance welding, induction heating and water coo[...]

A-3 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-3 INST ALLA TION PRODUCT OVERVIEW The LIGHTED POWER SWITCH is located at the left side of the control panel (A). Cooler will be “ON” when pressed to “ | “. Coolant INLET and OUTLET fittings are found at the rear of the unit (B). They are welding industry stan- dard English left-hand fitting[...]

A-4 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-4 When using the Magnum Cooler with other products, consult the manufacturer’s recommendations for coolant. Do not use oil based coolants. The unit can be filled either vertically or horizontally. UNPLUG THE COOLER BEFORE FILLING THE RESERVOIR. Upright: Tilt the unit backward and pour 2 gallons ([...]

A-5 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-5 Cooler 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 wit[...]

A-6 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-6 2. Route all water line connections onto connection block at back of Cooler as outlined in the IM manual provided with the Magnum Cooler. Self Tapping Screw (4 req'd) W ARNIN G ON COOLERS 20 & 20-I : Align holes A & B of mounting bracket with holes A & B of Magnum Cooler. Secure [...]

A-7 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-7 A POWER SOURCE HEIGHT 16.44" (417.6mm) POWER SOURCE HEIGHT 21.50" (546.1mm) B E POWER SOURCE HEIGHT 27.50" (698.5mm) POWER SOURCE HEIGHT 21.50" (546.1mm) D POWER SOURCE HEIGHT 16.44" (417.6mm) C Cooler 10-I Mounting Scheme Cooler 20-I Mounting Scheme FIGURE 3c Undercarria[...]

A-8 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-8 WATER COOLED EQUIPMENT INSTALLATION NOTE: Magnum Coolers operate at 45 psi (3.0 bar) (310 kPa) of pressure for Cooler 10-I and 60 psi (4.0 bar) (414 kPa) of pressure for Cooler 20-I. When used in the demand system, the pressure in the supply hose to the water solenoid or valve can surge to 20 psi[...]

A-9 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-9 FIGURE 5 Water Cooled MIG Gun Connection FIGURE 6 Water Cooled Plasma System Connection COOLANT IN COOLANT OUT COOLANT COOLANT GUN CABLE COOLANT IN COOLANT OUT PLASMA CUTTING POWER SOURCE COOLANT ELECTRODE CABLE & AIR COOLANT AIR[...]

A-10 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-10 K440-1 LN-7 GMA WIRE FEEDER WITH GAS AND WATER SOLENOID VALVE The K440-1 LN-7 GMA wire feeder is equipped with internal water lines and external connectors for attach- ment to a water cooled MIG gun and a Magnum Cooler. The water solenoid control of the K440-1 LN-7 GMA enables the feeder to tri[...]

A-11 INST ALLA TION MAGNUM COOLER 10-I & 20-I A-11 K529-10 POWER INPUT CABLE WITH WATER AND GAS LINES The K529 power input cable connects from the front of a Lincoln power source to the back of LN-7 and LN-7 GMA wire feeders equipped with a water solenoid control. K529-10 is 10 ft. (3.0m) long and includes two water hoses and a gas line. The le[...]

B-1 OPERA TION B-1 SAFETY PRECAUTIONS - Even when using the Magnum Cooler in an “on- demand” application, the power to the Cooler should be turned off when welding is not taking place for a long period of time. - Be certain that the Cooler is on (power switch in the “|” position) before beginning to weld, especially when using the Cooler in[...]

B-2 OPERA TION B-2 You will be able to hear the fan running and feel air flow out of the back of the unit when the Cooler is operating. The Cooler will run continuously when operated without a water solenoid or valve. If a water solenoid or valve is used, the Cooler will run for a short period of time until the demand system is acti- vated and the [...]

B-3 OPERA TION B-3 - Abrasion failure due to particulate in coolant. - Corrosion failure due to deionized water and pure glycol mixtures. - Cavitation failure due to air bubbles introduced by an intake screen ( or any other source). - Dry operation failure due to the reservoir being emp- tied. - Over pressure failure due to crimping or blocking of [...]

B-4 OPERA TION B-4 MAGNUM COOLER 10-I & 20-I FIGURE 9 Circulation of Magnum Cooler T ABLE 3 Approximate Cooling Rate and Recommended Use (1) ROOM AIR IN HEATED AIR OUT HEAT EXCHANGER FAN PUMP COOLANT RETURN COOLANT INTAKE COOLANT COOLANT NOTE: COOLANT OUT COOLANT IN = = BLUE HOSE RED HOSE Model Cooler 10-I Cooler 20-I Product No. K873-1 K879-1 [...]

C-1 A CCESSORIES C-1 PARTS DESCRIPTION FOR MAGNUM COOLER ACCESSORIES S20095-1 Pump Replacement Kit (60 psi) (4.0 bar) (414 kPa) for Magnum Cooler 20-I Models Includes: * (1) Complete 40-60 psi (3.0-4.0 bar) (310-414) kPa) Pressure switch assembly. * (1) Complete 60 psi (4.0 bar) (414 kPa) Pump with all internal components and hose connec tions. * ([...]

D-1 MAINTENANCE D-1 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 perfo[...]

E-1 TR OUBLESHOO TING E-1 MAGNUM COOLER 10-I & 20-I TR OUBLESHOO TING GUIDE This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per- formed 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[...]

a. Power cord unplugged. b. No power at outlet. c. Power cordset damaged. d. Unit too hot. Thermal protector tripped. e. Water lines blocked or crimped. f. Unit is used in a demand system and water valve or solenoid dam- aged. g. Leak in gun or water hoses. h. Reservoir empty. I. Power switch faulty. j. Solenoid valve is closed. k. Female quick-con[...]

E-3 TR OUBLESHOO TING E-3 MAGNUM COOLER 10-I & 20-I Observe all Safety Guidelines detailed throughout this manual 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.[...]

E-4 TR OUBLESHOO TING E-4 MAGNUM COOLER 10-I & 20-I Observe all Safety Guidelines detailed throughout this manual 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.[...]

F-1 DIA GRAMS F-1 MAGNUM COOLER 10-I & 20-I          ?[...]

+ - + - FAN MOTOR MOTOR PUMP FAN MOTOR MOTOR PUMP M M L M M M L V 115 Hz 60 V Hz 220 50/60 COOLER 10 COOLER 10-I V 115 Hz 60 V Hz 220 50/60 COOLER 20 COOLER 20-I COOLER 10 & 10-I WIRING DIAGRAM COOLER 20 & 20-I WIRING DIAGRAM FOR CODES 9984 THRU 9987 1* BLACK BROWN 2* 3* WHITE BROWN 2* WHITE 3* 1* BLACK PUMP MOTOR INTERNAL TO LEADS 3 FOR CO[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA EL[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]