Lincoln Electric Cool Arc 22 User manual

Operator’s Manual
Cool Arc
®
22
Register your machine:
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IM10454 | Issue Date Oct-18
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12733
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
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.
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.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
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.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.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
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 pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018

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.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. 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
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also 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 manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

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.
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.
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.
6.j. Do not use a welding power source for pipe thawing.
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, 14501 George Carter Way
Chantilly, VA 20151.
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 manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

2
TABLE OF CONTENTS
INSTALLATION .............................................................................................................................................SECTION A
Technical Specifications ............................................................................................................................................A-1
Unpacking the Cool Arc®22......................................................................................................................................A-1
Installation on Power Source .....................................................................................................................................A-1
OPERATION ................................................................................................................................................SECTION B
General Description...................................................................................................................................................B-1
Location ............................................................................................................................................................B-1
Recommended power source ....................................................................................................................................B-1
Input Supply Connection............................................................................................................................................B-1
Controls and Operational Features.............................................................................................................................B-2
Circulation of Coolant in the Cooler............................................................................................................................B-3
Coolant and Filling the Reservoir................................................................................................................................B-3
Priming Pump (only for first time use) and Bleeding the Cooling System....................................................................B-3
Connecting the Cooling System Hoses.......................................................................................................................B-4
Transport ............................................................................................................................................................B-4
Symbols Used ...........................................................................................................................................................B-4
MAINTENANCE .............................................................................................................................................SECTION D
Routine maintenance ................................................................................................................................................D-1
Periodic maintenance (not less than once a year) ......................................................................................................D-1
Pump inlet strainer maintenance...............................................................................................................................D-2
Access the strainer....................................................................................................................................................D-2
TROUBLESHOOTING......................................................................................................................................SECTION E
DIAGRAMS .................................................................................................................................................SECTION F
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PARTS.LINCOLNELECTRIC.COM
CONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTION MANUALS, GO TO
PARTS.LINCOLNELECTRIC.COM.

A-1
INSTALLATIONCOOL ARC®22
TECHNICAL SPECIFICATIONS -
K3475-1 COOL ARC 22
* The correction factor for cooling power in a +40°C ambient is .575.
UNPACKING THE COOL ARC
®
22
The packaging of the Cooler is designed to withstand shipping
abuse. If any shipping damage has occurred, contact your certified
Lincoln Electric distributor or service center. When unpacking the
unit, avoid thrusting sharp objects through the carton liner, which
may puncture the plastic reservoir. Save this instruction manual
for parts orders and future maintenance service.
INSTALLATION ON POWER SOURCE
The Cool Arc®22 is designed to mount beneath a Lincoln Electric
TIG welding power source that lists the Cool Arc 22 as an
approved accessory.
Always place the Cool Arc®22 on a level surface to avoid toppling.
Once mounted to a machine, the assembly can be mounted to the
K4441-1 two wheel cart.
FIGURE 1
INPUT
INPUT VOLTAGE U1INPUT AMPERES I1MAX
390 Vdc 0.8 A
PARAMETERS RATING
THE COOLING POWER OF FLOW
1LITER PER MINUTE AT TEM-
PERATURE OF 77°F (25°C)
MAXIMUM PRESSURE RATE
0.87 kW* 62 psig (0.43 MPa)
PARAMETERS OF THE COOLER’S RESERVOIR
MINIMUM RESERVOIR
CAPACITY
MAXIMUM RESERVOIR
CAPACITY
0.4 gallons 0.6 gallons
COOLANT
RECOMMENDED COOLANT
KP4159-1 low conductivity coolant
Do not use pre-packaged welding industry coolants. These
coolants may contain oil-based substances, which attack the
plastic components of the cooler. Once added to the cooler,
these substances are impossible to purge from the water lines
and heat exchanger.
Do not use automotive anti-freeze. These coolants will
damage the pump and block the heat exchanger, affecting
cooling performance.
PHYSICAL DIMENSIONS
Height Width Depth Weight
10.87 in
(276 mm)
9.68 in
(246 mm)
21.26 in
(540 mm)
39 lb
(18 kg)
TEMPERATURE RANGES
OPERATING TEMPERATURE
RANGE
STORAGE TEMPERATURE
RANGE
from 14 ºF to 104 ºF
(from -10 ºC to +40 ºC)
from -13 ºF to 131 ºF
(from -25 ºC to +55 ºC)
PROTECTION RATING OPERATING HUMIDITY
(T=68°F=20°C)
IP23 ≤ 90 %

B-1
OPERATIONCOOL ARC®22
OPERATION
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
ELECTRIC SHOCK can kill.
• Do not operate with covers removed.
• Do not operate if cables are wet or
immersed in water.
MOVING PARTS can injure.
• Moving parts can injure. Never place
fingers into openings of Cooler.
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.
Observe additional guidelines
detailed in the beginning of this manual.
GENERAL DESCRIPTION
The Cool Arc®22 is a cooling system designed to work
specifically with Lincoln Electric TIG welding power sources.
Included Accessories:
• 8-inch jumper hose with quick water connector
The Cool Arc®22 is delivered empty with no coolant in the
system. Lincoln Electric KP4159-1 low conductivity coolant is
recommended.
LOCATION
This cooler will operate in harsh environments. However, it is
important that preventive measures are followed to assure long
life and reliable operation:
• Do not place or operate this cooler on a surface with an
incline greater than 15° from horizontal.
• The cooler must be located where there is free circulation of
clean air without restrictions for air movement to and from
the air vents. Do not cover the cooler with paper, cloth or rags
when switched on.
• Dirt and dust that can be drawn into the cooler should be kept
to a minimum.
• This cooler has a protection rating of IP23. Keep it dry, shelter
it from rain & snow and do not place it on wet ground or in
puddles.
• Locate the cooler away from radio controlled machinery.
Normal operation may adversely affect the operation of
nearby radio controlled machinery, which may result in injury
or equipment damage. Read the section on regarding Electric
and Electromagnetic Fields in the safety section of the
manual.
• Do not operate in areas with an ambient temperature greater
than 104°F (40°C).
Warning: The ambient air temperature
influences the parameters of cooling. If the ambient
temperature is higher, the cooling system will be less
effective.
Avoid placing the cooler near a flux hopper or an area where
dust build-up is extreme.
Avoid placing the cooler near areas of extreme heat.
RECOMMENDED POWER SOURCE
The Cool Arc®22 is designed for use with water-cooled torches.
The Cool Arc®22 must be used with a Lincoln Electric TIG welding
power source that lists the Cool Arc 22 as an approved accessory.
INPUT SUPPLY CONNECTION
The Cool Arc®22 must be powered directly from the welding
power sources listed above.
To connect or disconnect the input supply to the Cool Arc®22,
turn off the welding power source and then connect or disconnect
it from the cooler.
Caution must be observed because the input voltage to the cooler
is 390Vdc.
An internal electronic board adapts this voltage for the pump, fan
and light.
Welding power sources are equipped with protection,
however, do not connect or disconnect a CA22 to or from a
welding power source that is on. Always turn OFF the
welding power source.
Do not apply power to the welding power source when the
cooler reservoir is insufficiently filled and/or the torch’s
hoses are disconnected from the cooling unit. Failure to
observe this warning may cause internal damage to the
cooler.
WARNING
WARNING
WARNING

B-2
OPERATIONCOOL ARC®22
CONTROLS AND OPERATIONAL FEATURES
FIGURE 2
1. Power Indicator Light: This lamp will illuminate when the
pump and internal fan are on. The light does not indicate the
Cool Arc®22 is being supplied by the power source.
2. Flow Sensor Switch: The Cool Arc®22 comes equipped with
a flow sensor that triggers an error code to the machine to
protect the TIG Torch from over-heating when inadequate
coolant flow is detected through the flow sensor. The Error
Code fault (Error 11) could indicate a possible kink in the
torch lines, damage and/or a leak in the TIG Torch coolant
lines, or signal the need to use a TIG Torch that is of a higher
amperage capacity and rating. The flow sensor can be turned
off ‘O’ or on ‘I’. The default position is on when first powered
on out of the box. When in ‘O’ off position, the flow sensor is
inactive: in this condition the missing coolant flow is not
detected.
A flow sensor is incorporated to detect low coolant flow. A
low or no flow condition will disable the welding output to
protect the torch.
3. Reservoir for Coolant with Cap: The translucent reservoir
enables control of volume of the coolant. A tank filter to catch
400um dust material is located in opening tank. See
Maintenance section for more details.
4. Quick Connect Coupling Outlet: Supplies cool coolant to the
torch/gun.
5. Quick Connect Coupling Inlet: Takes warm coolant from
torch/gun.
6. Minimum and Maximum Liquid Level: The minimum
recommended liquid level is 0.4 gallons.
FIGURE 3
7. Power Lead with 9-pin connector. Table below indicates the
Pin-out and description:
8. Fuse Receptacle: A 2A fuse is present to protect the motor
pump.
9. Removable Strainer. The pump is equipped with a 150um
strainer: an external cover is supplied to protect the
accessible strainer. See Maintenance section for more
details.
Moving parts can injure. Never place fingers or tools into
the louvers of the cooler.
1
2
3
4
5
6
WARNING
Pin # Signal name Description
1 COM Reference
2 +15V/1 Aux power supply
3 Coolant Error Coolant flow error
4 Presence To indicate to Power generator
CA22 is active
5 NC Not used
6 VBUS Power supply 390Vdc
7 NC Not used
8 ON_OFF To enable pump and cooling
9 EARTH Earth ground
WARNING
9
8
7

B-3
OPERATIONCOOL ARC®22
CIRCULATION OF COOLANT IN THE COOLER
FIGURE 4
Avoid kinking or putting sharp bends in any coolant lines.
Never operate the cooler with the case off.
COOLANT AND FILLING THE RESERVOIR
Before filling the coolant reservoir, turn off the welder and
disconnect the cooler’s power lead from the welder.
Avoid contact with coolant. Wear waterproof gloves and
protective eye wear.
Warning: The cooler can be filled and used only in the horizontal
position.
Use Lincoln Electric KP4159-1 low conductivity coolant.
Do not use pre-packaged welding industry coolants. These
coolants may contain oil-based substances, which attack the
plastic components of the cooler. Once added to the cooler, these
substances are impossible to purge from the water lines and heat
exchanger.
Do not use automotive anti-freeze. These coolants will damage
the pump and block the heat exchanger, affecting cooling
performance.
Never operate the cooler with the reservoir empty.
Do not start the cooler with less than 0.4 gallons of coolant.
Operating without enough coolant can prevent full priming of the
system and may damage the pump.
Priming Pump (only for first
time use) and Bleeding the
Cooling System
FIGURE 5
• Assemble the welding setup.
• Connect the short hose with quick water connectors (included
with the equipment) to the cooler’s inlet and outlet sockets
(Figure 5).
• Fill the coolant reservoir.
• Remove the reservoir cap to prevent generating a partial
vacuum.
• Place the flow sensor to the off ‘0’ position.
• Turn the power source on.
• Wait 30 seconds until the coolant fully circulates through the
cooling system and returns into the reservoir.
• Turn the power source off.
• Disconnect the short hose with quick water connectors.
• Connect the torch hoses – Figure 6.
• Turn the power source on.
• Wait 30 seconds until the coolant fully circulates through the
cooling system.
• Review the coolant level and add coolant if coolant level is
below the minimum mark.
• Tighten the cap.
• Return the flow sensor to the on ‘I’ position.
WARNING
WARNING
WARNING
Short Hose

B-4
OPERATIONCOOL ARC®22
After priming the pump and/or bleeding the cooling system,
be sure the reservoir’s cap is tightened. Operating the
cooler without the cap tightened can cause poor cooling
efficiency, evaporation loss of coolant, and low product life.
• The welding set is ready to work.
CONNECTING THE COOLING SYSTEM HOSES
• Turn Power Source off.
• Connect the "inlet" hose of torch/gun (colored or tagged red
on most hoses) to the inlet quick connect coupling [Item 4
fig.2] located on the front panel of the cooler.
• Connect the "outlet" hose of torch/gun (colored or tagged
blue on most hoses) to the outlet quick connect coupling
[Item 5 fig.2] located on the front panel of the cooler.
FIGURE 6
Warning: The water-cooler hoses are connected into the quick
connect coupling type, which automatically close when hoses are
disconnected.
Before installing the hoses to the cooler, verify that the hose
connectors match the quick connect couplings located on the
front panel of the cooler.
Avoid kinking or putting sharp bends in any lines.
Keep all lines clean and free of any blockage.
Keep the reservoir full especially after changing lines.
TRANSPORT
To avoid freeze damage and water leakage during transport, the
coolant must be removed from the cooler’s reservoir.
SYMBOLS USED
cool outlet
hot inlet
WARNING
WARNING
Direct Current
Cooling Power
Power On
Flow Sensor ON
Flow Sensor OFF
Cooled Coolant Out
Warm Coolant In

MAINTENANCE
Safety Precautions
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground
• Always wear dry insulating gloves.
• Disconnect input power by removing plug from
receptacle before working inside Cooler.
• Do not touch electrically “hot” parts inside Cooler.
• Have qualified personnel do the installation,
maintenance and troubleshooting work.
• Unplug the cooler before performing general
maintenance.
MOVING PARTS can injure.
• Do not operate with doors open or guards off.
• Keep away from moving parts.
See additional warning information throughout
this Operator’s Manual
FOR ANY REPAIR OPERATIONS, MODIFICATIONS OR
MAINTENANCE, IT IS RECOMMENDED TO CONTACT
THE NEAREST TECHNICAL SERVICE CENTER OR
LINCOLN ELECTRIC. REPAIRS AND MODIFICATIONS
PERFORMED BY UNAUTHORIZED SERVICE OR PER-
SONNEL WILL CAUSE THE MANUFACTURER’S WAR-
RANTY TO BECOME NULL AND VOID.
ANY NOTICEABLE DAMAGE SHOULD BE REPORTED
IMMEDIATELY AND REPAIRED.
ROUTINE MAINTENANCE
• Check the condition of water-cooler hoses and connections of
the power lead.
• Check the welding torch condition: replace it, if necessary.
• Check condition and operation of the cooling fan. Keep airflow
slots clean.
• The reservoir volume should be checked daily before using
the cooler.
• Keep the reservoir full, especially after disconnecting the
water lines or changing the accessory being cooled.
• Clean the tank filter.
PERIODIC MAINTENANCE (NOT LESS THAN ONCE A
YEAR)
Perform the routine maintenance and, in addition:
• Keep the machine clean. Using a dry (and low pressure)
airflow, remove the dust from the external case and from the
heat exchanger inside.
• 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.
Hot coolant can burn skin. Always ensure coolant is NOT
HOT before servicing the cooler.
Special precautions have to be taken when the coolant is
removed from the cooler reservoir. The coolant must not be
poured out into ground water, sewerage, or soil. Read
"Material Safety Data Sheet" (coolant used) and contact the
local Department of Environmental Protection office to
obtain information on recycling coolant.
The frequency of the maintenance operations may vary in
accordance with the working environment where the machine is
placed.
Do not touch electrically live parts.
Before the case of machine will be removed,
the machine has to be turned off and the
power lead has to be disconnected from
mains socket.
The power must be disconnected from the machine before
each maintenance and service. After each repair, perform
proper tests to ensure safety.
WARNING
WARNING
WARNING
D-1
MAINTENANCECOOL ARC®22

D-2
MAINTENANCECOOL ARC®22
PUMP INLET STRAINER MAINTENANCE
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
• Damage to the pump head’s inlet areas
• Torch damage from overheating due to insufficient coolant
flow rate.
A new or properly cleaned pump inlet strainer should restore the
cooler’s performance.
It is recommended to clean or replace the pump's inlet strainer at
least once a year.
ACCESS THE STRAINER
• DISCONNECT WELDER AND COOLER FROM POWER
• The strainer access panel is located on the back lower left,
remove two screws - see Figure 7
FIGURE 7
• Next remove the large brass bolt (approx. 15/16-inch hex).
See Figure 8. A deep well socket or tongue and groove pliers
may be used. A small amount of coolant may leak.
FIGURE 8
• Strainer will be removed with bolt
• Clean strainer and reassemble
Brass Bolt

E-1
TROUBLESHOOTINGCOOL ARC®22
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
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 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the obvious
external possibilities that may contribute to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the Possible Cause,
generally it states to contact your local Lincoln Authorized Field
Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your local Lincoln
Authorized Field Service Facility.
WARNING
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR

E-2
TROUBLESHOOTINGCOOL ARC®22
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
PROBLEM POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION
Cooler does not operate. Power lead unplugged. Plug in power lead.
No power at outlet. Check power supply output.
Power lead is damaged. Repair damaged lead or order new lead set.
Water lines blocked or crimped. Clear blockage in hose. Avoid kinking or putting sharp
bends in water lines.
Leak in gun or water hoses. Repair leak.
Reservoir empty. Fill reservoir.
Internal water leak. Internal quick connector loose. Insert tube correctly in quick connector clamp.
Internal hose punctured. Replace punctured hose with new hose.
Heat exchanger leaking. Replace heat exchanger.
Leak at inlet/outlet
connector block.
Hose clamp loose. Tighten hose clamp onto hose.
Torch or gun runs hot. Fan not operating. Reference fan section.
Fan operates but there is
low coolant flow. Leak in torch/gun or hoses. Repair leak.
Torch/gun or hoses partially obstructed. Clear obstruction.
Reservoir empty or very low. Refill reservoir.
Fan operates but there is no
coolant flow.
Pump failure. Replace pump.
Pump seized. Replace pump.
2A Fuse opened Replace 2A fuse
Pump operates, but fan does
not. Fan motor failure. Replace fan.
Weld output disabled
Low or no coolant flow. Fill reservoir.
Faulty flow sensor. Replace flow sensor.

F-1
DIAGRAMSCOOL ARC®22
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.
220
150
Wiring Diagram (12733)

F-2
DIAGRAMSCOOL ARC®22
10.87 in
9.68 in
21.26

WARNIN
AVISO DE
PRECAUCION
ATTENTION
WARNUN
ATENÇÃO
Spanish
French
erman
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW OUR EMPLO ER’S SAFET PRACTICES.
SE RECOMIENDA LEER ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO 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 EMPLO ES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLO EUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
l Do not touch electrically live parts or
electrode with skin or wet clothing.
l Insulate yourself from work and
ground.
l No toque las partes o los electrodos
bajo carga con la piel o ropa moja-
da.
l Aislese del trabajo y de la tierra.
l Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
l Isolez-vous du travail et de la terre.
l Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
l Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
l Isole-se da peça e terra.
l Keep flammable materials away.
l Mantenga el material combustible
fuera del área de trabajo.
l Gardez à l’écart de tout matériel
inflammable.
l Entfernen Sie brennbarres Material!
l Mantenha inflamáveis bem guarda-
dos.
l Wear eye, ear and body protection.
l Protéjase los ojos, los oídos y el
cuerpo.
l Protégez vos yeux, vos oreilles et
votre corps.
l Tragen Sie Augen-, Ohren- und Kör-
perschutz!
l Use proteção para a vista, ouvido e
corpo.

WARNIN
AVISO DE
PRECAUCION
ATTENTION
WARNUN
ATENÇÃO
Spanish
French
erman
Portuguese
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.
l Keep your head out of fumes.
l Use ventilation or exhaust to
remove fumes from breathing zone.
l Los humos fuera de la zona de res-
piración.
l Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
l Gardez la tête à l’écart des fumées.
l Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
l Vermeiden Sie das Einatmen von
Schweibrauch!
l Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para
remover fumo da zona respiratória.
l Turn power off before servicing.
l Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
l Débranchez le courant avant l’entre-
tien.
l Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
l Não opere com as tampas removidas.
l Desligue a corrente antes de fazer
serviço.
l Não toque as partes elétricas nuas.
l Do not operate with panel open or
guards off.
l No operar con panel abierto o
guardas quitadas.
l N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
l Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
l Mantenha-se afastado das partes
moventes.
l Não opere com os paineis abertos
ou guardas removidas.

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 customer’s particular
purpose, with respect to such information or advice. As a matter
of practical consideration, we also cannot assume any respon-
sibility 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.
TABLE OF CONTENTS
INSTALLATION
OPERATION
MAINTENANCE
TROUBLESHOOTING
DIAGRAMS