Lincoln Electric COOL ARC 60 User manual

IM3154
11/2022
REV03
COOL ARC®60
OPERATOR’S MANUAL
ENGLISH
Lincoln Electric Bester Sp. z o.o.
ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

English English
I
12/05
THANKS! For having chosen the QUALITY of the Lincoln Electric products.
Please Examine Package and Equipment in case of Damage. Claims for material damaged in shipment must be
notified immediately to the dealer.
For future reference record in the table below your equipment identification information. Model Name, Code & Serial
Number can be found on the machine rating plate.
Model Name:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased:
…………………………………………………………………... ……………………….…………………………………………..
INDEX
Technical Specifications...............................................................................................................................................................1
Electromagnetic Compatibility (EMC) ..........................................................................................................................................2
Safety............................................................................................................................................................................................3
Introduction...................................................................................................................................................................................5
Unpacking.....................................................................................................................................................................................5
Installation on Power Source .......................................................................................................................................................5
Installation and Operator Instructions ..........................................................................................................................................7
WEEE .........................................................................................................................................................................................19
Spare Parts.................................................................................................................................................................................19
REACh........................................................................................................................................................................................19
Authorized Service Shops Location...........................................................................................................................................19
Electrical Schematic ...................................................................................................................................................................19
Accessories ................................................................................................................................................................................20

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Technical Specifications
NAME INDEX
COOL ARC®60 K14297-1
INPUT
Input Voltage U1Input Current I1max
COOL ARC®60
230 V ± 15% 1,5 A
400 V ± 15% 1A
440 V ± 15% 0,9A
Frequency EMC Class
COOL ARC®60 50/60 Hz A
PARAMETERS RATING
Cooling capacity with a cooling liquid flow of
1 liter / min at a temperature of: Maximum pressure rate
COOL ARC®60 25 ° C 40 ° C 0,47 MPa
1,1 kW 0,61 kW
PARAMETERS O FTHE COOLER’S RESERVOIR
Maximum reservoir capacity Minimum required reservoir capacity
COOL ARC®60 4,5 liters 3 liters
COOLANT
COOL ARC®60 Recommended coolant FREEZCOOL - W000010167 - don’t use conductive cooling liquids.
COOL ARC®60 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.
Automotive anti-freeze. These coolants will damage the pump and block of
the heat exchanger, affecting cooling performance.
PHYSICAL DIMENSIONS
Weight Height Width Length
COOL ARC®60 22 kg 224 mm 291 mm 663 mm
OTHERS
Protection Rating Operating Humidity
(t=68°F=20°C) Operating Temperature Storage Temperature
IP23 ≤90 % from 14 ºF to 104 ºF
(from -10 ºC to +40 ºC)
from -13 ºF to 131 ºF
(from -25 ºC to +55 ºC)

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Electromagnetic Compatibility (EMC)
11/04
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand this
section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
Consider the following guidelines to reduce electromagnetic emissions from the machine.
Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.
The output cables should be kept as short as possible and should be positioned together. If possible connect the work
piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting the work
piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.
WARNING
The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radiated disturbances.

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Safety
01/11
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment.
Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages
caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury, loss
of life, or damage to this equipment. Protect yourself and others from possible serious injury or death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this
equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could cause
serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the electrode,
work clamp, or connected work pieces when this equipment is on. Insulate yourself from the electrode,
work clamp, and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the fuse
box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode holder
directly on the welding table or any other surface in contact with the work clamp to avoid the risk of
accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some pacemakers,
and welders having a pacemaker shall consult their physician before operating this equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and
EN 12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal
Protective Equipments (PPE) having filter with a protection degree up to a maximum of 15, as required by
EN169 Standard.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use enough
ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel with
suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to the arc.

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WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding area
and have a fire extinguisher readily available. Welding sparks and hot materials from the welding process
can easily go through small cracks and openings to adjacent areas. Do not weld on any tanks, drums,
containers, or material until the proper steps have been taken to insure that no flammable or toxic vapors
will be present. Never operate this equipment when flammable gases, vapors or liquid combustibles are
present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.
CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the correct
shielding gas for the process used and properly operating regulators designed for the gas and pressure
used. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or
transport gas cylinders with the protection cap removed. Do not allow the electrode, electrode holder,
work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be located away
from areas where they may be subjected to physical damage or the welding process including sparks and
heat sources.
HOT COOLANT CAN BURN SKIN: Always be sure coolant is NOT HOT before servicing the cooler.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an
environment with increased hazard of electric shock.
The manufacturer reserves the Right to make changes and/or improvements in design without upgrade at the same time
the operator’s manual.

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Introduction
The COOL ARC® 60 is a recirculating cooling system
designed to use with welding power sources that lists the
COOL ARC® 60 as an approved accessory.
The COOL ARC® 60 cooler includes the following
accessories:
User manual on the USB stick.
Red hose with quick couplings (150 mm) used for the
filling procedure.
The COOL ARC® 60 is delivered without the coolant.
FREEZCOOL - W000010167 is recommended.
Unpacking
Unpacking the COOL ARC®60
The packaging of the Cooler is designed to withstand
shipping abuse and contains a cardboard liner that
surrounds the unit. If any shipping damages have been
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. Save the manual instruction and service
directory supplied with the COOL ARC® 60 for parts
orders and future maintenance service.
Installation on Power Source
The COOL ARC® 60 needs to be connected directly to the
chassis of welding power source which lists the
COOL ARC® 60 as an approved accessory.
WARNING
Only a qualified electrician can connect the welding
machine to the supply. Installation had to be made in
accordance with the appropriate National Electrical Code
and local regulations.
WARNING
Before connecting COOL ARC® 60 turn off the power
source and disconnect it from the input supply.
INSTALATION:
Place the cooler on a four-wheeled cart (Figure 1).
Place the SPEEDTEC on top of the cooler (Figure 2).
Unscrew and remove the Speedtec side cover –
unscrew the two M5x20 screws (Figure 3).
Connect the 10-pin plug to the socket and screw the
green – yellow protective wire to the grounding bolt –
unscrew the M6 nut, remove the serrated washer,
install the cable, put on the serrated washer and screw
on the M6 nut.(Figure 4).
Place the side panel (Figure 5).
Assembly the side panel screw the two M5x20 screws
(Figure 5).
Final assembly – the cooler should be assembled to
the Speedtec with M6x16 screws (Figure 6).

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Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6

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Installation and Operator Instructions
Read this entire section before installation or operation of
the machine.
WARNING
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.
LOCATION
This machine will operate in harsh environments.
However, it is important that simple preventative
measures are followed to assure long life and reliable
operation.
Do not place or operate this machine on a surface with
an incline greater than 15° from horizontal.
Do not use this machine for pipe thawing.
This machine 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
machine with paper, cloth or rags when switched on.
Dirt and dust that can be drawn into the machine
should be kept to a minimum.
This machine has a protection rating of IP23. Keep it
dry when possible and do not place it on wet ground
or in puddles.
Locate the machine 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 electromagnetic compatibility in this
manual.
Do not operate in areas with an ambient temperature
higher than 40°C. The ambient air temperature
influences the parameters of cooling. If the ambient
temperature is higher, the cooling system will be less
effective.
WARNING
Avoid placing the cooler near areas of extreme heat.
RECOMMENDED POWER SOURCE
The COOL ARC® 60 is designed for use with water-
cooled torches. The COOL ARC® 60 must be used with
the welding power sources that lists the COOL ARC® 60
as an approved accessory.
Input Supply Connection
The COOL ARC® 60 is supplied by a welding power
source in accordance with installation procedure that can
be done only by qualified electrician. Installation must be
made in accordance with the appropriate National
Electrical Code and local regulations.
WARNING
Do not run cooler if the reservoir was not filled and the
torch’s/gun’s hoses are disconnected from the cooling
unit. Not observing this warning may cause internal
damage to the cooler unit.
Controls and Operational Features
14
5
2
3
456
Figure 7

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7
Figure 8
The COOL ARC® 60 is equipped with a flow sensor which
triggers an error code to the machine to protect the Torch
from over-heating when coolant flow is not detected
through the flow sensor. The Error Code fault (Error 0092)
can indicate a possible kink in the torch lines, damage
and/or a leak in the Torch coolant lines.
WARNING
Incorporated into the cooler is an automatic flow sensor to
detect low or no coolant flow. A low or no flow condition
will cause welding output to automatically stop to protect
the torch.
1. Minimum and maximum Liquid Level: The minimum
recommended liquid level is 3 liters, the maximum
recommended liquid level is 4,5 liters.
2. Reservoir for Coolant with Cap: The translucent
reservoir enables control of the coolant level.
3. Reservoir filter: 400µm.
4. Quick Connect Coupling: Coolant outlet (supplies cool
coolant to the torch/gun).
5. Quick Connect Coupling: Coolant inlet (takes warm
coolant from torch/gun).
6. Rocker switch – used to manually add coolant to the
radiator. Its inclusion results in shorting of the flow
sensor.
7. Airflow Slots: Enable proper circulation of air cooling.
Figure 9

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Circulation of Coolant in the Cooler
Figure 10
Circulation of coolant in case of using connectors at front
Figure 11
Circulation of coolant in case of using connectors at rear
WARNING
Avoid kinking or putting sharp bends in any water lines.
WARNING
Never operate the cooler with case off.

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Modes of operation
COOL ARC® 60 can be operate using two interfaces. The
standard version (Figure 13) uses two LED displays.
While the advance version (Figure 12) uses a 7 '' display.
The method of operating both interfaces is describe in the
operating instructions for the dedicated power source.
COOL ARC® 60 can be set in modes:
Status Description
Auto
(default)
The cooler switches on after starting of
the welding and turns off after the time
that is required to cool down the torch
after welding.
OFF Cooler is permanently off.
ON Cooler is permanently on.

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Advanced User Interface
Cooler
Configur ation
Settings
Auto Off On
Figure 12

English 12 English
Standard User Interface
Figure 13

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Filling the reservoir and water lines
WARNING
Avoid contact with coolant. Wear waterproof
gloves and protective eye wear.
The cooler should be filled and used only in the horizontal
position.
Use only recommended coolant FREEZCOOL -
W000010167.
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 of the heat exchanger,
affecting cooling performance.
WARNING
Never operate the cooler with the empty reservoir.
WARNING
Do not start the cooler with less than 3 liters of coolant.
Operating without enough coolant can prevent full priming
of the system and may damage the pump.
Assemble the welding set (see Installation on Power
Source chapter).
Turn the power source on. If COOL ARC® 60 is
connected properly, power source will recognize it.
When the COOL ARC® 60 was connected for a first
time welding source will automatically starts the filling
procedure (Figure 14 or 22). Remove the reservoir
cap to prevent generating a partial vacuum.
Fill the coolant reservoir to the maximum level – 4,5
liter - (Figure 15 or 23).
Connect the short red hose with quick water
connectors (BYPASS included with the equipment) to
blue and red outlet socket on front of the cooler
(Figure 16 or 24). Observe the coolant circuit.
Wait until the coolant fully circulates through the
cooling system and returns into the reservoir -
(Figure 17 or 25).
Disconnect the BYPASS.
Connect the torch hoses and interconnection cable
when using power source with separate wire feeder –
(Figure 18 or 26).
Wait until the coolant fully circulates through the
cooling system - (Figure 19 or 27).
Check the coolant level and add if required fill in
coolant to reach level between minimum and
maximum, which is present on front label
COOL ARC® 60 - (Figure 20 or 28).
Tighten the cap.
If the filling process is successful (Figure 21 or 29), the
cooler switches to AUTO mode.
Advanced User Interface
Figure 14
Figure 15
Figure 16
Figure 17

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Figure 18
Figure 19
Figure 20
Figure 21
Standard User Interface
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29

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WARNING
If different product is connected, filling procedure should
be started manually.
First follow as shown Figure 30 or 31 and then repeat
steps shown on Figure 14 or 22 to Figure 21 or 29.
Advanced User Interface
Filling
Cooler
Configur ation
Figure 30
Standard User Interface
Figure 31
Filling procedure failed
Filling the reservoir and liquid lines first time
If filling procedure can not be finished at the first time, an
image will be shown on the screen as on Figure 32 or 33.
Figure 32
Figure 33
If during the second attempt filling procedure failed
(Figure 34 or 35) please turn the power source off and
check:
cooling system hoses conditions (bent or damaged);
coolant level.
Figure 34
Figure 35
After review turn on the power source. Machine will
automatically start with filling procedure again.

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Priming Pump (only first use the cooler)
and Bleeding the Cooling System
Figure 36
Assemble the welding set.
Connect the hose with quick water connector (added
to the equipment) to the cooler’s inlet and outlet socket
(Figure 36).
Fill the coolant reservoir – minimum 3l.
Undo the nut.
WARNING
At first using of the COOLARC®60 reservoir’s nut has to
be removed to avoid generate partial vacuum in cooling
system during priming pump.
Turn the power source on.
Force circulation of coolant: simultaneously press and
hold the flow sensor off switch and torch’s/gun’s
trigger until the coolant does not circulate the cooling
system and does not return the reservoir.
Turn the power source off.
Disconnect the hose with quick water connector.
Connect the water-cooler hoses.
Turn the power source on.
Force circulation of coolant: simultaneously press and
hold the flow sensor off switch and torch’s/gun’s
trigger until the coolant does not circulate the cooling
system and does not return the reservoir.
Tighten the nut.
WARNING
After priming pump and/or bleeding the cooling system,
be sure the reservoir’s nut is tightened up. Operating the
cooler without the nut can cause poor cooling efficiency,
evaporation loss of coolant, and low product life.
The welding set is ready to work.
WARNING
If the filling procedure fails, contact with the nearest
Technical Service Center or Lincoln Electric. Machine
usage without proper functioning of COOL ARC® 60 can
cause thermal damage of water torch or COOL ARC® 60
machine.
Error Message - lack coolant flow
If coolant flow is not detected by system during welding,
an image will be shown on the screen as on Figure 37 or
38. Machine will protect itself automatically by stopping
welding process. The message should appear 3 seconds
after the error was displayed.
0092
Description
Cooler Shutdown
Press left button to exit
Figure 37
Figure 38
Press the left button / knob to delete error message. If
COOL ARC® 60 is in ON mode machine reset is required
to continue welding. This behavior is to protect the pump
from damage and the torch from overheating.
WARNING
If during next welding attempts machine still display error
0092 Figure 37 please contact with the Technical Service
Center or Lincoln Electric.
Transport
To avoid freeze damage and water leakage during
transport, the coolant must be removed from the cooler
reservoir.

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Maintenance
WARNING
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 personnel will cause
the manufacturer’s warranty 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 / gun condition: replace it, if
necessary.
Check condition and operation of the cooling fan. Keep
its 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.
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.
WARNING
Hot coolant can burn skin. Always be sure coolant is NOT
HOT before servicing the cooler.
WARNING
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.
WARNING
Do not touch electrically live parts.
WARNING
Before the case of machine will be removed, the machine
has to be turned off and the power lead has to be
disconnected from main socket.
WARNING
Main supply network must be disconnected from the
machine before each maintenance and service. After each
repair, perform proper tests to ensure safety.
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 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.

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Troubleshooting
This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs performed on
this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For
your safety, please observe all safety notes and precautions detailed in the Safety Section of this manual to avoid electrical
shock or danger while troubleshooting this equipment.
WARNING
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the
nearest authorized Technical Service Center or Lincoln Electric for technical troubleshooting assistance before you proceed.
LOCATE PROBLEM
(SYMPTOM). POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION
Cooler does not
operate
Power lead unplugged.
No power at outlet.
Power lead is damaged.
Water lines blocked or crimped.
Leak in gun or water hoses.
Reservoir empty.
Blown fuse.
Plug in power lead.
Check outlet circuit breaker.
Repair damaged lead or order new lead set.
Clear blockage in hose. Avoid kinking or
putting sharp bends in water lines.
Repair leak.
Fill reservoir.
Replace fuse.
Internal water leak
Hose clamp loose on one of internal hoses.
Internal hose punctured.
Heat exchanger leaking.
Tighten or replace hose clamp.
Replace punctured hose with new hose.
Replace heat exchanger.
Leak at inlet/outlet
connector block Hose clamp loose. Tighten hose clamp onto hose.
Torch or gun runs hot Unit placed by area of extreme heat.
Fan not operating.
Move unit away from hot air.
Reference fan section.
Fan operates but there
is low coolant flow
Leak in torch/gun or hoses.
Torch/gun or hoses partially obstructed.
Reservoir empty or very low.
Repair leak.
Clear obstruction.
Refill reservoir.
Fan operates but there
is no coolant flow
Pump failure.
Pump seized.
Replace pump.
Replace pump.
Pump operates, but fan
does not
Fan blade contacting heat exchanger.
Fan motor failure.
Replace fan.
Replace fan.
Cooler trips outlet
circuit breaker
Circuit overloaded.
Cooler electrical component failure.
Check outlet circuit breaker in the power
source.
Replace electrical component.
Weld output disabled Low or no coolant flow.
Faulty flow sensor.
Fill reservoir.
Replace flow sensor.