Lincoln Electric PRISM CIRCULATOR 4000 User manual

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IM10629 | Issue Date Jun - 22
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For use with machines having Code Numbers:
13232 - PRISM CIRCULATOR 4000, 460V
13233 - PRISM CIRCULATOR 4000, 230V
PRISM
®CIRCULATOR®0004
®
®
®
®

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 - 10/08/2021

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 usedfor welding or
cutting, produces fumes or gases which contain
chemicals known to the State ofCalifornia 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. 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.
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
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
causes localized Electric and Magnetic Fields (EMF).
and welding machines
welders having a pacemaker should consult their physician
before welding.
which are now not known.
2.d. All welders should use the following procedures in order to
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 - 10/08/2021
1.c. Do not add the fuel near an open ame welding
with hot engine parts and igniting. Do not spill fuel when lling
2.a. Electric current owing through any conductor
Welding current creates EMF elds around welding cables
2.b. EMF elds may interfere with some pacemakers, and
2.c. Exposure to EMF elds in welding may have other health effects
minimize exposure to EMF elds from the welding circuit:
1.i. Using a generator indoors CAN KILL YOU IN
MINUTES.
1.j. Generator exhaust contains carbon monoxide. This is a poison
you cannot see or smell.
1.k. NEVER use inside a home or garage,
EVEN IF doors and windows are open.
1.l. Only use OUTSIDE and far away from
windows, doors and vents.
1.m. Avoid other generator hazards. READ
MANUAL BEFORE USE.

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 - 10/08/2021

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 - 10/08/2021

2
SAFETY
As a rule of thumb, for many mild steel electrode, if the air is
visibly clear and you are comfortable, then the ventilation is
generally adequate for your work. The most accurate way to
determine if the worker exposure does not exceed the applicable
exposure limit for compounds in the fumes and gases is to have
an industrial hygienist take and analyze a sample of the air you
are breathing. This is particularly important if you are welding with
stainless, hardfacing or Special Ventilation products. All Lincoln
MSDS have a maximum fume guideline number. If exposure to
total fume is kept below that number, exposure to all fume from
the electrode (not coatings or plating on the work) will be below
the TLV.
There are steps that you can take to identify hazardous
substances in your welding environment. Read the product label
and material safety data sheet for the electrode posted in the work
place or in the electrode or ˜ux container to see what fumes can
be reasonably expected from use of the product and to determine
if special ventilation is needed. Secondly, know what the base
metal is and determine if there is any paint, plating, or coating that
could expose you to toxic fumes and/or gases. Remove it from the
metal being welded, if possible. If you start to feel uncomfortable,
dizzy or nauseous, there is a possibility that you are being
overexposed to fumes and gases, or suffering from oxygen
deÿciency. Stop welding and get some fresh air immediately.
Notify your supervisor and co-workers so the situation can be
corrected and other workers can avoid the hazard. Be sure you
are following these safe practices, the consumable labeling and
MSDS to improve the ventilation in your area. Do not continue
welding until the situation has been corrected.
NOTE: The MSDS for all Lincoln consumables is available on Lincoln’s web-
site: www.lincolnelectric.com
Before we turn to the methods available to control welding fume
exposure, you should understand a few basic terms:
Natural Ventilation is the movement of air through the
workplace caused by natural forces. Outside, this is usually
the wind. Inside, this may be the flow of air through open
windows and doors.
Mechanical Ventilation is the movement of air through the
workplace caused by an electrical device such as a portable
fan or permanently mounted fan in the ceiling or wall.
Source Extraction (Local Exhaust) is a mechanical device
used to capture welding fume at or near the arc and filter
contaminants out of the air.
The ventilation or exhaust needed for your application depends
upon many factors such as:
• Workspace volume
• Workspace configuration
• Number of welders
• Welding process and current
• Consumables used (mild steel, hardfacing, stainless, etc.)
• Allowable levels (TLV, PEL, etc.)
•Material welded (including paint or plating)
• Natural air˜ow
Your work area has adequate ventilation when there is enough
ventilation and/or exhaust to control worker exposure to
hazardous materials in the welding fumes and gases so the
applicable limits for those materials is not exceeded. See chart of
TLV and PEL for Typical Electrode Ingredients, the OSHA PEL
(Permissible Exposure Limit), and the recommended guideline, the
ACGIH TLV (Threshold Limit Value), for many compounds found in
welding fume.
Ventilation
There are many methods which can be selected by the user to
provide adequate ventilation for the specific application. The
following section provides general information which may be
helpful in evaluating what type of ventilation equipment may be
suitable for your application. When ventilation equipment is
installed, you should confirm worker exposure is controlled within
applicable OSHA PEL and/or ACGIH TLV. According to OSHA
regulations, when welding and cutting (mild steels), natural
ventilation is usually considered sufficient to meet requirements,
provided that:
1. The room or welding area contains at least 10,000 cubic feet
(about 22' x 22' x 22') for each welder.
2. The ceiling height is not less than 16 feet.
3. Cross ventilation is not blocked by partitions, equipment, or
other structural barriers.
4. Welding is not done in a confined space.
Spaces that do not meet these requirements should be equipped
with mechanical ventilating equipment that exhausts at least 2000
CFM of air for each welder, except where local exhaust hoods or
booths, or air-line respirators are used.
Important Safety Note:
When welding with electrodes which require special
ventilation such as stainless or hardfacing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings which
produce hazardous fumes, keep exposure as low as
possible and below exposure limit values (PEL and TLV)
for materials in the fume using local exhaust or
emosnirosecapsdennocnI.noitalitnevlacinahcem
circumstances, for example outdoors, a respirator may
be required if exposure cannot be controlled to the PEL
or TLV. (See MSDS and chart of TLV and PEL for Typical
Electrode Ingredients.) Additional precautions are also
required when welding on galvanized steel.
PRISM CIRCULATOR 4000
®®

3
SAFETY
BIBLIOGRAPHY AND SUGGESTED READING
ANSI Z87.1, Practice for Occupational and Educational Eye and
Face Protection, American National Standards Institute, 11 West
42nd Street, New York, NY 10036.
Arc Welding and Your Health: A Handbook of Health Information
for Welding. Published by The American Industrial Hygiene
Association, 2700 Prosperity Avenue, Suite 250, Fairfax, VA
22031-4319.
NFPA Standard 51B, Cutting and Welding Processes, National Fire
Protection Association, 1 Batterymarch Park, P.O. Box 9146,
Quincy, MA 02269-9959.
OSHA General Industry Standard 29 CFR 1910 Subpart Q. OSHA
Hazard Communication Standard 29 CFR 1910.1200. Available
from the Occupational Safety and Health Administration at
http://www.osha.org or contact your local OSHA ofÿce.
The following publications are published by The American Welding
Society, P.O. Box 351040, Miami, Florida 33135. AWS publi-
cations may be purchased from the American Welding society at
http://www.aws.org or by contacting the AWS at 800-443-9353.
ANSI, Standard Z49.1, Safety in Welding, Cutting and Allied
Processes. Z49.1 is now available for download at no charge at
http://www.lincolnelectric.com/community/safety/ or at the AWS
website http://www.aws.org.
AWS F1.1, Method for Sampling Airborne Particulates Generated
by Welding and Allied Processes.
AWS F1.2, Laboratory Method for Measuring Fume Generation
Rates and Total Fume Emission of Welding and Allied Processes.
AWS F1.3, Evaluating Contaminants in the Welding Environment: A
Strategic Sampling Guide.
AWS F1.5, Methods for Sampling and Analyzing Gases from
Welding and Allied Processes.
AWS F3.2, Ventilation Guide for Welding Fume Control
AWS F4.1, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances.
AWS SHF, Safety and Health Facts Sheets. Available free of charge
from the AWS website at http://www.aws.org.
Supplemental Information:
(*) Not listed. Nuisance value maximum is 10 milligrams per cubic
meter. PEL value for iron oxide is 10 milligrams per cubic meter.
TLV value for iron oxide is 5 milligrams per cubic meter.
(**) As respirable dust.
(*****) Subject to the reporting requirements of Sections 311, 312,
and 313 of the Emergency Planning and Community Right-
to-Know Act of 1986 and of 40CFR 370 and 372.
(b) The PEL for chromium (VI) is .005 milligrams per cubic meter as
an 8 hour time weighted average. The TLV for water-soluble
chromium (VI) is 0.05 milligrams per cubic meter. The TLV for
insoluble chromium (VI) is 0.01 milligrams per cubic meter.
(c) Values are for manganese fume. STEL (Short Term Exposure
Limit) is 3.0 milligrams per cubic meter. OSHA PEL is a ceiling
value.
(****) The TLV for soluble barium compounds is 0.5 mg/m3.
TLV and PEL values are as of October 2013. Always check Safety
Data Sheet (SDS) with product or on the Lincoln Electric website at
http://www.lincolnelectric.com
LISTED BELOW ARE SOME TYPICAL INGREDIENTS IN WELDING ELECTRODES AND
THEIR TLV (ACGIH) GUIDELINES AND PEL (OSHA) EXPOSURE LIMITS
INGREDIENTS CAS No. TLV mg/m3PEL mg/m3
Aluminum and/or aluminum alloys (as AI)***** 7429-90-5 1.0 15
Aluminum oxide and/or Bauxite***** 1344-28-1 1.0 5**
Barium compounds (as Ba)***** 513-77-9 0.5 0.5
Chromium and chromium alloys or compounds (as Cr)***** 7440-47-3 0.5(b) 0.5(b)
Hexavalent Chromium (Cr VI) 18540-29-9 0.05(b) .005(b)
Copper Fume 7440-50-8 0.2 0.1
Cobalt Compounds 7440-48-4 0.02 0.1
Fluorides (as F) 7789-75-5 2.5 2.5
Iron 7439-89-6 10* 10*
Limestone and/or calcium carbonate 1317-65-3 10* 15
Lithium compounds (as Li) 554-13-2 15 10*
Magnesite 1309-48-4 10 15
Magnesium and/or magnesium alloys and compounds (as Mg) 7439-95-4 10* 10*
Manganese and/or manganese alloys and compounds (as Mn)***** 7439-96-5 0.02 5.0(c)
Mineral silicates 1332-58-7 5** 5**
Molybdenum alloys (as Mo) 7439-98-7 10 10
Nickel***** 7440-02-0 0.1 1
Silicates and other binders 1344-09-8 10* 10*
Silicon and/or silicon alloys and compounds (as Si) 7440-21-3 10* 10*
Strontium compounds (as Sr) 1633-05-2 10* 10*
Zirconium alloys and compounds (as Zr) 12004-83-0 5 5
PRISM
®CIRCULATOR 4000 ®

TABLE OF CONTENTS
INSTALLATION .............................................................................................................................................SECTION A
TECHNICAL SPECIFICATIONS .....................................................................................................................................A-1
TRANSPORT AND ERECTION......................................................................................................................................A-2
SELECT SUITABLE LOCATION.....................................................................................................................................A-2
ENVIRONMENTAL AREA .............................................................................................................................................A-2
PRISM® CIRCULATOR® 4000 SYSTEM LAYOUTS.....................................................................................................A-3
INSTALLATION OF PRISM® CIRCULATOR® 4000......................................................................................................A-4
ELECTRICAL CONNECTIONS.......................................................................................................................................A-6
OPERATION ................................................................................................................................................SECTION B
CONTROL. ............................................................................................................................................................B-2
SOFTWARE FUNCTIONS.............................................................................................................................................B-3
OPERATION...............................................................................................................................................................B-3
ACCESSORIES ..............................................................................................................................................SECTION C
REPLACEMENT FILTER OPTIONS................................................................................................................................C-1
MAINTENANCE.............................................................................................................................................SECTION D
MALFUNCTIONS AND EMERGENCIES EFFECTING THE FILTER UNIT ............................................................................D-1
ESCAPE OF NOXIOUS SUBSTANCES OR RADIATION ...................................................................................................D-1
PERIODIC MAINTENANCE...........................................................................................................................................D-2
MAINTENANCE SCHEDULE.........................................................................................................................................D-2
REPLACING FILTER CARTRIDGES OR EMPTYING DUSTBINS .......................................................................................D-3
REPLACING FILTER CARTRIDGES...............................................................................................................................D-4
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.
OUTLET VANES..........................................................................................................................................................B-1
PRISM
®CIRCULATOR 4000 ®

TECHNICAL SPECIFICATIONS
Air Consumption CFM, (L/MIN)
Cleaning Cycle
Pause Time (Sec)
551.6 (1464)
10 25.8 (732)
15 17.2 (488)
20 12.9 (366)
25 10.3 (293)
30 8.6 (244)
35 7.4 (209)
40 6.5 (183)
45 5.7 (163)
50 5.2 (146)
55 4.7 (133)
60 4.3 (122)
FILTER CLASS (ACCORDING TO ASHRAE 52.2)
KP4519-2 MERV 16 NANO
AMBIENT CONDITIONS
MINIMUM TEMPERATURE -4°F (-20°C)
MAXIMUM TEMPERATURE 113°F (45°C)
MAXIMUM RELATIVE HUMIDITY 75%
A-1
TECHNICAL SPECIFICATIONS
NOTE: Compressed air must be clean and dry, and have a dew point
of -40°F (-40°C).
Capacity 4000 SCFM @ 6.5"WG
Motor Power Nominal 7.6HP
Input Voltage Nominal +/- 10%380-480V/3~/50-60Hz
Rated Current 9 A
Frequency 50/60 HZ
SUPPLY FUSE Class J OR CC 15A/600V
Protection Class fan MotorIP55
Sound Level 72db
Footprint (Dimensions) 45 X 65 (Inches)
Overall Height147 (inches)
Overall Weight1830 lbs
Filter Merv 16 Nano
Number of Filters 4
Filter area 1280 Sq Ft
ALARM LEVEL 1500Pa (factory default)
Capacity 4000 SCFM @ 6.5"WG
Motor Power Nominal 8.6HP
Input Voltage Nominal +/- 10%200-240V/3~/50-60Hz
Rated Current 19.5 A
Frequency 50/60 HZ
SUPPLY FUSE Class J OR CC 30A/600V
Protection Class fan MotorIP55
Sound Level 72db
Footprint (Dimensions) 45 X 65 (Inches)
Overall Height147 (inches)
Overall Weight1830 lbs
Filter Merv 16 Nano
Number of Filters 4
Filter area 1280 Sq Ft
ALARM LEVEL 1500Pa (factory default)
K5140-1 - PRISM® CIRCULATOR®4000, 460V
K5140-2 - PRISM®CIRCULATOR®4000, 230V
PRISM
®CIRCULATOR 4000 ®
FILTER CLEANING COMPRESSED AIR CONSUMPTION

INSTALLATION
TRANSPORT AND ERECTION
Instruct all persons whose presence is not
required to stay out of the hazard area
Do not stand under or next to the load when it is being
lifted up or set down
Transport the unit or erection components on the pallets
provided, and secure them against falling over or
slipping.
Transport them with a suitable pallet truck or forklift
truck
Taller units should be built up on site
Filter units must be secured to the foundations
The foundations must have adequate load-bearing
strength and be free of vibration
• The installer is responsible for following
federal, state and local safety codes and
regulations.
• Before drilling, verify locations of existing
gas, water or electrical conduits.
Excluded Uses!
• Welding fumes containing oil
• Aluminium dust
• Burning or incandescent materials
• Cigarettes
• Aggressive media
• Water and moisture
• Explosive gases and/or dust mixtures
• Dusts with toxic characteristics other than welding
fumes
• The installation of this product is exclusively reserved
to authorized, well-trained and qualified professional
electrical and mechanical contractors.
• Inspect the product and check it for damage. Verify the
functioning of the safety features.
• Electrical connection to be executed in accordance
with local requirements. Ensure compliance with the
EMC regulatory arrangements.
• Check the working environment. Do not allow
unauthorized persons to enter the working
environment.
• Protect the product against water and humidity.
• Use common sense. Stay alert and keep your attention
to your work. Do not use the product when you are
under the influence of drugs, alcohol or medicine.
• Ensure the workspace is well-illuminated.
• Never install the product in front of entrances and exits
which must be used for emergency services.
• Make sure that the workshop, in the vicinity of the
product, contains sufficient approved fire extinguishers.
• Make sure the wall, ceiling or support system are
strong enough to carry the product.
• Air containing particles such as chromium, nickel,
beryllium, cadmium, lead etc., which is a health hazard,
should never be recycled. This air must always be
brought outside the working area.
SELECT SUITABLE LOCATION
• Do not place equipment near radiant heat sources.
• Do not place in a confined space. Allow a minimum of 3 feet
of clearance around machine at all times for maintenance
requirements.
ENVIRONMENTAL AREA
Keep the machine inside and dry at all times. Do not place on wet
ground or in puddles. Never place liquids on top of the machine.
ATTENTION
WARNING
ATTENTION
A-2
INSTALLATION
PRISM
®CIRCULATOR 4000 ®

PRISM® CIRCULATOR® 4000 SYSTEM LAYOUTS
A-3
INSTALLATION
PRISM
®CIRCULATOR 4000 ®
Each Prism® Circulator® 4000 unit is designed to ter 40,000
pace at a rate of 6 air changes per hour. In many
applications, multiple units can be strategically located to push
air.
The Prism® Circulator® 4000 can be placed in high-dust and
fume producingareas or placed strategically throughout the
guidelines:
Install circulator along the perimeter of shop, away from
open doors and exhaust fans.
Position near input power and compressed air.
Do not place near radiant heat sources.
(0.91 m) of clearance around the machine for maintenance.
1) One Circulator Unit
m) every 10 minutes.
2) Two Circulator Units: Two units at opposite ends of the
minutes.
3) Three Circulator Units
(557.41 sq. m)every 10 minutes.
One unit lters 2,000 sq. ft. (185.80 sq.

A-4
INSTALLATION
INSTALLATION OF PRISM® CIRCULATOR® 4000
( K5140-1 & K5140- 2)
TOOLS NEEDED
Step 2 - Fan section Installation (FIG A.2)
•
•
•
•
•
•
Fasten the 1/4"-20
PRISM
®CIRCULATOR 4000 ®
Remove the rear panel from fan section as shown.
NOTE-Don't drag the top section it will damage the
sealing gasket.
Lift the fan section using appropriately rated
lifting sling/chain through lifting brackets. Align
the fan section with 3 guide bolts at rear and
section as it will damage the sealing gasket.
Secure the fan section using ¼” thread forming
bolts at 35 places from hardware kit. Install
3/8” nuts on to guide bolts at 1 place.
Step 1 - Unpacking the Unit
removing the lag bolts & banding. Lift & move
area.
5/16” Nutdriver
9/16” Nutdriver
Ladder/Lift
Drill
The installer is responsible for following
federal, state and local safety codes and
regulations.
WARNING
FALLING EQUIPMENT can cause injury
Remove the side access panel as shown.
Connect the mating connector from fan section and
controls.
Connect the pressure tube from controls with quick
connect below the fan section.
Reinstall side access panel reusing the existing 3/8"
thread forming bolts at 22 places.
•Fasten the fan section at inside locations using
¼” thread forming bolts at 11 places. Install
3/8” nuts on to the guide bolts inside at 2 places.
•Reinstall the rear panel reusing the existing
hardware at 18 places.
NOTE: Use lifting sling or chains rated to 700 lbs. when used
with corner lifting brackets on the fan section. Lift with fork truck
or crane.
Unit ships on 2 pallets in 2 sections:
• Filter section - Approximate weight 1190 lbs. (540 kg.)
• Fan section - Approximate weight 640 lbs. (290 kg.)

A-5
INSTALLATION
•
PRESSURE TUBE FROM
CONTROLS
6
cable.
•
•
•
5
•Connect the Prism Circulator control cable to 115V
outlet.
PRISM
®CIRCULATOR 4000 ®
5
6
lanyard decal on the cable. It is also compatible with
230V single phase.
1/4"). Adjust regulator pressure to) 5-6 bar(72-87psi)
Motor cable with the unit is 20ft long.
Note - Check the voltage rating on the yellow Lanyard decal on the
Prism® Circulator® 4000 models have 460V or 230V three phase
identify the appropriate plug (not included) for the outlet to be used
and install the plug to the fan cable.
Prism® Circulator® 4000 can be connected directly to a
power disconnect.
460V units require a 15A fused circuit.
230V units require a 30A fused circuit.

A-6
INSTALLATION
ELECTRICAL CONNECTIONS
Make all electrical connections compatible to your local city / state
code.
ELECTRIC SHOCK can kill.
• Only qualied personnel should perform
this installation.
• Turn the input power OFF and unplug the
machine from the receptacle before
working on this equipment.
• Insulate yourself from the work and ground.
• Always connect the unit to a power supply grounded
according to the National Electrical Code and local
codes.
All electrical wiring which includes primary, secondary
electrician.
ELECTROCUTION HAZARD.
Disconnect mains before servicing. Failure to do so
could result in serious personal injury or death.
Do not attempt installation of this unit unless you are
familiar with the necessary tools, equipment, utility
connections and potential hazards. Installation should be
do so could result in reduced performance of the unit,
serious personal injury or death.
WARNING
WARNING
PRISM
®CIRCULATOR 4000 ®

A-7
INSTALLATION
Step 5 - Install Filters (See section D for filter
replacement instructions)
Before opening door, unit must be off and the power
switch on the side of the control panel turned to the off
position.
FIGURE A.5
FIGURE A.6
FIGURE A.7
FIGURE A.8
Step 6 - lock door
FIGURE A.9
WARNING
PRISM
®CIRCULATOR 4000 ®
d. Reclasp lter handles.

B-1
OPERATION
OPERATION
Outlet Vanes:
•
layer without obstruction.
•
FIGURE B.1
There are vertical & horizontal vanes in the fan exhaust. This can
different fan speed.
Fan SpeedAirflow
CFM (m³/hr)
Max Throw
Distance
� (m)
Low 2000 (3398) 70 (21.3)
Medium 3000 (5097) 90 (27.4)
High 4000 (6796) 120 (36.6)
PRISM
®CIRCULATOR 4000 ®
the highest concentration of welding fume.
To optimize system performance of the Prism Circulator

B-2
OPERATION
CONTROL
FIGURE B.2
A. Power On (Light)
B. Alarm (Light)
C. Fan Running (Light)
D. Reset Drive Alarm (Switch)
E. Start/Stop fan (Switch)
F. Main Switch - Input Power
G. Air Flow (Switch)
Display System Control Panel
FIGURE B.3
Functions
A. POWER Light (white): indicates the unit has power, is online,
and available for operation. Blinking light indicates that filter
cleaning is in progress.
B. ALARM Light (red): indicates one of two potential issues with
the unit. Blinking light indicates the filter differential pressure
has surged above the maximum DP Alarm set point for two
hours continuously and the filter should be changed. Solid
light indicates that the EC motor drive has faulted.
C. FAN RUNNING Light (green): indicates the unit is operational
and fan is running.
D. RESET DRIVE ALARM Button: When RESET DRIVE ALARM
PUSH BUTTON pressed long for more than 4 seconds, the
system TRIGGERS MANUAL CLEANING .
E. START/STOP FAN Button: 1. When Fan Start PUSH BUTTON
pressed momentary, fan turns ON, except when cleaning is in
progress. 2. When Fan Start PUSH BUTTON pressed long for
more than 4 seconds, the system toggle between Auto mode
and Manual mode. In auto mode the fan turn ON / OFF is
programmed using PLCs weekly timer. In Manual mode the
fan is turned ON /OFF by the operator every time by pressing
this push button.
F. AIR FLOW (Switch): Regulates the fan speed. Fan speed can
be set to Low, Medium and High.
A
BC
E
F
D
PRISM
®CIRCULATOR 4000 ®
G
FIGURE B.1

B-3
OPERATION
SOFTWARE FUNCTIONS
1) Start/Stop Fan feature activated by push button on cabinet
front.
2) Remote Start/Stop Fan feature activated by an external switch
or remote control.
3) Automatic main lter cleaning function triggered in the
following cases:
a) Filter bank ofne/online cleaning active immediately,
cleaning is dependent upon fan differential pressure-- the
pressure the lter creates to air ow-- and your set points.
b) Ofne cleaning when fan is off.
c) Online cleaning when fan is on.
d) Ofne lter pressure cleaning active at three levels of lter
pressure drop (low, medium, high). Each level gradually
increases lter cleaning.
e) Low pressure default value is 400Pa, with a range of
300Pa to 1000Pa. Medium pressure default value is 600Pa,
with a range of 500Pa to 1200Pa. High pressure default
value is 800Pa, with a range of 700Pa to 1400Pa.
f) When the fan is running the lter pressure is monitored.
Once a level is reached, the system will wait for the fan to
shut down before ofne cleaning begins. Aside from
hearing air blasts cycling to each lter, the white light will
ash as a visual indication that the unit is cleaning. The
white light will return to steady once the cleaning cycle is
completed. Each valve starting from the top is pulsed with
compressed air. The default pulse time is 250ms. After the
rst valve is pulsed, the next one is delayed. This delay is
the valve pulse timer at work, and the default delay time is
15 seconds. The delay allows the air accumulators within
the lter bank to charge.
g) When all the lter have been pulsed, the cleaning cycle has
completed. At the low pressure limit the the cleaning cycle
is 2X. At the medium pressure limit the cleaning cycle is 4X.
And at the high pressure limit the cleaning cycle is 6X. Each
level cleans the lter more aggressively but takes longer to
clean when the cycle is off.
h) If the fan is turned on before the cleaning cycle has
completed ofne cleaning will pause. Once the fan is turned
off, lter cleaning will resume at the same sequence it was
stopped at.
i) Online cleaning is activated with the Delta P pressure drop
settings. Default level is 1000Pa with a range of
100Pa-2500Pa. When the fan is running, and the Delta P
level has been reached, the Power On white light will ash
and lter cleaning will start from the top. The same pulse
and pause times from the ofine cleaning are used. Online
cleaning will not stop until the lter pressure falls below the
Delta P level.
j) Once the fan is off, ofne cleaning will be active.
4) The Delta P Alarm default is set at 1500Pa. When the alarm is
active, the red Alarm light will blink on the main control cabinet.
At this time lter should be ordered from Lincoln Electric.
OPERATION
1. FAN RUNNING:
When fan is turned on, PID controller in the PLC will look for Duct
pressure reference and set duct pressure, which can be set to
Low, Medium and High air ow setting using front selector switch.
The default setting of duct pressure based on selection switch
position:
1. High- 585 pa (501 – 1200)
2. Medium- 331 pa (201 – 500)
3. Low- 147 pa (100 – 200)
2. CLEANING:
When lter pressure exceeds the lter limit pressure, then
ONLINE cleaning is initiated. The lter pressure reading will be
taken once the fan speed stabilized to provide set air ow
delivery.
If user presses the RESET DRIVE ALARM PUSH BUTTON for more
than 4 seconds, it initiates MANUAL CLEANING process:
1. Cleaning pulses are generated based on pause time, pulse time
and number cycles.
2. The fan will continue to be ON if online cleaning. It will be
turned OFF if Ofine cleaning.
3. PRE-COATED FILTER:
1. The product has function to inhibit cleaning when new lters
installed with pre-coating till the pre-coat hours crossed.
2. There is an hour counter to count the number of hours the fan
run from the date of lter change.
3. The pre-coat hours can be adjusted using PLC display, default
is 0 hours.
4. DATALOG:
1. The product has function log following data into SD card
mounted on PLC
a) Time stamp
b) Filter pressure
c) Duct pressure
d) % Fan Speed
e) Set point pressure
2. Data log intervals can be adjusted, default set is 30 seconds
(adjustable 10-255 second)
PRISM
®CIRCULATOR 4000 ®

B-4
OPERATION
1. Following screens in PLC will display the system status
a) Home screen
The above is PLC default screen indicating the current IO status. By
custom screens.
panel.
to High.
Medium.
Low.
By pressing P1 key on PLC will navigate to subsequent screens
CLngCycle#- is used to set number of cleaning cycles per one
trigger, it is default set at 2.
Alarm indication will be activated after this set delay. Default delay
is 100 seconds adjustable 0-255 second.
DelayCLn- This variable will provide delay after cleaning is done
set value. Default delay is 100 seconds adjustable 0-255 second.
PrecoatHr- Pre-coat hour, variable set to mute cleaning till the set
PauseTm- It is adjustable time between two solenoid pulses,
default is 20 second, adjustable 10 to 120 second.
PulseS1- Adjustable pulse duration for Solenoid 1, default is set
to 200 millisecond adjustable 100 to 1500 millisecond.
PulseS2- Adjustable pulse duration for Solenoid 2, default is set
to 200 millisecond adjustable 100 to 1500 millisecond.
PulseS3- Adjustable pulse duration for Solenoid 3, default is set
to 200 millisecond adjustable 100 to 1500 millisecond.
PulseS4- Adjustable pulse duration for Solenoid 4, default is set
to 200 millisecond adjustable 100 to 1500 millisecond.
The data logger will save following parameters in SD card at
internals indicated in DLint.
DLint is set at default 60 second and it is adjustable 10 to 255
second.
DIAGNOSTIC MODE:
This will help to set Speed Set to check the fan motor operation,
it is set to 0 to 4096, which is equivalent to 0 to 100% fan speed.
Aout will show the actual speed in %.
Selecting Solenoid check boxes with activate corresponding
solenoids, by which the operation of solenoids can be tested.
PRISM
®CIRCULATOR 4000 ®
AUTO: By checking this check box will make the system to enter
L18518 X.XX indicates the current software version.
improve the lter life. Default is set to 24Hr. Range 0-255Hr.

B-5
OPERATION
FAN RUNNING:
Fan running when alarm active with RED background.
The above screen appears during Fan running to indicate
following:
FanRunningManual: this to indicate fan is running in manual
mode. In auto mode FanRunning Auto will be displayed.
FiltrPr: Filter differential pressure in Pascal, measured across
filter.
DuctPr: Duct pressure in Pascal
FanSpeed: Fan running speed in % of full speed
SetSpeed: Using selector the airflow levels can be set to Low,
Medium and High.
SetFltPr- Set filter pressure, is limit for differential pressure
across filter, if exceed above this set limit will trigger cleaning
cycle
FAN RUNNING:
The above screen appears during Fan running to indicate
following:
FanRunningManual: this to indicate fan is running in manual
mode. In auto mode FanRunning Auto will be displayed.
FiltrPr: Filter differential pressure in Pascal, measured across
filter.
DuctPr: Duct pressure in Pascal.
FanSpeed: Fan running speed in % of full speed.
SetSpeed: Using selector the airflow levels can be set to Low,
Medium and High.
SetFltPr- Set filter pressure, is limit for differential pressure
across filter, if exceed above this set limit will trigger cleaning
cycle.
Alarm:
Fan running when alarm active with RED background.
Online cleaning
PulseTm: Indicates solenoid on time.
Pause Tm: Time delay between two cleaning pulses.
CleanCy#: Number of cleaning cycles
Pulse#: elapsed number of pulse and total number of cycles.
PRISM
®CIRCULATOR 4000 ®