Lincoln Electric COOLARC-25 User manual

IM3013
09/2007
Rev. 3
COOLARC-25
OPERATOR’S MANUAL
MANUALE OPERATIVO
BEDIENUNGSANLEITUNG
MANUAL DE INSTRUCCIONES
MANUEL D'UTILISATION
BRUKSANVISNING OG DELELISTE
GEBRUIKSAANWIJZING
BRUKSANVISNING
INSTRUKCJA OBSŁUGI
KÄYTTÖOHJE
LINCOLN ELECTRIC BESTER S.A.
ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland
www.lincolnelectric.eu

II
Declaration of conformity
Dichiarazione di conformità
Konformitätserklärung
Declaración de conformidad
Déclaration de conformité
Samsvars erklæring
Verklaring van overeenstemming
Försäkran om överensstämmelse
Deklaracja zgodności
Vakuutus yhteensopivuudesta
LINCOLN ELECTRIC BESTER S.A.
Declares that the welding machine:
Dichiara che Il generatore per saldatura tipo:
Erklärt, daß die Bauart der Maschine:
Declara que el equipo de soldadura:
Déclare que le poste de soudage:
Bekrefter at denne sveisemaskin:
Verklaart dat de volgende lasmachine:
Försäkrar att svetsomriktaren:
Deklaruje, że spawalnicze źródło energii:
Vakuuttaa, että hitsauskone:
COOLARC-25
conforms to the following directives:
è conforme alle seguenti direttive:
den folgenden Bestimmungen entspricht:
es conforme con las siguientes directivas:
est conforme aux directives suivantes:
er i samsvar med følgende direktiver:
overeenkomt conform de volgende richtlijnen:
överensstämmer med följande direktiv:
spełnia następujące wytyczne:
täyttää seuraavat direktiivit:
73/23/CEE, 89/336/CEE
and has been designed in compliance with the following
standards:
ed è stato progettato in conformità alle seguenti norme:
und in Übereinstimmung mit den nachstehenden normen
hergestellt wurde:
y ha sido diseñado de acuerdo con las siguientes
normas:
et qu'il a été conçu en conformité avec les normes:
og er produsert og testet iht. følgende standarder:
en is ontworpen conform de volgende normen:
och att den konstruerats i överensstämmelse med
följande standarder:
i że zostało zaprojektowane zgodnie z wymaganiami
następujących norm:
ja on suunniteltu seuraavien standardien mukaan:
EN 60974-2, EN 60974-1, EN 60974-10
(2007)
PawełLipiński
Operations Director
LINCOLN ELECTRIC BESTER S.A., ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland
12/05

III
07/06
English
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE) and its
implementation in accordance with national law, electrical equipment that has reached the end of its life must be
collected separately and returned to an environmentally compatible recycling facility. As the owner of the
equipment, you should get information on approved collection systems from our local representative.
By applying this European Directive you will protect the environment and human health!
Italiano
Non gettare le apparecchiature elettriche tra i rifiuti domestici!
In ottemperanza alla Direttiva Europea 2002/96/CE sui Rifiuti di Apparechiature Elettriche ed Elettroniche (RAEE)
e la sua attuazione in conformità alle norme nazionali, le apparecchiature elettriche esauste devono essere
raccolte separatamente e restituite ad una organizzazione di riciclaggio ecocompatibile. Come proprietario
dell’apparecchiatura, Lei potrà ricevere informazioni circa il sistema approvato di raccolta, dal nostro
rappresentante locale.
Applicando questa Direttiva Europea Lei contribuirà a migliorare l’ambiente e la salute!
Deutsch
Werfen Sie Elektrowerkzeuge nicht in den Hausmüll!
Gemäss Europäischer Richtlinie 2002/96/EG über Elektro- und Elektronik- Altgeräte (Waste Electrical and
Electronic Equipment, WEEE) und Umsetzung in nationales Recht müssen verbrauchte Elektrowerkzeuge
getrennt gesammelt und einer umweltgerechten Wiederverwertung zugeführt werden. Als Eigentümer diese
Werkzeuges sollten sie sich Informationen über ein lokales autorisiertes Sammel- bzw. Entsorgungssystem
einholen.
Mit der Anwendung dieser EU Direktive tragen sie wesentlich zur Schonung der Umwelt und ihrer Gesundheit bei!
Español
No tirar nunca los aparatos eléctricos junto con los residuos en general!.
De conformidad a la Directiva Europea 2002/96/EC relativa a los Residuos de Equipos Eléctricos o Electrónicos
(RAEE) y al acuerdo de la legislación nacional, los equipos eléctricos deberán ser recogidos y reciclados
respetando el medioambiente. Como propietario del equipo, deberá informar de los sistemas y lugares
apropiados para la recogida de los mismos.
Aplicar esta Directiva Europea protegerá el medioambiente y su salud!
Français
Ne pas jeter les appareils électriques avec les déchets ordinaires!
Conformément à la Directive Européenne 2002/96/EC relative aux Déchets d' Équipements Électriques ou
Électroniques (DEEE), et à sa transposition dans la législation nationale, les appareils électriques doivent être
collectés à part et être soumis à un recyclage respectueux de l’environnement. En tant que propriétaire de
l’équipement, vous devriez vous informer sur les systèmes de collecte approuvés auprès nos représentants
locaux.
Appliquer cette Directive Européenne améliorera l’environnement et la santé!
Norsk
Kast ikke elektriske artikler sammen med vanlig søppel.
I følge det europeiske direktivet for Elektronisk Søppel og Elektriske Artikler 2002/96/EC (Waste Electrical and
Electronic Equipment, WEEE) skal alt avfall kildesorteres og leveres på godkjente plasser i følge loven.
Godkjente retur plasser gis av lokale myndigheter.
Ved å følge det europeiske direktivet bidrar du til å bevare naturen og den menskelige helse.
Nederlandse
Gooi elektrische apparatuur nooit bij gewoon afval!
Met inachtneming van de Europese Richtlijn 2002/96/EC met betrekking tot Afval van Elektrische en
Elektronische Apparatuur (Waste Electrical and Electronic Equipment, WEEE) en de uitvoering daarvan in
overeenstemming met nationaal recht, moet elektrische apparatuur, waarvan de levensduur ten einde loopt, apart
worden verzameld en worden ingeleverd bij een recycling bedrijf, dat overeenkomstig de milieuwetgeving
opereert. Als eigenaar van de apparatuur moet u informatie inwinnen over goedgekeurde verzamelsystemen van
onze vertegenwoordiger ter plaatse.
Door het toepassen van deze Europese Richtlijn beschermt u het milieu en ieders gezondheid!
Svenska
Släng inte uttjänt elektrisk utrustning tillsammans med annat avfall!
Enligt Europadirektiv 2002/96/EC ang. Uttjänt Elektrisk och Elektronisk Utrustning (Waste Electrical and
Electronic Equipment, WEEE) och dess implementering enligt nationella lagar, ska elektrisk utrustning som tjänat
ut sorteras separat och lämnas till en miljögodkänd återvinningsstation. Som ägare till utrustningen, bör du skaffa
information om godkända återvinningssystem från dina lokala myndigheter.
Genom att följa detta Europadirektiv bidrar du till att skydda miljö och hälsa!
Polski
Nie wyrzucaćosprzętu elektrycznego razem z normalnymi odpadami!
Zgodnie z DyrektywąEuropejską2002/96/EC dotyczącąPozbywania sięzużytego Sprzętu Elektrycznego i
Elektronicznego (Waste Electrical and Electronic Equipment, WEEE) i jej wprowadzeniem w życie zgodnie z
międzynarodowym prawem, zużyty sprzęt elektryczny musi byćskładowany oddzielnie i specjalnie utylizowany.
Jako właściciel urządzeńpowinieneśotrzymaćinformacje o zatwierdzonym systemie składowania od naszego
lokalnego przedstawiciela.
Stosując te wytyczne bedziesz chroniłśrodowisko i zdrowie człowieka!
Suomi
Älä hävitä sähkölaitteita sekajätteiden mukana!
Noudatettaessa Euroopan Unionin Direktiiviä 2002/96/EY Sähkölaite- ja Elektroniikkajätteestä ( WEEE ) ja
toteutettaessa sitä sopusoinnussa kansallisen lain kanssa, sähkölaite, joka on tullut elinkaarensa päähän pitää
kerätä erilleen ja toimittaa sähkö- ja elektroniikkaromujen keräyspisteeseen. Lisätietoja tämän tuotteen
käsittelystä, keräämisestä ja kierrätyksestä saa kunnan ympäristöviranomaisilta.
Noudattamalla tätä Euroopan Unionin direktiiviä, autat torjumaan kielteiset ynpäristö- ja terveysvaikutukset!

IV
12/05
THANKS! For having choosen the QUALITY of the Lincoln Electric products.
•Please Examine Package and Equipment for 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.
GRAZIE! Per aver scelto la QUALITÀ dei prodotti Lincoln Electric.
•Esamini Imballo ed Equipaggiamento per rilevare eventuali danneggiamenti. Le richieste per materiali danneggiati dal
trasporto devono essere immediatamente notificate al rivenditore.
•Per ogni futuro riferimento, compilare la tabella sottostante con le informazioni di identificazione equipaggiamento.
Modello, Codice (Code) e Matricola (Serial Number) sono reperibili sulla targa dati della macchina.
VIELEN DANK! Dass Sie sich für ein QUALITÄTSPRODUKT von Lincoln Electric entschieden haben.
•Bitte überprüfen Sie die Verpackung und den Inhalt auf Beschädigungen. Transportschäden müssen sofort dem Händler
gemeldet werden.
•Damit Sie Ihre Gerätedaten im Bedarfsfall schnell zur Hand haben, tragen Sie diese in die untenstehende Tabelle ein.
Typenbezeichnung, Code- und Seriennummer finden Sie auf dem Typenschild Ihres Gerätes.
GRACIAS! Por haber escogido los productos de CALIDAD Lincoln Electric.
•Por favor, examine que el embalaje y el equipo no tengan daños. La reclamación del material dañado en el transporte
debe ser notificada inmediatamente al proveedor.
•Para un futuro, a continuación encontrará la información que identifica a su equipo. Modelo, Code y Número de Serie los
cuales pueden ser localizados en la placa de características de su equipo.
MERCI! Pour avoir choisi la QUALITÉ Lincoln Electric.
•Vérifiez que ni l’équipement ni son emballage ne sont endommagés. Toute réclamation pour matériel endommagé doit
être immédiatement notifiée à votre revendeur.
•Notez ci-dessous toutes les informations nécessaires à l’identification de votre équipement. Le nom du Modèle ainsi que
les numéros de Code et Série figurent sur la plaque signalétique de la machine.
TAKK! For at du har valgt et KVALITETSPRODUKT fra Lincoln Electric.
•Kontroller emballsjen og produktet for feil eller skader. Eventuelle feil eller transportskader må umiddelbart rapporteres
dit du har kjøpt din maskin.
•For fremtidig referanse og for garantier og service, fyll ut den tekniske informasjonen nedenfor i dette avsnittet. Modell
navn, Kode & Serie nummer finner du på den tekniske platen på maskinen.
BEDANKT! Dat u gekozen heeft voor de KWALITEITSPRODUCTEN van Lincoln Electric.
•Controleert u de verpakking en apparatuur op beschadiging. Claims over transportschade moeten direct aan de dealer of
aan Lincoln electric gemeld worden.
•Voor referentie in de toekomst is het verstandig hieronder u machinegegevens over te nemen. Model Naam, Code &
Serienummer staan op het typeplaatje van de machine.
TACK! För att ni har valt en KVALITETSPRODUKT från Lincoln Electric.
•Vänligen kontrollera förpackning och utrustning m.a.p. skador. Transportskador måste omedelbart anmälas till
återförsäljaren eller transportören.
•Notera informationen om er utrustnings identitet i tabellen nedan. Modellbeteckning, code- och serienummer hittar ni på
maskinens märkplåt.
DZIĘKUJEMY! Za docenienie JASKOŚCI produktów Lincoln Electric.
•Proszęsprawdzićczy opakownie i sprzęt nie sąuszkodzone. Reklamacje uszkodzeńpowstałych podczas transportu
musząbyćnatychmiast zgłoszone do dostawcy (dystrybutora).
•Dla ułatwienia prosimy o zapisanie na tej stronie danych identyfikacyjnych wyrobów. Nazwa modelu, Kod i Numer
Seryjny, które możecie Państwo znaleźć na tabliczce znamionowej wyrobu.
KIITOS! Kiitos, että olet valinnut Lincoln Electric LAATU tuotteita.
•Tarkista pakkaus ja tuotteet vaurioiden varalta. Vaateet mahdollisista kuljetusvaurioista on ilmoitettava välittömästi
jälleenmyyjälle.
•Tulevaisuutta varten täytä alla oleva lomake laitteen tunnistusta varten. Mallin, Koodin ja Sarjanumeron voit löytää
konekilvestä.
Model Name, Modello, Typenbezeichnung, Modelo, Nom du modèle, Modell navn, Model Naam, Modellbeteckning, Nazwa
modelu, Mallinimi:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number, Code (codice) e Matricola, Code- und Seriennummer, Code y Número de Serie, Numéros de Code et
Série, Kode & Serie nummer, Code en Serienummer, Code- och Serienummer, Kod i numer Seryjny, Koodi ja Sarjanumero:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased, Data e Luogo d’acquisto, Kaufdatum und Händler, Fecha y Nombre del Proveedor, Lieu et Date
d’acquisition, Kjøps dato og Sted, Datum en Plaats eerste aankoop, Inköpsdatum och Inköpsställe, Data i Miejsce zakupu,
Päiväys ja Ostopaikka:
…………………………………………………………………... ……………………….…………………………………………..

A
-1
Safety
11/04
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.
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.
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.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.

A
-2
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.
Installation and Operator Instructions
Read this entire section before installation or operation
of the machine.
Product Description
COOLARC-25 cooler is a stand alone recirculating
cooling system designed for use with water cooled TIG,
MIG, PAC (Plasma Arc Cutting) and PAW (Plasma Arc
Welding). Additional applications include resistance
welding, water cooled inductive heating.
The fittings located on the back of the COOLARC-25 are
two a female left-hand threaded quick water fittings.
(type 21KATS09MPX). Quick Connect Water Adapter
converting quick water fitting to a male 5/8"-18 left hand
hose fitting is supplied with each COOLARC-25. The
cooler is also equipped with a bracket so it can be
mounted at the rear of a Lincoln power source, to the
dual cylinder undercarriage.
COOLARC-25 cooler is designed for use with all water-
cooled TIG and medium duty MIG torches and guns.
The COOLARC-25 coolers bring new technology in the
areas of pump, heat exchanger and reservoir designs to
the water cooler market. These technologies allow the
COOLARC-25 coolers to be lighter in weight, lower in
energy consumption.
Warranty
Warranty for this product is 3 year after the date of
purchase. For any warranty claim, contact a certified
Lincoln service center.
Installation
FIGURE 1
Coolant INLET and OUTLET fittings are placed at the
rear of the unit (A). The right side fitting is marked
"coolant out" (supplies coolant to the welding
equipment); the left side one is marked "coolant in"
(takes warm coolant from the welding equipment).
The FILL CAP of the coolant reservoir is on the top of
the unit (B). Fill Cap can be removed by twisting it off.
The coolant FLOW INDICATOR is accessed by removal
of the reservoir fill cap. Actual return flow is directly
visible by the fill opening (C) with the unite in the vertical
position.
Coolant volume can be monitored through sight window
on the front panel (D). The maximum coolant level is
indicated by the upper marker, the minimum level by the
lower one.
Air flow louvers (E): Design of he front case allows for
ease access to internal parts at repairing. Air flow
louvers secure adequate air circulation. The louvers on
the front of the case allow to suck in cold air from bottom
of the unit. Hot air is removed by the side and rear
louvers.
Filling The Reservoir
Proper Coolant Addition
Acorox is recommended coolant for COOLARC-25.
For use above freezing: Tap, distilled, deionized, mineral
water. For use below freezing: water and pure ethylene
glycol mixture (10% glycol between at 0°C and 30% at -
15°C).
WARNING
DO NOT USE PREPACKAGED WELDING INDUSTRY
COOLANTS. These coolants may contain oil-based
substances which attack the plastic components in the
pump of the COOLARC-25 cooler and severely reduce
pump life. Once added to the cooler, the substances are
virtually impossible to purge from the water lines and
heat exchanger.
To avoid freeze damage and water leakage in shipment,
every COOLARC-25 unit is delivered empty with no
coolant in the system. To fill the unit, locate the plastic
reservoir fill cap at the front middle of the unit.
NOTE: The unit can be filled only vertically.
WARNING
UNPLUG THE COOLER BEFORE FILLING THE
RESERVOIR.
Filling:
Tilt the unit backward and pour 8,5 liters of coolant into
the reservoir fill hole through a funnel.
or
If 2,5 liter antifreeze fill bottle or fill bottle is available, tilt
the unit forward until the bottle mates with the reservoir

A
-3
fill hole. Then tilt the unit backward until the fill bottle is
emptied.
WARNING
AVOID SPILLING COOLANT INTO THE FRONT
CASING OF THE UNIT.
Unit will be full when coolant lies just below the reservoir
opening with the unit in its upright position.
NOTE: DO NOT ADD MORE THAN 8.5 LITERS OF
COOLANT INTO THE RESERVOIR.
The fill cap contains a pressure release air hole which
must not be blocked by overfilling the reservoir with
coolant.
Be certain to replace the reservoir fill cap when the
reservoir is full. Operation of the COOLARC-25 cooler
without the fill cap in place can cause poor cooling
efficiency, evaporation loss of coolant, and low product
life.
Water Hoses Connection
A FROM HEAT SOURCE (RED)
B TO HEAT SOURCE (BLUE)
FIGURE 2:
Water Hoses Connection Diagram
Water hoses connection is made with quick water fittings
(type 21KATS09MPX). In case of hoses with 5/8"-18 left
hand nut, you have to use Quick Connect Water
Adapter, which is delivered with the unit. In this case,
firstly you should connect the adapters to the water
hoses and then connect them to the quick water fittings
of the cooler.
In case of disconnection water hoses from the cooler,
firstly you should disconnect quick water fittings, which
are equipped with the automatic outflow blockade.
If you firstly unplug the connection quick water fitting -
5/8"/18 nut, it can cause coolant outflow from the cooler
reservoir.
Before water hoses installing to the cooler, you should
check if the tread of the connector water hose nut
matches the quick water connectors placed in the
connector block on the back of the unit.
All Lincoln products have water hoses which are
equipped with 5/8"-18 left hand nuts so hose connectors
must be matched the quick water fittings on the back of
the cooler, in the following way:
•Take the two quick connect water adapters (5/8-18
left hand hose fitting to quick water fitting) supplied
with the cooler and thread hoses nuts into the
adapters. Secure the connector nuts of the hoses
tightly with a wrench so that leaking does not occur.
Then take the INLET hose (colored or tagged blue
on most hoses) and attach it into the coolant OUT
line located on the right side of the connector block
at the back of the cooler. Then take the OUTLET
hose (colored or tagged red on most hoses) and
attach it into the coolant IN line located on the left
side of the connector block.
For products having water hoses equipped with quick
water fittings which mate with fittings on the connector
block at the back of the cooler, you should:
•Save the two quick water adapters for future use.
Take INLET hose (colored or tagged blue on most
hoses) and attach it into the coolant OUT line
located on the right side of the connector block at
the back of the cooler. Then take the OUTLET hose
(colored or tagged red on most hoses) and attach it
into the coolant IN line located on the left side of the
connector block.
WARNING
BE CERTAIN THAT NO LEAKS EXIST WHEN COOLER
IS TURNED ON. A LEAK WILL DEPLETE RESERVOIR
VOLUME, CAUSE POOR OR COOLING
PERFORMANCE AND REDUCE GUN, TORCH OR
PUMP LIFE.
NOTE: Be certain that only 5/8"-18 left hand male nuts
with clean and smooth threads are used on your water
hoses. Wrong nuts and bad connections can cause
coolant leaking, cooling system efficiency reducing and
at last the cooler damaging.
Mounting
FIGURE 3a:
Bracket Mounting Depending on the Power Source
Height

A
-4
FIGURE 3b:
COOLARC-25 Mounting to the Power Source
Diagram
1. Main Mounting Bracket
2. Water Hoses Bracket
3. Blackened Screw B6P 4,8x13
4. Bolt M6x16 S6K
5. Plain Washer M6 P/M-82005
Before mounting COOLARC-25 to the power source
firstly you must mount the water hoses bracket. Use
blackened screw B6P 4,8x13 and thread the water
hoses bracket to the power source case, paying
attention to the bracket stamp which must be fit into the
hole bellow the hole for the blackened screw. After
mounting you should hang the water hoses on it. It
allows to arrange water hoses without squeezing or
sharp bends.
Vertical Installation COOLARC-25 on a Power
Source with a Cylinder Undercarriage
For the COOLARC-25 vertically mounted on a power
source with a cylinder undercarriage, you should use the
main mounting bracket. For proper installation, you
should see Figure 3a and Figure 3b. Using provided
blackened screws and proper holes in the cooler case,
fasten the bracket to the cooler back. Then place the
cooler on the undercarriage on its left side. Align the
holes of the cooler bracket with the holes on the rivet nut
in the back of the power source. Using provided bolt
M6x16 S6K and plain washer M6 PN/M-82005 fasten
the cooler bracket to the power source back. After
installation you should check if the connection is firm.
1. Gas In/Out
2. to Work
3. Gas
4. Power Cable Adapter
5. Hot Coolant from the Torch
6. Coolant
7. Coolant Out
8. Coolant In
9. Argon Gas Cylinder
10. Regulator Flowmeter
11. TIG Torch
FIGURE 4:
Water Cooled TIG Torch Connection
87
6
6
12
6. COOLANT
7. COOLANT OUT
8. COOLANT IN
12. GUN CABLE
FIGURE 5
Water cooled MIG gun connection
87
6
6
13
14
15
6. COOLANT
7. COOLANT OUT
8. COOLANT IN
13. AIR
14. PLASMA, CUTTING, POWER SOURCE
15. ELECTRODE CABLE & AIR
FIGURE 6
Water cooled Plasma system connection
The following should always be observed when
operating the COOLARC-25:
•Never operate the cooler with case off.
•Immersion in water around electrical lines can
cause electrical shock.
•Never place fingers into openings of cooler. Moving
parts can injure.
•Unplug the cooler before filling the reservoir.
•Never operate the cooler with the reservoir fill cap
off.
•Never operate the cooler with the reservoir empty.
Operating Precautions
The following should always be observed when
operating any COOLARC-25 cooler:
•Check the reservoir daily.
•Keep the reservoir full especially after changing any
water lines.

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•Never operate the cooler with the reservoir fill cap
removed.
•Avoid placing the cooler near areas of extreme heat.
•Avoid placing the cooler near a flux hopper or an
area where dust build-up is extreme.
•Avoid kinking or putting sharp bends in any water
lines.
•Keep all water lines clean.
Turning The System ON
After filling the reservoir and connecting the coolant
hoses to the COOLARC-25 cooler per the Installation
Sections, plug the unit into an electrical receptacle for
start-up operation. Be certain that the power input into
the unit matches the cooler’s rated input. COOLARC-25
cooler cordsets contains a 90 angled CEE 7/4, 7/7
Schuko compatible plug. The plug mates with an
auxiliary receptacle located at the back of many
international Lincoln power sources for power supply to
a COOLARC-25 cooler.
You will be able to hear the fan running and feel air flow
out of the back of the unit when the cooler is operating.
When first starting the unit, check all of the water lines to
insure that no water leaks are present. Water leakage
causes poor welding performance, poor cooling
performance, low welding component and pump life and
potential electrical safety hazards.
Cooling Efficiency
1. COOLANT RETURN
2. COOLANT IN TAKE
3. PUMP
4. FAN
5. HEAT EXCHANGER
6. HEATED AIR OUT
7. COOLANT OUT
8. COOLANT IN
9. RESERVOIR
FIGURE 7
Circulation of COOLARC-25.
The high cooling efficiency COOLARC-25 offers a
cooler, more comfortable weld than conventional air-
cooled procedures as well as leading competitors water
cooled systems. The corrugated radiator of the heat
exchanger improves heat convection with minimal air
flow restriction. This design ensures a durable
construction which is able to withstand impact of
different objects through air slots. Figure 7 shows work
principles of the COOLARC-25.
The COOLARC-25 cooler effectively removes the heat
of the arc away from the gun or torch handle and places
it into the exiting air flow at the back of the cooler.
Ambient air temperature can affect the cooling
parameters of the COOLARC-25.
For example:
•COOL day (50°F, 10°C): More HEAT is transferred
from the water in the heat exchanger to the air. The
water is COOLER and more HEAT is transferred
from the gun or torch to the water.
RESULT: THE GUN OR TORCH FEELS COOLER
•HOT day (100°F, 38°C): Less HEAT is transferred
from the water in the heat exchanger to the air. The
water is HOTTER and less HEAT is transferred from
the gun or torch to the water.
RESULT: THE GUN OR TORCH FEELS HOTTER.
Unlike other water coolers that depend on bulky
reservoir size, the high efficiency components of
COOLARC-25 cooler allows the reservoir size to be
small. The result is a lightweight, portable unit.
Cooling Efficiency - Recommended Values
COOLARC-25 ref: K14037
Max welding current TIG 100% duty cycle 350A
Max welding current MIG 100% duty cycle 350A
Maintenance
WARNING
For any maintenance or repair operations it is
recommended to contact the nearest Technical Service
Center or Lincoln Electric. Maintenance or repairs
performed by unauthorized service centers or personnel
will null and void the manufacturer's warranty.
Heat Exchanger Maintenance
To maintain maximum efficiency, the heat exchanger
should be kept clean from dust and dirt buildup. Clean
the heat exchanger periodically using a vacuum hose or
low pressure air line. Avoid placing the unit near a flux
hopper or a flux waste container. A clean heat
exchanger offers better cooling performance and longer
product life. If extremely dirty conditions exist, it may be
necessary to remove the heat exchanger completely
from the cooler for a thorough soap and water cleaning
of the cooling fins. Use care to avoid damaging the fins.
Reservoir Maintenance
The reservoir volume should be checked daily before
using the cooler. You can do it by observation the level
of the coolant in the sight window on the front panel..
The unit is full when the coolant level reaches upper
marker. Keep the reservoir full especially after changing
the water lines. The cooler should always be operated
with the reservoir fill cap on. In areas where dust can be
introduced into the reservoir through water lines or
reservoir fill cap removal, periodically flush the unit out.
Dump the old coolant and rinse the inside of the
reservoir. Add new coolant when finished. A reservoir
free from particle buildup and dirt offers better cooling
efficiency and longer pump, gun and torch life.

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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
your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
Cooler does not operate
with power switch on
(Switch pushed to "1"
position).
•Power cord unplugged.
•No power at outlet.
•Power cordset damaged.
•Water lines blocked or crimped.
•Leak in gun or water hoses.
•Reservoir empty.
•Power switch faulty.
•Plug in power cord.
•Check outlet circuit breaker.
•Repair damaged cord or order new cordset.
•Clear blockage in hose. Avoid kinking or
putting sharp bends in water lines.
•Repair leak.
•Fill reservoir.
•Replace power switch.
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.
•Loose connector fitting.
•Hose clamp loose.
•Tighten connector nut. (5/8-18 left hand
thread).
•Tighten hose clamp onto hose.
Torch or gun runs hot. •Unit placed by area of extreme heat.
•Low coolant flow.
•No coolant flow.
•Fan not operating.
•Move unit away from hot air.
•See Low Coolant FlowSection.
•See No Coolant Flow Section.
•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
nocoolant flow.
•Pump failure.
•Pump seized.
•Replace pump.
•Replace pump.
Pump operates, but fan
does not.
•Fan blade contacting heat exchanger.
•Fan motor failure
•If fan blades are plastic, replace. Reset fan
clearance and secure fan to motor shaft.
•Replace fan motor with Fan Motor and Mount
Assembly.
Cooler trips outlet circuit
breaker.
•Circuit overloaded.
•Cooler electrical component failure.
•Check outlet circuit breaker.
•Replace suppressor assembly and rectifier
bridge inside of cooler.
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.
This machine has been designed to operate in an industrial area. To operate in a domestic area it is
necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The
operator must install and operate this equipment as described in this manual. If any electromagnetic
disturbances are detected the operator must put in place corrective actions to eliminate these disturbances
with, if necessary, assistance from Lincoln Electric.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
•Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the
machine.
•Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
•Safety and control equipment for industrial processes. Equipment for calibration and measurement.
•Personal medical devices like pacemakers and hearing aids.
•Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure
that all equipment in the area is compatible. This may require additional protection measures.
•The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.
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.

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•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.
Technical Specifications
INPUT
Input Voltage
230 ±10%
single phase
Rated current
0,95A
Frequency
50 Hz
RATED OUTPUT AT 40°C
Flow range
MIG
TIG
Open flow
0,5 to 3,3 l/min
with torch 4,5m: 1,7 ÷1,8 l/min
with torch 3,8m: 1,3 ÷1,4 l/min
3,3 l/min
Reservoir size 8,5 l
Coolant requirement:
Do not use prepackaged welding industry coolants. These
coolants may contain oil-based substances which attack
the plastic components in the pump.
Recommended coolant for COOLARC-25: Acorox
Water or water and pure ethylene glycol mixture can be
used interchangeably.
The glycol % must not exceed 30%.
PHYSICAL DIMENSIONS
Height
748 mm
Width
238 mm
Length
248 mm
Weight
17 Kg
Operating Temperature
–10°C to +40°C
Storage Temperature
-25°C to +55°C