Lincoln Electric COOLARC-50C User manual

IM3038
02/2011
Rev. 00
COOLARC-50C
OPERATOR’S MANUAL
LINCOLN ELECTRIC BESTER Sp z o.o.
ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland
www.lincolnelectriceurope.com

II
Declaration of conformity
Deklaracja zgodnoĞci
LINCOLN ELECTRIC BESTER Sp z o.o.
Declares that the welding cooler:
Deklaruje, Īe spawalnicze Ĩródło energii:
COOLARC-50C
conforms to the following directives:
spełnia nastĊpujące wytyczne:
73/23/CEE, 89/336/CEE
and has been designed in compliance with the following standards:
i Īe zostało zaprojektowane zgodnie z wymaganiami nastĊpujących norm:
EN 60974-2, EN 60974-1, EN 60974-10
(2011)
Paweł LipiĔski
Operational Director
LINCOLN ELECTRIC BESTER Sp z o.o., ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

III
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!
12/05
THANKS! For having chosen 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.
Model Name:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased:
…………………………………………………………………... ……………………….…………………………………………..
ENGLISH INDEX
Safety...................................................................................................................................................................................................1
Installation and Operator Instructions ...................................................................................................................................................2
Electromagnetic Compatibility (EMC) ...................................................................................................................................................5
Technical Specifications .......................................................................................................................................................................6
SKOROWIDZ POLSKI
BezpieczeĔstwo UĪytkowania...............................................................................................................................................................7
Instrukcja Instalacji i Eksploatacji..........................................................................................................................................................8
KompatybilnoĞü Elektromagnetyczna (EMC) ......................................................................................................................................11
Dane Techniczne ...............................................................................................................................................................................12

1
Safety
04/07
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.

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-50C is the cooler for semi automatic welding
with water cooled TIG, MIG.
COOLARC-50C cooler is designed for use with all water-
cooled gun’s up to 500A, TIG and MIG torches and
guns.
The COOLARC-50C coolers bring new technology in the
areas of pump, heat exchanger and reservoir designs to
the water cooler market. These technologies allow the
COOLARC-50C 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 (A) type
21KATS09MPX are placed at the front of the unit. The
blue fitting is marked (supplies coolant to the welding
equipment); the red ones is marked (takes warm
coolant from the welding equipment).
The FILL CAP of the coolant reservoir is on front of 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).
Coolant volume can be monitored through translucent
reservoir in the front (D). The minimum coolant level is
indicated by the line “MINIMUM LIQUID LEVEL” on
label.
Air flow louvers (E): Air flow louvers secure adequate air
circulation. The side louvers allows to suck in cold air
from bottom of the unit. Hot air is removed by the rear
louvers.
Power Switch and Power Indicator (F): After input power
is connected and the power switch is turned on, the
indicator will light up to indicate the machine is running.
Filling The Reservoir
Proper Coolant Addition
Acorox is recommended coolant for COOLARC-50C.
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-50C 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-50C unit is delivered empty with no
coolant in the system. To fill the unit, locate the plastic
reservoir fill cap (B).
NOTE: The unit can be filled only horizontal.
WARNING
UNPLUG THE COOLER BEFORE FILLING THE
RESERVOIR.
Filling:
Pour 6 liters at last of coolant into the reservoir.
WARNING
AVOID SPILLING COOLANT INTO THE FRONT
CASING OF THE UNIT.
NOTE: DO NOT ADD MORE THAN 9 LITERS OF
COOLANT INTO THE RESERVOIR.

3
WARNING
AT FIRST STARTING OF THE COOLARC-50C
RESERVOIR FILL CUP MUST BE REMOVED FOR A
MOMENT TO AVOID GENERATE PARTIAL VACUUM
IN COOLING SYSTEM DURRING FILLING (THE
PUMP MUST BE FLOODING)
WARNING
IN ORDER TO EASY PUMP FLOODING DURING
FIRST START THE BYPASS (SHORT WATER HOSE)
CAN BE USED BY CONNECTING IT TO QUICK-
CONNECTORS INSTEAD OF THE TORCH.
The fill cap contains a pressure release air hole.
Be certain to replace the reservoir fill cap when the
reservoir is full. Operation of the COOLARC-50C cooler
without the fill cap in place can cause poor cooling
efficiency, evaporation loss of coolant, and low product
life.
Water Hoses Connection
FIGURE 2:
Water Hoses Connection Diagram
A TO HEAT SOURCE (BLUE)
B FROM HEAT SOURCE (RED)
Water hoses connection is made with quick water fittings
(type 21KATS09MPX) which are equipped with the
automatic outflow blockade.
Before water hoses installing to the cooler, you should
check if the water hose connectors matches to the quick
water connectors placed in the connector block on the
front of the unit. You should:
•Take INLET hose (colored or tagged blue on most
hoses) and attach it into the coolant OUT line
marked . Then take the OUTLET hose (colored
or tagged red on most hoses) and attach it into the
coolant IN line marked .
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.
The following should always be observed when
operating the COOLARC-50C:
•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-50C cooler:
•Check the reservoir daily.
•Keep the reservoir full especially after changing any
water lines.
•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-50C cooler per the Installation
Sections, be certain that the power input into the unit
matches the cooler’s rated input. Plug the unit into an
electrical socket for start-up operation.
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.

4
Cooling Efficiency
FIGURE 3
Circulation of COOLARC-50C.
1. COOLANT RETURN
2. COOLANT IN TAKE
3. PUMP
4. FAN
5. HEAT EXCHANGER
6. HEATED AIR OUT
7. COOLANT IN
8. COOLANT OUT
9. RESERVOIR
The high cooling efficiency COOLARC-50C offers a
cooler, more comfortable weld than conventional air-
cooled procedures as well as leading competitors water
cooled systems. Radiator improves heat convection with
minimal air flow restriction.
The COOLARC-50C cooler effectively removes the heat
of the arc away from the 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-50C.
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 torch to the water.
RESULT: THE 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 torch to the water.
RESULT: THE TORCH FEELS HOTTER.
Unlike other water coolers that depend on bulky
reservoir size, the high efficiency components of
COOLARC-50C cooler allows the reservoir size to be
small. The result is a lightweight, portable unit.
Cooling Efficiency - Recommended Values
COOLARC-50C ref: K14050-2
Max welding current TIG 100% duty cycle 500A
Max welding current MIG 100% duty cycle 500A
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 front panel. The unit is full when the
coolant level reaches upper part of reservoir. 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.

5
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.
•
Blown fuses.
•Cord unplugged.
•No power at outlet.
•Cord damaged.
•Water lines blocked or crimped.
•Leak in gun or water hoses.
•Reservoir empty.
•
Replace fuses.
•Plug in cord.
•Check outlet circuit breaker.
•Repair damaged cord or order new cord.
•Clear blockage in hose. Avoid kinking or
putting sharp bends in water lines.
•Repair leak.
•Fill reservoir.
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 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 Flow Section.
•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
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.
•Replace component 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.
•The output cables should be kept as short as possible and should be positioned together. If possible connect the

6
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 V ±10%
single phase
Rated current
1,2A
Frequency
50/60 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 9,2 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
-
50C
: Acorox
Water or water and pure ethylene glycol mixture can be
used interchangeably.
The glycol % must not exceed 30%.
PHYSICAL
DIMENSIONS
Height
265 mm
Width
355 mm
Length
680 mm
Weight
20 Kg
Operating Temperature
–10°C (14°F) to +40°C (104°F)
Storage Temperature
-25°C (-13°F) to +55°C (131°F)