Lincoln Electric FlexCool 35 User manual

O erator’s Manual
FlexCool™35
Register your machine:
www.lin olnele tri . om/register
Authorized Service and Distributor Locator:
www.lin olnele tri . om/lo ator
IM10423 | Issue D ate Apr-18
© Lin oln Global, In . All Rights Reserved.
For use with ma hines having Code Numbers:
12748
Save for future reference
Date Pur hased
Code: (ex: 10859)
Serial: (ex: U1060512345)

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting -
ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

INSTALLATION............................................................................................................................................. SECTION A
TECHNICAL SPECIFICATIONS - K4816-1 - FLEXCOOL™ 35....................................................................................... A-1
GENERAL DESCRIPTION.............................................................................................................................................A-2
RECOMMENDED PROCESSES AND EQUIPMENT......................................................................................................... A-2
DESIGN FEATURES.................................................................................................................................................... A-2
UNPACKING THE FLEXCOOL™ 35..............................................................................................................................A-3
MOUNTING THE FLEXCOOL™ 35 UNDERNEATH THE FLEXCUT™200.......................................................................A-3
FILLING THE COOLANT RESERVOIR............................................................................................................................A-3
COOLANT "IN" AND "OUT" CONNECTIONS.................................................................................................................A-4
INPUT POWER AND ARCLINK CONNECTIONS..............................................................................................................A-4
OPERATION ................................................................................................................................................SECTION B
TURNING THE SYSTEM "ON"..................................................................................................................................... B-1
OPERATING PRECAUTIONS AND WARNINGS...............................................................................................................B-1
COOLING EFFICIENCY................................................................................................................................................ B-1
OPTIONS / ACCESSORIES.............................................................................................................................SECTION C
MAINTENANCE............................................................................................................................................. SECTION D
ROUTINE MAINTENANCE............................................................................................................................................D-1
PUMP MOTOR MAINTENANCE................................................................................................................................... D-1
PERIODIC MAINTENANCE ..........................................................................................................................................D-1
DRAWER REMOVAL PROCEDURE............................................................................................................................... D-2
FILTER ELEMENT REPLACEMENT PROCEDURE.......................................................................................................... D-2
PUMP STRAINER CLEANSING PROCEDURE................................................................................................................ D-3
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.
2
TABLE OF CONTENTS

A-1
INSTALLATION
FLEXCOOL™35
Technical SpecificaTionS -
K4816-1 - flexcool™ 35
*Cooling Power is measured at a 1 L/min. low rate with a 40°C coolant temper-
ature rise in a 25°C (77ºF) environment.
INPUT POWER RATINGS
FREQUENCY PHASE VOLTAGE
CURRENT
DRAW
@ 60 HZ
CURRENT
DRAW
@ 50 HZ
50/60 HERTZ SINGLE 115 VAC 4.7 AMPS 5.0 AMPS
PUMP HYDRAULIC RATING
NO FLOW -
DISCHARGE PRESSURE (GAGE)
(RELIEF VALVE SETTING)
162 PSIG (414 KPA) (4.14 BAR)
MAX.
NO PRESSURE - FLOW RATE 1.66 GAL/MIN (6.28 LITER/MIN)
MAX.
TYPICAL OPERATION -
DISCHARGE PRESSURE (GAGE) 120 PSIG (0.83 MPA)
TYPICAL OPERATION -
FLOW RATE 1.10 GAL/MIN (4.2 LITER/MIN)
RATED COOLING POWER
PER IEC-60974-2 1.78 KW @ 1.00 LITER/MIN
6075 BTU/HR @ .26 GAL/MIN
DEGREE OF EN IRONMENTAL PROTECTION
IP 23
RESER OIR CAPACITY
2.375 GALLONS (9.0 LITERS)
AGENCY COMPLIANCE
IEC-60974-2, CCSAUS,
PHYSICAL DIMENSIONS
LENGTH WIDTH HEIGHT SHIPPING
WEIGHT
WEIGHT W/
RESERVOIR
FULL
30.70 IN
(78.0 CM)
15.99 IN
(40.6 CM)
14.93 IN
(37.9 CM)
92 LB
(41.7 KG)
114 LB
(51.7 KG)
RECOMMENDED COOLANT
BK500695 - TORCH COOLANT
DO NOT USE: AUTOMOTIVE ANTI-FREEZE THAT CONTAINS RUST
INHIBITORS OR LEAK STOPPERS. THESE COOLANTS WILL
DAMAGE THE PUMP AND BLOCK THE SMALL INTERNAL
PASSAGEWAYS OF THE HEAT EXCHANGER, AFFECTING COOLING
PERFORMANCE.

A-2
INSTALLATION
FLEXCOOL™35
INSTALLATION
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
• Turn off input power to the power
source at the disconnect switch or
fuse box before working on this equipment. Turn off
the input power to any other equipment connected to
the welding system at the disconnect switch or fuse
box before working on the equipment.
• To not touch electrically hot parts.
GeneRal DeScRipTion
The FlexCool™ 35 is a cooler designed for PAC (Plasma Arc
Cutting) and specifically designed to integrate with the
FlexCut™ 200 system (FlexCut™ 200, FlexStart™ console,
FlexCool™ 35, and T5 torch). This cooler could be used in the
future with other power sources and for other processes. The
coolant "IN" and "OUT" connections are specific CGA fittings
designed for Burny-Kaliburn coolant hoses to connect the cooler to
the FlexStart™ console. The FlexCool™ 35 is a continuous duty
cooler.
DO NOT USE A SOLENOID AL E with the
FlexCool™35.
RecoMMenDeD pRoceSSeS anD eQUipMenT
The FlexCool™ 35 is designed for use in PAC (Plasma Arc Cutting)
applications. It is designed to work with the FlexCut™ 200 and
FlexStart™ console and to connect with the T5 Burny-Kaliburn HD
torch. This entire system is specifically designed to work together
to provide high quality reliable cuts at a fraction of the price of
standard HD plasma.
DeSiGn feaTUReS
The FlexCool™ 35 provides adequate and reliable cooling for the
T5 plasma torch up to 200 Amps of continuous use:
• Industry proven reliable Procon Pump. Pump rating of 150
PSIG and 121-131 GPH.
• Robust single phase motor. Thermally protected.
• Reliable 115 VAC tubeaxial fans.
• Manufactured by the Lincoln Electric Company in Cleveland,
OH.
• 5 micron replaceable cartridge filter to eliminate coolant
contaminants
• Cabinet and drawer design for easy access to internal
components
• Quick lock system to securely mount underneath the
FlexCut™ 200 power source
• Arclink enabled to “talk” and integrate with the
FlexCut™ 200 and require no user interaction
• NTC thermistor to accurately monitor the coolant temperature
and protect the torch
• Coolant level switch in reservoir to protect pump (~0.9 gallons
minimum)
• Coolant flow switch to ensure proper flow rate (0.5
gallons/min)
• Designed for use with Lincoln Electric’s Low Conductivity
Coolant for corrosion and algae resistance as well as
operations below freezing
• Designed to IEC-60974-2, IP 23.
• Pump operates smoothly without vibrations being transferred
to the cutting torch.
• Input cord on the 115V cooler has a three-prong plug NEMA
type 5-15P.
WARNING
CAUTION

A-3
INSTALLATION
FLEXCOOL™35
UnpacKinG The flexcool™ 35
The packaging of the cooler is designed to withstand shipping
abuse. If any shipping damage has occurred, contact your certified
Lincoln distributor or service center. When unpacking the unit,
avoid thrusting sharp objects through the carton, which may
damage the machine. Below is the recommended procedure for
unpacking the cooler:
• Cut and remove banding straps around skid and carton
• Remove carton
• Cut and remove banding straps around skid and cooler
• Remove cooler, literature, and other items
Save the instruction manual and service directory supplied with
the FlexCool™ 35 for parts orders and future maintenance
service.
MoUnTinG The flexcool™ 35 UnDeRneaTh The
flexcUT ™ 200
The FlexCool™ 35 can be mounted underneath the FlexCut™ 200
machine or by itself on a flat surface. No power source should
ever be installed underneath the FlexCool™ 35.
Securing the FlexCut™ 200 to the FlexCool™ 35 (see Figure A.1):
1. Begin by setting the FlexCool™ 35 on a hard flat surface.
2. Remove the two 7/16” bolts and the locking bracket from the
front mounting bracket
3. Lift the FlexCut™ 200 and place on top and slightly forward
of the FlexCool™ 35
4. Carefully guide the FlexCut™ 200 so that the quick lock feet
on the bottom of the power source slide into the channels of
the mounting brackets on top of the FlexCool™ 35. Be sure
all 4 feet are within the channels.
5. Slide the FlexCut™ 200 all the way back so that it is sitting
exactly overtop of the FlexCool™ 35. The feet should be all
the way at the back of the channels.
6. Replace the locking bracket into the front mounting bracket of
the FlexCool™ 35. Torque both 7/16” bolts to 50 in-lbs.
FIGURE A.1
fillinG The coolanT ReSeRVoiR
DO NOT USE: Automotive anti-freeze that contains rust
inhibitors or leak stoppers. These coolants will damage the
pump and block the small internal passageways of the heat
exchanger, affecting cooling performance.
To avoid freeze damage and fluid leakage in shipment, the
FlexCool™ 35 unit is delivered with very little coolant in the
system. To fill the unit, unscrew the plastic reservoir cap from the
front middle of the unit.
The opening of the reservoir neck mates with most coolant
containers, but to avoid spillage of coolant, a funnel should be
placed into the reservoir hole when filling the FlexCool™ 35.
Pure solutions and mixtures of, or materials (i.e. towels)
wetted with ethylene glycol are toxic to humans and
animals. They must not be haphazardly discarded,
especially by pouring liquids down the drain. Contact the
local EPA office for responsible disposal methods or for
recycling information. Avoid unnecessary contact.
RECOMMENDED COOLANT
BK500695 - TORCH COOLANT
(SOLD IN 1 GALLON UGS)
WARNING
CAUTION

A-4
INSTALLATION
FLEXCOOL™35
Filling:
Pour 2.375 gallons (9.0 liters) of coolant into the coolant reservoir
fill hole through a funnel.
Use the coolant purge command in the machine UI menus to help
prime the system.
While priming, add additional coolant to keep the reservoir full.
The cooler is "FULL" when the coolant lies just below the coolant
reservoir opening.
Be certain to replace the reservoir fill cap when the reservoir is
full. Operation of the FlexCool™ 35 without the reservoir cap can
cause unnecessary contamination and could be hazardous to
others.
coolanT "in" anD "oUT" connecTionS
The fittings located on the front of the FlexCool™ 35 are CGA B-
size inert gas fittings (“Out” is RH and “In” is LH). Use only the
specified hoses to attach the cooler to the FlexStart™ console.
Refer to Figure A.2.
Coolant Line Connections to the FlexCool™ 35:
FIGURE A.2
1. Coolant “In” / “ eturn”
2. eservoir Fill Neck
3. Front Mounting and Locking Bracket
4. Status LED
5. Coolant “Out” / “Supply”
FIGURE A.3
6. Arclink Connector
7. 115 VAC C14 eceptacle
(Reference Figure A.2) Take the “Supply” hose (right hand
threads, no groove on outside of nut) and thread it into the coolant
“OUT” fitting located on the right side of the front of the cooler.
Secure the connector nut of the hose tightly into the fitting with a
wrench so that leaking does not occur. Then take the accessory
“Return” hose (left hand threads, groove cut around hex nut) and
thread it into the coolant “IN” fitting located on the left side of the
front of the cooler. Again, tightly secure the connector nut of the
hose into the fitting of the cooler with a wrench to ensure that no
leaking occurs. BE CE TAIN THAT NO LEAKS EXIST WHEN THE
COOLE IS TU NED ON. A LEAK WILL DEPLETE ESE VOI
VOLUME AND POTENTIALLY BE HAZA DOUS.
NOTE: BE CERTAIN THAT ONLY THE SPECIFIED HOSES
ARE USED AND THAT THE THREADS AND MATING METAL
SURFACES ARE CLEAN. POOR CONNECTIONS CAN
CAUSE COOLANT LEAKS AND WILL DEPLETE THE
COOLANT IN THE RESER OIR.
inpUT poWeR anD aRclinK connecTionS
Attach the supplied input power cord into the rear of the
FlexCool™ 35 and into the 115V NEMA 5-15 receptacle on the
rear of the FlexCut™ 200 power source.
Thread the supplied Arclink cable into the 5 pin Amphenol on the
rear of the FlexCool™ 35 and into the 5 pin Amphenol on the rear
of the FlexCut ™200.
CAUTION
1
2
3
4
5
6
7

B-1
OPERATION
FLEXCOOL™35
OPERATION
SAFETY PRECAUTIONS
Rea this entire section of operating instructions
before operating the machine.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet
clothing.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be danger-
ous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire
or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
• Do not cut aluminum over water tables
ARC RAYS can burn.
• Wear eye, ear, and body protection.
The following should always be observed when operating
the FlexCool™ 35:
• Never operate the cooler with any case parts off or
removed. The drawer must always be slid all the way
into the cabinet and secured with two screws in the
front.
• Unplug the cooler before removing the drawer or
servicing the unit.
• High voltage typical of welding operations can kill.
• Immersion in water around electrical lines can cause
electrical shock.
• Moving parts can injure. Never place fingers into
openings of Cooler.
• Unplug the cooler before filling the reservoir.
• Never operate the cooler with the reservoir fill cap off.
• Hot coolant can burn skin. Always be sure coolant is
NOT HOT before servicing the cooler.
• Do not pour used ethylene glycol coolant down the
drain.
•Do not remove the pump relief valve's 3/4" hex nut or
attempt to adjust the relief valve setting.
Observe additional guidelines detailed in the
beginning of this manual.
TURninG The SYSTeM "on"
After connecting the FlexCool™ 35 per the installation instructions
above, turn on the FlexCut™ 200 power source. You should see
the LED on the front of the cooler turn green and you will be able
to hear the fan running and feel airflow out of the side of the unit
when the cooler is operating. The cooler will run when a cut is
initiated and for some time afterward.
When first starting the unit, check all of the coolant hoses to
ensure that no coolant leaks are present. Coolant leakage causes
poor cooling performance, potential health and electrical safety
hazards, and will eventually cause the system to shut down.
opeRaTinG pRecaUTionS anD WaRninGS
The following should always be observed when operating the
FlexCool™ 35:
• Check the coolant reservoir level daily
• Keep the reservoir full especially after changing any
lines/torches
• Never operate the cooler with the reservoir fill cap removed
unless checking coolant flow
• 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 coolant lines
• Keep all coolant lines clean and free of any blockage
• Do not attempt to operate cooler without coolant in reservoir
coolinG efficiencY
The high cooling efficiency of the FlexCool™ 35 helps to extend
the life of the plasma consumables. Heat from the cutting arc is
transferred into the coolant and removed via the exiting air flow at
the side of the cooler.
Ambient air temperature affects the cooling performance of the
FlexCool™ 35. Maximum coolant temperature is 162˚F and
controlled by a thermistor mounted to the radiator inlet.
WARNING

C-1
ACCESSORIES
FLEXCOOL™35
OPTIONS / ACCESSORIES
Fiel Installe Options/Accessories
K1543-8, -25, -50, -100 Arclink Cable - An Arclink cable is used to
communicate between the FlexCool™ 35 and the FlexCut™ 200.
Available lengths include 8’, 25’, 50’, and 100’.
Coolant Hoses
Only the specified coolant hoses should be used between the
FlexCool™ 35 and the FlexStart™ console.
BK200307-XX – Coolant supply hose (10’-150’ lengths available in
increments of 10’)
BK200308-XX – Coolant return hose (10’-150’ lengths available in
increments of 10’)
Coolants
BK500695 - 25% Propylene Glycol Torch Coolant - Sold in 1
gallon containers, this coolant provides freezing protection down
to 9°F (-13°C).
BK500895 - 50% Propylene Glycol Torch Coolant - Sold in 1
gallon containers, this coolant provides freezing protection down
to -33°F (-36°C).

MAINTENANCE
Safety Precautions
ELECTRIC SHOCK can kill.
• Observe all Safety Guidelines detailed
throughout this manual. Be sure to
disconnect the FlexCool™ 35 power and
communication cables before performing
any maintenance procedures.
General service notes:
Always use a back-up wrench on pump head when
loosening or tightening pump fittings.
Never run the pump dry. Always use a recommended
coolant, otherwise pump damage may result. Dispose of
coolant and any coolant soaked items properly.
See additional warning information throughout
this Operator’s Manual
RoUTine MainTenance
The reservoir volume should be checked regularly. The system will
indicate a low liquid level because of the float switch, but for
maximum cooling it is recommended to keep the reservoir full.
Remove the reservoir fill cap and check the coolant level. The
reservoir is full when the coolant level is just below the reservoir
fill opening.
Remove accumulated dust and dirt from the internal components
of the cooler by blowing it out with a low-pressure air hose or
removing it with a vacuum hose.
To maintain maximum cooler efficiency, the heat exchanger
should be kept free of dust and dirt build-up. 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. In extremely dirty environments, it may be necessary to
remove the heat exchanger completely from the cooler and clean
the fins with soap and water. Use care to avoid damaging the
fins.
pUMp MoToR MainTenance
The FlexCool™ 35 is rated for continuous operation. It is
recommended to re-oil the pump motor bearings once a year as
follows:
• Remove the plastic plugs located on the top of both the
inboard and outboard bearing end-caps.
• Re-oil each bearing with 30-35 drops of SAE 20 oil then
reinstall both plugs.
peRioDic MainTenance
The torch coolant and particulate filter should be replaced every 6
months. The pump strainer should also be cleaned before refilling
the coolant.
Replacing coolant and filter cartridge:
1. Remove power from the system
2. Remove power/communication cables from rear of cooler
3. Remove 2 screws from the front of the cooler and slide the
drawer out of the cabinet
4. Remove and dispose of the old coolant out of the reservoir
- Use clean siphoning equipment or carefully tip the drawer
forward to remove coolant
5. Remove the coolant supply hose from the front of the cooler
and use compressed air to force the coolant through the
hoses/FlexStart™/torch and back into the reservoir
6. Dump and dispose of the remaining coolant from the reservoir
7. Loosen two nuts holding filter housing bracket to rear of
drawer
8. Unscrew the filter housing to expose the element
9. Replace filter element, reassemble filter housing, and reattach
to drawer
10. Clean pump strainer:
- Hold the pump head firmly and loosen the strainer's 7/8"
acorn nut located on the bottom of the pump. Do not confuse
with 3/4" acorn nut. Remove nut and slide inlet strainer down
and out from the pump head.
- Gently rinse the strainer under running water to thoroughly
clean it.
- Reinstall the strainer and 7/8 acorn nut, tightening with 75+/-
15 in-lbs. of torque.
11. Wipe dry all areas wetted with coolant. Dispose of coolant
soaked towels properly.
12. Slide drawer back into cabinet, secure drawer to cabinet,
reattach coolant supply hose, fill reservoir with new coolant,
and reattach power/communication cables to the rear of the
cooler
13. Power up FlexCut™ 200 system and perform cooler priming
procedure while topping off coolant
Pure solutions and mixtures of, or materials (i.e. towels)
wetted with ethylene glycol are toxic to humans and
animals. They must not be haphazardly discarded,
especially by pouring liquids down the drain. Contact the
local EPA office for responsible disposal methods or for
recycling information
WARNING
CAUTION
D-1
MAINTENANCE
FLEXCOOL™35

D-2
MAINTENANCE
FLEXCOOL™35
DRaWeR ReMoVal pRoceDURe
ELECTRIC SHOCK can kill.
• Disconnect input power before servicing.
• Do not operate with covers removed.
• Do not touch electrically live parts.
• Only qualified persons should install, use or service this
equipment.
See Figure D.1
1. Turn off input power to the power source and any other
equipment connected to the cutting system at the disconnect
switch or fuse box before working on the equipment.
2. Disconnect the 115VAC and Arclink cables from the rear of
the cooler.
3. Remove the two screws from the front of the cooler with a
3/8” bit.
4. Slide the drawer out of the cabinet.
FIGURE D.1
filTeR eleMenT ReplaceMenT pRoceDURe
1. Remove the cooler drawer as described earlier.
2. Loosen the two 5/16” nuts securing filter bracket to the
drawer back. See figure D.2
FIGURE D.2
3. Hold the top of the filter housing and twist the lower clear
section to loosen. See Figure D.3
FIGURE D.3
4. Remove the lower half of the filter housing with coolant and
element inside.
5. Remove and replace the filter element.
6. Reconnect both halves of the filter housing with the element
properly seated.
7. Secure the filter bracket to the drawer back.
8. Insert the cooler drawer back in the cabinet and secure with 2
screws at the front.
WARNING
Loosen
Tighten

D-3
MAINTENANCE
FLEXCOOL™35
pUMp STRaineR cleanSinG pRoceDURe
1. Remove the cooler drawer as described earlier.
2. While holding the pump head securely, remove the 15/16”
acorn nut from the pump body. be prepared for some coolant
to escape from the pump when removing the nut.
3. Gently pull the strainer to remove it from the pump. See
Figure D.4
FIGURE D.4
4. Clean and remove any debris from the strainer. Replace the
strainer if it is damaged or excessively dirty.
5. Reinsert the strainer into the pump body.
6. Replace the 15/16” nut and torque to 6.25 ft-lbs (8.5 N-m)
with the pump head securely.
7. Insert the cooler drawer back in the cabinet and secure with 2
screws at the front.

E-1
TROUBLESHOOTING
FLEXCOOL™35
TROUBLESHOOTING
How to Use troUblesHooting gUide
Service and Repair should only be performed by Lincoln
Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the
technician and machine operator and will invalidate your
factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions
detailed throughout this manual.
This Troubleshooting Guide is provided to help you locate and
repair possible machine malfunctions. Simply follow the three-
step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This
column describes possible symptoms that the machine may
exhibit. Find the listing that best describes the symptom that the
machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the obvious
external possibilities that may contribute to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the Possible Cause,
generally it states to contact your local Lincoln Authorized Field
Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your local Lincoln
Authorized Field Service Facility.
USinG The STaTUS leD To TRoUbleShooT
SYSTeM pRobleMS
The FlexCool 35 is equipped with an externally mounted status
light. If a problem occurs it is important to note the condition of
the status light. Therefore, prior to cycling power to the system,
check the power source status light for error sequences as noted
below.
The STATUS LIGHT is a dual-color LED that indicates system
errors. Normal operation is steady green. Error conditions are
indicated in the following Table E.1.
TABLE E.1
WARNING
LIGHT
CONDITION
MEANING
Steady
Green
System OK. Cooler is operational, and is
communicating normally with all healthy
equipment connected to its ArcLink network.
Blinking
Green
Occurs during power up or a system reset,
and indicates the FlexCool™ 35 is mapping
(identifying) each component in the system.
Normal for first 1-10 seconds after power is
turned on, or if the system configuration is
changed during operation.
Fast Blinking
Green
Under normal conditions indicates Auto-
mapping has failed.
Also used by the Diagnostics Utility to identify
the selected machine when connecting to a
specific IP address.
Alternating
Green and
Red
Non-recoverable system fault. If the Status
light is flashing any combination of red and
green, errors are present. Read the error
code(s) before the machine is turned off.
Error Code interpretation through the Status
light is detailed in the Service Manual.
Individual code digits are flashed in red with a
long pause between digits. If more than one
code is present, the codes will be separated
by a green light. Only active error conditions
will be accessible through the Status Light.
To clear the active error(s), turn power source
off, and back on to reset.
Steady Red Not applicable.
Blinking Red Not applicable.
I or any reason you do not understand the test procedures or are unable to per orm the tests/repairs sa ely, contact your
Lincoln Authorized Service Facility or technical troubleshooting assistance be ore you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR

E-2
TROUBLESHOOTING
FLEXCOOL™35
I or any reason you do not understand the test procedures or are unable to per orm the tests/repairs sa ely, contact your
Lincoln Authorized Service Facility or technical troubleshooting assistance be ore you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
Observe all Sa ety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
BASIC MACHINE P OBLEMS
Error 446 – Cooler Not Found 1. Arclink cable disconnected
If all recommended possible areas of misad-
justment have been checked and the problem
persists, Contact your local Lincoln
Authorized Field Service Facility.
2. 40V circuit breaker on machine is
tripped
Error 817 – Coolant Temp Too High 1. Heat exchanger clogged/dirty
2. Fan(s) disconnected, obstructed, or
failed
3. Exceeded cooling limit
Error 814 – Coolant Flow Too Low 1. Power cord not plugged in between
machine and cooler
2. 15A circuit breaker on machine tripped
3. Leak in torch/gun or hoses.
4. Torch/gun or hoses partially obstructed
5. Internal filter is clogged
6. Pump Strainer is dirty
7. Damaged pump
Error 815 – Coolant Level Too Low 1. Heat exchanger clogged/dirty
2. Fan(s) disconnected, obstructed, or
failed
3. Exceeded cooling limit
Internal Coolant Leak 1. Hose clamp or fitting loose on an
internal connection
2. Internal hose punctured
3. Heat exchanger leaking
4. Pump seal is leaking
5. Poor seal between level switch and
reservoir
Front LED does not light up 1. LED disconnected from case front lens
Pump operates, but fan does not. 1. Loose or disconnected fan lead.
2. Obstruction in fan blade
3. Fan motor failure.

G-1
DIAGRAMS
FLEXCOOL™35
NOTE: Thi diagram i for reference only. It may not be accurate for all machine covered by thi manual. The pecific diagram for a particular code i pa ted in ide the machine on one of the enclo ure
panel . If the diagram i illegible, write to the Service Department for a replacement. Give the equipment code number.
A.03
M26345PRINT
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B
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FLOW SWITCH (0.50GPM) SS
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W
B
FAN2
LEVEL
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Wiring Diagram FlexCool™ 35

G-2
DIAGRAMS
FLEXCOOL™35
L17334
A.02
28.85
15.99
30.70
14.10
14.93

G-3
DIAGRAMS
FLEXCOOL™35