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IM723-A
January, 2004
UNDER-COOLER CART
For use with machines having Code Numbers: 10808, 11068
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 thought-
ful 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 carefu
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� as much pride as we have in bringing this product to you! 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
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vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions. ..............................................................................................................A-2 Unpacking ..........................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – UNDER- WATER COOLER Model / Make Under-Cooler Cart K1828-1 Input 100-120 VAC 50/60 Hz 1 Phase Rated Current Draw 60 Hz (2.8-3.5 Amps) 50 Hz (3.5-5.3 Amps) Operating Pressure 60 psig (413 kPa) (4.1 bar) Pump Hydraulic Rating No Flow Discharge Pressure (gage) (Relief Valve Setting) 60 PSIG (414 kPa) (4.14 bar) Max. No Pressure Flow Rate 1.66 gal/min (6.28 liter/min) Max. Pump Hydraulic Rating (Typical Operation) Discharg
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A-2 A-2 INSTALLATION Save the instruction manual and service directory sup- SAFETY PRECAUTIONS: plied with the Under-Cooler cart for parts orders and future maintenance service. WARNING FILLING COOLANT RESERVOIR ELECTRIC SHOCK Can Kill � Only qualified persons should per- (See Section A-1 for recommended coolant.) form this installation. To avoid freeze damage and water leakage in ship- ment, the Under-Cooler cart is delivered empty with HOT COOLANT CAN BURN SKIN no coolant in the system. To
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A-3 A-3 INSTALLATION If you have hose to make replacement hose assem- blies but need to order the fittings and hardware, see below for the correct part numbers to mate with the CAUTION Under-Cooler cart and the Precision TIG Machine. Then follow the given instructions. NOTE: DO NOT ADD MORE THAN 2 GALLONS (7.6 LITERS) OF COOLANT INTO THE RESER- (2) T15007-2 Connector Nuts VOIR. The fill cap contains a pressure release air (2) T15008 Nipples for 3/16" I.D. hose hole, which must not be blocked
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A-4 A-4 INSTALLATION Assembly of the Under-Cooler cart to the Precision INPUT POWER CONNECTION TIG machine is actually quite simple. Read carefully the prior warnings and precautions to assembling to a Precision TIG machine. Plug the input power cord on the Under-Cooler cart into the standard bottom 115V NEMA circuit breaker Assembly: protected receptacle, located on the back of the 1. Lift the Precision TIG machine approximately 24" Precision TIG machine. Using this receptacle is taking (610
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A-5 A-5 INSTALLATION FASTENER QUICK REFERENCE (FULL SCALE) SEE FIGURE A-2 Assembly for fastener placement. -4- -7- -8- -5- -6- -11- -12- -9- -10- CONNECTION OF TIG TORCHES Installation of TIG torches to be used with this Precision TIG Under-Cooler cart is explained in the Precision TIG machine literature. The torch does not directly attach to the cooler but through a connection box mounted on the TIG machine. UNDER-COOLER CART
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B-1 B-1 OPERATION SAFETY PRECAUTIONS GENERAL DESCRIPTION The Under-Cooler cart is an internal type, re-circula- WARNING tion cooling system designed for use with water- cooled TIG torches. The coolant "IN" and "OUT" con- ELECTRIC SHOCK can kill. nections are 5/8-18 left-hand female threads which � Disconnect input power by remov- match the standard connector nut of domestic water ing plug from receptacle before hoses (CGA style) and water-cooled TIG torches. working inside Cooler. The Under-Cool
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B-2 B-2 OPERATION TURNING THE SYSTEM "ON" COOLING EFFICIENCY The high cooling efficiency of the Under-Cooler cart CAUTION offers a cooler, more comfortable weld than conven- tional air-cooled procedures as well as leading com- After connecting the Precision Tig and Tig petitors water cooled systems. Torches per Installation Section, plug the unit into a 115V NEMA electrical receptacle for start-up The Under-Cooler cart effectively removes the heat of operation. Be certain that the power input i
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D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS PUMP WARNING The pump head has a "built in" strainer on the inlet Have qualified personnel do the maintenance side of the pump. It is recommended to clean or work. In some cases, it may be necessary to replace the pump’s inlet strainer at least annually remove safety guards to perform required as follows: maintenance. Remove guards only when necessary and replace them when the mainte- � Drain the coolant reservoir and all coolant lines. nance requiring thei
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D-2 D-2 MAINTENANCE RESERVOIR COOLANT LEVEL Preparation: � Always switch off the Precision TIG machine power. The reservoir volume should be checked daily before � Always disconnect the Under-Cooler cart from the using the cooler. Remove the reservoir fill cap and TIG machine receptacle. check the coolant level. The reservoir is full when the � Be sure that the coolant presently in the system is at coolant level is just below the input elbow of the reser- room temperature to avoid being burned
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D-3 D-3 MAINTENANCE Disinfect the cooling system: PROCEDURE Preparation: � Prepare the disinfectant: Make a quantity of only is needed to avoid an excess. � Always switch off the Precision TIG machine power � Bulk preparation (for coolers serviced in quantity): � Always disconnect the Under-Cooler cart from the 2.325 gals. (8.775 liters) of pure, fresh water per Tig machine receptacle. cooler 1.625 ml of additive per cooler � Always allow the coolant in the system to cool � Example: for 100 co
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D-4 D-4 MAINTENANCE Service the pump’s inlet strainer: a. Place absorbent towels underneath pump head to prevent stray coolant from wetting cooler’s electrical components. b. Hold pump head to apply counter torque when loos- ening strainers 7/8 acorn nut. Do not confuse with 3/4 acorn nut. Remove nut and slide inlet strainer down and out from pump head. See figure 3A. c. Inspect strainer for damage or excessive clogging: � Replace or Gently rinse strainer under running water to thoroughly clean
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E-1 E-1 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING 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. _______________________________________________________________
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E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION Cooler does not operate 1. Input cord unplugged. 2. Power harness damaged. 3. Water lines blocked or crimped. 4. Leak in gun or water hoses. 5. Coolant reservoir empty. 6. The system needs to be primed. Internal water leak. 1. Hose clamp loose on one of internal hoses. 2. Internal hose punctured. 3. Heat exchanger leaking. 4. Pump
