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IM438-B
™
March, 1999
MAGNUM COOLERS 1 0-I AND 20-I
For use with machines having Code Number 9743, 9745, 9984, 9986,10266 and 10268
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
importa
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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 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent 6. Eloigner les matériaux inflammables ou les recouvrir afin de dans ce manuel aussi bien que les précautions de sûreté prévenir tout risque d’incendie dû aux étincelles. générales su
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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 Product Description ...............................................................................................A-2 Warranty .......................................................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – MAGNUM COOLERS 10-I AND 20-I Model Cooler 10-I Cooler 20-I Product No. K873-1 K879-1 Input 220V 50/60 Hz 1 Phase 220V 50/60 Hz 1 Phase Current Draw at Input .75 Amps 1.25 Amps Rated Current Draw 1.0 Amps 1.6 Amps Operating Pressure 45 psi (310 kPa) (3.0 bar) 60 psi (410 kPa) (4.0 bar) Shutdown Pressure 60-65 psi (414-446 kPa) (No delay after flow is (4.0-4.4 bar) stopped) Flow Range 0.1 to 0.8 gal/min (0.4 to 3.0 liters/min) Typical MI
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A-2 A-2 INSTALLATION PRODUCT DESCRIPTION The unique “On-Demand” system (when used with a Magnum Coolers 10-I and 20-I are stand alone recir- water valve or solenoid in the system) only pumps culating cooling systems designed for use with water coolant when it is needed, saves energy, reduces cooled TIG, MIG, PAC (Plasma Arc Cutting) and PAW noise and increases pump and fan motor life by turn- (Plasma Arc Welding) guns and torches. Additional ing off the system between welds. applications incl
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A-3 A-3 INSTALLATION INSTALLATION The FILL CAP is at the front of the unit (C). WARNING Cap removal: While pressing the bulls-eye ELECTRIC SHOCK can kill. inward, grip the tab and remove the cap with � Disconnect input power by removing a peeling motion. plug from receptacle before working inside Cooler. Cap replacement: Install by pressing inward on the � Use only grounded receptacle. bulls-eye; the cap will “snap” into position. � Do not remove the power cord ground prong. � Do not touch
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A-4 A-4 INSTALLATION The case front sheet metal design allows for ease of When using the Magnum Cooler with other products, access to repair all internal components. The Phillips consult the manufacturer’s recommendations for head fasteners used to secure the casing match the coolant. Do not use oil based coolants. style of fasteners used in the pump head and other major components. In this manner, an operator can The unit can be filled either vertically or horizontally. repair all major com
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A-5 A-5 INSTALLATION Cooler and insert the nipple into the connector nut so that the HORIZONTALLY MOUNTING MAGNUM COOLERS threaded end of the connector nut points away from the barbed ON LINCOLN TIG POWER SOURCES end of the nipple. Twist the barbed end of the nipple into the hose until the shoulder of the nipple is flush with the end of the Magnum Coolers can be mounted either upright or hose. Secure the hose onto the nipple with a hose clamp to horizontally. For a complete compact system, in
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POWER SOURCE FRONT WARNING A-6 A-6 INSTALLATION FIGURE 3a FIGURE 3b NOTE: FOR PROPER INSTALLATION WHEN USED WITH LINCOLN K835, K840, K841 OR K842 UNDERCARRIAGES, THE RUBBER FEET MAY NEED TO BE REMOVED FROM THE BOTTOM OF THE MOUNTING BRACKET. COOLER HOLE "A" COOLER HOLE "B" COOLER HOLE "C" BRACKET HOLE "A" BRACKET HOLE "B" BRACKET HOLE "C" Door Bumper (Factory Installed) (6 req'd) SEE NOTE Optional Mounting Bracket Undercarriage Arm (shown detatched from Cooler bac
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A-7 A-7 INSTALLATION FIGURE 3c Undercarriage Mounting Bracket Layout A B POWER SOURCE HEIGHT POWER SOURCE HEIGHT 16.44" (417.6mm) 21.50" (546.1mm) Cooler 10-I Mounting Scheme C D E POWER SOURCE HEIGHT POWER SOURCE HEIGHT POWER SOURCE HEIGHT 16.44" (417.6mm) 21.50" (546.1mm) 27.50" (698.5mm) Cooler 20-I Mounting Scheme MAGNUM COOLER 10-I & 20-I
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A-8 A-8 INSTALLATION WATER COOLED EQUIPMENT INSTALLATION NOTE: Magnum Coolers operate at 45 psi (3.0 bar) (310 kPa) of pressure for Cooler 10-I and 60 psi (4.0 bar) (414 kPa) of pressure for Cooler 20-I. When used in the demand system, the pressure in the supply hose to the water solenoid or valve can surge to 20 psi (1.4 bar) (138 kPa) above holding pressure just before shutdown. The holding pressure will be 60-65 psi (4.0-4.4 bar) (414-448 kPa). When using the Magnum Cooler with other wate
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A-9 A-9 INSTALLATION FIGURE 5 Water Cooled MIG Gun Connection COOLANT COOLANT IN OUT COOLANT COOLANT GUN CABLE FIGURE 6 Water Cooled Plasma System Connection COOLANT COOLANT IN OUT COOLANT PLASMA CUTTING ELECTRODE POWER CABLE & AIR SOURCE AIR COOLANT MAGNUM COOLER 10-I & 20-I
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A-10 A-10 INSTALLATION K440-1 LN-7 GMA WIRE FEEDER WITH GAS AND K527 WATER SOLENOID KIT FOR LN-7 2-ROLL WATER SOLENOID VALVE AND LN-7 2-ROLL AND 4-ROLL GMA WIRE FEED- ERS The K440-1 LN-7 GMA wire feeder is equipped with internal water lines and external connectors for attach- For LN-7 2-Roll Model Above Code 9484 ment to a water cooled MIG gun and a Magnum For LN-7 GMA 2-Roll and 4-Roll Models Above Code Cooler. The water solenoid control of the K440-1 LN-7 9100 GMA enables the feeder to trig
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A-11 A-11 INSTALLATION K529-10 POWER INPUT CABLE WITH WATER AND GAS LINES The K529 power input cable connects from the front of a Lincoln power source to the back of LN-7 and LN-7 GMA wire feeders equipped with a water solenoid control. K529-10 is 10 ft. (3.0m) long and includes two water hoses and a gas line. The lengths of the two water hoses and gas line are designed for proper con- nection to a Magnum Cooler and a gas cylinder locat- ed on the back of a Lincoln K874, K840-1*, K841-1* or K
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B-1 B-1 OPERATION SAFETY PRECAUTIONS - Even when using the Magnum Cooler in an “on- demand” application, the power to the Cooler should be turned off when welding is not taking place for a WARNING long period of time. ELECTRIC SHOCK can kill. � Do not touch electrically live parts or - Be certain that the Cooler is on (power switch in the electrode with skin or wet clothing. “|” position) before beginning to weld, especially � Insulate yourself from work and when using the Cooler in the demand s
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B-2 B-2 OPERATION You will be able to hear the fan running and feel air and the internal components of the Cooler turn off. flow out of the back of the unit when the Cooler is When the arc is started and the trigger and the sole- operating. The Cooler will run continuously when noid are enabled, the system pressure is relieved and operated without a water solenoid or valve. If a water the Cooler immediately begins to run. When a water solenoid or valve is used, the Cooler will run for a valve or
