RETURN TO MAIN INDEX
IM438-B
â„?
MAGNUM COOLERS 1 AND 20-I
0-I March, 1999
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
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
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 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
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 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers before welding.
and devices in position and in good
repair.Keep hands, hair, clothing and tools 2.c. Exposure to EMF fields in welding may have other health
away from V-belts, gears, fans and all other effects which are now not known.
moving parts when starting, operating or
repairing equipment. 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
1.e. In some cases it may be necessary to remove safety
them with tape when possible.
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.2. Never coil the electrode lead around your body.
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
2.d.3. Do not place your body between the electrode and
parts.
work cables. If the electrode cable is on your right
___________________________________________________
side, the work cable should also be on your right side.
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. 2.d.4. Connect the work cable to the workpiece as close as
___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
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 hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
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 suivantes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
Sûreté Pour Soudage A L’Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse électrique:
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
8. S’assurer que la masse est connectée le plus prés possible
quand la machine à souder est en marche. Eviter toujours
de la zone de travail qu’il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d’autres
ou les vétements mouillés. Porter des gants secs et sans
endroits éloignés de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de lev-
b. Faire trés attention de bien s’isoler de la masse quand on
age, câbles de grue, ou autres circuits. Cela peut provoquer
soude dans des endroits humides, ou sur un plancher
des risques d’incendie ou d’echauffement des chaines et des
metallique ou des grilles metalliques, principalement dans
câbles jusqu’� ce qu’ils se rompent.
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
9. Assurer une ventilation suffisante dans la zone de soudage.
masse.
Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble
galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état
produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir.
d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension
chaleur ou les rayons de l’arc peuvent réagir avec les
des porte-électrodes connectés à deux machines à soud-
vapeurs du solvant pour produire du phosgéne (gas forte-
er parce que la tension entre les deux pinces peut être le
ment toxique) ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions
voir le code “Code for safety in welding and cutting� CSA
pour le porte-électrode s’applicuent aussi au pistolet de
Standard W 117.2-1974.
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
PRÉCAUTIONS DE SÛRETÉ POUR
partie du corps.
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc:
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde l’arc. de l’électricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché Ã
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste
soudage à l’aide d’écrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? 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 is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
EXPLANATION OF SYMBOLS THAT APPEAR ON THIS EQUIPMENT
O OFF
ON
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Product Description ...............................................................................................A-2
Warranty ................................................................................................................A-2
Safety Precautions.................................................................................................A-3
Product Overview. .................................................................................................A-3
Filling the Reservoir ..............................................................................................A-4
Water Line Connection ..........................................................................................A-4
Horizontally Mounting Magnum Coolers to Lincoln TIG Power Sources ...............A-5
Vertically Mounting Magnum Coolers to Lincoln Undercarriages ..........................A-5
Water Cooled Equipment Installation ....................................................................A-8
K440-1 LN-7 GMA Wire Feeder with Gas and Water Solenoid Valve.................A-10
K527 Water Solenoid Kit for LN-7........................................................................A-10
K529-10 Power Input Cable with Water and Gas Lines ......................................A-11
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
Operating Precautions ...........................................................................................B-1
Lighted Power Switch ............................................................................................B-1
Turning the System On..........................................................................................B-1
Magnum System Monitor.......................................................................................B-2
Demand System with Water Valve or Solenoid .....................................................B-2
Surge Protection ....................................................................................................B-2
Fan Motor and Fan Blade ......................................................................................B-2
Pump and Pump Pressure.....................................................................................B-2
Pump Failure .........................................................................................................B-3
Cooling Efficiency ..................................................................................................B-3
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Heat Exchanger Maintenance ...............................................................................D-1
Reservoir Maintenance..........................................................................................D-1
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams ..............................................................................................Section F
Wiring Diagrams ..............................................................................................F-1,F-2
Parts List ..........................................................................................................Appendix
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 MIG with Magnum 15� (4.5m) gun 0.55-0.60 gal/min (2.1-2.3 liters/min)
Operating
Flow TIG with Magnum 12.5� (3.8m) torch 0.25-0.30 gal/min (1.0-1.2 liters/min)
Open Flow 0.8 (3.0 liters/min)
Reservoir Size 2.0 ga. (8.0 liters)
Coolant Requirement For Use Above Freezing: Tap, distilled, de-ionized, mineral water or well water.
For Use Below Freezing: 50% water and 50% automotive antifreeze mixture
such as Prestone, Peak or Zerex or 50% water and 50% pure ethylene glycol
mixture or any water alcohol mixture.
DO NOT USE: Prepackaged welding industry coolants. These coolants may
contain oil-based substances which attack the plastic components in the pump
of the Magnum Cooler and severely reduce pump life.
Weight Shipping 30 lbs. (13.6 kg) 34 lbs. (15.4 kg)
Reservoir 43 lbs. (19.5 kg) 47 lbs. (21.3 kg)
Full
Dimensions L 9.0 in. (229mm) 9.0 in. (229mm)
W 9.0 in. (229mm) 9.0 in. (229mm)
H Top Face 26.5 in. (673mm) 32.00 in. (815mm)
H Top 28.75 in. (730mm) 34.25 in. (870mm)
Handle
Undercarriage Use K874 K840-1*, K841-1*, K842-1*,
K874
* Not available at the time of printing.
MAGNUM COOLER 10-I & 20-I
MAR97
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 include resistance welding, induction
heating and water cooled fixtures such as EDM’s and
The Magnum Cooler is capable of operating continu-
small Verti-Shield dams. The connection block located
ously; however, the "on-demand" feature is strongly
at the back of the Cooler contains 5/8-18 left hand
recommended in ALL APPLICATIONS TO ASSURE
female thread. A 5/8-18 left hand nut and matching
GOOD PUMP AND MOTOR LIFE.
nipple are supplied with each Magnum Cooler 10-Iand
Cooler 20-I unit to convert hoses that may have differ-
Magnum Cooler are easy to service. Removal of the
ent connectors. The international Cooler 10-I and 20-I
front case provides access to all internal components.
are also furnished with a bracket so that the Cooler
The Phillips head fasteners used to anchor the casing
can be anchored at the back of a Lincoln K874 double
of the unit match those of the pump and other internal
cylinder undercarriage.
component connections. In this manner, an operator
can repair all major components using just a Phillips
With lower 45 psi (310 kPa) (3.0 bar) output pressure
head screwdriver.
delivery to increase TIG torch component life,
Magnum Cooler 10-I is made for all water cooled TIG
WARRANTY
applications and low to medium duty MIG applica-
tions. The higher 60 psi (410 kPa) (4.0 bar) output
pressure delivery of Magnum Cooler 20-I supports Warranty for this product is one year after the date of
higher demand water cooled applications without purchase. For any warranty claim, contact a certified
decreasing component life. Lincoln service center.
The Magnum Coolers bring new technology in the
areas of pump, heat exchanger and reservoir designs
to the water cooler market. These technologies allow
the Magnum Coolers to be lighter in weight, lower in
energy consumption, mounted either vertically or hori-
zontally, and operated even in the case of a “soft�
pump failure. The unique “soft� pump failure feature
allows some pump stages to continue to pump coolant
even if one or two stages have failed.
MAGNUM COOLER 10-I & 20-I
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 electrically “hot� parts inside Cooler. The coolant FLOW INDICATOR is accessed by
� Have qualified personnel do the installation, main- removal of the fill cap. Actual return flow is directly vis-
tenance and troubleshooting work. ible, via the fill opening (D) with the unit in vertical or
--------------------------------------------------------------------- horizontal position.
Air flow vents (E).
PRODUCT OVERVIEW
The LIGHTED POWER SWITCH is located at the left
side of the control panel (A). Cooler will be “ON� when
pressed to � | �.
Coolant INLET and OUTLET fittings are found at the
rear of the unit (B). They are welding industry stan-
dard English left-hand fittings for water coolant lines.
The right side fitting is marked “coolant out� (coolant
supply to the welding equipment); the left side fitting is
marked “coolant in� (coolant returning from the weld-
ing equipment).
FIGURE 1
A
E
E
B
C
D
MAGNUM COOLER 10-I & 20-I
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
coolant. Do not use oil based coolants.
head fasteners used to secure the casing match the
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 components in the unit using just a UNPLUG THE COOLER BEFORE FILLING THE
Phillips head screwdriver. The case back trapezoidal RESERVOIR.
shape eliminates the possibility of the exit airflow of
the Cooler being choked when the Cooler is operated Upright: Tilt the unit backward and pour 2 gallons (8.0
lying horizontally. The exiting airflow is also pushed liters) of coolant into the reservoir fill hole through a
back away from the unit so that hot air does not recir- funnel.
culate through the louvers in the case front. or
A blow molded, high density one piece polyethylene If 1 gallon (4 liters) antifreeze or fill bottle is available,
housing serves as both the reservoir and support tilt the unit forward until the bottle mates with the
frame for the Coolers. The use of polyethylene plastic reservoir fill hole. Then tilt the unit backward until the
gives a design that is lightweight and durable. fill bottle is emptied. Fill the unit with 2 gallons (8
liters) of coolant.
FILLING THE RESERVOIR
Lying down: Carefully add 2 gallons (8.0 liters) of
coolant through a funnel into the reservoir fill hole.
PROPER COOLANT ADDITION
AVOID SPILLING COOLANT INTO THE FRONT
CASING OF THE UNIT.
FOR USE ABOVE FREEZING: Tap, distilled,
Unit will be full when coolant lies just below the reser-
deionized, mineral water, or well water.
voir opening with the unit in its upright position.
FOR USE BELOW FREEZING: 50% water and
NOTE: DO NOT ADD MORE THAN 2 GALLONS
50% automotive antifreeze mixture such as
(8 LITERS) OF COOLANT INTO THE RESERVOIR.
Prestone, Peak or Zerex or 50% water and 50%
The fill cap contains a pressure release air hole
pure ethylene glycol mixture or any water alcohol
which must not be blocked by overfilling the reser-
mixture.
voir with coolant.
DO NOT USE: Prepackaged welding industry
Be certain to replace the reservoir fill cap when the
coolants. These coolants may contain oil-based
reservoir is full. Simply press on the inside center of
substances which attack the plastic components in
the fill cap until the cap snaps into place. Operation of
the pump of the Magnum Cooler and severely
the Magnum Cooler without the fill cap in place can
reduce pump life. Once added to the Cooler, the
cause poor cooling efficiency, evaporation loss of
substances are virtually impossible to purge from
coolant, and low product life.
the water lines and heat exchanger.
WATER LINE CONNECTION
To avoid freeze damage and water leakage in ship- Two connector nuts and mating nipples are supplied
ment, every Cooler 10-I and 20-I unit is delivered in each Cooler 10-I and 20-I model. The connector
empty with no coolant in the system. To fill the unit, and nipple fit tightly onto 4.0mm (5/32�) to 4.0mm
locate the plastic snap-on reservoir fill cap at the front (3/16�) inner diameter hose, but if clamped tightly to
middle of the unit. Remove the fill cap by pressing the the hose can fit up to 6.4mm (.250�) inner diameter
center of the cap inward while pulling at the tab on the
hose.
outer edge.
To install water lines onto the Cooler, check if your
NOTE: The unit can be filled either vertically or hori-
coolant hose mates with the 5/8-18 left hand female
zontally. UNPLUG THE COOLER BEFORE FILLING
thread in the connector block at the back of the unit.
THE RESERVOIR.
If the connector nut on your water hose does not mate
For best results when using the Magnum Cooler with
with the connector block at the back of the Magnum
Lincoln guns or torches, use distilled, deionized or
Cooler:
demineralized water, although if not available, tap
water can be used. If protection from freezing is
Remove the connector nut from the INLET hose by
desired, use a 1 gallon (4 liter) automotive antifreeze
making a straight cut 6-12mm (1/4-1/2�) away from
and 1 gallon (4 liter) tap water mixture. An alcohol or the end of the nipple located inside of the hose. Take
glycol mixture with water is also acceptable. the nipple and the connector nut supplied with the
MAGNUM COOLER 10-I & 20-I
MAR97
A-5 A-5
INSTALLATION
HORIZONTALLY MOUNTING MAGNUM COOLERS
Cooler and insert the nipple into the connector nut so that the
ON LINCOLN TIG POWER SOURCES
threaded end of the connector nut points away from the barbed
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,
insure that the connection is water tight. No water can leak from
Magnum 10-I or 20-I Cooler can be mounted horizon-
the connection if it is properly attached. Repeat the procedure for
tally on the roof of Lincoln TIG Power Sources using
the OUTLET hose. When complete, reference Figure 2 and fol-
the optional K559-2 Horizontal TIG Mounting Bracket.
low the connection procedure detailed below for connector nuts
For proper installation, follow the instructions provided
that mate to the Magnum Cooler connector block.
with the kit. (See Figures 3a and 3b)
For additional water lines that do not mate with Magnum Cooler
connections, order:
VERTICALLY MOUNTING MAGNUM COOLERS TO
LINCOLN UNDERCARRIAGES K874, K840-1*, K841-
Order: (2) T15007-2 Connector Nuts*
1*, or K842-1*
(2) T15008 Nipples*
(2) S10888-35 Hose Clamps*
When placing the Cooler 10-I or 20-I at the back of a
For all Lincoln products and those with a connector nut on the Lincoln Undercarriage used in tandem with a Lincoln
water hose which mates with the connector block at the back of
MIG power source, order K559-3 Magnum Cooler
a Magnum Cooler:
MIG Mounting Bracket.
Save the two connector nuts and nipples provided with the unit
Reference Figure 3c and Table 2 for proper connec-
for future use. (Reference Figure 2). Take the water INLET hose
(colored or tagged blue on most hoses) and thread it into the tion of the bracket to the back bolt pattern of the
coolant OUT line located on the right hand side of the connector Cooler. With the four Phillips head screws supplied,
block at the back of the Cooler. Secure the connector nut of the
align the bracket onto the back of the Cooler at the
hose tightly into the connector block with a wrench so that leak-
proper holes displayed in Figure 3c. Do not fully tight-
ing does not occur. Then take the OUTLET hose (colored or
en the bracket allowing the bracket to slightly move up
tagged red on most hoses) and thread it into the coolant IN line
and down. Place the Cooler at the back right of the
located on the left hand side of the connector block. Again, tight-
ly secure the connector nut of the hose into the connector block undercarriage so that the lip of the Cooler bracket
of the Cooler with a wrench to insure that no leaking occurs. BE rests on the top of the undercarriage upper cylinder
CERTAIN THAT NO LEAKS EXIST WHEN COOLER IS
support. Align the holes of the Cooler bracket with the
TURNED ON. A LEAK WILL DEPLETE RESERVOIR VOLUME,
holes on the undercarriage upper cylinder support.
CAUSE POOR OR COOLING PERFORMANCE AND REDUCE
Fasten the Cooler bracket with the holes on the
GUN OR TORCH LIFE.
undercarriage upper cylinder support. Fasten the
NOTE: Be certain that only 5/8-18 left hand male nuts with Cooler bracket onto the undercarriage support with
clean and smooth threads are used on your water hoses. Poor both 1/4-20 bolts, 1/4-20 hex nuts, plain washers and
connections cause water to leak at connector block, down
lock washers provided. Be certain to tighten all the
hose lines, and eventually out the case sides of the unit.
fasteners when the installation is complete.
* The connector and nipples listed fit tightly onto 4mm (5/32�) to
4.8mm (3/16�) inner diameter hose, but if clamped tightly to the * Not available at time of printing.
hose, can fit up to 6.4mm (1/4� inner diameter hose.
FIGURE 2
Inlet and Outlet Hose Connection Diagram
COOLANT COOLANT
IN OUT
FROM TO
HEAT HEAT
SOURCE SOURCE
(RED) (BLUE)
MAGNUM COOLER 10-I & 20-I
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)
WARNING
SEE NOTE
Optional
Mounting Bracket
Undercarriage Arm
(shown detatched
from Cooler back
Self Tapping Screw for clarity)
(4 req'd)
Plain Washer
Lock Washer
1/2-13 Hex Nut
1. ON COOLERS 10 & 10-I :
Align holes A & C of mounting bracket with holes B & C of Magnum Cooler. Secure bracket to the back
of Cooler with 4 self tapping screws provided.
ON COOLERS 20 & 20-I :
Align holes A & B of mounting bracket with holes A & B of Magnum Cooler. Secure bracket to the back
of Cooler with 4 self tapping screws provided. PO
WE 1/2-13x1.50HHCS
2. Route all water line connections onto connection block at back of Cooler as outlined in the IM manual
FR R S
provided with the Magnum Cooler. ON OU Large Plain Washer
T RC *NOT REQ'D WHEN USING
E UNDERCARRIAGE OPTION
TABLE 2
Recommended Magnum Cooler Use with Lincoln
Power Source / Undercarriage Combination
Figure 3c
Power Source Cooler Undercarriage Mtg. Bkt.
Scheme
CV-200-I Cooler 10-I K874 A
CV-300-I Cooler 10-I or 20-I** K874 A or C
CV-400-I Cooler 10-I or 20-I** K874 B or D
CV-500-I Cooler 20-I K841-1* E
R3R-375-I Cooler 20-I K841-1* E
R3R-500-I Cooler 20-I K841-1* E
R3R-600-I Cooler 20-I K841-1* E
** Use 20-I model for demanding welding applications.
* Not available at the time of printing.
MAGNUM COOLER 10-I & 20-I
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
21.50" (546.1mm) 27.50" (698.5mm)
16.44" (417.6mm)
Cooler 20-I Mounting Scheme
MAGNUM COOLER 10-I & 20-I
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 water cooled TIG, MIG and
plasma systems, consult the manufacturer’s instruc-
tion manual.
FIGURE 4
Water Cooled TIG Torch Connection
REGULATOR
FLOWMETER
ARGON GAS
CYLINDER
COOLANT
COOLANT
OUT
IN
POWER SOURCE GAS*
GAS COOLANT
OUT IN
IN OUT COOLANT*
GAS
COOLANT*
TIG TORCH
POWER CABLE ADAPTER*
POWER / COOLANT
COOLANT
TO WORK *INCLUDED IN
GAS KP504 HOOK-UP KIT
MAGNUM COOLER 10-I & 20-I
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
OUT
IN
COOLANT
PLASMA
CUTTING ELECTRODE
POWER
CABLE & AIR
SOURCE
AIR COOLANT
MAGNUM COOLER 10-I & 20-I
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 trigger the demand system
of a Magnum Cooler. (Reference Operation Section The K527 water solenoid kit can be added to an LN-7
for an explanation of the Magnum Cooler demand or LN-7 GMA wire feeder for conversion from an air
system). Follow the instruction manual supplied with cooled to a water cooled MIG system. The added
the wire feeder and Figure 7 for proper connection of solenoid control enables the feeder to trigger the
the K440-1 LN-7 GMA wire feeder to a Magnum demand system of a Magnum Cooler. Follow the kit
Cooler and a water cooled MIG gun. instructions provided for proper installation of the
K527 water solenoid kit to an LN-7 or LN-7 GMA wire
feeder and Figure 7 for proper connection of the con-
verted wire feeder to a Magnum Cooler and a water
cooled MIG gun. Reference Operation Section for an
explanation of the Magnum Cooler demand system.
FIGURE 7
Connection to Wire Feeder Equipped with Solenoid Control
COOLANT
COOLANT COOLANT
OUT
IN COOLANT
COOLANT
COOLANT
GUN CABLE
COOLANT =
NOTE:
BLUE HOSE
OUT
COOLANT =
RED HOSE
IN
MAGNUM COOLER 10-I & 20-I
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
K842-1* double cylinder undercarriage. The water
connections are 5/8-18 left hand thread while the gas
connection is 5/8-18 right hand thread. Reference
Figure 8 when using the K529 power input cable.
* Not available at time of printing.
Figure 8
K529-10 POWER INPUT CABLE CONNECTION
SHIELDING
GAS
COOLANT
IN WITHOUT
SOLENOID CONNECTIONS
COOLANT
OUT
CONTROL CABLE
COOLANT
IN COOLANT
OUT
COOLANT
COOLANT
ELECTRODE CABLE
TO WORK
GUN CABLE
K529-XX
NOTE:
COOLANT
= BLUE HOSE
OUT
COOLANT
= RED HOSE
IN
MAGNUM COOLER 10-I & 20-I
B-1 B-1
OPERATION
SAFETY PRECAUTIONS - Even when using the Magnum Cooler in an “on-
demand� application, the power to the Cooler should
WARNING be turned off when welding is not taking place for a
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 system.
ground.
� Always wear dry insulating gloves. - Never operate the Cooler with the reservoir fill cap
------------------------------------------------------------------------ removed.
FUMES AND GASES can be danger-
- Avoid placing the Cooler near areas of extreme
ous.
heat.
� Keep your head out of fumes.
� Use ventilation or exhaust to remove
- Avoid placing the Cooler near a flux hopper or an
fumes from breathing zone.
area where dust build-up is extreme.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or - Avoid kinking or putting sharp bends in any water
explosion. lines.
� Keep flammable material away.
� Do not weld on closed containers. - Keep all water lines clean.
LIGHTED POWER SWITCH
------------------------------------------------------------------------
ARC RAYS can burn eyes and skin.
A long life, lighted power switch is located at the left
� Wear eye, ear and body
side on the control panel. When switched “ON�, the
protection.
switch will be pressed toward the “|� symbol.
------------------------------------------------------------
Because it will only light when the Cooler is pumping
coolant, the switch serves as an indicator for the
See additional warning information at Magnum system monitor. For proper operation, the
front of this operator’s manual. switch should beam steadily when coolant is pumping
and remain unlit when flow is stopped. Reference the
-----------------------------------------------------------
Magnum system monitor sections for an explanation.
The following should always be observed when oper-
ating any Magnum Cooler:
TURNING THE SYSTEM ON
- Never operate the Cooler with case off.
After filling the reservoir and connecting the coolant
- Immersion in water around electrical lines can hoses to the Magnum Cooler per the Installation
cause electrical shock. Sections, plug the unit into an electrical receptacle for
start-up operation. Be certain that the power input into
- Never place fingers into openings of Cooler. Moving the unit matches the Cooler’s rated input. Both Cooler
parts can injure. 10-I and 20-I cordsets contain a 90 angled CEE 7/4,
7/7 Schuko compatible plug. The plug mates with an
- Unplug the Cooler before filling the reservoir.
auxiliary receptacle located at the back of many inter-
national Lincoln power sources for power supply to a
- Never operate the Cooler with the reservoir fill cap off.
Magnum Cooler 10-I and 20-I when placed at the
OPERATING PRECAUTIONS back of a Lincoln K874, K840-1*, K841-1*, and K842-
1* undercarriage.
The following should always be observed when oper-
ating any Magnum Cooler: * Not available at time of printing.
- Check the Magnum system monitor to verify ade-
quate flow for the applicationr.
- Check the reservoir daily.
- Keep the reservoir full especially after changing any
water lines.
MAGNUM COOLER 10-I & 20-I
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 solenoid is not used, the pump does not
short period of time until the demand system is acti- sense any build up of pressure and the Cooler runs
vated and the unit shuts off. continuously.
When first starting the unit, check all of the water lines
to insure that no water leaks are present. Water leak-
CAUTION
age causes poor welding performance, poor cooling
performance, low welding component life and poten-
tial electrical safety hazards. NEVER BYPASS THE COOLER POWER SWITCH.
MAGNUM SYSTEM MONITOR When using a water valve or solenoid, be certain to
turn the Magnum Cooler off (“O� position) when not in
Always check the Magnum System Monitor before use. Cooler will appear to be off in the demand system
beginning to weld. The power switch light located at but will be supplied as long as the switch is on (“|�
the top of the unit functions as the system monitor. position). Leaving the Cooler on can eventually cause
The light will beam steadily when coolant is flowing the system to turn on and off when not in use (light will
and remain unlit when flow is stopped. The light will turn on and off) and, over time, decrease the demand
flicker if there is inadequate flow through the sys- system performance.
tem. Be sure to check the operation periodically ------------------------------------------------------------------------
SURGE PROTECTION
and each time your welding setup is changed.
Coolers are factory set to deliver coolant for the most To protect components from voltage spikes in power
common welding setups. lines, an MOV-Capacitor suppressor assembly attach-
es across the AC input of the rectifier bridge. The sup-
IF COOLANT STILL FLOWS, BUT THE LIGHT pressor blocks spikes up to 3000V for 1 ms.
FLICKERS:
FAN MOTOR AND FAN BLADE
1. The System Monitor light indicates if there is a
restriction somewhere downstream from the The smaller Cooler 10-I model contains one fan while
Cooler. Be certain that water lines and welding the larger Cooler 20-I model contains two fans. All
apparatus are not crimped, partially blocked or Cooler 10-I and 20-I units use the same fan blade
obstructed. capable of moving a large volume of air in a small
area of space. Each fan blade is independently driven
2. Uncoil the water lines to remove any kinks from the by a high torque, AC, small industrial fan motor. A
lines. one-time blow fuse prevents a failed fan motor from
overheating and further damaging the Cooler or caus-
3. Unhook the input and output lines from the Cooler. ing a safety problem. The fan motor is capable of
Blow out the welding apparatus lines and/or con- operating both vertically or horizontally although verti-
nection lines to remove any particulate. Reattach cal operation offers longer fan motor life.
and check flow again.
PUMP AND PUMP PRESSURE
NOTE: If the system uses a water valve, check to
make sure that the valve is working properly. All Cooler 10-I and 20-I units contain a DC motored
diaphragm pump manufactured with an integral pres-
DEMAND SYSTEM WITH WATER VALVE OR SOLE- sure sensing control switch. The positive displace-
NOID ment self-priming pump consists of 3 separate, self-
regulating, parallel pumping stages. If one stage fails,
When linked to a water solenoid or valve, the demand the other two continue pumping with a slight decrease
system works as follows: in flow. This “soft� failure protects the water cooled
gun or torch from meltdown and allows the operator to
When the weld is complete and the trigger circuit continue welding until a repair can be made. The
opened, the solenoid stops water flow into the torch or pump’s plastic design resists the common causes of
the gun. The pump senses the buildup of pressure water cooler pump failure such as:
MAGNUM COOLER 10-I & 20-I
B-3 B-3
OPERATION
- Abrasion failure due to particulate in coolant. The Magnum Cooler effectively removes the heat of
the arc away from the gun or torch handle and places
- Corrosion failure due to deionized water and pure it into the exiting air flow at the back of the Cooler.
glycol mixtures. Outside temperature can affect the cooling perfor-
mance of a Magnum Cooler.
- Cavitation failure due to air bubbles introduced by
an intake screen ( or any other source).
For example:
- Dry operation failure due to the reservoir being emp-
A. COOL day (50°F, 10°C): More HEAT is trans-
tied.
ferred from the water in the heat exchanger to the
- Over pressure failure due to crimping or blocking of air. The water is COOLER and more HEAT is
water hoses. transferred from the gun or torch to the water.
RESULT: THE GUN OR TORCH FEELS COOL-
- Catastrophic sudden failure due to wear of carbon ER
vanes in turbine pumps.
B. HOT day (100°F, 38°C): Less HEAT is transferred
from the water in the heat exchanger to the air.
The spring actuated normally closed pressure switch
The water is HOTTER and less HEAT is trans-
is located at the top of the pump head. The springs
ferred from the gun or torch to the water.
sense a pressure buildup in the pump head and, with
RESULT: THE GUN OR TORCH FEELS HOT-
a buildup of pressure above the operating pressure,
TER.
enable the switch which shuts off power to the fan
motor and pump motor. The pressure switch allows
Unlike other water coolers that depend on bulky reser-
the Cooler to run intermittently “On Demand� when
voir size, the high efficiency components of Magnum
connected to a water valve or solenoid only providing
Coolers allows the reservoir size to be small. The
cooling water when it is needed. This feature saves
result is a lightweight, portable unit.
energy, but more importantly, drastically increases
pump and fan motor life. For best operation, no delay
time should exist from the time flow stops and when
the pump is turned off. (Refer to “Magnum System
Monitor� Section).
PUMP FAILURE
Magnum Cooler pumps are designed to fail “soft� so
that welding can continue until a repair is made. In the
unlikely event of a “soft� pump failure, water will slowly
leak from the pump head and drip out the case sides
of the unit. The internal electrical components are iso-
lated away from the pump and are in no danger from
the leak. S20095-1 and S20095-3 Pump Replacement
Kits and S20095-2 Pump Rebuild Kit are available for
repair of the pump. The only tool required is a Phillips
head screwdriver.
COOLING EFFICIENCY
The high cooling efficiency of Magnum Coolers offers
a cooler, more comfortable gun or torch than conven-
tional air cooled procedures as well as leading com-
petitors water cooled systems. The heat exchanger’s
corrugated fin improves heat convection transfer while
minimizing air flow restriction. This design offers a
durable construction capable of withstanding impact of
objects through air slots. Table 3 states the recom-
mended use and cooling rate for 10-I and 20-I Cooler
models. Refer to Figure 9 for a description of how
Magnum Coolers perform.
MAGNUM COOLER 10-I & 20-I
B-4 B-4
OPERATION
FIGURE 9
Circulation of Magnum Cooler
ROOM AIR
IN
HEATED
AIR OUT
HEAT
FAN
COOLANT
EXCHANGER = BLUE HOSE
OUT
NOTE:
COOLANT = RED HOSE
IN
PUMP
NT
COOLA
COOLANT
RETURN
NT
COOLA
COOLANT
INTAKE
TABLE 3
Approximate Cooling Rate and Recommended Use(1)
Model
Cooler 10-I Cooler 20-I
Product No. K873-1 K879-1
Max. Welding Current 350A 550A
TIG 100% duty cycle 100% duty cycle
Max. Welding Current 350A 550A
MIG 100% duty cycle 100% duty cycle
Max. Arc Current Test each application
PAW for cooling requirements
PAC
Misc. Applications
The values listed are based on lab test results. Some applications may vary.
(1)
MAGNUM COOLER 10-I & 20-I
C-1 C-1
ACCESSORIES
PARTS DESCRIPTION FOR MAGNUM COOLER
ACCESSORIES
S20095-1 Pump Replacement Kit (60 psi) (4.0 bar)
(414 kPa) for Magnum Cooler 20-I Models
Includes:
* (1) Complete 40-60 psi (3.0-4.0 bar) (310-414)
kPa) Pressure switch assembly.
* (1) Complete 60 psi (4.0 bar) (414 kPa) Pump
with all internal components and hose connec
tions.
* (1) Drive assembly
(1) Installation instructions
* All of the above assembled together with three short
screws and retaining hex nuts.
S20095-2 Pump Rebuild Kit for Magnum Cooler
10-I and 20-I Models
Includes:
(1) Teflon shim
(1) Diaphragm
(2) 45 psi (3.0 bar) (310 kPa) spring
(1) 60 psi (4.0 bar) (414 kPa) spring
(1) 80 psi (5.4 bar) (551 kPa) spring
(3) Conical spring seats
(1) Installation instructions
S20095-3 Pump Replacement Kit (45 psi) (3.0 bar)
(310 kPa) for Magnum Cooler 10-I Models
Includes:
* (1) Complete 40-60 psi (3.0-4.0 bar) (310-414 kPa)
Pressure switch assembly.
* (1) Complete 45 psi (3.0 bar) (310 kPa) Pump with
all internal components and hose connections.
* (1) Drive assembly
(1) Installation instructions
* All of the above assembled together with three short
screws and retaining hex nuts.
MAGNUM COOLER 10-I & 20-I
D-1 D-1
MAINTENANCE
Both the S20095-1 and S20095-3 Pump Replacement
WARNING Kits consist of a molded pump head equipped with all
ELECTRIC SHOCK can kill. internal pump components to replace a failed pump or
cracked pump head of a Magnum Cooler. The Pump
� Disconnect input power by removing
Replacement Kit includes a complete pre-assembled
plug from receptacle before working
pressure switch assembly and pump assembly.
inside Cooler.
Although the Pump Replacement Kit costs more than
� Do not operate with covers removed.
the Pump Rebuild Kit, the time to install it is less and
� Use only grounded receptacle.
saves money when down time is costly. When repair-
� Do not remove the power cord ground prong.
ing the Cooler pump, follow the instructions supplied
� Do not touch electrically “hot� parts inside Cooler.
with the kit. The only tool needed for installing the
� Have qualified personnel do the installation, main-
S20095-1 or S20095-3 Pump Replacement Kit is a
tenance and troubleshooting work.
Phillips head screw driver. Reference Parts Section
---------------------------------------------------------------------
for a parts list of the Pump Replacement Kit.
S20095-2 Pump Rebuild Kit for Magnum Cooler 10-I
and 20-I Units:
The S20095-2 Rebuild Kit consists of a all the neces-
sary internal components to rebuild the most common
HEAT EXCHANGER MAINTENANCE
“soft� pump failure that occurs in a Magnum Cooler.
Water will slowly drip from the pump head when the
To maintain maximum efficiency, the heat exchanger
pump experiences a “soft� failure. The rebuild proce-
should be kept clean from dust and dirt buildup. Clean
dure is more involved than the pump replacement pro-
the heat exchanger periodically using a vacuum hose
cedure but is more cost efficient when labor rates are
or low pressure air line. Avoid placing the unit near a
low or when down time is not critical. The only tool
flux hopper or a flux waste container. A clean heat
needed for rebuilding the pump is a Phillips head
exchanger offers better cooling performance and
screw driver. Follow the instructions supplied with the
longer product life. If extremely dirty conditions exist, it
kit when rebuilding the pump head. Reference Parts
may be necessary to remove the heat exchanger
Section for the S20095-2 Magnum Cooler Pump
completely from the Cooler for a thorough soap and
Rebuild Kit.
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. Remove the reservoir fill cap and
check the coolant level. Unit is full when the coolant
lies just below the reservoir fill opening with the unit in
an upright position. Keep the reservoir full especially
after changing the water lines.
The Cooler should always be operated with the reser-
voir 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 parti-
cle buildup and dirt offers better cooling efficiency and
longer pump, gun and torch life.
S20095-1 Pump Replacement Kit (60 psi) for Magnum
Cooler 20-I Units:
S20095-3 Pump Replacement Kit (45 psi) for Magnum
Cooler 10-I Units:
MAGNUM COOLER 10-I & 20-I
E-1 E-1
TROUBLESHOOTING
TROUBLESHOOTING GUIDE
WARNING
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts such
as internal wiring.
� Turn OFF input power at welding power
source and accessory power source
before installation or service.
� Cooler must be connected to system
ground per any National Electrical Code
or any applicable local codes.
� Only qualified personnel should
perform installation or service.
Observe all additional Safety Guidelines detailed
throughout this manual.
WARNING
This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs per-
formed 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.
_________________________________________________________________________________________
CAUTION
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.
MAGNUM COOLER 10-I & 20-I
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
Cooler does not operate with power a. Power cord unplugged. a. Plug in power cord.
switch on. b. No power at outlet. b. Check outlet circuit breaker.
(Switch pushed to c. Power cordset damaged. c. Repair damaged cord or order
"1" position.) new cordset.
d. Unit too hot. Thermal protector d. Allow unit to cool. Relocate unit
tripped. away from source of heat.
e. Water lines blocked or crimped. e. Clear blockage in hose. Avoid
kinking or putting sharp bends in
water lines.
f. Unit is used in a demand system f. Repair water valve or solenoid.
and water valve or solenoid dam-
aged.
g. Leak in gun or water hoses. g. Repair leak.
h. Reservoir empty. h. Fill reservoir.
I. Power switch faulty. I. Replace power switch.
j. Solenoid valve is closed. j. Pull trigger on welding gun to open
solenoid valve.
k. Female quick-connect fittings are k. Connect all quick connect fittings
not connected to male fittings. to their mating parts.
Power switch blinks or flickers while a. Water lines partially blocked or a. Clear blockage in hose. Avoid
coolant is flowing. (Continuous use, obstructed. kinking or putting sharp bends in
NO Water Valve or Solenoid in the water lines.
system.) b. Internal hose or heat exchanger is b. Carefully clear blockage. Clean all
blocked. hoses and the reservoir.
c. Restriction is too high for the c. Use the Cooler 20-I for MIG appli-
Cooler being used. cations. Cooler 10-I can be used
for either MIG or TIG applications.
Using a water valve or solenoid and a. Water lines partially blocked or a. Clear blockage in hose. Avoid
power switch blinks or flickers while obstructed. kinking or putting sharp bends in
coolant is flowing or when flow is water lines.
stopped. b. Water valve or solenoid failure. b. Repair or replace water valve or
solenoid.
c. Internal hose or heat exchanger is c. Carefully clear blockage. Clean all
blocked. hoses and the reservoir.
d. Restriction is too high for the d. Use the Cooler 20-I for MIG appli-
Cooler being used. cations. Cooler 10-I can be used
for either MIG or TIG applications.
Using water valve or solenoid and a. Leak in gun or water hoses. a. Repair leak.
power switch light turns on and off b. Demand system stress. System b. Turn power switch off when not in
when not in use. not used for long period of time use. (Power switch pushed to
with Cooler left on. (Power switch “O�). DO NOT LEAVE POWER
pushed to “|�). ON WHEN COOLER IS NOT IN
USE FOR A LONG PERIOD OF
TIME.
Internal water leak. a. Hose clamp loose on one of inter- a. Tighten or replace hose clamp.
nal hoses.
b. Internal hose punctured. b. Replace punctured hose with new
hose.
c. Heat exchanger leaking. c. Replace heat exchanger.
d. Pump experiencing “soft� failure d. Repair pump with S20095-1 or
and leaking around plastic hous- S20095-3 Pump Replacement Kit
ing of pump head. or S20095-2 Pump Rebuild Kit.
e. Replace pump head with S20095-
e. Pump head cracked. 1 or S20095-3 Pump
Replacement Kit.
MAGNUM COOLER 10-I & 20-I
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
Leak at inlet/outlet connector a. Loose connector fitting. a. Tighten connector nut. (5/8-18
block. left hand thread).
b. Hose clamp loose. b. Tighten hose clamp onto hose.
Torch or gun runs hot. a. Unit placed by area of extreme a. Move unit away from hot air.
heat.
b. Low coolant flow. b. See Low Coolant Flow
Section.
c. No coolant flow. c. See No Coolant Flow Section.
d. Fan not operating. d. Reference fan section.
e. Heat exchanger clogged. e. Clean heat exchanger.
Fan operates but there is low a. Leak in torch/gun or hoses. a. Repair leak.
coolant flow. b. Torch/gun or hoses partially b. Clear obstruction.
obstructed.
c. Reservoir empty or very low. c. Refill reservoir.
d. DC+ or DC- connection loose d. Secure DC+ or DC- connec-
on rectifier bridge. tors on rectifier bridge.
e. Pressure low (pump motor fail- e. Replace pump motor.
ing).
f. One or more pump stages f. Repair the pump with S20095-
have failed. 1 or S20095-3 Pump
Replacement Kit or S20095-2
Pump Rebuild Kit.
Fan operates but there is no a. Pump motor failure. a. Replace pump motor.
coolant flow. b. Pump head seized (bearing b. Replace pump head with
failure). S20095-1 or S20095-3 Pump
Replacement Kit.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAGNUM COOLER 10-I & 20-I
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
Pump operates, but fan does not. a. Internal AC circuit open. a. Secure AC connectors on rec-
tifier bridge.
b. Fan blade contacting heat b. If fan blades are plastic,
exchanger. replace. Reset fan clearance
and secure fan to motor shaft.
c. Fan motor failure c. Replace fan motor with Fan
Motor and Mount Assembly.
Cooler trips outlet circuit breaker. a. Circuit overloaded. a. Check outlet circuit breaker.
b. Cooler electrical component b. Replace suppressor assembly
failure. and rectifier bridge inside of
Cooler.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
MAGNUM COOLER 10-I & 20-I
F-1 F-1
DIAGRAMS
MAGNUM COOLERS CODES 10266 THRU 10269
PUMP PRESSURE
INTERNAL
SWITCH
TO
B
B
N X2
PUMP
2*
1*
MOTOR
* L
B PUMP
H3 MOTOR
3* W
+ -
M
18V
G
H2
M M
FAN
MOTOR
W H1
X1
W
W
CONNECTED TO H2 FOR
SECOND FAN ON
COOLER 10 AND 20 MODELS
COOLER 20 AND 20-I
MODELS CONNECTED TO H3 FOR
COOLER 10-I AND 20-I MODELS
* NUMBERS EMBOSSED
COOLER 10-I 220 V
115 V
INPUT: COOLER 10
ON SWITCH HOUSING
AND
AND
ELECTRICAL SYMBOLS PER E1537
50/60 Hz
COOLER 20-1
60 Hz
COOLER 20
COLOR CODE:
- BLACK N - BROWN
B
- WHITE
W
- GREEN
G
A
S22534
MAGNUM COOLER 10-I & 20-I
F-2 F-2
DIAGRAMS
MAGNUM COOLERS CODES 9743 THRU 9746
BLACK BROWN INTERNAL
TO
2
1
PUMP
V
115
*
COOLER 10 WHITE
3
60 Hz
+ - PUMP
L M
MOTOR
5
V
220
FAN LEADS
M
COOLER 10-I MOTOR
EXTERNAL
50/60 Hz
FOR CODES 9743 THRU 9746
* NUMBERS EMBOSSED
ON SWITCH HOUSING COOLER 10 & 10-I WIRING DIAGRAM
BROWN
BLACK INTERNAL
TO
1 2
PUMP
V
115
*
COOLER 20 3 WHITE
60 Hz
+ - PUMP
L M MOTOR
5
V
220 FAN LEADS
M M
MOTOR EXTERNAL
COOLER 20-I
50/60 Hz
FOR CODES 9743 THRU 9746
* NUMBERS EMBOSSED COOLER 20 & 20-I WIRING DIAGRAM
ON SWITCH HOUSING
10-22-93
S20690
MAGNUM COOLERS CODES 9984 THRU 9987
BLACK BROWN INTERNAL
TO
2*
1*
PUMP
V
115
* MOTOR
COOLER 10 3* WHITE
60 Hz
+ - PUMP
L M
MOTOR
3
V
220
FAN LEADS
M
COOLER 10-I MOTOR
50/60 Hz
* NUMBERS EMBOSSED FOR CODES 9984 THRU 9987
ON SWITCH HOUSING
COOLER 10 & 10-I WIRING DIAGRAM
INTERNAL
BROWN
BLACK
TO
1* 2*
PUMP
MOTOR
V
115
*
COOLER 20 3* WHITE
60 Hz
+ - PUMP
L M MOTOR
3
V
220 FAN LEADS
M M
MOTOR
COOLER 20-I
50/60 Hz
FOR CODES 9984 THRU 9987
* NUMBERS EMBOSSED
COOLER 20 & 20-I WIRING DIAGRAM
ON SWITCH HOUSING
10-22-93
S20691
q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Portuguese
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
q Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
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