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B-2
OPERATION
B-2
You will be able to hear the fan running and feel air
flow out of the back of the unit when the Cooler is
operating. The Cooler will run continuously when
operated without a water solenoid or valve. If a water
solenoid or valve is used, the Cooler will run for a
short period of time until the demand system is acti-
vated and the unit shuts off.
When first starting the unit, check all of the water lines
to insure that no water leaks are present. Water leak-
age causes poor welding performance, poor cooling
performance, low welding component life and poten-
tial electrical safety hazards.
MAGNUM SYSTEM MONITOR
Always check the Magnum System Monitor before
beginning to weld. The power switch light located at
the top of the unit functions as the system monitor.
The light will beam steadily when coolant is flowing
and remain unlit when flow is stopped. The light will
flicker if there is inadequate flow through the sys-
tem. Be sure to check the operation periodically
and each time your welding setup is changed.
Coolers are factory set to deliver coolant for the most
common welding setups.
IF COOLANT STILL FLOWS, BUT THE LIGHT
FLICKERS:
1. The System Monitor light indicates if there is a
restriction somewhere downstream from the
Cooler. Be certain that water lines and welding
apparatus are not crimped, partially blocked or
obstructed.
2. Uncoil the water lines to remove any kinks from the
lines.
3. Unhook the input and output lines from the Cooler.
Blow out the welding apparatus lines and/or con-
nection lines to remove any particulate. Reattach
and check flow again.
NOTE: If the system uses a water valve, check to
make sure that the valve is working properly.
DEMAND SYSTEM WITH WATER VALVE OR SOLE-
NOID
When linked to a water solenoid or valve, the demand
system works as follows:
When the weld is complete and the trigger circuit
opened, the solenoid stops water flow into the torch or
the gun. The pump senses the buildup of pressure
and the internal components of the Cooler turn off.
When the arc is started and the trigger and the sole-
noid are enabled, the system pressure is relieved and
the Cooler immediately begins to run. When a water
valve or solenoid is not used, the pump does not
sense any build up of pressure and the Cooler runs
continuously.
NEVER BYPASS THE COOLER POWER SWITCH.
When using a water valve or solenoid, be certain to
turn the Magnum Cooler off (“O” position) when not in
use. Cooler will appear to be off in the demand sys
tem
but will be supplied as long as the switch is on (“|
”
position). Leaving the Cooler on can eventually cause
the system to turn on and off when not in use (light will
turn on and off) and, over time, decrease the demand
system performance.
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SURGE PROTECTION
To protect components from voltage spikes in power
lines, an MOV-Capacitor suppressor assembly attach-
es across the AC input of the rectifier bridge. The sup-
pressor blocks spikes up to 3000V for 1 ms.
FAN MOTOR AND FAN BLADE
The smaller Cooler 10-I model contains one fan while
the larger Cooler 20-I model contains two fans. All
Cooler 10-I and 20-I units use the same fan blade
capable of moving a large volume of air in a small
area of space. Each fan blade is independently driven
by a high torque, AC, small industrial fan motor. A
one-time blow fuse prevents a failed fan motor from
overheating and further damaging the Cooler or caus-
ing a safety problem. The fan motor is capable of
operating both vertically or horizontally although verti-
cal operation offers longer fan motor life.
PUMP AND PUMP PRESSURE
All Cooler 10-I and 20-I units contain a DC motored
diaphragm pump manufactured with an integral pres-
sure sensing control switch. The positive displace-
ment self-priming pump consists of 3 separate, self-
regulating, parallel pumping stages. If one stage fails,
the other two continue pumping with a slight decrease
in flow. This “soft” failure protects the water cooled
gun or torch from meltdown and allows the operator to
continue welding until a repair can be made. The
pump’s plastic design resists the common causes of
water cooler pump failure such as:
MAGNUM COOLER 10-I & 20-I
CAUTION