Lincoln Electric IM645-A Installation Instructions, Replacing a G2725 Cooler with a G3503- Cooler

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INSTALLATION INSTRUCTIONS

WARNING

ELECTRIC SHOCK Can Kill

Only qualified persons should perform this installa- tion.

HOT COOLANT CAN BURN SKIN

Always be sure coolant is not hot before doing any work on cooler parts.

ROTATING FAN BLADES ARE HAZARDOUS

• Do not put your hands near an operating fan.

Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from fans and all other moving parts when starting, operating or repair- ing equipment.

In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when neces- sary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

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REPLACING A G2725 COOLER WITH A G3503-[ ] COOLER

1.Preparation:

Always switch off the Power Wave machine power.

Always disconnect the Power Wave machine from service input power.

2.Remove the G2725 cooler assembly:

a.Remove gas cylinder(s) from machine’s rear tray.

b.Remove cooler access panel P/N L9387-1 and set aside. It is no longer needed.

c.Remove machine’s left side panel (adjacent to power input cord).

d.Disconnect coolant hoses’ mounting bracket from machine’s case back.

e.Disconnect all of the coolant hoses’ tie-down points. These plastic clips may be removed and discarded if desired.

f.Remove and save both fasteners from Power Wave base holding cooler in place. Carefully pull cooler rearward, partially out of the Power Wave.

g.Disconnect Molex in-line connectors P4 or P5 (cooler power) and P3 (cooler relay and pres- sure switch) and slide cooler completely from machine.

h.Optionally remove circuit breaker from case back and install replacement.

i.Peal off "coolant in / coolant out" decal from machine’s case back and discard. Remove residual adhesive from case back with an alco- hol wipe.

j.Remove auxiliary transformer #2 (mounted to Power Wave base, ahead of G2725 cooler) and set aside. It is no longer needed.

3.Slide electrical sleeving over the non-P4 connector in the Power Wave’s harness that runs from its ter- minal strip.

Fold sleeving over itself and firmly secure it to the harness with a cable tie.

4.Install cooler G3503-[ ]:

a.Install plugs into case back to fill coolant hose holes. Bend tabs as required to secure plugs in place.

b.Install new circuit breaker into case back if replacing the old part.

c.Install new P4 electrical harness into Power Wave:

Mate together the labeled P4 connectors.

Note: H[X]A lead in new harness carries 230

VAC cooler power: (See Table for [X] valve).

[X]

Power Wave

Wiring

 

Code Numbers

Diagram

 

 

 

2

10406

G2153-5

2

10431

G2153-4

2

10433

G2153-6

3

10106, 10195, 10366

G2153-1

3

10197, SPLC14895

G2153-2

3

10345, 10347

G2153-3

3

10512

G2153-7

3

10514, 10516

G2153-8

3

10520

G3177-1

 

 

 

Connect insulated terminals to circuit breaker (order is unimportant).

d.Connect P3 electrical extension harness to the machine.

e.Apply ground decal to cooler’s base:

Apply next to mounting screw hole nearest to circuit breaker.

f.Mate cooler’s connector to the P3 extension harness.

g.Mate cooler’s power connector to the P4 electri- cal harness.

h.Carefully slide retrofit cooler G3503-[ ] forward into Power Wave. Verify that front tabs on cool- er base are properly guided into slots in base of Power Wave (base’s underside may be exam- ined with a mirror and flashlight).

i.Attach ground lead in P4 harness to top of cool- er’s base or top of mounting bracket, ( if brack- ets are necessary). Secure cooler to Power Wave base by installing both fasteners.

j.Install Power Wave machine’s left side panel.

G3503-[ ] POWER WAVE 450 WATER COOLER UPGRADE KIT

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Contents General Description SafetyRecommended Coolants Recommended Tools for Installation or ServiceG3503- Installation or SER Vice Tool Usage S24505 Water Cooler Upgrade KIT ContentsReplacing a G2725 Cooler with a G3503- Cooler Installation InstructionsRemoving and Installing the G3503 Cooler G3503- Cooler Periodic Maintenance G3503- Cooler Service Cooler Assembly Parts Recommended Spare Parts are Highlighted in Bold Specified coolant level Cooler Electrical Harness PIN-OUTS

IM645-A specifications

The Lincoln Electric IM645-A is a highly regarded multi-process welding machine, designed to meet the needs of both professional welders and serious DIY enthusiasts. It seamlessly integrates multiple functionalities, allowing users to perform MIG, TIG, Stick, and flux-cored welding. This versatility makes it an essential tool in various applications, from metal fabrication to repairs and maintenance tasks.

One of the standout features of the IM645-A is its advanced inverter technology. This innovation reduces the machine's weight and size, making it more portable and easier to maneuver compared to traditional transformer-based welders. Additionally, the inverter technology provides superior energy efficiency, leading to lower operating costs over time.

The IM645-A is equipped with an intuitive digital display that provides real-time information on voltage, amperage, and other critical parameters. This user-friendly interface allows welders to make precise adjustments on-the-fly, ensuring high-quality welds across different materials and thicknesses. Furthermore, the machine supports a wide range of wire diameters, accommodating a variety of welding tasks.

A notable characteristic of the Lincoln Electric IM645-A is its robust construction. Built with high-quality materials, the machine is designed to withstand demanding work environments, ensuring durability and longevity. The cooling system is also well-designed, preventing overheating during prolonged use, which is an important factor for maintaining performance and extending the life of the machine.

The IM645-A supports advanced technologies such as Synergic Control, which automatically adjusts the welding parameters based on the chosen wire diameter and material type. This feature simplifies the setup process, allowing users to focus on the quality of their work rather than struggling with settings.

Moreover, safety is a top priority for Lincoln Electric, and the IM645-A includes multiple safety features such as overcurrent protection and thermal overload shutdown. These safeguards enhance user safety while minimizing the risk of damage to the machine itself.

In conclusion, the Lincoln Electric IM645-A stands out in the market for its multi-process capabilities, advanced inverter technology, user-friendly interface, durable construction, and safety features. Whether you're a seasoned professional or a hobbyist, this welding machine provides an excellent balance of performance, versatility, and reliability, making it a valuable addition to any workshop.