Lincoln Electric IM645-A Installation Instructions, REPLACING A G2725 COOLER WITH A G3503- COOLER

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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