Lincoln Electric 12748 Service Manual
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Lincoln Electric 12748 Service Manual

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FlexCool ™ 35
For use with machines having Code Numbers:
FlexCool ™ 35: 12748
SERVICE MANUAL
SVM293
| Issue D ate 18-Sep
© Lincoln Global, Inc. All Rights Reserved.

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Summary of Contents for Lincoln Electric 12748

  • Page 1 FlexCool ™ 35 For use with machines having Code Numbers: FlexCool ™ 35: 12748 SERVICE MANUAL SVM293 | Issue D ate 18-Sep © Lincoln Global, Inc. All Rights Reserved.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...

  • Page 3: Section A: Warnings

    W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

  • Page 4: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    LINCOLN ELECTRIC FlexCool™ 35 Service Manual FlexCool™ 35 Service Manual Last update: 2018/09/01 FLEXCOOL™ 35 .............................. 1 Service Manual ..............................1 Troubleshooting & Repair ..........................3 HOW TO USE TROUBLESHOOTING GUIDE ..................... 3 PC BOARD TROUBLESHOOTING PROCEDURES ....................4 Troubleshooting guide ............................5 USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS ..............
  • Page 7 LINCOLN ELECTRIC FlexCool™ 35 Service Manual HEAT EXCHANGER REMOVAL AND REPLACEMENT PROCEDURE ..............38 PUMP MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE ............ 40 NTC THERMISTOR REMOVAL AND REPLACEMENT PROCEDURE ..............43 FAN REMOVAL AND REPLACEMENT PROCEDURE ..................45 LEVEL SWITCH REMOVAL AND REPLACEMENT PROCEDURE ............... 47 FLOW SWITCH REMOVAL AND REPLACEMENT PROCEDURE ..............

  • Page 8: Troubleshooting & Repair

    Troubleshooting & Repair HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 9: Pc Board Troubleshooting Procedures

    ELECTRIC SHOCK can kill. remove them until installation is complete. • If you return a PC board to The Lincoln Electric Company • Have an electrician install and service this for credit, it must be in the static-shielding bag. This will equipment.

  • Page 10: Troubleshooting Guide

    9. Perform the NTC Thermistor Test Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 11 4. Check for coolant leaks. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 12: Using The Status Led To Troubleshoot System Problems

    LINCOLN ELECTRIC FlexCool™ 35 Service Manual USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS The FlexCool 35 is equipped with a status light. If a problem occurs it is important to note the condition of the status lights. Therefore, prior to cycling power to the system, check the power source status light for error sequences in Table F.1.

  • Page 13: Error Codes

    LINCOLN ELECTRIC FlexCool™ 35 Service Manual ERROR CODES ERROR CODES Observe Safety Guidelines detailed in the beginning of this manual. ERROR CODE POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Communication error between Cycle power to the machine to power board and control see if error clears.
  • Page 14 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Peak current through the Verify connections to the transformer primary has switch board, transformer and exceeded threshold (140 output rectifier assemblies are amps). made correctly and there are no damaged components in the machine.
  • Page 15 LINCOLN ELECTRIC FlexCool™ 35 Service Manual The water cooler object was Connect a water cooler that not found and is required in the has a control board (FlexCool system. 35). If not using a water cooler, reset the 'Fault if No Cooler' attribute using Power Wave Manager Misc tab.
  • Page 16 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Trigger locked. Release the trigger before continuing. The trigger must be disabled at machine startup or when changing modes. The door to the Flexstart Close the Flexstart door and console is open. latch it tightly.
  • Page 17 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Thermistor missing. NTC thermistor is not plugged in, ambient temperature is too low or thermistor is damaged.

  • Page 18: Test Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 19 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.1 – Input power and arclink cable connections Figure F.2 – Coolant line connections...
  • Page 20 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.3 – Drawer assembly mounting screw locations...

  • Page 21: Arclink I/O Board Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 22 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Table F. 2 – Arclink I/O board voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING INPUT VOLTAGE FROM PLUG J61 PIN 4 PLUG J61 PIN 3 40 VDC ARCLINK RECEPTACLE (LEAD 52) (LEAD 51)
  • Page 23 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.4 – Arclink I/O board location Figure F.5 – Arclink I/O board plug and LED locations...
  • Page 24 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.6 – Arclink I/O board lead locations...

  • Page 25: 12 Vdc Relay Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 26 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.7 – 12 VDC relay location Figure F.8 – 12 VDC relay lead locations...

  • Page 27: Pump Motor Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 28 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.9 – Pump motor assembly location Figure F.10 – 12 VDC relay lead locations...

  • Page 29: Ntc Thermistor Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 30 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.11 – NTC Thermistor location Figure F.12 – Arclink I/O board plug J64 location...

  • Page 31: Fan Motor Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 32 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.13 – Fan locations Figure F.14 – Fan motor terminal locations...

  • Page 33: Level Switch Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 34 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Table F. 5 – Level switch resistance tests TEST POINT TEST POINT EXPECTED READING COOLANT LEVEL CLOSED MORE THAN .9 GALLONS PLUG J62 PIN 1 PLUG J62 PIN 6 (LOW RESISTANCE) OF COOLANT OPEN LESS THAN .9 GALLONS...
  • Page 35 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.16 – Arclink I/O board plug J62 terminal location...

  • Page 36: Flow Switch Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 37 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Table F. 6 – Flow switch resistance tests TEST POINT TEST POINT EXPECTED READING FLOW RATE MORE THAN .5 GALLONS CLOSED PLUG J62 PIN 2 PLUG J62 PIN 7 PER MINUTE COOLANT (LOW RESISTANCE)
  • Page 38 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.18 – Arclink I/O board plug J62 terminal locations...

  • Page 39: Removal And Replacement Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 40 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.19 –Arclink I/O board mounting nut locations Figure F.20 –Arclink I/O board plug locations...

  • Page 41: 12 Vdc Relay Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 42 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.21 – 12 VDC relay lead locations Figure F.22 – 12 VDC relay mounting hardware locations...

  • Page 43: Heat Exchanger Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 44 LINCOLN ELECTRIC FlexCool™ 35 Service Manual 2. Connect leads 31D, 32C, 31A and 32D to the fan terminals. See Wiring Diagram. Replace cable ties necessary. 3. Carefully position the 115 VAC receptacle and press into the machine. See Wiring Diagram.

  • Page 45: Pump Motor Assembly Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 46 LINCOLN ELECTRIC FlexCool™ 35 Service Manual 2. Using a 1/4” nutdriver, attach the screws securing the ground lead to the motor. See Wiring Diagram. 3. Using a 1/4” nutdriver, attach the two screws securing the cover plate to the motor.
  • Page 47 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.25 – Pump motor mounting hardware locations Figure F.26 – Motor terminal locations...

  • Page 48: Ntc Thermistor Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 49 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.27 – NTC mounting location Figure F.28 – Arclink I/O board plug J64 location...

  • Page 50: Fan Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 51 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.29 – Fan mounting nut locations...

  • Page 52: Level Switch Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 53 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.30 – Arclink I/O board plug J62 locations Figure F.31 – Level switch mounting location...

  • Page 54: Flow Switch Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 55 LINCOLN ELECTRIC FlexCool™ 35 Service Manual Figure F.32 – Flow switch mounting location Figure F.33 – Arclink I/O board plug J62 location...

  • Page 56: Retest After Repair

    LINCOLN ELECTRIC FlexCool™ 35 Service Manual RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components.

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Flexcool 35

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