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Common questions
Common Questions
10 totalWhat coolant should I use in my Miller Coolmate 4 cooling system?
For GTAW welding or where high frequency current is used, use Low Conductivity Coolant (part 043810), distilled or deionized water (above 32°F), or Aluminum Protecting Coolant (043809). For GMAW welding or where high frequency current is not used, you can use Low Conductivity Coolant (043810), Aluminum Protecting Coolant (043809), or distilled/deionized water (above 32°F). Do not use conductive coolant. Using any coolant other than those listed voids the warranty on parts that contact the coolant.
How do I install and set up the Miller Coolmate 4?
Select the proper coolant from Section 4-3 and fill the tank, maintaining the coolant level at approximately 1 inch from the filler neck. Connect the coolant hoses (with 5/8-18 left-hand threads) to the Coolant In and Coolant Out fittings, not to a water valve if present on the power source. Plug the unit into a 115 Volt AC grounded receptacle on an individual branch circuit capable of carrying 15 amperes. The unit turns on automatically when plugged in.
What is the Miller Coolmate 4 cooling capacity and specifications?
The Coolmate 4 has a coolant tank capacity of 4 gallons (15 L), rated cooling power of 1.78 kW at 1.1 qt/min at 77°F (6070 BTU/hr at 1 L/min at 25°C), and maximum cooling power of 5.5 kW at 5.9 qt/min at 77°F. It operates on 115 VAC single phase at 50 or 60 Hz, drawing 5.9 A at 60 Hz or 4.7 A at 50 Hz. The unit weighs 44 lb and measures 18.75 x 15.25 x 16.25 inches.
What routine maintenance does the Coolmate 4 require?
Monthly: blow out heat exchanger fins and clean the coolant strainer (failure to clean voids pump warranty). Every 6 months: replace cracked hoses, replace unreadable labels, and change coolant if using water. Every 12 months: change coolant if using Miller brand coolant. Always turn off and unplug the unit before performing maintenance.
How do I change the coolant in the Coolmate 4?
Disconnect the cooler plug from the welding power source receptacle. Drain coolant by tipping the unit forward. Fill with clean water and run for 10 minutes, then drain and refill with the selected coolant. Dispose of used coolant according to national, state, and local codes—do not pour down the drain. If replacing hoses, use hoses compatible with ethylene glycol such as Buna-n, Neoprene, or Hypalon (oxy-acetylene hoses are not compatible).
What should I do if the Coolmate 4 has decreased or no coolant flow?
First, add coolant to the tank. Check for clogged hoses or a clogged coolant filter and clean or replace as needed. Disconnect the pump and check for a sheared coupling, replacing it if necessary.
Full Manual
19 pages
Coolmate4 Processes Description TIG (GTAW) Welding
Om-624
126174Aa
File: TIG (GTAW) CE And Non-CE 2017-03 MIG (GMAW) Welding For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided. Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System Standard. Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. From Miller to You Mil_Thank 2009−09
Table Of Contents
Section 1 − Safety Precautions - Read Before Using
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Cooling Equipment Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 2 − Consignes De Sécurité − Lire Avant Utilisation
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Symboles utilisés 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers liés aux équipements de refroidissement 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 3 . . . . . 2-4. Proposition californienne 65 Avertissements 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Principales normes de sécurité 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 3 − Definitions
5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Additional Safety Symbols And Definitions 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Miscellaneous Symbols And Definitions 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 4 − Specifications
7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Serial Number And Rating Label Location 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Specifications 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Coolant Specifications 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Environmental Specifications 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 5 − Installation
8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Connections 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 6 − Maintenance & Troubleshooting
9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Routine Maintenance 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Coolant Maintenance 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Adjusting Relief Valve 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Troubleshooting 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 7 − Electrical Diagram
11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section 8 − Parts List
11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Recommended Spare Parts 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPLETE PARTS LIST − Available at www.MillerWelds.comWarranty
Declaration Of Conformity
for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number Coolmate 3 043007,043008 Coolmate 3.5 300245 Coolmate 4 042288015 Council Directives: • 2014/35/EU Low voltage • 2014/30/EU Electromagnetic compatibility • 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment Standards: • IEC 60974-2:2013 Arc welding equipment – Part 2: Liquid cooling systems • IEC 60974-10:2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements Signatory: _____________________________________ ___________________________________________ David A. Werba Date of DeclarationManager, Product Design Compliance
March 24, 2017242094F
OM-624 Page 1
Section 1 − Safety Precautions - Read Before Using
coolers 2016-08 7 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or ex- plained in the text. NOTICE − Indicates statements not related to personal injury. Indicates special instructions. This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym- bols and related instructions below for necessary actions to avoid the hazards. 1-2. Cooling Equipment Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. HOT PARTS can burn. Do not touch hot parts bare handed. Allow cooling period before working on equipment. To handle hot parts, use proper tools and/or wear heavy, insu- lated welding gloves and clothing to prevent burns. FLYING METAL or DIRT can injure eyes. Wear approved safety glasses with side shields even under your welding helmet. Touching live electrical parts can cause fatal shocks or severe burns. The input power circuit and machine internal circuits are also live when power is on. Incorrectly installed or improperly grounded equip- ment is a hazard. ELECTRIC SHOCK can kill. Do not touch live electrical parts. Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes. Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring can kill. Turn off all equipment when not in use. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Keep all panels and covers securely in place. 1-3. Additional Symbols For Installation, Operation, And Maintenance FALLING EQUIPMENT can injure. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manu- ally lifting heavy parts or equipment. OVERUSE can cause OVERHEATING Allow cooling period; follow rated duty cycle. Do not block or filter airflow to unit.Read Instructions.
Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. Use only genuine replacement parts from the manufacturer. Perform installation, maintenance, and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
OM-624 Page 2 STEAM AND HOT COOLANT can burn. Hose may rupture if coolant overheats. Visually inspect condition of hoses before each use. Do not use damaged hoses. Allow cooling period before working on equipment. HIGH PRESSURE FLUIDS can injure or kill. Coolant can be under high pressure. Release pressure before working on cooler. If ANY fluid is injected into the skin or body seek medical help immediately. MOVING PARTS can injure. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power. 1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains or produces a chemical known to the state of California to cause cancer or birth defects (or other reproductive harm). (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Glob- al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Com- bustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protec- tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website: www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- site: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Applications Manual for the Revised NIOSH Lifting Equation, The Na- tional Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).
OM-624 Page 3
Section 2 − Consignes De Sécurité − Lire Avant Utilisation
Cooler 2016−08_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. AVIS − Indique des déclarations pas en relation avec des blessures personnelles. Indique des instructions spécifiques. Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger. 2-2. Dangers liés aux équipements de refroidissement Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité. Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil. Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil. LES PIÈCES CHAUDES peuvent provoquer des brûlures. Ne pas toucher à mains nues les parties chaudes. Prévoir une période de refroidissement avant de travailler à l’équipement. Ne pas toucher aux pièces chaudes, utiliser les outils recomman- dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux. Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger. UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort. Ne pas toucher aux pièces électriques sous tension. Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). Installez, mettez à la terre et utilisez correctement cet équipement conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales. Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes. Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu peut entraîner la mort. L’équipement doit être hors tension lorsqu’il n’est pas utilisé. N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ les pièces endommagées. Entretenir l’appareil conformément à ce manuel. S’assurer que tous les panneaux et couvercles sont correctement en place. 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures. Utiliser un équipement de levage de capacité suffisante pour lever l’appareil. En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur. Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds.L’Emploi
Excessif
peutSurchauffer L’Équipement.
Prévoir une période de refroidissement ; respecter le cycle opératoire nominal. Ne pas obstruer les passages d’air du poste.
OM-624 Page 4
Lire Les Instructions.
Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. N’utiliser que les pièces de rechange recommandées par le constructeur. Effectuer l’installation, l’entretien et toute intervention selon les manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux. Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux. Les PIÈCES MOBILES peuvent causer des blessures. S’abstenir de toucher des organes mobiles tels que des ventilateurs. Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié. Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.La Vapeur Et Le Liquide De
REFROIDISSEMENT CHAUD peuvent provoquer des brûlures. Un tuyau peut se rompre lorsque le liquide de refroidissement surchauffe. Vérifiez visuellement l’état des tuyaux avant chaque utilisation. N’utilisez pas de tuyaux endommagés. Laissez refroidir avant d’intervenir sur l’équipement.Les Liquides Sous Haute Pression
peuvent provoquer des blessures ou la mort. Liquide de refroidissement sous haute pression. Libérez la pression avant d’intervenir sur le refroidisseur. En cas d’injection d’un liquide QUELCONQUE dans la peau ou le corps, consultez immédiatement un médecin. 2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants) Ce produit contient ou forme un produit chimique reconnu par l’état de Californie de provoquer le cancer ou malformations de naissance (ou autre problèmes reproductifs. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants). Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation. 2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website: www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).
A complete Parts List is available at www.MillerWelds.com OM-624 Page 5
Section 3 − Definitions
3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Disconnect input plug or power before working on machine. Safe30 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information. Safe37 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05Xxxxx
Use coolant suggested by the manufacturer. Safe52 2012−05 Recycle. Safe103 2012−09 Read the Owner’s Manual before working on this machine. Safe70 2012−06 Read the labels on the welding power source, wire feeder, or other major equipment for welding safety information. Safe71 2012−06 Safe50 2012−05 Plugged filter or hoses can cause overheating to the power source and torch. 100 h. Std. Safe51 2012−05 Every 100 hours, check and clean filter and check condition of hoses.
A complete Parts List is available at www.MillerWelds.com OM-624 Page 6 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products.
A
AmperesV
Volts Hz Hertz Alternating Cur- rent Water (Coolant) InputIp
Degree Of ProtectionU1
Primary Voltage Water (Coolant) OutputI1
Primary Current Single Phase Line Connection Cooling I1max Rated Maximum Supply CurrentP1
Rated Cooling Power pmax Rated Maximum Pressure Notes
A complete Parts List is available at www.MillerWelds.com OM-624 Page 7
Section 4 − Specifications
4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the lower right side. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on cover of this manual. 4-2. Specifications The correction factor on the cooling power at an ambient temperature of 104F (40C) is 0.625. Recirculating Coolant System For Water-Cooled GTAW Torches And GMAW Guns Use With Guns/Torches Rated Up To 600 Amperes Coolant Tank Capacity 4 gal (15 L) Rated Cooling Power 1.78 kW at 1.1 qt/min at 77°F (6070 BTU/hr at 1 L/min at 25°C) Maximum Cooling Power 5.5 kW at 5.9 qt/min at 77°F (18,000 BTU/hr at 5.6 L/min at 25°C) Dimensions (Length x Width x Height) 18.75 x 15.25 x 16.25 in. (476 x 387 x 413 mm) Weight 44 lb (20 kg) Input Voltage 115 VAC, Single Phase, 50 or 60 Hz Input Amperage 5.9 A 60 Hz 4.7 A 50 Hz 4-3. Coolant Specifications Do not use conductive coolant. Application Coolant GTAW Or Where High Frequency Current Is Used Low Conductivity Coolant 043810* Distilled Or Deionized Water Okay Above 32°F (0°C) GMAW Or Where High Frequency Current Is Not Used Low Conductivity Coolant 043810* Aluminum Protecting Coolant 043809* Distilled Or Deionized Water Okay Above 32°F (0°C) Where Coolant Contacts Aluminum Parts Aluminum Protecting Coolant 043809* *Coolants 043810 and 043809 protect to -37°F (-38°C) and resist algae growth. NOTICE − Use of any coolant other than those listed in the table voids the warranty on any parts that come in contact with the coolant (pump, radiator, etc.). 4-4. Environmental SpecificationsA.
IP Rating IP RatingIp21
This equipment is designed for indoor use and is not intended to be used or stored outside.Ip21 2014−06
B.
Information On Electromagnetic Compatibility (EMC) ! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low− voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con- ducted as well as radiated disturbances. This equipment complies with IEC 61000-3-11 and IEC 61000-3-12. ce-emc 4 2014-07C.
Temperature Specifications Operating Temperature Range Storage/Transportation Temperature Range 14 to 104 °F (-10 to 40°C) −4 to 131°F (−20 to 55°C) Temp1_2016- 08
A complete Parts List is available at www.MillerWelds.com OM-624 Page 8
Section 5 − Installation
5-1. Connections160556-A / 160555-C
! Do not move or operate unit where it could tip. To prevent overheating, make sure cooling unit is positioned so airflow is not restricted. NOTICE − If welding power source has a water valve, do not connect hoses to water valve. Connect hoses as shown. 1 Filler Cover 2 Coolant Out 3 Coolant In Fittings have 5/8-18 left-hand threads. See Section 4-3 to select proper coolant, and fill tank. Maintain cool- ant level at approximately 1 in. (25 mm) from filler neck. 4 115 Volt AC Grounded Re- ceptacle Unit turns On when plugged in. An individual branch circuit capable of carrying 15 amperes and pro- tected by fuses or circuit breakers is recommended. Recommended fuse or circuit breaker size is 15 amperes. GTAW Connections GMAW Connections 1 2 3 4 Tools Needed: 5/8 in. 1 2 3 4
A complete Parts List is available at www.MillerWelds.com OM-624 Page 9
Section 6 − Maintenance & Troubleshooting
6-1. Routine Maintenance ! Turn Off all power and unplug unit before maintaining. 1 Month Blow Out Heat Exchanger Fins NOTICE − Clean coolant strainer. Severe condi- tions may require more frequent cleaning (contin- uous use, high/low temperatures, dirty environ- ment, etc.). Failure to properly clean coolant strainer voids pump warranty. 6 Months Replace Cracked Hoses Replace Unreadable Labels Change Coolant (If Using Water) 12 Months Change Coolant (If Using Miller Coolant) 6-2. Coolant Maintenance 1 15/16 in. Tools Needed:160559-A
! Disconnect cooler plug from welding power source receptacle before maintaining. ! Dispose of used coolant accord- ing to national, state, and local codes. Do not pour down drain. 1 Coolant Filter Remove nut to remove filter. Clean filter and reinstall. Changing Coolant Drain coolant by tipping unit forward. Fill with clean water and run for 10 minutes. Drain and refill. NOTICE − If replacing hoses, use hoses compatible with ethylene glycol, such as Buna-n, Neoprene, or Hypalon. Oxy-acetylene hoses are not compati- ble with any product containing ethylene glycol.
A complete Parts List is available at www.MillerWelds.com OM-624 Page 10 Tools Needed: 6-3. Adjusting Relief Valve
160558-B
Relief valve is factory set at 60 psi (414 kPa), and normally needs no adjustment: Only ad- just if replacing motor. 1 Pressure gauge 2 Relief Valve Adjustment Screw Connect gauge to Coolant Out fit- ting as shown. Block or plug any output fitting on gauge. Turn On power, and adjust pres- sure adjustment screw as needed. Turn Off power. Disconnect gauge and reinstall nut. 3/4 in. 2 1 Increase Decrease 6-4. Troubleshooting Trouble Remedy Coolant system does not work. Be sure input power cord is plugged in to energized receptacle. Check line fuses or circuit breaker, and replace or reset if necessary. Motor overheated. Unit starts running when motor has cooled. Have Factory Authorized Service Agent check motor. Decreased or no coolant flow. Add coolant. Check for clogged hoses or coolant filter. Disconnect pump, and check for sheared coupling. Replace coupling if necessary.
A complete Parts List is available at www.MillerWelds.com OM-624 Page 11
Section 7 − Electrical Diagram
187313Section 8 − Parts List
8-1. Recommended Spare Parts Description Part No. Dia. Mkgs. Recommended Spare Parts Quantity 146249 Strainer, Screen 100x90 Mesh 2.125 Lg X .687 Dia 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes 16 Gauge (.063 in.) 22 Gauge (.031 in.) 24 Gauge (.025 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in. (.313 in.) 3/8 in. (.375 in.) 1/2 in. (.5 in.)
Material Thickness Reference Chart
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
Effective January 1, 2017 (Equipment with a serial number preface of MH or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
Lieu Of All Other Warranties, Express Or Implied,
Including The Warranties Of Merchantability And
Fitness.
Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. If notification is submitted as an online warranty claim, the claim must include a detailed description of the fault and the troubleshooting steps taken to identify failed components and the cause of their failure. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed twelve months after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor.(Note:
Digital Recorders are Warranted Separately by the Manufacturer.)Miller Products Are Intended For Purchase And
Use By Commercial/Industrial Users And Persons
Trained
And
Experienced
In
The
Use
And
Maintenance Of Welding Equipment.
In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.To The Extent Permitted By Law, The Remedies
Provided Herein Are The Sole And Exclusive
Remedies. In No Event Shall Miller Be Liable For
Direct,
Indirect,
Special,
Incidental
Or
Consequential Damages (Including Loss Of Profit),
Whether Based On Contract, Tort Or Any Other
Legal Theory.
Any Express Warranty Not Provided Herein And Any
Implied Warranty, Guaranty Or Representation As
To Performance, And Any Remedy For Breach Of
Contract Tort Or Any Other Legal Theory Which,
But For This Provision, Might Arise By Implication,
Operation Of Law, Custom Of Trade Or Course Of
Dealing, Including Any Implied Warranty
Of
Merchantability
Or
Fitness
For
Particular
Purpose, With Respect To Any And All Equipment
Furnished By Miller Is Excluded And Disclaimed By
Miller.
Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. Warranty Questions? Call1-800-4-A-Miller
for your local Miller distributor. miller_warr 2017-01 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
Original Instructions − Printed In Usa
© 2017 Miller Electric Mfg. Co. 2017−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Please complete and retain with your personal records. Always provide Model Name and Serial/Style Number. Contact a DISTRIBUTOR or SERVICE AGENCY near you. Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to: For Service Owner’s Record File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. Contact your Distributor for:To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller