Miller COOLMATE 3 Owner's Manual

OWNER’S MANUAL

OM-628

February 2000

And Non-CE Models

174 791G

Coolmate



3

1.

Specifications

Recirculating Coolant System For Water-Cooled GTAW Torches And GMAW Guns

Use With Guns/Torches Rated Up To 600 Amperes

IP Rating: 23

3 gal (11.4 L) Coolant Tank Capacity;

Maximum Cooling Capacity: 14,000 BTU/hr At 1.25 qt/min (1.2 L/min)

115 Volt Models Use 5.9 Amperes, 50/60 Hertz, Single-Phase Input Power

230 Volt Models Use 3 Amperes, 50/60 Hertz, Single-Phase Input Power

2.

Safety Symbol Definitions

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

Symbole graphique d’avertissement! Attention! Cette procédure comporte des risques possibles! Les dangers

éventuels sont représentés par les symboles graphiques joints.

Beware of electric shock from wiring.

Attention! Risque d’électrocution due au contact avec des fils.

Have only trained and qualified persons install, operate, or service this unit. Call your distributor if you do not understand the directions. For WELDING SAFETY and

EMF information, read wire feeder and welding power source manuals.

L’installation, l’exploitation et l’entretien de cet appareil doivent être confiés uniquement à des personnes qualifiées et convenablement formées. S’adresser à un distributeur si l’on ne comprend pas les directives. Pour des renseignements ayant trait à la SÉCURITÉ lors du soudage et aux champs électromagnétiques, consulter les manuels traitant les dévidoirs et les sources de courant pour le soudage.

Beware of moving parts.

Attention! Pièces en mouvement.

Wear safety glasses with side shields.

Porter des lunettes de sécurité avec protections latérales.

Recycle or dispose of used coolant in an environmentally safe way.

Recycler ou éliminer tout liquide de refroidissement usé conformément aux méthodes prescrites pour assurer la protection de l’environnement.

3.

Warning Label Definitions For CE Products

1 2 3 4 5

6

1 Warning! Watch Out! There are possible hazards as shown by the symbols.

2 Electric shock from wiring can kill.

3 Disconnect input plug or power before working on machine.

7

4 Moving parts, such as fans, can cut fingers and hands and cause injury.

Keep away from moving parts.

5 Wear safety glasses with side shields.

6 Read the Owner’s Manual before working on this machine.

7 Read the labels on the welding power

S-180 663

8 9 source, wire feeder, or other major equipment for welding safety information.

8 Recycle or dispose of used coolant in an environmentally safe way.

9 Do not remove or paint over (cover) the label.

1 2 3

100 h. std.

4

6 =

5

7

043 810 (HF)

043 809 (AL)

S-178 910

1 Warning! Watch Out! There are possible hazards as shown by the symbols.

2 Disconnect input plug or power before working on machine.

3 Wear safety glasses with side shields.

4 Plugged filter or hoses cause overheating and damage.

5 Read Owner’s Manual.

6 Check and clean filter every 100 hours; also check condition of hoses.

7 Use Low Conductivity Coolant No. 043

810 for High-Frequency assisted or

Gas Tungsten Arc Welding applications. Use Aluminum Protecting

Coolant No. 043 809 where coolant contacts aluminum parts or for Gas

Metal Arc Welding applications or where High Frequency is not used.

4/96

OM-628 Page 2

4.

Rating Label

U

1

I

1

=

LR5071

NRTL/C

S/N: KG085472

043007

COOLMATE 3

115 V

5.9

A

1 50/60 Hz

IP 23

5.

Symbols And Definitions

NOTE

Some symbols are found only on CE products.

A

Amperes

V

Volts

Protective Earth

(Ground)

On

Alternating Current

Water (Coolant) Input

IP

Degree Of

Protection

I

1

Off

U

1

Voltage Input

Water (Coolant)

Output

Primary Current

Primary Voltage

Circulating Unit

With Coolant Pump

Line Connection

Hz

Hertz

Single Phase

OM-628 Page 3

6.

Preparing Cooling Unit For Use

1 Coolant Out Hose

2 Coolant In Hose

Fittings have 5/8-18 left-hand threads. Connect hoses with proper fittings as shown.

3 Coolant Tank Cap

Use table to select proper coolant, and fill tank. Maintain coolant level at approximately 1 in (25 mm) below top of filler neck.

4 Flow Indicator

5 Power Switch

1

2

3

4 5

Application

GTAW Or Where

HF* Is Used

GMAW Or Where

HF* Is Not Used

Low Conductivity Coolant

No. 043 810**;

Distilled Or Deionized Water

OK Above 32

°

F (0

°

C)

Low Conductivity Coolant

No. 043 810**; Or

Aluminum Protecting Coolant

No. 043 809**;

Distilled Or Deionized Water

OK Above 32

°

F (0

°

C)

Coolant

*HF: High Frequency Current

**Coolants 043 810 and 043 809 protect to -37

°

F (-38

°

C) and resist algae growth.

Y

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.).

Where Coolant Contacts

Aluminum Parts

Aluminum Protecting

Coolant No. 043 809**

Tools Needed:

5/8 in

ST-801 193-B

OM-628 Page 4

7.

Connections

GTAW Connections

1

1 Lift -Eye

If placing cooling unit on welding power source, slots are provided in bottom of unit so it fits over lift-eye.

To prevent overheating, make sure cooling unit is positioned so airflow is not restricted.

Y

If welding power source has a water valve, do not connect hoses to water valve. Connect hoses as shown.

Operation:

Turn power switch On. Flow indicator spins to indicate that at least

0.53 qt/min (0.5 L/min) of coolant is flowing.

GMAW Connections

ST-801 190-B / ST-801 191-B

OM-628 Page 5

8.

Routine Maintenance

3 Months

Y

Clean coolant strainer. Severe conditions may require more frequent cleaning (continuous use, high/low temperatures, dirty environment, etc.). Failure to properly clean coolant strainer voids pump warranty.

6 Months

Replace

Cracked

Hoses

Change

Coolant (If

Using Water)

12 Months

Oil Motor

Y Disconnect power before maintaining.

Blow Out Heat

Exchanger Fins

Replace

Unreadable

Labels

Change

Coolant (If

Using 043 809 or 043 810

Coolant)

9.

Coolant Maintenance And Oiling Motor

1

1 Coolant Filter

Unscrew housing to clean filter.

Changing coolant: Drain coolant by tipping unit forward. Fill with clean water and run for 10 minutes. Drain and refill.

2 Motor

Remove plugs and put about 15 drops of SAE 20 motor oil into each oil port. Replace plugs.

.

If replacing hoses, use hoses compatible with ethylene glycol, such as Buna-n, Neoprene, or Hypalon. NOTE:

Oxy-acetylene hoses are not compatible with any product containing ethylene glycol.

2

Tools Needed:

3/8 in

ST-801 195-B / Ref. ST-801 194

OM-628 Page 6

10. Troubleshooting

Trouble

Coolant system does not work.

Decreased or no coolant flow.

Remedy

Be sure input power cord is plugged in to energized receptacle.

Check line fuses or circuit breaker, and fuses F1, F2 if applicable, and replace or reset if necessary.

Motor overheated. Unit starts running when motor has cooled.

Have Factory Authorized Service Agent check Power switch S1 and motor Mot.

Add coolant.

Check for clogged hoses or coolant filter. Clean filter or clean / replace hoses if necessary.

Disconnect pump, and check for sheared coupling. Replace coupling if necessary.

F1

F2

SA-187 733

SA-135 796-D

Figure 10-1. Circuit Diagram For 115 And 230 Volt Figure 10-2. Circuit Diagram For 230 Volt (CE Models)

OM-628 Page 7

11. Parts List

*Included in Item 24

ST-801 196-H

Figure 11-1. Complete Assembly

Item

No.

Dia.

Mkgs.

Description

Figure 11-1. Complete Assembly

Quantity

. . . . 1 . . . . . . . . . . . . . . . +166 562

. . . . 2 . . . . . . . . . . . . . . . . . 192 449

. . . . 3 . . . . . . . . . . . . . . . . . 197 361

. . . . 4 . . . . . . . . . . . . . . . . . 126 978

. . . . 5 . . . . . . . . . . . . . . . . . 134 795

. . . . 6 . . . . . . . . . . . . . . . . . 196 990

. . . . 7 . . . . . . . . . . . . . . . . . 089 120

. . . . 8 . . . . . . . . . . . . . . . . . 196 991

. . . . 9 . . . . . MOT . . . . . . . 173 264

. . . . 9 . . . . . MOT . . . . . . . 173 263

. . . . 10 . . . . . . . . . . . . . . . . . 166 570

. . . . 11 . . . . . . . . . . . . . . . . . 174 044

. . . . 12 . . . . . . . . . . . . . . . . . 094 263

. . . . 13 . . . . . . . . . . . . . . . . . 192 454

. . . . 14 . . . . . . . . . . . . . . . . . 139 042

. . . . 15 . . . .

. . . . 15 . . . .

PLG1

PLG1

. . . . . . 192 458

. . . . . . 192 457

. . . . 15 . . . . PLG1 . . . . . . 192 456

. . . . 16 . . . . . . . . . . . . . . . . . 196 515

. . . . 17 . . . . . . . . . . . . . . . . . 168 267

. . . . 18 . . . . . . . . . . . . . . . . . 174 043

. . . . 19 . . . . . . . . . . . . . . . . . 166 608

. . . . 20 . . . . . . . . . . . . . . . . . 182 994

. . . . 21 . . . . . . . . . . . . . . . . . 136 369

. . . . 22 . . . . . . . . . . . . . . . . . 136 731

. . . . 23 . . . . . . . . . . . . . . . . . 166 560

. . . . 24 . . . . . . . . . . . . . . . . . 166 564

. . . . 25 . . . . . . . . . . . . . . . . . 168 254

. . . . . . . . . . . F1, F2 . . . . . . 011 116

. . . . . . . . . . . . . . . . . . . . . . . . 098 376

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . . . .

. . . . . . . .

. . . . . .

WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP COOLANT w/CLAMPS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FITTING, hose brs barbed M 3/8tbg x 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COUPLER, drive pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FITTING, hose brs barbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

CLAMP, hose .375 – .450 clip

HOSE, nprn brd no 1 x .250ID

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTOR, 1/4hp 230VAC 50/60Hz 1425/1725rpm (230V model) . . . . . . . . . . . . . . . . . . . . . . . .

MOTOR, 1/4hp 115VAC 50/60Hz 1425/1725rpm (115V model)

BLADE, fan 9.000 5wg 38deg .500 bore cw (setscrew included)

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

TUBING, PVC .375 x .625 OD X 18.000

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLAMP, 1-ear type nom dim .718 x .276 wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BUSHING, strain relief .270/.480 id x .804 mtg hol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

CABLE, power 16ga 3c (230V model)

CABLE, power 10ft 16ga (115V model)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE, pwr 10ft (230V CE Models only)

RADIATOR, heat exchanger

CAP, tank screw-on w/vent

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TANK COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TUBING, PVC .375 ID x .625 OD x 1.250

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TUBE, pick-up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TUBING, PVC .375 ID x .625 OD x 10.000

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOSE, nprn brd No. 1 x .375 ID x 10.50 black

RING, ring ext .500 shaft grv x .042thk

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FILTER, in-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLIP, filter mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUSE, mintr gl slo-blo 7A 250V (230V CE Models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOLDER, fuse mintr (230V CE Models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

2

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

OM-628 Page 8

Part

No.

043 007

043 008

Item

No.

Dia.

Mkgs.

Part

No.

043 007

043 008

Description

Figure 11-1. Complete Assembly (Continued)

Quantity

. . . . 26 . . . . . . . . . . . . . . . . .

. . . . 27 . . . . . . . . . . . . . . . . .

. . . . 28 . . . . . . . . . . . . . . . . .

186 003

166 568

166 566

. . . . . . INDICATOR, flow (consisting of)

. . . . . . . .

. . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PADDLE, flow indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O-RING, 1.301 ID x .070CS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . .

29

30

. . . . . . . . . . . . . . . . .

. . . . . S1 . . . . . . . .

186 005

177 396

. . . . 31 . . . . . . . . . . . . . . . . . 177 399

. . . . . . . .

. . . . . .

LENS, flow indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCH, rocker DPST 15A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. . . . 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 33 . . . . . . . . . . . . . . . . . 166 571 . . . . . .

PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NAMEPLATE, (order by model and serial number)

FITTING, coolant barbed 3/8tbg 5/8-18 female

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

1

1

1

1

1

1

1

2

OM-628 Page 9

Declaration of Conformity for

European Community (CE) Products

NOTE

This information is provided for units with CE certification (see rating label on unit).

Manufacturer’s Name:

Manufacturer’s Address:

Miller Electric Mfg. Co.

1635 W. Spencer Street

Appleton, WI 54914 USA

Declares that the product:

COOLMATE



3 conforms to the following Directives and Standards:

Directives

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Low Voltage Directive: 73/23/EEC

Machinery Directives: 898/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC

Standards

Electromagnetic compatibility (EMC) Product standard for arc welding equipment: EN50199: August 1995

Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1989

Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1 (April 1995 - Draft revision)

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989

European Contact:

Telephone:

Fax:

Danilo Fedolfi, Managing Director

ITW WELDING PRODUCTS ITALY S.r.l.

Via Privata Iseo 6/E

20098 San Giuliano

Milanese, Italy

39(02)98290-1

39(02)98290-203

U

1

I

1

=

S/N: KG085472

043007

COOLMATE 3

115 V

5.9

A

1 50/60 Hz

IP 23

MILLER ELECTRIC MFG. CO., APPLETON, WI USA



1996 MILLER Electric Mfg. Co.

dec_con1_11/02