Miller COOLMATE 12 Owner's Manual

| June 1975 FORM: OM-621
MODEL STOCK NC
Coolmate 12 041 174
MODEL/STOCK NO. |SERIAL /STYLE NO. DATE
OWNER'S MANUAL
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
NWSA CODE NO. 4579
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WARRANTY
MILLER Electric Mfg. Co., Appleton, Wisconsin, warrants all new equipment to be free from defects in
material and factory workmanship for the periods indicated below, provided the equipment is installed and
operated according to manufacturer's instructions.
MILLER Electric Mfg. Co.'s obligation, under this warranty, is limited to replacing or repairing any defective
part or correcting any manufacturing defect without charge during the warranty period if MILLER’S inspec-
tion confirms the existence of such defects. MILLERS option of repair or replacement will be f.o.b. factory at
Appleton, Wisconsin or f.0.b. a MILLER authorized service facility, and therefore no compensation for trans-
portation costs of any kind will be allowed.
The warranty period, beginning on the date of sale to the original purchaser-user of the equipment, will be as
follows: |
1. Arcwelders, power sources, and components —— 1 year
2. Original main power rectifiers — 3 years (unconditionally)
3. MHFC-L1 Feeder, MHG-35C1, 20E, 20K,
and all guns and torches — 90 days
4. All other Millermatic Feeders — 1 year
5. Mag-Diesel engine on DEL-200 — 6 months
6. All other engines — 1 year
Engine Warranties are covered by the engine manufacturers, subject to their procedures and to be handled
through their authorized local Service Stations or agencies. No warranty will be made in respect to trade
accessories, such being subject to the warranties of their respective manufacturers.
MILLER Electric Mfg. Co. will not be liable for any loss or consequential damage or expense accruing
directly or indirectly from the use of equipment covered in this warranty.
This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or
warranties expressed or implied.
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—— SECTION ; - INTRODUCTION
1-1.
1-2.
Overali Dimensions Motor Motor | Ampere Tank
{Inches} Weight | Input Frequency | Speed Input | Capacity
Width | Height | Length | (Pounds) | Voltage | Phase | (Hertz) |I(RPM) | (Full Load} | (US Gallons}
31-1/4 | 11-1/16 23 112 |115VACI Single 60 1725 5.0 12
Figure 1-1. Specifications
GENERAL 1-4. SAFETY
This manual has been prepared especially for use in familiar-
izing personnel with the design, instaltation, operation, main-
tenance, and troubleshooting of this equipment. All informa-
tion presented herein should be given careful consideration to
assure optimum performance of this equipment.
RECEIVING-HANDLING
Prior to installing this equipment, clean all packing material
from around the unit and carefully inspect for any damage
that may have occurred during shipment. Any claims for loss
or damage that may have occurred in transit must be filed by
the purchaser with the carrier. A copy of the bill of lading
and freight bill will be furnished by the carrier on request if
occasion to file claim arises.
When requesting information concerning this equipment, it is
essential that Model Description and/or Stock Number and
Serial lor Style) Numbers of the equipment be supplied.
DESCRIPTION
This coolant system consists of an electric motor, steel tank,
and a high pressure pump to circulate the coolant. A bypass
valve is installed in the pump discharge line as a pressure
relief,
The delivery rate is as follows: {Water Coolant — 60°0F)
0 pounds pressure 1.49 gallons per minute
20 pounds pressure 1.35 gallons per minute
40 pounds pressure 1.21 gallons per minute
60 pounds pressure 1.07 gallons per minute
80 pounds pressure 0.94 gallons per minute
100 pounds pressure 0.80 gallons per minute
LOCATION (Figure 2-1)
Holes are provided in the coolant system top and bottom for
mounting purposes. The top holes are provided to mount the
welding power source onto the coolant system. The bottom
holes are provided to mount the coolant system onto a sta-
tionary object or optional running gear, if desired. Figure 2-1
gives overall dimensions and mounting hole layout.
2-7/8"
3/8"-1 6
4 Threaded
Holes
9/16" Dia.
4 Holes
25-1/2" а||
1-1/4" TC-003 557
Figure 2-1. Overall Dimensions and Mounting Hole Layout
SECTION 2- INSTALLATION
The following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
ERTL \
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may create a safety hazard to
| personnel, ]
IMPORTANT
Under this heading, installation, operating, and main-
tenance procedures or practices will be found that if
not carefully followed may result in damage to equip-
i ment. ]
Under this heading, explanatory statements wiil be
found that need special emphasis to obtain the most
efficient operation of the equipment.
2-2. ELECTRICAL INPUT CONNECTIONS {Figure 2-2)
Motor/Pumpb
Access Panel
Viewing
Pump
Bypass
Valve &
Pump Qutlet
Receptacie
Return Line
Receptacle
Coolant Tank
Access Door
e
Cap Nut »
. voor мег quer cord
Lubrication 8
Ритр Cups
TC-003 558
Figure 2-2. Component Location
OM-621 Page 1
2-3.
A three foot cord with attached three prong piug is provided
to conduct power from a 115 volts ac, 60 hertz power supply
to the coolant system. It is recommended that the welding
power source 115 VAC receptacle be utilized to provide 115
VAC power for the coolant system. By doing thusly, the
coolant system will be operative whenever the welding power
source is energized.
COOLANT CONNECTIONS (Figure 2-2)
A PUMP OUTLET receptacle and a RETURN LINE recep-
tacle are provided to connect the welding gun coolant hoses.
Both of these receptacles have left-handed threading.
3-1.
BYPASS VALVE (Figure 2-2)
A bypass valve is installed in the pump discharge line for
providing pressure relief, if the discharge line should be
closed for any reason. Factory setting of the bypass valve is
at 45 Ibs. pressure. Pressures up to 100 Ibs. may be used for
elevating coolant to approximately 100 feet. Pressures in
excess of 100 PSI should be avoided as this will overload the
motor.
To adjust the bypass valve pressure, remove the motor/pump
access panel. Remove the cap nut and turn the pressure
2-4,
COOLANT AND
{Figure 2-2) |
LUBRICANT INSTALLATION
Coolant system pumps require some lubricant in the coolant
to lubricate the packings of the pump. The suggested ratio is
about one quart to every twelve gallons of coolant. This unit
15 shipped with the proper amount of lubricant which is to be
added to the solution when the coolant system is first placed
into operation.
The coolant tank may be filled by 100sening the access door
screw and lifting the access door. The tank should then be
filled with coolant until the coolant level is to the center of
the viewing port. Replace the access door.
3-2.
adjustment screw clockwise to increase pressure. Replace cap
nut to lock the pressure adjustment screw at the desired
pressure. Replace the motor/pump access panel.
VIEWING PORT (Figure 2-2)
The viewing port purposes are twofold: When the coolant
ievel is in the center of the viewing port the coolant tank is
filled to the proper capacity. In addition, the splashing of the
coolant against the viewing port indicates that the coolant
system is functioning properly.
4-1,
Page 2
COOLANT SYSTEM TANK
Coolant system tanks should be cleaned and fresh coolant
and lubricant added periodically. For every twelve gallons of
coolant, a single teaspoonful of common laundry bleach
should be added to the coolant system after fresh coolant
and lubricant are added. The bleach prevents bacteria growth.
Useful life of the coolant mixture will be measurably
extended.
The use of demineralized coolant is also advised in the
i coolant system, if available. ]
4-2.
4-3.
COLD WEATHER MAINTENANCE
Where freezing conditions may be encountered, permanent
antifreeze may be substituted for the lubricant mentioned
above except that the mixture will be determined by the
temperature conditions anticipated. Permanent antifreeze has
sufficient lubricity for adequate pump lubrication. The pump
has graphite bearings which require no more lubrication than
that contained in the coolant.
MOTOR LUBRICATION {Figure 2-2)
The motor is provided with lubrication cups which shouid be
filled with SAE 20 oil periodically.
| June 1975 FORM: OM-621
MODEL STOCK NO.
Coolmate 12 041 174
MODE L/STOCK NO. SERIAL/STYLE NO. DATE PURCHASED
PARTS LIST
®
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
NWSA CODE NO. 4579
G66 £00-ad4
AJquassy aje|duroo — y aanbig
OM-621 Page 1
Item Factory
No. Part No. Description Quantity
Figure A Complete Assembly
1 010494 BUSHING, snap 1-3/8 ID X 1-3/4 hole .. oo oti re ite ee RR a LL 1
2 601890 RIVET, blind 1/8 dia 1/8 grip ................. 00.000 000íererrereorevocararede. 1
3 1000679 COVER, tank ......... eareracianedaorererereorneraranedaroeroererono oroeecue ramo 1
4 604 804 SCREW, sheet metal -hex washer hd No. 8X 3/8... citi ie te ee eee eee eee an 6
5 000678 TANK Lt ee ee La aan LL FE 1
6 603105 HOSE, braided 5/16 ID x 1 {order by foot) ........ ee ee La ea 4 4 44 La ea ee 5 ft.
/ 023562 CLAMP, hose 5/16 to 7/8 clamp dia.........222222 21001 a LL LL La a La a La aa aa A 5
8 602958 COUPLING, brass - male 1/4 ID hose 1/4 MPT .........., Ce ee ee ee. 4
9 035632 STRAINER ......... RR RR RR aa 1
10 602240 WASHER, flat - steel standard 1/4 ................ RER era LL 4
17 601 954 SCREW, cap - steel hex hd 1/4-20 x 3/4 1111111100 0 4440 0 44 a à ae a a La Rad ALL eae 5
12 000654 CORD SET, power 3ft.....22210 00102 LA 4e 44 4 4 a a a 8 ee a de 4 4 0 a a ea ea da a La aa ae 1
13 010610 CONNECTOR, clamp - cable 1/72 ......... 2... нее кники ee aa a de ee a a a aa aa a a an a 1
14 027803 MOTOR ......212 104 64484 4 a 4 844 RR A RAR Aa 4 4 4e a 4 4 A ee a 4 a eee a a aa ue 1
15 6010357 RECEPTACLE, clip on No. 2screw .....12212000 00124 a ea a a 8 a 8 a 8 a 4 0 a 4 eau a 4 ea a 0 aan 5
16 602 207 WASHER, lock - steel Split 1/4 1.000000 ite ee te ee eee ee ee ee eee ee ieee eens 5
17 601865 NUT, steel - hex {#011 1/4-20 .. 5... 5.5... ie ee RER RER ea 0 5
18 (010594 GROMMET, rubber 1/2 1D x 1 inch hole 1/16 groove ...........m_e.reavedadadnoaaonea 1
19 010678 ELBOW, brass - pipe street 90 degree 1/4 PT ..............e000- so nricorr rarecnerereo 3
20 010428 COUPLER, motor to pump ..........ee se. 9unedareaaaareada raro» eee hee 1
21 602180 SCREW, set - steel socket hd 5/16-18 x 1/4 ooo viii. ee 4
22 000848 PUMP, coolant «titre ee ee ee eee ee ee ne eee 1
23 000868 BRACKET, mounting- pump........qeew_woeeeroeerernroraoroooroeovarooranonedaoo 1
24 015715 GROMMET, rubber 11/16 1D x 1 inch hole 5/64 groove ...............eeesaexv e e eea, 1
25 010853 FASTENER, screw - slotted hd No. 2........e _ec-merredorreraaaroceararene na nena 5
26 000664 DOOR, access ..............eo—.—.memaroaaecrereraororoooaaooorodredraradrvarneererere. 1
27: 010855 RETAINER, screw NO. 2 ..........e es ]neeooreroorere.enerearanenmerónenennaea 5
28 000655 BLOCK, connecting ...........ñeeesxnenoonronanedarerenaneoonoaaoraarocornora co 1
29 010378 GROMMET, rubber 9/16 ID x 3/4 hole 1/16 groove ..........._eeoereroonooorooooaa. | 1
30 605795 SCREW, self tapping - flat hd 8-32 x 1/2 ..,....................,.. eee, 4
31 000741 PORTHOLE, view - Gauge oo oot tt ites tt tree tees tate etree eee etree ann, 1
32 000660 COVER, filler box iti ttt tt tet eee ete ee eee ees een 1
33 NAMEPLATE (order by stock, model and style numbers) ............eorrecvoerooreeras 1
34 602200 WASHER, lock - steel split No. 8 ............—...0r0-...r0n0a eerie 3
35 602082 SCREW, machine - steel round hd 8-32 X 1/2 «oir ee eee ieee 3
601 965 SCREW, cap - steel hex hd 3/8-16 x 1 {attaching tank to weldingunit) ................... 4
602 243 WASHER, flat - steel standard 3/8 {attaching tank to weldingunit) ...................... 4
602 224 WASHER, lock - steel split 3/8 {attaching tank to weldingunit} ........................ 4
BE SURE TO PROVIDE STOCK, MODEL, AND STYLE NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-621 Page 2