Miller COOLMATE 3.5 User manual

Miller COOLMATE 3.5 User manual
OWNER’S MANUAL
OM-231 313E
2008−01
Coolmate™ 3.5
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
3-1/2 gal (13.2 L) Coolant Tank Capacity;
Maximum Cooling Capacity: 15,000 BTU/hr At 1.25 qt/min (1.3 L/min)
804 839-A
2.
Dimensions: 26 in (660 mm) Long, 15
15-3/4
3/4 in (400 mm) Wide, 11
11-3/4
3/4 in (298 mm) High
Weight: 60 lb (27 kg)
115 Volt Models Use 3.1 Amperes, 50/60 Hertz, Single-Phase Input Power
Safety Symbol Definitions
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.
Wear safety glasses with side shields.
Porter des lunettes de sécurité avec des protections latérales.
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.
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 explained in
the text.
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.
NOTICE
Indicates statements not related to personal injury.
Indique des déclarations pas en relation avec des blessures personnelles.
Indicates special instructions.
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 owner’s manual(s).
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 les
renseignements ayant trait à la SECURITE 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. Keep guards and panels in
place, covers closed, and hands away from moving parts.
Attention aux pièces mobiles. Maintenir les dispositifs de
sécurité et les panneaux en place, les couvercles fermés
et garder les mains éloignées des pièces mobiles.
Indique des instructions spécifiques.
Beware of electric shock from wiring. Disconnect input
power before installing this kit. Reinstall all panels and
covers.
Prendre garde aux chocs électriques dus au câblage.
Avant d’installer cet ensemble, couper l’alimentation.
Réinstaller tous les panneaux et couvercles.
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.
Declaration of Conformity for
European Community (CE) Products
. This information is provided for units with CE certification (see rating label on unit).
Manufacturer:
European Contact:
Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that the product:
CoolmateE 3.5
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC, 2006/95/EC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC, 2004/108/EC
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Marking Directive: 93/68/EEC
Standards
Arc Welding Equipment − Part 2: Liquid Cooling Systems. IEC 60974-2 Ed. 1, 2202-06
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10, Ed. 1.1, 2004-10
Degrees of Protection Provided By Enclosure (IP Code): IEC 60529 Ed. 2.1, 2001-02
Insulation Coordination For Equipment Within Low-Voltage Systems − Part 1: Principles, Requirements, And Tests.
IEC 60664-1 Ed. 1.1
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_cooler_1/07
© 2007 MILLER Electric Mfg. Co.
3.
Warning Labels
OM-231 313 Page 1
4.
Warning Labels Continued
1
2
3
4
5
S-180 663
1
6
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.
4
5
6
7
7
Moving parts, such as fans, can cut
fingers and hands and cause injury.
Keep away from moving parts.
Wear safety glasses with side shields.
Read the Owner’s Manual before
working on this machine.
Read the labels on the welding power
1
8
9
8
9
source, wire feeder, or other major
equipment for welding safety
information.
Recycle or dispose of used coolant in
an environmentally safe way.
Do not remove or paint over (cover)
the label.
2
3
100 h. std.
4
=
6
5
7
043 810 (HF)
043 809 (AL)
S-178 910
1
2
3
4
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Disconnect input plug or power before
working on machine.
Wear safety glasses with side shields.
Plugged filter or hoses cause
OM-231 313 Page 2
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.
5.
Rating Label
S/N: KG085472
043007
COOLMATE 3
U1
=I1=
1
50/60 Hz
IP 23
LR5071
NRTL/C
231 308-B
6.
Symbols And Definitions
Hz
I1max
Hertz
Input Power
Power On Indicator
Water (Coolant) Input
Line Connection
Single-Phase
Alternating
Current
Rated Maximum
Supply Current
IP
Degree Of
Protection
Pmax
Rated maximum
power
Water (Coolant)
Output
U1
Pl/min
Primary Voltage
Power liters per
minute
OM-231 313 Page 3
7.
Coolant Chart
GTAW Or Where
HF* Is Used
Application
Low Conductivity Coolant No. 043 810**; Distilled Or Deionized Water OK Above 32° F (0° C)
Coolant
*HF: High Frequency Current
**Coolant 043 810, a 50/50 solution, protects to -37° F (-38°C) and resist algae growth.
NOTICE − Use of any coolant other than that listed in the table voids the warranty on any parts that come in contact with the coolant (pump,
radiator, etc.).
Notes
OM-231 313 Page 4
8.
GTAW Connections
4
3
2
1
Tools Needed:
5/8 in
804 846-A
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
Coolant Out Hose
2
Coolant In Hose
Fittings have 5/8-18 left-hand threads.
Connect hoses with proper fittings as
shown. Some power sources may require
a TIG block.
3
Coolant Tank Cap
4
115 Volt AC Grounded Receptacle
An individual branch circuit capable of carrying 15 amperes and protected by fuses
or circuit breakers is recommended. Rec-
ommended fuse or circuit breaker size is
15 amperes.
Operation:
Fill tank with proper coolant. Use table in
Section 7 to select proper coolant. Maintain
coolant level at approximately 1 in (25 mm)
below top of filler neck. Connect hoses as
shown. Unit turns on when plugged in.
OM-231 313 Page 5
9.
GMAW Connections
4
3
2
1
Tools Needed:
5/8 in
804 845-A
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
Coolant Out Hose
2
Coolant In Hose
OM-231 313 Page 6
Fittings have 5/8-18 left-hand threads.
Connect hoses with proper fittings as
shown.
3
Coolant Tank Cap
4
115 Volt AC Grounded Receptacle
An individual branch circuit capable of carrying 15 amperes and protected by fuses
or circuit breakers is recommended. Rec-
ommended fuse or circuit breaker size is
15 amperes.
Operation:
Fill tank with proper coolant. Use table in
Section 7 to select proper coolant. Maintain
coolant level at approximately 1 in (25 mm)
below top of filler neck. Connect hoses as
shown. Unit turns on when plugged in.
10. Routine Maintenance
!
Δ = Repair
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
Disconnect power
before maintaining.
l = Replace
~ Blow out heat exchanger fins.
nCheck coolant level. Top off with
distilled or deionized water if necessary.
~
~Coolant
Strainer,,
d i heavy
durning
h
service,
i
clean more frequently.
Every
6
Months
nlHoses
nl Labels
ZReplace coolant.
11. Coolant Maintenance And Oiling Motor
!
Disconnect input power before maintaining.
1
Coolant Filter
Unscrew housing to clean filter.
1
Changing coolant: Drain coolant by
tipping unit to rear, or use suction
pump. Fill with clean water and run
for 10 minutes. Drain and refill with
coolant (see section 7).
.
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.
Install cover if removed.
Tools Needed:
m30 Torx
804 649-A / Ref. 801 194
OM-231 313 Page 7
12. Troubleshooting
Trouble
Coolant system does not work.
Remedy
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 Power switch S1 and motor (Mot).
Decreased or no coolant flow.
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.
13. Circuit Diagram For Cooler
228 525-B
OM-231 313 Page 8
Notes
OM-231 313 Page 9
14. Parts List
7
6
11
8
12
2
1
18
9
41
10
5
39
4
16
15
42
31
13
40
43
3
36
17
14
21
22
37
23
24
35
34
33
28
32
27
26
25
20
15
15
29
30
19
38
804 838-C
Figure 13-1. Complete Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
. . . . . . . . . . 230 156
. . . . . . . . . +192 449
. . . . . . . . . . 228 551
. . . . . . . . . . 226 965
. . . . . . . . . . 228 519
. . . . . . . . . . 228 508
. . . . . . . . . . . . . 5523
. . . . . . . . . . 173 999
. . . . . . . . . . 134 795
. . . . . . . . . . 196 990
. . . . . . . . . . 173 263
. . . . . . . . . . 226 966
. . . . . . . . . . 166 608
. . . . . . . . . . 226 932
. . . . . . . . . . 228 529
. . . . . . . . . . 155 436
. . . . . . . . . . 163 562
. . . . . . . . . . 231 308
. . . . . . . . . . 213 053
. . . . . . . . . . 230 151
. . . . . . . . . . 226 940
. . . . . . . . . . 230 155
. . . . . . . . . . 226 964
. . . . . . . . . . 226 931
. . . . . . . . . . 232 424
. . . . . . . . . . 231 341
OM-231 313 Page 10
. . Cover, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, warning/caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Plug, W/Leads Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, nprn brd no 1 X .250 ID X .455 OD X 9.000 . . . . . . . . . . . . . . . . . . . . . .
. . Pump, Coolant W/Fittings (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ftg, Hose Brs Barbed Elbow M 3/8 TBG X 3/8 NPT . . . . . . . . . . . . . . . . . . .
. . . . Pump, Coolant 100 Gph W/Clamps Cw Rotation . . . . . . . . . . . . . . . . . . . . . .
. . . . Coupler, Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ftg, Brs Barbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, 1/4hp 115vac 50/60hz 1425/1725 Rpm Dual . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Motor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cap, Tank Screw−on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tank, Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, .375 ID X .650 OD X 19.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Ground/Protective Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Light, Ind Wht Lens 125vac Snap−in Neon Non−relampa . . . . . . . . . . . . . . . . .
. . Label, Rating Card CSA C US 300245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Louver Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Plate, Indicator Front Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Valve, Check Bidirectional Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Backet, Valve Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Base, Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Radiator, Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Plenum, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
2
1
1
1
1
1
1
1
3
1
1
1
1
1
2
2
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly (continued)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
213 072
233 164
228 498
196 312
228 520
215 667
228 532
231 311
226 967
236 084
228 530
231 368
231 367
231 284
180 663
178 910
219 178
. . Fan, Muffin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, Power 11 ft 4 in. 16 ga 3c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Filter, Assy W/Fittings (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hose, .375 ID X .650 OD X 1.415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ftg, Hose Nyl Elbow Barbed 3/8 X 3/8 90 Deg . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hose, .375 ID X .650 OD X 10.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hose, .375 ID X .650 OD X 8.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Elbow/Tubing Assy, Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Elbow/Tubing Assy, Pick-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Tank Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning General Precautionary Static&wire Fe . . . . . . . . . . . . . . . . . . .
. . Label, Caution Incorrect Coolant Wordless Intl . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Caution Incorrect Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
2
2
1
1
1
1
1
2
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-231 313 Page 11
Notes
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
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.
PRINTED IN USA
© 2008 Miller Electric Mfg. Co. 2008−01
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
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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