Miller COOLMATE V3 Owner's Manual
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Miller Coolmate V3: Coolant Recirculator for GTAW and GMAW Welding
The Miller Coolmate V3 is a recirculating coolant system designed for use with water-cooled GTAW torches and GMAW guns rated up to 600 amperes. It has a 3-gallon (11.4 L) coolant tank capacity and a maximum cooling capacity of 14,000 BTU/hr at 1.3 qt/min (1.25 L/min). The Coolmate V3 is easy to use, with a single-phase input power requirement of 115 volts AC, 4.7 amps at 60 Hz or 5.9 amps at 50 Hz. It features a built-in coolant filter and a pressure gauge to monitor the system's performance.
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OWNER’S MANUAL OM-618 194 463 March 1999 And Non-CE Models Coolmate™ V3 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 1.3 qt/min (1.25 L/min) Dimensions: 12-1/4 in (311 mm) Deep, 9-3/4 in (248 mm) Wide, 33 in (838 mm) High Weight: 50 lb (23 kg) Ref. ST-802 367 2. Single-Phase Input Power, 115 Volts AC, 4.7 A 60 Hz, 5.9 A, 50 Hz 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. 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 electric shock from wiring. Attention! Risque d’électrocution due au contact avec des fils. 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. © 1999 MILLER Electric Mfg. Co. 3. Warning Label Definitions For CE Products 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 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-618 Page 2 4. Rating Label S/N: KJ 043009 COOLMATE V3 U1 =I1= 115 V 5.5 A 1 50/60 Hz IP 23 LR5071 NRTL/C 5. Symbols And Definitions NOTE A V Some symbols are found only on CE products. Amperes Alternating Current Voltage Input Circulating Unit With Coolant Pump Volts Water (Coolant) Input Water (Coolant) Output Line Connection Protective Earth (Ground) On 6. MILLER ELECTRIC MFG. CO., APPLETON, WI USA IP Degree Of Protection Off I1 U1 Primary Current Primary Voltage Hz Hertz Single Phase Tipping Y Be careful when placing or moving unit over uneven surfaces. Ref ST-802 055 OM-618 Page 3 7. Preparing Cooling Unit For Use Fittings have 5/8-18 left-hand threads. Connect hoses with proper fittings as shown. Tools Needed: 11/16 in 1 2 Flow Indicator Filler Cover Use table to select proper coolant, and fill tank. Keep coolant level full. 3 3 4 Power Switch Coolant Out Fitting 5 Coolant In Fitting 1 5 2 4 GTAW Or Where HF* Is Used GMAW Or Where HF* Is Not Used Where Coolant Contacts Aluminum Parts MILLER Low Conductivity Coolant No. 043 810**; Distilled Or Deionized Water OK Above 32° F (0° C) MILLER Low Conductivity Coolant No. 043 810**; Or MILLER Aluminum Protecting Coolant No. 043 809**; Distilled Or Deionized Water OK Above 32° F (0° C) MILLER Aluminum Protecting Coolant No. 043 809** Application Coolant *HF: High Frequency Current **MILLER coolants protect to -37° F (-38°C) and resist algae growth. Ref. ST-802 367 OM-618 Page 4 8. Connections To prevent overheating, make sure cooling unit is positioned so airflow is not restricted. GTAW Connections Y When using coolant system with a welding power source with a water valve, bypass water valve on welding power source by connecting directly to torch/gun to avoid overheating, or damage to coolant system. Y To prevent tipping when placing unit on uneven or tilting surfaces, properly secure the coolant system to a wall, stationary support, or equivalent rigid structure. GMAW Connections ST-802 368 OM-618 Page 5 9. Coolant Maintenance And Oiling Motor Turn Off and unplug unit. 1 Motor Remove plugs and put about 15 drops of SAE 20 motor oil into each oil port. Replace plugs, and reassemble unit. 2 3 1 Coolant Pump Filter Cap Place cloth or suitable container under nut, and remove nut. 4 Strainer Rinse strainer with clean water. Reinstall parts. Remove cloth or container, and reinstall wrapper. . Relief valve is factory set at 60 psi (414 kPa), and normally needs no adjustment: Only adjust if replacing motor. 5 6 Pressure Gauge Relief Valve Adjustment Screw Connect gauge to Coolant Out fitting as shown. Block or plug any output fitting on gauge. 4 Turn On power, and adjust pressure adjustment screw as needed. 3 Turn Off power. Disconnect gauge and reinstall nut and wrapper. . 5 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 6 Tools Needed: Decrease Increase 3/8 in 15/16, 3/4 in OM-618 Page 6 ST-802 369 10. Routine Maintenance Y Turn Off all power and unplug unit before maintaining. 1 Month Blow Out Heat Exchanger Fins Clean Coolant Filter 6 Months Change Coolant (If Using Water) Replace Cracked Hoses Replace Unreadable Labels 12 Months Change Coolant (If Using MILLER Coolant) Oil Motor 11. 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 and 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. PLG1 BLK S1 11 INPUT POWER WHT MOT 12 GRN/YEL SA-135 796-D Figure 11-1. Circuit Diagram OM-618 Page 7 12. Parts List . Hardware is common and not available unless listed. 12 15 11 16 13 14 17 10 9 8 4A 1 2 4B 3 5A 5B 7 6 18 32 2 5A 21 22 4B 31 5B 30 9 19 24 21 23 4A 29 28 27 26 25 20 23 ST-802 364 Figure 12-1. Complete Assembly OM-618 Page 8 Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-1. Complete Assembly . . . 1 . . . . . . . . . . 166 608 . . . 2 . . . . . . . . . . 194 179 . . . 3 . . . . . . . . . . 192 852 . 4A,4B . . . . . . . . 194 174 . 5A,5B . . . . . . . . 174 044 . . . 6 . . . . . . . . . . 166 569 . . . 7 . . . . . . . . . . 174 042 . . . 8 . . . . . . . . . . 126 992 . . . 9 . . . . . . . . . . 194 173 . . . 10 . . . . . . . . . . 134 795 . . . 11 . . . MOT . 173 263 . . . 12 . . . . . . . . . . 166 570 . . . 13 . . . . . . . . . . 192 848 . . . 14 . . . . . . . . . . 192 856 . . . 15 . . . . . . . . . . 192 858 . . . 16 . . PLG1 . 192 457 . . . 17 . . . . . . . . . . 139 042 . . . 18 . . . . . . . . . . 192 854 . . . 19 . . . . . . . . . . 192 857 . . . 20 . . . . . . . . . . 192 449 . . . 21 . . . . . . . . . . 166 564 . . . 22 . . . . . . . . . . 168 254 . . . 23 . . . . . . . . . . 186 003 . . . 24 . . . . . . . . . . 166 560 . . . 25 . . . . . . . . . . 166 571 . . . 26 . . . . . . . . . . 166 568 . . . 27 . . . . . . . . . . 166 566 . . . 28 . . . . . . . . . . 186 005 . . . 29 . . . . . . . . . . 193 710 . . . 30 . . . . S1 . . 177 396 . . . 31 . . . . . . . . . +192 859 . . . 32 . . . . . . . . . . 177 448 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. CAP, tank screw-on w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBE, pick-up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TANK, reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBING, PVC .375 ID x .625 OD x 15.000 clear brd . . . . . . . . . . . . . . . . . . . . . TUBING, PVC .375 ID x .625 OD x 18.000 clear brd . . . . . . . . . . . . . . . . . . . . . RADIATOR, heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FITTING, hose brs barbed elbow M 3/8tbg x 3/8NPT . . . . . . . . . . . . . . . . . . . . HOSE, NPRN brd No. 1 x .375 ID x 21.000 black . . . . . . . . . . . . . . . . . . . . . . . COUPLER, drive pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTOR, 1/4hp 115VAC 50/60Hz 1425/1725RPM . . . . . . . . . . . . . . . . . . . . . . . BLADE, fan 9.000 5wg 38deg .500 bore CW AL . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg motor/pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLENUM, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, power 11ft 5 in 16ga 3/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, strain relief .270/.470 ID x .804mtg hole . . . . . . . . . . . . . . . . . . . . . . CASE SECTION, wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CASE SECTION, main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning/caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILTER, in-line low profile 100 screen 3/8 hose bar . . . . . . . . . . . . . . . . . . . . . . CLIP, filter mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDICATOR, flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RING, rtng ext .500 shaft x .042thk E style bowed . . . . . . . . . . . . . . . . . . . . . . . FITTING, coolant barbed 3/8tbg 5/8-18 female . . . . . . . . . . . . . . . . . . . . . . . . . . PADDLE, flow indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-RING, 1.301 ID x .070 CS 70 Duro Buna−N . . . . . . . . . . . . . . . . . . . . . . . . . . LENS, flow indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . SWITCH, rocker DPST 15A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEATHERSTRIPPING, adh .250 x .375 x 8.500 . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 +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. OM-618 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). Miller Electric Mfg. Co. Manufacturer’s Name: Manufacturer’s Address: Declares that the product: 1635 W. Spencer Street Appleton, WI 54914 USA COOLMATE™ V3 conforms to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Standards Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1989 Arc Welding Equipment Part 2: Cooling Systems: IEC 974-2 (July 1997 - Draft revision) Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989 European Contact: Telephone: Fax: Mr. Luigi Vacchini, Managing Director MILLER Europe S.P.A. Via Privata Iseo 20098 San Giuliano Milanese, Italy 39(02)98290-1 39(02)98281-552 S/N: KJ 043009 COOLMATE V3 U1 =I1= 115 V 5.5 A 1 50/60 Hz IP 23 MILLER ELECTRIC MFG. CO., APPLETON, WI USA dec_con1 1/96 © 1996 MILLER Electric Mfg. Co.
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