Miller COOLMATE V3 User manual

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Miller COOLMATE V3 User manual
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
..
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..
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..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
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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