Miller FLOWMAX Owner's Manual

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Miller FLOWMAX Owner's Manual | Manualzz
OWNER’S MANUAL
Flowmax
1.
OM-248 626B
2011−01
And Non-CE Models
Safety Symbol Definitions
NOTICE
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.
Indicates statements not related to personal injury.
Recycle or dispose of used coolant in an environmentally
safe way.
Indicates special instructions.
Recycler ou éliminer tout liquide de refroidissement usé
conformément aux méthodes prescrites pour assurer la
protection de l’environnement.
Wear safety glasses with side shields.
Porter des lunettes de sécurité avec protections
latérales.
CALIFORNIA PROPOSITION 65 WARNINGS
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects
and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive
harm. Wash hands after use.
Avertissements issus de la «Proposition 65»
Les équipements de soudage ou de coupe produisent des émanations ou des gaz qui contiennent des agents chimiques réputés selon
l’État de Californie causer des déficiences congénitales et, dans certains cas, le cancer. (Section 25249.5 et suivantes du «California
Health & Safety Code»)
Ce produit contient des agents chimiques, notamment du plomb, réputés selon l’État de Californie causer des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation.
2.
EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
1. Keep cables close together by twisting or taping them, or using
a cable cover.
About Implanted Medical Devices:
2. Do not place your body between welding cables. Arrange
cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding,
spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures
is recommended.
3.
Important Information Regarding CE Products (Sold Within The EU)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
4.
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
Specifications
Recirculating Coolant System For Water-Cooled GTAW Torches, GMAW Guns, And Induction Heaters
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)
Dimensions: 23 in. (584 mm) Long, 12 in. (305 mm) Wide, 13-1/4 in. (337 mm) High
Weight: 39 lb (18 kg)
115 Volt Model Use 5.9 Amperes, 50/60 Hertz, Single-Phase Input Power
230 Volt CE Model Use 3 Amperes, 50/60 Hertz, Single-Phase Input Power
801 189-A
5.
Ratings Developed At An Ambient Temperature Of 68F to 77 F (20 C To 25 C)
Operating Temperature Is 14 F To 104 F (−10 C To 40 C)
Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
OM-248 626 Page 2
6.
Warning Label Definitions
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-248 626 Page 3
7.
Symbols And Definitions
A
V
Amperes
Alternating Current
Voltage Input
Circulating Unit
With Coolant Pump
Volts
Water (Coolant)
Input
Water (Coolant)
Output
Line Connection
Protective Earth
(Ground)
On
8.
IP
Degree Of
Protection
Off
I1
U1
Primary Current
Primary Voltage
Hz
Hertz
Single Phase
WEEE Label (For Products Sold Within The EU)
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collection facility.
Contact your local recycling office
or your local distributor for further
information.
OM-248 626 Page 4
9.
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
Power Switch
1
3
2
4
GTAW Or Where
HF* Is Used
GMAW Or Where
HF* Is Not Used
Where Coolant Contacts
Aluminum Parts
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)
Aluminum Protecting
Coolant No. 043 809**
Application
Coolant
*HF: High Frequency Current
**Coolants 043 810 and 043 809 protect to -37 F (-38C) and resist algae growth.
NOTICE − 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.).
Tools Needed:
5/8 in.
803 560-A
OM-248 626 Page 5
10. Connections
1
Lift -Eye
If placing cooling unit on welding
power source, slots are provided in
bottom of unit so it fits over lift-eye.
GTAW Connections
1
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.
Operation:
Turn power switch On.
GMAW Connections
803 558-A / 803 559-A
OM-248 626 Page 6
11. Routine Maintenance
!
Disconnect power
before maintaining.
3 Months
NOTICE − 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.
Blow Out Heat
Exchanger Fins
6 Months
Change
Coolant (If
Using Water)
Replace
Cracked
Hoses
Replace
Unreadable
Labels
12 Months
Change
Coolant (If
Using 043 809
or 043 810
Coolant)
12. Coolant Maintenance
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.
1
.
If replacing hoses, use hoses
compatible with ethylene glycol, such as Buna-n, Neoprene, or Hypalon. Oxy-acetylene hoses are not compatible
with any product containing
ethylene glycol.
Tools Needed:
3/8 in.
803 557-A
OM-248 626 Page 7
13. Troubleshooting
Trouble
Remedy
Coolant system does not work.
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).
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.
F1
Input power
Input power
F2
187 733
135 796-D
Figure 10-2. Circuit Diagram For 230 Volt (CE Model)
Figure 10-1. Circuit Diagram For 115 Volt Model
14. Parts List
3
2
11
Plug included w/
115V Model Only
14
1
16
15
10
4
5
24
23
22
6
13
12
23
12
21
25
7
21
26 8
9
22
17
20
19
31
18
27
30
OM-248 626 Page 8
*
29
19
28
*included with item 24
805 487-A
Figure 11-1. Complete Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Flowmax-115
Flowmax-230 CE
Description
Quantity
Figure 11-1. Complete Assembly
1 . . . . . . . . . . +166 562 . . . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . 203 990 . . . . . LABEL, warning general precautionary static (115V model) . . . . . . . . . . .
. . . 2 . . . . . . . . . . . 180 663 . . . . . LABEL, warning general precautionary static (230V CE model) . . . . . . .
. . . 3 . . . . . . . . . . . 188 980 . . . . . LABEL, caution incorrect coolant (115V model) . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . 178 910 . . . . . LABEL, warning incorrect coolant wordless intl (230V CE model) . . . . .
. . . 4 . . . . . . . . . . . 197 361 . . . . . PUMP COOLANT w/CLAMPS, (includes) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . 126 978 . . . . . . . FITTING, hose brs barbed M 3/8tbg x 3/8 . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . 134 795 . . . . . . . COUPLER, drive pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . 196 990 . . . . . FITTING, hose brs barbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . 089 120 . . . . . CLAMP, hose .375 − .450 clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . 196 991 . . . . . HOSE, nprn brd no 1 x .250ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . MOT . . 173 264 . . . . . MOTOR, 1/4hp 230VAC 50/60Hz 1425/1725rpm (230V CE model) . . . .
. . . 10 . . . MOT . . 173 263 . . . . . MOTOR, 1/4hp 115VAC 50/60Hz 1425/1725rpm (115V model) . . . . . . . .
. . . 11 . . . . . . . . . . . 166 570 . . . . . BLADE, fan 9.000 5wg 38deg .500 bore cw (setscrew included) . . . . . . .
. . . 12 . . . . . . . . . . . 174 044 . . . . . TUBING, PVC .375 x .625 OD X 18.000 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . 094 263 . . . . . CLAMP, 1-ear type nom dim .718 x .276 wide . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . 192 454 . . . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . 139 042 . . . . . BUSHING, strain relief .270/.480 id x .804 mtg hol . . . . . . . . . . . . . . . . . . .
. . . 16 . . PLG1 . . 192 457 . . . . . CABLE, power 10ft 16ga (115V model) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . PLG1 . . 192 456 . . . . . CABLE, pwr 10ft (230V CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . 196 515 . . . . . RADIATOR, heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . 168 267 . . . . . TANK COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . 194 179 . . . . . TUBE, pick-up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . 166 608 . . . . . CAP, tank screw-on w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . 182 994 . . . . . TUBE, pick-up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . 136 369 . . . . . TUBING, PVC .375 ID x .625 OD x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . 136 731 . . . . . HOSE, nprn brd No. 1 x .375 ID x 10.50 black . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . 166 560 . . . . . RING, ring ext .500 shaft grv x .042thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . 166 564 . . . . . FILTER, in-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . 168 254 . . . . . CLIP, filter mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . F1, F2 . . . 011 116 . . . . . FUSE, mintr gl slo-blo 7A 250V (230V CE Model) . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 098 376 . . . . . HOLDER, fuse mintr (230V CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . S1 . . . 177 396 . . . . . SWITCH, rocker DPST 15A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . 177 399 . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . GB0002 . . . . . PLUG, knock-out 1-11/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . 166 571 . . . . . FITTING, coolant barbed 3/8tbg 5/8-18 female . . . . . . . . . . . . . . . . . . . . . .
....
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
8
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
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-248 626 Page 9
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Stock Number
043008001
Product
FLOWMAX 3 230VAC CE
Council Directives:
 2006/95/EC Low Voltage
 2004/108/EC Electromagnetic Compatibility
Standards:




IEC 60974­1:2005 Arc welding equipment – Part 1: Welding power sources
IEC 60974­2:2007 Arc welding equipment – Part 2: Liquid cooling systems
IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,
arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz)
Signatory:
January 27, 2011
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
245863B
Notes
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
Resources Available
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
Replacement Parts
Owner’s Manuals
Circuit Diagrams
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.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
2011−01

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