Miller FLOWMAX Owner's Manual
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Miller FLOWMAX is a recirculating coolant system designed for water-cooled GTAW torches, GMAW guns, and induction heaters, providing a maximum cooling capacity of 14,000 BTU/hr at 1.25 qt/min (1.2 L/min). With a 3-gallon (11.4 L) coolant tank capacity, it effectively cools equipment up to 600 amperes. The unit features an IP rating of 23, ensuring protection against ingress of solid objects and water.
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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 68F 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 (-38C) 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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