Miller | MF302369D | Owner Manual | Miller HYDRACOOL 2 CE User manual

Miller HYDRACOOL 2 CE User manual
OM-254 203D
2015−06
Processes
TIG (GTAW) Welding
MIG (GMAW) Welding
Description
Hydracool 1
Hydracool 2
CE
OWNER’S MANUAL
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior quality.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.
Miller Electric manufactures a full line of
welders and welding related equipment. For
information on other quality Miller products, contact your local Miller
distributor to receive the latest full line catalog or individual catalog sheets.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Specifications* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Coolant Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Control Panel Hydracool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Control Panel Hydracool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
1
1
1
3
4
4
4
5
5
6
7
7
7
7
8
8
8
9
9
9
10
10
10
11
12
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the prod­
uct(s) identified in this declaration conform to the essential requirements and provisions of the stat­
ed Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
HYDRACOOL 1 V.115 50/60HZ
HYDRACOOL 1 V.230 50/60HZ
HYDRACOOL 2 V.115 50/60HZ
HYDRACOOL 2 V.230 50/60HZ
028042103
028042104
028042105
028042106
Council Directives:
·2006/95/EC Low Voltage
·2004/108/EC Electromagnetic Compatibility
·2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
·IEC 60974-1:2012 Arc Welding Equipment – Part 1: Welding Power Sources
·IEC 60974-2:2013 Arc Welding Equipment – Part 2: Liquid cooling systems
·IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic Compatibility Requirements
EU Signatory:
June 30th, 2015
___________________________________________________________________________________
Massimigliano Lavarini
Date of Declaration
ITW WELDING ITALY PRODUCTION MANAGER
956 172 232
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
coolers 2013-10
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
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.
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.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Cooling Equipment Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The input power circuit and machine
internal circuits are also live when power is on.
Incorrectly installed or improperly grounded equipment is a hazard.
Do not touch live electrical parts.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Keep all panels and covers securely in place.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
FLYING METAL or DIRT can injure eyes.
Wear approved safety glasses with side
shields even under your welding helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FALLING EQUIPMENT can injure.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle.
Do not block or filter airflow to unit.
MOVING PARTS can injure.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
OM-254 203 Page 1
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local codes.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
1-4. 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.
This product contains or produces a chemical known to the
state of California to cause cancer or birth defects (or other
reproductive harm). (California Health & Safety Code Section
25249.5 et seq.)
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:
www.cganet.com).
OM-254 203 Page 2
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
SECTION 2 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions
Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
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.
Safe37 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
Recycle.
Safe103 2012−09
Use coolant suggested by the manufacturer.
XXXXX
Safe52 2012−05
Please drain fluid according to instructions.
2012−05
Read the labels on the welding power source, wire feeder, or other
major equipment for welding safety information.
Safe71 2012−06
Read the Owner’s Manual before working on this machine.
Safe70 2012−06
OM-254 203 Page 3
Plugged filter or hoses can cause overheating to the power source
and torch.
Safe50 2012−05
100 h. Std.
Every 100 hours, check and clean filter and check condition of hoses.
Safe51 2012−05
2-2. Miscellaneous Symbols And Definitions
A
Amperage
Water (Coolant)
Output
Alternating
Current
Line Connection
On
Voltage Input
Protective Earth
(Ground)
Off
Circulating Unit
With Coolant
Pump
V
Voltage
Water (Coolant)
Input
Notes
OM-254 203 Page 4
IP
I1
Degree of
Protection
Primary Current
Hz
U1
Hertz
Primary Voltage
Single Phase
SECTION 3 − SPECIFICATIONS
3-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back panel. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on cover of this manual.
3-2. Specifications*
Input Power
Cord with
Plug
Model
Coolant Tank
Capacity
Maximum Cooling
Capacity
Input Power
Dimensions
Weight
Hydracool 1
8L
1670 Watts
(5698 BTU/hr)
1.0 L/min
(1.1 qt/min)
Single Phase
115 VAC
50/60 Hz
2.5 Amperes
2m
Length: 305 mm
Height: 674 mm
Width: 263 mm
20.7 kg
8L
1670 Watts
(5698 BTU/hr)
1.0 L/min
(1.1 qt/min)
Single Phase
230 VAC
50/60 Hz
1.3 Amperes
2 m**
Length: 305 mm
Height: 674 mm
Width: 263 mm
20.7 kg
8L
1760 Watts
(6005 BTU/hr)
1.0 L/min
(1.1 qt/min)
Single Phase
115 VAC
50/60 Hz
2.5 Amperes
2m
Length: 585 mm
Height: 286 mm
Width: 324 mm
20.8 kg
8L
1760 Watts
(6005 BTU/hr)
1.0 L/min
(1.1 qt/min)
Single Phase
230 VAC
50/60 Hz
1.3 Amperes
2 m**
Length: 585 mm
Height: 286 mm
Width: 324 mm
20.8 kg
Hydracool 2
*IEC Cooling Capacity States That The Water Inlet Temperature Can Not Exceed 40° C Above Ambient Temperature At A 1l/ Min Flow Rate.
**Plug Is Customer Supplied.
Recirculating Coolant System For Water-Cooled GTAW Torches And GMAW Guns.
Use With Guns/Torches Rated Up To 600 Amperes
3-3. Coolant Chart
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.
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.).
Ref. 956142645-4-5
OM-254 203 Page 5
3-4. Environmental Specifications
A. IP Rating
IP Rating
Operating Temperature Range
Storage Temperature Range
−10 to 40°C (14 to 104 °F)
20 to 25°C (68 to 77 °F)
Operating Temperature Range
Storage Temperature Range
−10 to 40°C (14 to 104 °F)
20 to 25°C (68 to 77 °F)
Hydracool 1 − IP21
This equipment is designed for indoor use and
is not intended to be used or stored outside.
IP Rating
Hydracool 2 − IP23
This equipment is designed for outdoor use. It
may be stored, but is not intended to be used
outside during precipitation unless sheltered.
B. Information On Electromagnetic Fields (EMF)
!
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.
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.
ce-emf 1 2010-10
SECTION 4 − INSTALLATION
4-1. Selecting a Location
Position unit so air can circulate.
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
956142899_1-A, 956142900_1-A
OM-254 203 Page 6
SECTION 5 − OPERATION
5-1. Control Panel Hydracool 1
1
2
3
4
5
6
7
Quick Connect; Water In
Quick Connect; Water Out
Flow Indicator
Circuit Breaker (CB1)
Power On/Off switch
Tank Filler Neck
Coolant level Indicator
6
7
1
2
5
4
3
956142899_2-A
5-2. Control Panel Hydracool 2
1
2
3
4
5
6
7
4
3
Flow Indicator
Power On/Off switch
Circuit Breaker CB1
Tank Filler Neck
Coolant Level
Quick Connect; Water Out
Quick Connect; Water In
2
6
7
1
5
Front
Back
956142900_2-A
OM-254 203 Page 7
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance
!
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
Disconnect power
before maintaining.
= Replace
NOTICE − Clean coolant filter. Severe conditions may require more frequent cleaning (continuous use, high/low temperatures, dirty environment, etc.). Failure to properly clean coolant filter voids pump warranty.
Coolant Filter
Every
6
Months
Cracked Parts
Change Coolant (If Using
Water)
Replace Unreadable Labels
Every
12
Months
Change Coolant (If Using (B)050024004)
6-2. Troubleshooting
Trouble
Remedy
Coolant system does not work.
Be sure input power cord is plugged in to energized receptacle.
Check circuit breakers on cooler and welding power source, and reset if necessary.
Motor overheated. Unit starts running when motor has cooled.
Have Factory Authorized Service Agent check Power switch, capacitor, and motor.
Decreased or no coolant flow.
Add coolant.
Check for clogged or damaged hoses.
Check in-line filter, clean if require.
OM-254 203 Page 8
Reference
SECTION 7 − ELECTRICAL DIAGRAM
956142901_B
OM-254 203 Page 9
SECTION 8 − PARTS LIST
26
Hardware is common and
28
12
13
14
15
16
17
18
19
6
5
7
9
10
3
8
11
2
1
20
21
22
23
24
25
27
not available unless listed.
Figure 8-1. Main Assembly, Hydracool 1
OM-254 203 Page 10
956142899_3-A
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 8-1. Main Assembly, Hydracool 1
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. . . FM . . . . . . 213072
. . . FM . . . 056126077
. . . . . . . . . . +116117082
. . . . . . . . . . . 056082099
. . . . . . . . . . . 956142629
. . . . . . . . . . . . . . 207290
. . . . . . . . . . . 956142621
. . . . . . . . . . . . . . 180663
. . . . . . . . . . +156121044
. . . . . . . . . . . 656049051
. . . . . . . . . . . 156009079
. . . . . . . . . . . 027042002
. . . M1 . . . 057010059
. . . M1 . . . 057010060
. . . . . . . . . . . 556049386
. . . . . . . . . . . . . . 166564
. . . CB1 . . . . . . 083431
. . . . . . . . . . . 556049410
. . . . . . . . . . . . . . 215279
. . . . S1 . . . 056067251
. . . . . . . . . . . 316029721
. . . . . . . . . . . 756007013
. . . . . . . . . . . 156033034
. . . . . . . . . . . . . . 195585
. . . . . . . . . . . 556049409
. . . . . . . . . . . 156006074
. . . . . . . . . . . V57011071
. . . . . . . . . . . 027112327
. . . . . . . . . . . 027112328
. . . . . . . . . . . 156009147
. . . . . . . . . . . 656110013
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..
..
..
..
..
..
..
..
..
..
..
..
..
..
Fan, Muffin 115V 60HZ 3400 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . .
Fan Assy, Radiator Cooling 230 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Advisory Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Primary Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Barb, Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank, Water 8 L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, 170 W, 230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, 170 W, 230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, Male 3/8 D.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, In−Line Low Profile 100 Screen 3/8 Hose Bar . . . . . . . . . . . . . . . . . .
Breaker, Circuit 5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Connection, Quick Connect, Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicator, Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Power On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Front, Hydracool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, Switch 37 X 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot, Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Connection, Quick Connect, Red . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front, Base & Rear Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Primary, 115VAC C/W Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Primary, 230VAC C/W Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Bracket, Tank Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot, Rubber Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
+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-254 203 Page 11
Hardware is common and
not available unless listed.
3
2
1
4
12
11
10
9
8
7
6
5
18
17
19
16
20
15
14
21
13
22
29
23
24
28
27
25
26
Figure 8-2. Main Assembly, Hydracool 2
OM-254 203 Page 12
956142900_3-A
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 8-2. Main Assembly, Hydracool 2
...
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1
2
3
4
5
5
6
7
8
9
9
10
11
12
13
14
15
16
17
18
19
20
21
21
22
23
24
25
26
27
28
29
. . . . . . . . . . . . . . 207290
. . . . . . . . . . +156121028
. . . . . . . . . . . . . . 195585
. . . . . . . . . . . . . . 180663
. . . M1 . . . 057010059
. . . M1 . . . 057010060
. . . . . . . . . . . . . . 166564
. . . . . . . . . . . V57011071
. . . . . . . . . . . 556049386
. . . FM . . . . . . 213072
. . . FM . . . 056126077
. . . . . . . . . . +116117082
. . . . . . . . . . . 956142629
. . . . . . . . . . . 056082099
. . . . . . . . . . . 956142621
. . . . . . . . . . . 316029722
. . . CB1 . . . . . . 083431
. . . . . . . . . . . 027042002
. . . . . . . . . . . 116122306
. . . . . . . . . . . 956142908
. . . . . . . . . . . 556049410
. . . . . . . . . . . 556049409
. . . . . . . . . . . 027112327
. . . . . . . . . . . 027112328
. . . . . . . . . . . 156006075
. . . . . . . . . . . 656049051
. . . . . . . . . . . 156009079
. . . . S1 . . . 056067251
. . . . . . . . . . . 656110013
. . . . . . . . . . . . . . 215279
. . . . . . . . . . . 756007013
. . . . . . . . . . . 156033034
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Label, Advisory Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Primary Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, 170 W, 115 Vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, 170 W, 230 Vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, In−Line Low Profile 100 Screen 3/8 Hose Bar . . . . . . . . . . . . . . . . . .
Pump Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, Male 3/8 D.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan, Muffin 115V 60HZ 3400 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . .
Fan Assy, Radiator Cooling 230 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Front, Hydracool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breaker, Circuit 5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank, Water 8 L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Bracket, Tank Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Rear, Water Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Connection, Quick Connect, Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Connection, Quick Connect, Red . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Primary, 115VAC C/W Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Primary, 230VAC C/W Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Barb, Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Power On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot, Rubber Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicator, Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, Switch 37 X 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boot, Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
4
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-254 203 Page 13
Notes
Effective January 1, 2015
(Equipment with a serial number preface of MF or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, ITW Welding Products Italy warrants to its original retail
purchaser that new Miller equipment sold after the effective date
of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed. If notification is submitted as an
online warranty claim, the claim must include a detailed
description of the fault and the troubleshooting steps taken to
identify failed components and the cause of their failure.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date the
equipment was delivered to the original retail purchaser or one
year after the equipment is shipped to a European distributor or
twelve months after the equipment is shipped to an International
distributor.
1.
5 Years Parts — 3 Years Labor
*
2.
3 Years — Parts and Labor
*
*
*
*
*
3.
Auto-Darkening Helmet Lenses (No Labor)
Migmatic 175
HF Units
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
5.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
Inverter Power Sources (Unless Otherwise Stated)
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Transformer/Rectifier Power Sources
2 Years — Parts
*
*
*
4.
Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules with
exclusion of STR, Si, STi, STH and MPi series.
Automatic Motion Devices
Field Options
(NOTE: Field options are covered under True
Blue) for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
Motor-Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Powered Air Purifying Respirator (PAPR) Blower
Unit (No Labor)
Racks
Running Gear and Trailers
Subarc Wire Drive Assemblies
Water Coolant Systems
Work Stations/Weld Tables (No Labor)
6 Months — Parts
*
Batteries
6.
90 Days — Parts
*
*
*
*
*
*
Accessory (Kits)
Canvas Covers
Induction Heating Coils and Blankets
MIG Guns
Remote Controls
Replacement Parts (No Labor)
*
*
Spoolmate Spoolguns
Cables and Non-Electronic Controls
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, switches, slip
rings, relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at ITW Welding Products
Group Europe or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
milan_warr 2015-01
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
Country
Zip/Postal Code
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
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Italy S.r.l.
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
© 2015 Miller Electric Mfg. Co. 2015−01
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it
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