Miller | MJ010351G | Owner Manual | Miller PROHEAT HEAVY DUTY INDUCTION COOLER (24 VOLT) CE User manual

Miller PROHEAT HEAVY DUTY INDUCTION COOLER (24 VOLT) CE User manual
OM-271973D
2017−04
Processes
Induction Heating
Description
Heavy Duty Induction Cooler
ProHeatt Heavy Duty
Induction Cooler (24 Volt)
CE
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Induction Heating
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
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
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 specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
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. Induction Heating 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 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Installing Power Source To Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Coolant Hose Connections To Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Coolant Hose Connections To Single Output Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Coolant Hose Connections To Dual Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Installing Optional External Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Coolant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Flow Direction W/Single Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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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
907690
301298
Product
ProHeat 35, 400-460V (CE)
Cooler/ProHeat Heavy Duty Induction
Council Directives:
·2014/35/EU Low voltage
·2014/30/EU 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 60974-10:2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements
Signatory:
March 27, 2017
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
272703B
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
ihom _2016-08
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. Induction Heating 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 power circuit and output bus
bars or connections are electrically live whenever
the output is on. The input power circuit and machine
internal circuits are also live when power is on. Incorrectly installed or
improperly grounded equipment is a hazard.
D
Do not touch live electrical parts.
D
Enclose any connecting bus bars and coolant fittings to prevent
unintentional contact.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats or
covers big enough to prevent any physical contact with the work or
ground.
D
D
D
D
D
D
D
D
D
Additional safety precautions are required when any of the following
electrically hazardous conditions are present: in damp locations or
while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting,
kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions,
see ANSI Z49.1 listed in Safety Standards. And, do not work alone!
Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
Use only nonconductive coolant hoses with a minimum length of 18
inches (457 mm) to provide isolation.
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.
When making input connections, attach proper grounding
conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D
D
D
D
D
D
D
D
D
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.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
Do not touch power circuit if you are in contact with the work, ground,
or another power circuit from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Use GFCI protection when operating auxiliary equipment in damp or
wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER removal of input power.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any internal parts.
FUMES AND GASES can be hazardous.
Induction Heating of certain materials, adhesives,
and fluxes can produce fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation to remove fumes and gases. The recommended way to determine
adequate ventilation is to sample for the composition and quantity of
fumes and gases to which personnel are exposed.
D
D
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Always have a trained watchperson nearby. Fumes and gases from heating can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is
safe.
Do not heat in locations near degreasing, cleaning, or spraying operations. The heat can react with vapors to form highly toxic and
irritating gases.
Do not overheat coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
heated area, the area is well ventilated, and while wearing an airsupplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if overheated. See coating SDS
for temperature information.
D
D
D
OM-271973 Page 1
FIRE OR EXPLOSION hazard.
D
D
D
D
D
D
D Do not overheat parts.
D Watch for fire; keep extinguisher nearby.
D Keep flammables away from work area.
Do not locate unit on, over, or near combustible surfaces.
Do not install unit near flammables.
Do not operate where the atmosphere can contain flammable
dust, gas, or liquid vapors (such as gasoline).
After completion of work, inspect area to ensure it is free of
sparks, glowing embers, and flames.
INDUCTION HEATING can burn.
D Do not touch hot parts bare-handed.
D Allow cooling period before handling parts or
equipment.
D
D
D
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
Do not touch or handle induction head/coil during operation unless the equipment is designed and intended to be used in this
manner as specified in the owner’s manual.
Keep metal jewelry and other metal personal items away from
head/coil during operation.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D
1-3. Additional Symbols for Installation, Operation, and Maintenance
FALLING EQUIPMENT can injure.
D
D
D
D
D Use handle and have person of adequate
physical strength lift unit.
D Move unit with hand cart or similar device.
For units without a handle, use equipment of adequate capacity to
lift and support unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually
lifting heavy parts or equipment.
FLYING METAL OR DIRT can injure eyes.
D Wear approved safety glasses with side
shields or wear face shield.
STEAM AND HOT COOLANT can burn.
Hose may rupture if coolant overheats.
D
D
D
D
D Never disconnect both ends of hose when installed on hot workpiece.
If coolant flow stops, leave one end of hose connected to allow
coolant to return to cooler and relieve pressure.
Remove hose from hot workpiece to prevent damage.
Visually inspect condition of hoses, cords, and cables before
each use. Do not use damaged hoses, cords, or cables.
Allow cooling period before working on equipment.
HIGH PRESSURE FLUIDS can injure or kill.
D Coolant can be under high pressure.
D Release pressure before working on cooler.
D If ANY fluid is injected into the skin or body seek medical help
immediately.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
OM-271973 Page 2
D Allow cooling period.
D Reduce output or reduce duty cycle before
starting to heat again.
D Follow rated duty cycle.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
BATTERY EXPLOSION can injure.
D Do not use induction equipment to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
H.F. RADIATION can cause interference.
D
D
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified person familiar with electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut.
READ INSTRUCTIONS.
D 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.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
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.
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).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csa-international.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).
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).
Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.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).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton
Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
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.
About Implanted Medical Devices:
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. Do not coil or drape cables around your body.
OM-271973 Page 3
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
ihom 2016−08fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les
dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 2-5. Veuillez lire et respecter toutes
ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact de composants électriques peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit électrique et les barres collectrices
ou les connexions de sortie sont sous tension
lorsque l’appareil fonctionne. Le circuit d’alimentation et les circuits
internes de la machine sont également sous tension lorsque
l’alimentation est sur marche. Des équipements installés ou reliés à la
borne de terre de manière incorrecte sont dangereux.
D Ne pas toucher aux pièces électriques sous tension.
D Protéger toutes les barres collectrices et les raccords de refroidissement pour éviter de les toucher par inadvertance.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, voir ANSI Z49.1 énuméré dans les normes de sécurité. En outre, ne pas travailler seul !
D Couper l’alimentation d’entrée avant d’installer l’appareil ou d’effectuer l’entretien. Verrouiller ou étiqueter la sortie d’alimentation selon
la norme OSHA 29 CFR 1910.147(se reporter aux Principales normes de sécurité).
D N’utiliser que des tuyaux de refroidissement non conducteurs ayant
une longueur minimale de 457 mm pour garantir l’isolation.
D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
OM-271973 Page 4
D
D
D
D
D
D
D
D
D
D
D
borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et revérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé. Le
remplacer immédiatement s’il l’est. Un fil dénudé peut entraîner la
mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Ne pas toucher le circuit électrique si l’on est en contact avec la pièce, la terre ou le circuit électrique d’une autre machine.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS le
moteur coupé.
D
Avant de toucher des organes internes, couper l’onduleur,
débrancher l’alimentation et décharger les condensateurs
d’alimentation conformément aux instructions indiquées dans la
partie maintenance.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D
D
D
D
Le chauffage à induction de certains matériaux,
adhésifs et flux génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour votre santé.
Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces
vapeurs.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz. Pour déterminer la bonne ventilation, il est recommandé de procéder à un
prélèvement pour la composition et la quantité de fumées et de gaz
auxquels est exposé le personnel.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
Lire et comprendre les fiches de données de sécurité et les instructions
du fabricant concernant les adhésifs, les revêtements, les nettoyants,
D
D
D
les consommables, les produits de refroidissement, les dégraisseurs,
les flux et les métaux.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur. Demander toujours à un surveillant dûment
formé de se tenir à proximité. Des fumées et des gaz provenant du
chauffage peuvent déplacer l’air, abaisser le niveau d’oxygène et
provoquer des lésions ou des accidents mortels. S’assurer que l’air
ambiant ne présente aucun danger.
Ne pas chauffer dans des endroits se trouvant à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur
peut réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
Ne pas surchauffer des métaux munis d’un revêtement tels que l’acier
galvanisé, plaqué au plomb ou au cadmium, à moins que le revêtement
ne soit enlevé de la zone chauffée, que la zone soit bien ventilée et, si
nécessaire, en portant un respirateur. Les revêtements et tous les métaux contenant ces éléments peuvent dégager des fumées toxiques
s’ils sont surchauffés. Voir les informations concernant la température
dans les spécifications de revêtement SDS.
Risque D’INCENDIE OU
D’EXPLOSION.
D
D
D
D
D Ne pas surchauffer les composants .
D Attention aux risques d’incendie: tenir un extincteur à proximité.
Stocker des produits inflammables hors de la zone de travail.
Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces
inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace
d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des gants
de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D
D
D
D
LE CHAUFFAGE PAR INDUCTION peut
provoquer des brûlures.
D
D Ne pas toucher des parties chaudes à mains
nues.
D Laisser refroidir les composants ou équipements avant de les manipuler.
Ne pas toucher ou manipuler les câbles/enroulements d’induction durant l’opération à moins que l’équipement soit conçu à cet
effet comme indiqué dans le manuel d’utilisateur.
Tenir les bijoux et autres objets personnels en métal éloignés de la
tête/de l’enroulement pendant le fonctionnement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
D
D
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D
D
D
D
D
D Utiliser la poignée et demander à une personne
ayant la force physique nécessaire pour soulever l’appareil.
Déplacer l’appareil à l’aide d’un chariot ou d’un engin similaire.
Pour les unités sans poignée, utiliser un équipement de levage de
capacité suffisante pour lever l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94−110) lors du levage
manuelle de pièces ou équipements lourds.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Porter des lunettes de sécurité à coques latérales ou un écran facial.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D
Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par induction.
LE LIQUIDE DE REFROIDISSEMENT CHAUD ET
LA VAPEUR peuvent causer des brûlures.
D
Si le liquide de refroidissement est en surchauffe, un
boyau pourrait se sectionner.
D Ne jamais débrancher les deux extrémités du
tuyau lorsque l’appareil est installé sur une
pièce de travail chaude.
Si le liquide de refroidissement cesse de s’écouler, laisser une
extrémité du tuyau branchée pour permettre au liquide de
refroidissement chaud de revenir au refroidisseur et
dépressuriser.
Pour éviter tout risque de dommage, retirer le tuyau de la pièce de
travail chaude.
Effectuer une inspection visuelle des boyaux, cordons et câbles
avant chaque utilisation. Ne pas utiliser des boyaux, cordons ou
câbles endommagés.
Laissez refroidir avant d’intervenir sur l’équipement.
D
D
D
LES LIQUIDES SOUS HAUTE PRESSION
peuvent provoquer des blessures ou la
mort.
D Liquide de
pression.
refroidissement
sous
haute
D Libérez la pression avant d’intervenir sur le
refroidisseur.
D En cas d’injection d’un liquide QUELCONQUE dans la peau ou
le corps, consultez immédiatement un médecin.
D Les porteurs de stimulateurs cardiaques et autres
implants médicaux doivent rester à distance.
OM-271973 Page 5
L’EMPLOI EXCESSIF peut
CHAUFFER L’ÉQUIPEMENT.
D
SUR-
D Prévoir une période de refroidissement
D Réduire le courant de sortie ou le facteur de marche avant de recommencer le chauffage.
Respecter le cycle opératoire nominal.
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits imprimés.
D
D Établir la connexion avec la barrette de terre
AVANT de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes PC.
LE RAYONNEMENT HAUTE FRÉQUENCE (HF) risque de provoquer
des interférences.
D
D
D
D
D
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
L’EXPLOSION DE LA BATTERIE peut
provoquer des blessures.
D Le rayonnement haute fréquence (HF) peut
provoquer des interférences avec les équipements de radio-navigation et de communication,
les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage, sauf
si l’appareil dispose d’une fonctionnalité de
charge de batterie destinée à cet usage.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des
malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants).
Ce produit contient des éléments chimiques, dont le plomb,
reconnus par l’État de Californie pour leur caractère
cancérogène ainsi que provoquant des malformations
congénitales ou autres problèmes de procréation. Se laver les
mains après toute manipulation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.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).
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).
Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.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).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton
Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
OM-271973 Page 6
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. 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 remove or paint over (cover) the label.
Safe20 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
Recycle or dispose of used coolant in an environmentally safe way.
Safe119 2015−05
Disconnect input plug or power before working on machine.
Safe30 2012−05
Use coolant suggested by the manufacturer.
XXXXX
Safe52 2012−05
Read the Owner’s Manual before working on this machine.
Safe70 2012−06
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
OM-271973 Page 7
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
A
Line Connection
Alternating
Current
Protective Earth
(Ground)
Single Phase
Degree Of
Protection
U2
Conventional
Load Voltage
or
Load voltage
I2
Rated Current
Voltage Input
Circulating Unit
With Coolant
Pump
V
Notes
OM-271973 Page 8
U1
Amperage
Volts
IP
I1
Hz
Primary Current
Hertz
Water (Coolant)
Input
On
Water (Coolant)
Output
Off
Primary Voltage
Cooling
P1
pmax
Rated Cooling
Power (Coolers)
Rated Maximum
Pressure
(Coolers)
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front . 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.
4-2. Specifications
Input Power
Pump Motor
24 Volts DC Commutated
Weight
Blower
24 Volts DC
Overall Dimensions
Length (A): 30 in.
(762 mm)
Width (B): 21-1/4 in.
(540 mm)
Height (C): 12-3/4 in.
(324 mm)
Coolant Tank Empty
Coolant Tank Full
105 lb
(48 kg)
122 lb
(55 kg)
4-3. Coolant Specifications
Do not use conductive coolant.
Use Low Conductivity Coolant 043810.
Coolant 043810 protects to -37°F (-38°C) and resists algae growth.
NOTICE − Use of any coolant other than that listed voids the warranty on any parts that come in contact with the coolant (pump, radiator, etc.).
4-4. Environmental Specifications
A. IP Rating
IP Rating
IP23C
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23C 2014−06
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
ce-emc 3 2014-07
OM-271973 Page 9
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C. Temperature Specifications
ProHeat
°C
°F
60
140
55
131
50
122
45
113
40
104
35
95
30
86
25
77
20
68
15
59
10
50
5
41
0
32
−5
23
−10
14
−15
5
−20
-4
−25
-13
−30
-22
−35
-31
−40
-40
Storage
Operation
Cooler
Storage
Reduced
efficiencies
above 40°C
Rolling Inductor
Operation
Storage
Operation
Heating Cables
Storage
Operation
Reduced
efficiencies
above 40°C
Store dry
Energize
system
frequently to
maintain
coolant
temperature
above 14°F
(−10°C).
Store dry
Energize
system
frequently to
maintain
coolant
temperature
above 14°F
(−10°C).
Store dry
Energize
system
frequently to
maintain
coolant
temperature
above 14°F
(−10°C).
Not Recommended
With Qualifications
Normal Operation With Coolant
NOTICE − The Miller ProHeat 35 Rolling Inductor is rated for operation between 14°F and 140°F (−10°C to 60°C). For operation at -40°F to
14°F (−40°C to -10°C), take the following precautions to prevent equipment damage:
• Connect coolant lines to Rolling Inductor when dry, or when ambient temperature is above −4°F (−20°C).
• Operate ProHeat 35 Heavy Duty Induction Cooler only in temperatures between 14°F and 104°F (−10°C to 40°C) while operating Rolling Inductor/Liquid Cooled Cables.
• Always use Miller Coolant (Miller Part Number 043810).
• Coolant must flow continuously through the Rolling Inductor/liquid cooled cables, and power must be applied to the Rolling Inductor /liquid cooled
cables at regular intervals to maintain a coolant temperature of at least 14°F (−10°C).
• Store Rolling Inductor/liquid cooled cables dry. Dry unit by using compressed air at 40 psi (2.75 bar) max to blow coolant out of the Rolling Inductor
and power cable.
• Store ProHeat 35 Heavy Duty Induction Cooler at a temperature between−4°F and 131°F(−20°C to 55°C).
. Coolant will not begin to flow until it is 14°F (−105C).
NOTICE − For colder storage, the cooler must be stored dry. Dry unit by using compressed air at 40 psi (2.75 bar) max to blow coolant out of coolant
lines, filter bowls, pump, flow indicator, and heat exchanger.
. The correction factor on the cooling power at an ambient temperature of 1045F (405C) is 0.625.
OM-271973 Page 10
SECTION 5 − INSTALLATION
5-1. Selecting A Location
!
Do not move or operate
unit where it could tip.
Loc_cooler 2016-08
Notes
OM-271973 Page 11
5-2. Installing Power Source To Cooler
2
1
3
4
5
Tools Needed:
3/8 in.
272 546-B
!
Turn off and disconnect input
power from power source.
1
Power Source
2
Lift -Eye
3
Cooler Connection Cable
4
Cooler
5
Screw 0.250-20 (8)
Remove screws from right side panel,
unplug case fan connector, and remove
right side panel from power source.
OM-271973 Page 12
Remove snap-in blank from power source
base.
!
Locate and loosen cooler connection cable
from inside power source, and place
connectors through hole in base. Insert
snap-in grommet into hole.
Slowly lower power source onto top cover
of cooler making sure connection cable is
not pinched between power source base
and cooler.
Use lift-eye to suspend power source
above cooler and plug connection cable
into matching connectors in cooler top
cover.
Keep hands and fingers away from
pinch points when lowering power
source onto cooler.
Install supplied screws 8 places to secure
power source to cooler.
Reconnect case fan and install power
source right side panel.
5-3. Coolant Hose Connections To Cooler
1
5
2
3
6
4
2
272 547-A
1
Power Source/Cooler Assembly
2
Coolant Hose
3
Coolant Out Fitting
4
Coolant In Fitting
5
Coolant Tank Cap
. Coolant hose
fittings have left-hand
threads.
Connect coolant hoses to fittings on cooler.
See Fill tank as specified in Section 4-3.
Maintain coolant level at bottom of fill neck.
6
Flow Indicator/Sensor
Flow indicator/sensor spins to indicate
coolant is flowing in the system. If coolant
flow is reduced below 0.25 gal/min. (1.14
L/min.), the power source output will be
disabled.
OM-271973 Page 13
5-4. Coolant Hose Connections To Single Output Cable
Single Liquid-Cooled
Output Connection
1
2
3
To
Cooler
3
2
4
4
272 548-A
1 Power Source/Cooler Assembly
2 Liquid-Cooled Output Cable
3 Protective Cap
4 Coolant Hose
Connect output cable to output #1 on power
source. Connect protective plug to power
source output #2.
OM-271973 Page 14
Connect quick-connect fitting on both
coolant hoses from cooler to output cable
fittings by pushing coolant hose fitting onto
output cable fitting.
To remove coolant hoses, grasp black ring
on coolant hose fitting and pull away from
output cable fitting . Coolant hose fitting will
separate from output cable fitting.
. Fittings
have spring loaded valves
inside that close when fitting is disconnected from an output cable fitting to
minimize coolant leaks.
5-5. Coolant Hose Connections To Dual Output Cables
Dual Liquid−Cooled
Output Connections
1
2
2
3
To
Cooler
3
4
2
2
3
4
3
272 549-A
1
Power Source/Cooler Assembly
2
Liquid-Cooled Output Cable
. Cables must be the same length: 10 ft
(3 m), 25 ft (7.6 m), or 50 ft (15.2 m).
3
Coolant Hose
4
Dual Output Cable Coolant Hose
Connect output cables to output #1 and
output #2 on power source.
Coolant hoses between output cables and
cooler must be connected in series for dual
output operation. Connect dual output
coolant hose between output cable #1 and
output cable #2 fittings by pushing coolant
hose fitting onto output cable fitting.
Connect quick-connect fitting on both
coolant hoses from cooler to remaining
output cable fittings.
To remove coolant hoses, grasp black ring
on coolant hose fitting and pull away from
output cable fitting . Coolant hose fitting will
separate from output cable fitting.
. Fittings
have spring loaded valves
inside that close when fitting is disconnected from an output cable fitting to
minimize coolant leaks.
. Heating
cables must be the same
length: 30ft (9.1 m), 50 ft (15.2 m), 80ft
(24.2 m), or 140 ft (42.7 m).
. Total length of heating and extension
cables must not exceed 360 ft (110 m).
The extension cable is counted twice
the length because it has a supply and
return hose.
OM-271973 Page 15
5-6. Installing Optional External Heat Exchanger
1
Base Screw
Remove two screws from base of
unit as shown. Save screws for installing heat exchanger.
2
Cooler Mounting Screw
Remove cooler mounting screw on
left side of unit. Discard screw.
3
2
4
5
6
7
1
3
6
8
5
1/4-20 x 3/4 in. Self-Drilling
Screw
Secure bottom of heat exchanger
with self-drilling screw.
1
7
Heat Exchanger
Align heat exchanger mounting
holes with holes in base. Secure
heat exchanger with screws removed in previous step.
Hose
Cushion Clamp
1/4-20 x 3/4 in. Screw
Route hoses through supplied
cushion clamps.
Align clamps with vacated hole in
base and secure with supplied
screw.
Connect cooler hoses to accessories as shown in image below.
8
4
Label (Notice)
Apply label to power source where
shown.
8
269 886-A
OM-271973 Page 16
SECTION 6 − MAINTENANCE
6-1. 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
Replace
Unreadable
Labels
Replace
Cracked
Hoses
12 Months
Change Coolant (use Coolant 043810)
. Use only non-anaerobic pipe sealant, tape, or silicone when replacing quick-disconnect coolant couplers.
6-2. Coolant Maintenance
!
Disconnect cooler plug from
welding power source receptacle
before maintaining.
!
Dispose of used coolant according to national, state, and local
codes. Do not pour down drain.
1
Cooler Front Panel
2
Coolant Filter
Unscrew housing to clean filter and
housing. Rinse filter and housing.
Changing Coolant
Drain coolant by tipping unit forward. Fill
with clean water and run for 10 minutes.
Drain and refill.
1
1
NOTICE − If replacing hoses, use original equipment hoses compatible with
ethylene glycol, such as Buna-n, Neoprene, or Hypalon. Oxy-acetylene
hoses are not compatible with any product containing ethylene glycol. See Section 8.
272 550-A
OM-271973 Page 17
6-3. Flow Direction W/Single Accessory
A. Flow Direction With Single Accessory
Induction
Coil
Pump
Filter
Bypass
Flow
Indicator/Sensor
Radiator
Filter
Tank
B. Flow Direction With Two Accessories
Second
Induction
Coil
First
Induction
Coil
Pump
Bypass
Filter
Heat
Exchanger
Filter
Tank
OM-271973 Page 18
Flow
Sensor
C. Flow Direction With External Heat Exchanger
Second
Induction
Coil
First
Induction
Coil
Pump
Bypass
Filter
Flow
Sensor
External
Heat
Exchanger
Filter
Internal
Heat
Exchanger
Tank
6-4. Troubleshooting
Trouble
Coolant system does not work.
Remedy
Be sure cooler input power and communication cables from power source are connected to cooler
receptacles (see Section 5-2).
Check input power line fuses or circuit breaker, and replace or reset if necessary.
Have Factory Authorized Service Agent check motor.
Decreased or no coolant flow.
Add coolant.
Check for clogged hoses or coolant filters. Clean filters or clean / replace hoses if necessary.
Disconnect pump, and check for sheared coupler. Replace coupler if necessary.
OM-271973 Page 19
Notes
OM-271973 Page 20
SECTION 7 − ELECTRICAL DIAGRAM
272 646-A
Figure 7-1. Circuit Diagram
OM-271973 Page 21
SECTION 8 − PARTS LIST
. Hardware is common and not
available unless listed.
11
26
21
8
22
19
20
10
7
10
9
24
18
26
27
16
6
23
18
19
27
17
4
12
13
14
25
15
28
14
29
30
5
3
32
33
31
2
2
1
270 789-A
Figure 8-1. Complete Assembly
OM-271973 Page 22
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-1. Complete Assembly
. . 1 . . . . . . . . . . . . . +270790
. . 2 . . . . . . . . . . . . . . 271825
. . 3 . . . . . . . . . . . . . . 219968
. . 4 . . . . . . . . . . . . . . 249587
. . 5 . . . . . . . . . . . . . . 271099
. . 6 . . . . . . . . . . . . . . 270468
. . 7 . . . . . . . . . . . . . . 242783
. . 8 . . . . . . . . . . . . . . 271660
. . 9 . . . . . . . . . . . . . . 271090
. . 10 . . . . . . . . . . . . . . 271383
. . 11 . . . . . . . . . . . . . . 271092
. . 12 . . . . . . . . . . . . . . 271657
. . 13 . . . . . . . . . . . . . . 271664
. . 14 . . . . . . . . . . . . . . 271656
. . 15 . . . . . . . . . . . . . . 271086
. . 16 . . . . . . . . . . . . . . 271622
. . 17 . . . . . . . . . . . . . . 227936
. . 18 . . . . . . . . . . . . . . 270451
. . 19 . . . . . . . . . . . . . . 213317
. . 20 . . . . . . . . . . . . . . 271661
. . 21 . . . . . . . . . . . . . . 271632
. . 22 . . . . . . . . . . . . . . 271659
. . 23 . . . . . . . . . . . . . . 271658
. . 24 . . . . . . . . . . . . . . 166608
. . 25 . . . . . . . . . . . . . . 173955
. . 26 . . . . . . . . . . . . . . 271097
. . 27 . . . . . . . . . . . . . . 271655
. . 28 . . . . . . . . . . . . . . 271085
. . 29 . . . . . . . . . . . . . . 227150
. . 30 . . . . . . . . . . . . . . 227149
. . 31 . . . . . . . . . . . . . . 270470
. . 32 . . . . . . . . . . . . . . 134795
. . 33 . . . . . . . . . . . . . . 271617
. . . . . . . . . . . . . . . . . . . 027657
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Base Assy,Welded Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Gen Precaution Induction Cooler W/Fr . . . . . . . . . . . . . . .
Mount, Support Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer, Washer .31 ID X 1.00 OD X .25 Thk Rubber . . . . . . . . . . . . . . . . .
Radiator, Heat Exchanger W/Fittings 1/2in Tbg . . . . . . . . . . . . . . . . . . . . . .
Blower/ Motor Assy, 24VDC W/Leads (M2) . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Snap−In Nyl .875 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . . .
Hose, Nitrile .500 Id X .750 OD X 28.000 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Center Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Baffle, Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Cover Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose,Nitrile .500 ID X .750 OD X 13.250 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ftg, Brs Barbed Tee 1/2 X1/2 X 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, Nitrile .500 ID X .750 OD X 3.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Mtg Flow Sensor Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicator, Flow W/Ftgs 1/2in Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor, NTC 30k Ohm @ 25 Deg C 24.00in Lead . . . . . . . . . . . . . . . .
Filter, Inline 1/2in Barb 250 Micron Caged Long Blk . . . . . . . . . . . . . . . . . .
Bracket,Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, Nitrile .500 Id X .750 Od X 16.500 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, 1−Ear Type Nom Dim .827 X .276 Wide . . . . . . . . . . . . . . . . . . . . .
Hose, Nitrile .500 ID X .750 OD X 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, Nitrile .500 ID X .750 OD X 12.000 V−Cut . . . . . . . . . . . . . . . . . . . . .
Cap, Tank Screw−On W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ftg, Brs Barbed M 1/2 Tbg X M .625−18 LH . . . . . . . . . . . . . . . . . . . . . . . .
Hose,Nitrile .500 ID X .750 OD X 2.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Mtg Filter Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Coolant Out Wordless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Coolant In Wordless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor,1/4 HP 24VDC BLDC (M1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupler,Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Assy, 60gph W/Ftgs And Ext Bypass . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
6
1
1
3
1
1
2
1
1
1
2
1
1
1
2
2
1
16
1
1
1
1
2
2
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
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-271973 Page 23
1
2
804 441-A
Figure 8-2. Single Output Coolant Hose
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-2. Single Output Coolant Hose
. . 1 . . . . . . . . . . . . . . 201430 . . Hose Assy, Coolant 36 In Lh Thread To Quick Connect . . . . . . . . . . . . . . . 1
. . 2 . . . . . . . . . . . . . . 204955 . . Ftg, Plstc Qdisc Coupler X 1/4 Npt Female . . . . . . . . . . . . . . . . . . . . . . . . . 1
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.
2
1
804 442-A
Figure 8-3. Dual Output Coolant Hose
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-3. Dual Output Coolant Hose
. . 1 . . . . . . . . . . . . . . 227601 . . Hose Assy, Coolant Quick Connect To Quick Connect (Includes) . . . . . . 1
. . 2 . . . . . . . . . . . . . . 204955 . . . . Ftg, Plstc Qdisc Coupler X 1/4 Npt Female . . . . . . . . . . . . . . . . . . . . . . . . 2
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-271973 Page 24
1
7
2
3
5
4
6
269 866-A
Figure 8-4. External Heat Exchanger
Item
No.
Dia.
Mkgs.
Part
No.
Description
269871
.. 1 ..............
.. 2 ..............
.. 3 ..............
.. 4 ..............
.. 5 ..............
.. 6 ..............
.. 7 ..............
...................
269791
216257
023562
153403
137605
269221
269841
269841
Quantity
Figure 8-4. External Heat Exchanger
..
..
..
..
..
..
..
..
Bracket, Mtg External Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator, Heat Exchanger 8.0 X 18.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, Hose .312 − .875 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Snap−In Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . .
Rivet, Stl .125 Dia X .126−.187 Grip Blk Blind Dom . . . . . . . . . . . . . . . . . .
Hose Assy, Coolant Quick Connect To Bare . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Notice Coolant Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Tie, 0−4.500 Bundle Dia (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
2
2
1
1
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-271973 Page 25
Effective January 1, 2017
(Equipment with a serial number preface of MH or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
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, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective date of
6.
90
Days — Parts
this limited warranty is free of defects in material and workmanship at
* Accessory (Kits)
the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
* Canvas Covers
INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
* Induction Heating Coils and Blankets, Cables, and
FITNESS.
Non-Electronic Controls
Within the warranty periods listed below, Miller will repair or replace any
* M-Guns
warranted parts or components that fail due to such defects in material
* MIG Guns, Subarc (SAW) Torches, and External
or workmanship. Miller must be notified in writing within thirty (30) days
Cladding Heads
of such defect or failure, at which time Miller will provide instructions on
*
Remote
Controls and RFCS-RJ45
the warranty claim procedures to be followed. If notification is submitted
* Replacement Parts (No labor)
as an online warranty claim, the claim must include a detailed
* Spoolmate Spoolguns
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 delivery date of the equipment to the
original end-user purchaser, and not to exceed twelve months after the
equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* AugmentedArc and LiveArc Welding Systems
* Automatic Motion Devices
* Bernard BTB Air-Cooled MIG Guns (No Labor)
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* TIG Torches (No Labor)
* Tregaskiss Guns (No Labor)
* Water Cooling Systems
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
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.
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
Appleton, Wisconsin, 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.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2017-01
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
City
State
Zip
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
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
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
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2017 Miller Electric Mfg. Co.
2017−01
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