Miller | MB030166G | Owner Manual | Miller PROHEAT HEAVY DUTY INDUCTION COOLER (48 VOLT) User manual

Miller PROHEAT HEAVY DUTY INDUCTION COOLER (48 VOLT) User manual
OM-227 169K
Processes
Induction Heating
Description
Heavy Duty Induction Cooler
Heavy Duty
Induction Cooler
CE
Visit our website at
www.MillerWelds.com
File: Pipe Welding Products
2011−06
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. Warning Label Definitions For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Coolant Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Installing Power Source To Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Coolant Hose Connections To Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Coolant Hose Connections To Single Output Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Coolant Hose Connections To Dual Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Coolant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Flow Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − 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
195406
Product
Heavy Duty Induction Cooler
Council Directives:
 2006/95/EC Low Voltage
 2004/108/EC Electromagnetic Compatibility
Standards:
 IEC 60974­1:2005 Arc welding equipment – Part 1: Welding power sources
 IEC 60974­2:2007 Arc welding equipment – Part 2: Liquid cooling systems
 IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
January 26, 2011
_____________________________________
___________________________________________
David A. Werba
MANAGER, PRODUCT DESIGN COMPLIANCE
240845C
Date of Declaration
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
ihom _2010−03
Protect yourself and others from injury — read and follow these precautions.
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 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!
D Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
D Use only nonconductive coolant hoses with a minimum length of 18
inches (457 mm) to provide isolation.
D Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
D 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.
D
When making input connections, attach proper grounding
conductor first − double-check connections.
D
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
D
D
D
D
D
D
D
D
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.
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
D
D
D
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.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for adhesives, fluxes, metals,
consumables, coatings, cleaners, and degreasers.
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 MSDS
for temperature information.
OM-227 169 Page 1
FIRE OR EXPLOSION hazard.
D
D
D
D
D
INDUCTION HEATING can burn.
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 may 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.
D
D
D Do not touch hot parts bare-handed.
D Allow cooling period before handling parts or
equipment.
D Do not touch or handle induction head/coil
during operation.
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.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
1-3. Additional Symbols for Installation, Operation, and Maintenance
FALLING EQUIPMENT can injure.
OVERUSE can cause OVERHEATING
D Use handle and have person of adequate
physical strength lift unit.
D Move unit with hand cart or similar device.
D For units without a handle, use equipment of
adequate capacity to lift and support unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
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.
H.F. RADIATION can cause interference.
FLYING METAL OR DIRT can injure eyes.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Wear approved safety glasses with side
shields or wear face shield.
D
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-227 169 Page 2
D
D
D
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 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.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
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,
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, 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.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).
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).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field around
the welding circuit and welding equipment. EMF fields may interfere with
some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, access
restrictions for passers−by or individual risk assessment for welders. All
welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
1. Keep cables close together by twisting or taping them, or using a
cable cover.
About Implanted Medical Devices:
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.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
OM-227 169 Page 3
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
ihom _2010−03fre
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
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.
NOTE − 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.
D
D
D
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
D
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
D
D
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
D
Ne pas toucher aux pièces électriques sous tension.
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.
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
D
D
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 !
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).
N’utiliser que des tuyaux de refroidissement non conducteurs ayant
une longueur minimale de 457 mm pour garantir l’isolation.
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.
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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
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 afin de s’assurer qu’il
n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à
nu 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.
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.
Le chauffage à induction de certains matériaux,
adhésifs et flux génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour votre santé.
D
D
D
D
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.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les adhésifs, les
OM-227 169 Page 4
D
D
D
flux, les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
D
Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces
inflammables.
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.
D
D
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas faire fonctionner l’appareil si l’air ambiant est chargé de particules, gaz, ou vapeurs 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.
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
MSDS.
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas surchauffer les composants .
D Attention aux risques d’incendie: tenir un extincteur à proximité.
D
D
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D
LE CHAUFFAGE PAR INDUCTION peut
provoquer des brûlures.
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 la tête/l’enroulement à induction pendant le fonctionnement.
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
D
Stocker des produits inflammables hors de la zone de travail.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D
D
D
D
D Utiliser la poignée et demander à une personne
ayant la force physique nécessaire pour soulever l’appareil.
D 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.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
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.
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.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits imprimés.
D Porter des lunettes de sécurité à coques latérales ou un écran facial.
D Établir la connexion avec la barrette de terre
AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes PC.
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.
OM-227 169 Page 5
LE RAYONNEMENT HAUTE FRÉQUENCE (HF) risque de provoquer
des interférences.
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.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
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.
D
D
D
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’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
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).
Les batteries, les bornes et autres accessoires contiennent du
plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
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, 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.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).
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).
OM-227 169 Page 6
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle des
risques 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.
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.
OM-227 169 Page 7
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions For CE Products
1
2
3
4
5
S-180 663
1
6
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
2
Electric shock from wiring can kill.
3
Disconnect input plug or power before
working on machine.
4
5
6
7
7
Moving parts, such as fans, can cut
fingers and hands and cause injury.
Keep away from moving parts.
Wear safety glasses with side shields.
Read the Owner’s Manual before
working on this machine.
Read the labels on the welding power
8
9
8
9
source, wire feeder, or other major
equipment for welding safety
information.
Recycle or dispose of used coolant in
an environmentally safe way.
Do not remove or paint over (cover)
the label.
2
1
3
100 h. std.
4
=
6
5
7
043 810 (HF)
043 809 (AL)
S-178 910
1
2
3
4
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Disconnect input plug or power before
working on machine.
Wear safety glasses with side shields.
Plugged filter or hoses cause
5
6
7
overheating and damage.
Read Owner’s Manual.
Check and clean filter every 100
hours; also check condition of hoses.
Use Low Conductivity Coolant No. 043
810 for High-Frequency assisted or
Gas Tungsten Arc Welding
applications. Use Aluminum Protecting
Coolant No. 043 809 where coolant
contacts aluminum parts or for Gas
Metal Arc Welding applications or
where High Frequency is not used.
. This cooler must use 043 810 coolant for
high frequency.
4/96 − 178 910
OM-227 169 Page 8
3-2. WEEE Label (For Products Sold Within The EU)
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collection facility.
Contact your local recycling office
or your local distributor for further
information.
3-3. Symbols And Definitions
. Some symbols are found only on CE products.
A
V
Amperes
Alternating Current
Voltage Input
Circulating Unit
With Coolant Pump
Volts
Water (Coolant) Input
Water (Coolant)
Output
Line Connection
Protective Earth
(Ground)
IP
On
U2
Conventional Load
Voltage
or
Load voltage
Degree Of
Protection
Off
I2
I1
U1
Primary Current
Primary Voltage
Hz
Hertz
Single Phase
Rated Current
OM-227 169 Page 9
SECTION 4 − INSTALLATION
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.
Operating Temperature Range: 14 F (-10 C) to 104 F (40 C). Ratings were developed at an ambient temperature of 20 C to 25 C.
4-2. Specifications
Input Power
Pump
Blower
48 Volts DC Commutated
48 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)
4-3. Coolant Chart
Low Conductivity Coolant No. 043 810*
Coolant
*Coolant 043 810 protects to -37 F (-38C) and resist algae growth.
NOTICE − Use of any coolant other than that listed in the table voids the warranty
on any parts that come in contact with the coolant (pump, radiator, etc.).
OM-227 169 Page 10
Weight
Net
Weight
105 lb
(48 kg)
122 lb
(55 kg)
4-4. Installing Power Source To Cooler
2
1
3
4
5
Tools Needed:
3/8 in.
801 190-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.
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.
OM-227 169 Page 11
4-5. Coolant Hose Connections To Cooler
1
5
2
3
6
4
2
804 434-A
1
Power Source/Cooler Assembly
2
Coolant Hose
3
Coolant Out Fitting
4
Coolant In Fitting
5
Coolant Tank Cap
OM-227 169 Page 12
. Coolant hose fittings have left-hand
threads.
Connect coolant hoses to fittings on cooler.
See Section 4-3 for proper coolant
specification, and fill tank. 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.
4-6. Coolant Hose Connections To Single Output Cable
Single Liquid−Cooled
Output Connection
2
1
1
2
3
To
Cooler
3
2
4
4
804 435-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.
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 grey 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.
OM-227 169 Page 13
4-7. Coolant Hose Connections To Dual Output Cables
Dual Liquid−Cooled
Output Connection
1
2
1
2
2
3
To
Cooler
3
4
2
2
3
4
3
804 436-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
OM-227 169 Page 14
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 grey 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.
SECTION 5 − MAINTENANCE
5-1. 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
Cracked
Hoses
Change
Coolant (If
Using Water)
Replace
Unreadable
Labels
12 Months
Change Coolant (If Using
043 810 Coolant)
OM-227 169 Page 15
5-2. Coolant Maintenance
1
Coolant Filter
Unscrew housing to clean filter.
Discard fluid in 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.
.
If replacing hoses, use original
equipment hoses (see Parts
List Section 7).
1
1
804 437-A
OM-227 169 Page 16
5-3. Flow Direction
Induction
Coil
Pump
Filter
Bypass
Flow
Indicator/Sensor
Radiator
Filter
Tank
5-4. 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 4-4).
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 filter. Clean filter or clean / replace hoses if necessary.
Disconnect pump, and check for sheared coupling. Replace coupling if necessary.
OM-227 169 Page 17
SECTION 6 − ELECTRICAL DIAGRAM
Ref. 218 057-G
Figure 6-1. Circuit Diagram
OM-227 169 Page 18
Notes
OM-227 169 Page 19
SECTION 7 − PARTS LIST
. Hardware is common and not
available unless listed.
4
17
22
6
12
See Figure 7-2
17
21
3
21
14
17
17
19
17
20
10
17
17
13
12
20
14
2
11
20
5
21
17
10
9
17
21
17
24
17
23
8
7
16
18
17
16
15
22
See Figure 7-3
25
1
26
28
27
17
804 438-B
Figure 7-1. Complete Assembly
OM-227 169 Page 20
20
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Complete Assembly
. . . 1 . . . . . . . . . +213 312
. . . 2 . . . . . . . . . . 216 258
. . . 3 . . . . . . . . . . 216 259
. . . 4 . . . . . . . . . . 213 314
. . . 5 . . . . . . . . . . 253 233
. . . 6 . . . . . . . . . . 216 257
. . . 7 . . . . . . . . . . 173 955
. . . 8 . . . . . . . . . . 166 608
. . . 9 . . . . . . . . . . 227 026
. . . . . . . . . . . . . . . . 239 494
. . . 10 . . . . . . . . . . 213 317
. . . 11 . . . . . . . . . . 219 968
. . . 12 . . . . . . . . . . 249 587
. . . 13 . . . . . . . . . . 081 543
. . . 14 . . . . . . . . . . 030 170
. . . 15 . . . . . . . . . . 178 610
. . . 16 . . . . . . . . . . 126 978
. . . 17 . . . . . . . . . . 023 562
. . . 18 . . . . . . . . . . 227 103
. . . 19 . . . . . . . . . . 227 104
. . . 20 . . . . . . . . . . 227 105
. . . 21 . . . . . . . . . . 227 106
. . . 22 . . . . . . . . . . 227 107
. . . 23 . . . . . . . . . . 203 990
. . . 24 . . . . . . . . . . 180 663
. . . 25 . . . . . . . . . . 188 980
. . . 26 . . . . . . . . . . 178 910
. . . 27 . . . . . . . . . . 227 149
. . . 28 . . . . . . . . . . 227 150
. . . 29 . . . . . . . . . . 027 657
. . . 30 . . . . . . . . . . 227 958
. . . 31 . . . . . . . . . . 221 604
. . BASE, assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FAN/MOTOR Assy, 48 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RADIATOR, heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TANK, water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAP, tank screw-in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER, in-line high temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREEN, filter lp cyl 100x100x0.0045 sst . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOUNT, support motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, washer .31 ID X 1.00 OD X .25 THK rubber . . . . . . . . . . . . . . . . . . .
. . FTG, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, snap-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FTG, brs tee 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FTG, brs barbed 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, hose .312-.875 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, .375 ID x 4.50 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, .375 ID x 12.00 lg v-cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, .375 ID x 17.00 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, .375 ID x 22.00 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, .375 ID x 28.00 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, caution incorrect coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, caution incorrect coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, coolant in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, coolant out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, .375 ID X .660 OD X 19.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, .375 ID X .660 OD X 15.875 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
1
2
1
6
1
3
1
3
8
1
1
1
1
1
1
1
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-227 169 Page 21
8
6
6
5
6
2
4
1
7
3
804 440-A
Figure 7-2. Motor/Pump Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Motor/Pump Assembly
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
...........
...........
...........
...........
...........
...........
...........
...........
212 743
226 987
203 937
134 795
226 988
126 978
226 843
216 647
. . . . . MOTOR, 1/4 hp brushless 48 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . PUMP, coolant 35 gph 150 psi bypass (including) . . . . . . . . . . . . . . . . . . . .
. . . . . . . CLAMP, v-band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . COUPLER, drive pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . VALVE, bypass coolant 99 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . FTG, brs barbed nipple close 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . FTG, pipe brs nipple close 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . PUMP, coolant w/fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
3
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-227 169 Page 22
804 439-C
Figure 7-3. Filter/Flow Sensor Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Filter/Flow Assembly
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
...........
...........
...........
...........
...........
...........
...........
...........
...........
213 574
228 307
213 573
227 936
023 562
217 782
227 026
081 543
239 494
.....
.....
.....
.....
.....
.....
.....
.....
.....
HOUSING, flow sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDICATOR, flow w fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mounting flow sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR, NTC 30k ohms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, hose .312-.875 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE, nitrile .375 ID x 1.75 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FILTER, in-line high temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FTG, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCREEN, filter lp cyl 100x100x0.0045 sst . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
4
2
1
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-227 169 Page 23
2
1
804 441-A
Figure 7-4. Single Output Coolant Hose
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-4. Single Output Coolant Hose
. . . 1 . . . . . . . . . . . 201 430 . . . . . HOSE ASSY, coolant 36 in LH thread to quick connect . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . 204 955 . . . . . . . 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
2
804 442-A
Figure 7-5. Dual Output Coolant Hose
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-6. Dual Output Coolant Hose
. . . 1 . . . . . . . . . . . 227 601 . . . . . HOSE ASSY, coolant quick connect to quick connect (including) . . . . . . . 1
. . . 2 . . . . . . . . . . . 204 955 . . . . . . . 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-227 169 Page 24
Notes
Notes
Effective January 1, 2011
(Equipment with a serial number preface of MB 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 6. 90 Days — Parts
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its
* Accessory (Kits)
original retail purchaser that new Miller equipment sold after the
* Canvas Covers
effective date of this limited warranty is free of defects in material
* Induction Heating Coils and Blankets, Cables, and
and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* M-Guns
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* MIG Guns and Subarc (SAW) Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
* Replacement Parts (No labor)
any warranted parts or components that fail due to such defects in
* Roughneck Guns
material or workmanship. Miller must be notified in writing within
* Spoolmate Spoolguns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed.
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
one year 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.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Engine Driven Welding 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
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* 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.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (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 2011−01
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
 2011 Miller Electric Mfg. Co.
2011−01
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