Miller RADIATOR 2 Owner's Manual

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OWNERS
MANUAL
March 1983 FORM: OM-622C
Effective With Style No. JD-13
MODEL
RADIATOR 1
RADIATOR 2
MILLER ELECTRIC MFG. CO.
718 5. BOUNDS ST. P.O, Box 1079
APPLETON, WI 54912 USA
NWSA CODE NO. 4579
PRINTED IN U.S.A.
Aa TAR WEA ай AN Se Dd IE Pr ACL
LIMITED WARRANTY y
EFFECTIVE: JUNE 1, 1979 A
This warranty supersedes all previous MILLER warranties and is ex- \№
clusive with no other guarantees or warranties expressed or implied.
Ir;
LIMITED WARRANTY - Subject to the terms and conditions As a matter of general policy only, Miller may honor claims he
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants submitted by the original user within the toregoing periods. q
to its Distributor/ Dealer that ali new and unused Equipment Ye
furnished by Miller is free from defect in workmanship and In the case of Miller's breach of warranty or any other duty %
material as of the time and place of delivery by Miller. No war- with respect to the quality of any goods, the exclusive remedies Ne
ranty is made by Miller with respect to engines, trade ac- therefore shall be, at Miller's option {1) repair or (2) replacement :
cessories or other items manufactured by others. Such or, where authorized in writing by Miller in appropriate cases, (3) .
engines, trade accessories and other items are sold subject to the reasonable cost of repair or replacement at an authorized Nr
the warranties of their respective manufacturers, if any . All Miller service station or {4) payment of or credit for the purchase /
engines are warranted by their manufacturer for one year from price (less reasonable depreciation based upon actual use) upon №
date of original purchase, return of the goods at Customer's risk and expense. Upon receipt С
of notice of apparent defect or failure, Miller shall instruct the clai- Ir
Except as specified below, Miller's warranty does not apply mant on the warranty claim procedures to be followed. ;
to components having normal useful life of less than one (1) №
year, such as spot welder tips, relay and contactor points, ANY EXPRESS WARBANTY NOT PROVIDED HEREIN AND
= MILLERMATIC parts that come in contact with the welding ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA. 2
{ wire including nozzles and nozzle insulators where failure does TION AS TO PERFORMANCE, AND ANY REMEDY FOR :
A not result from defect in workmanship or material. BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, Nes
: MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, :
м Miller shall be required to honor warranty claims on war- CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING NW
ranted Equipment in the event of failure resulting from a defect ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
+ within the following pericds from the date of delivery of Equip- FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO .
; ment to the original user: ANY AND ALL EQUIPMENT FURNISHED BY MILLER !S EX- F.
{ CLUDED AND DISCLAIMED BY MILLER. u
À 1. Arc welders, power sources and components .. 1 year
2. Original main power rectifiers ................ 3 years EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
A (labor - 1 year only) WRITING, MILLER PRODUCTS ARE INTENDED FOR of
Ly 3. Allwelding guns and feeder/guns ............ 90 days ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL ;
2 4. All other Miltermatic Feeders. ................. 1 year USERS AND FOR OPERATION BY PERSONS TRAINED AND №
: 5. Replacement or repay parts, exclusive of labor . 60 days EXPERIENCED IN THE USE AND MAINTENANCE OF :
A 6. BatterleS —...0rresrerr recen, 6 months WELDING EQUIPMENT AND NOT FOR CONSUMERS OR Ne
CONSUMER USE. MILLER’ WARRANTIES DO NOT EXTEND
5 provided that Miller is notified in writing within thirty {30} days TO, AND NO RESELLER IS AUTHORIZED TO EXTENO у
: of the date of such failure. MILLER'S WARRANTIES TO, ANY CONSUMER. |
A X
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GES Bn En Bona. NT > Bn NRE E a Za Bra Na Na SN
ERRATA SHEET
February 28, 1984 FORM: OM-622C
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data
appearing later in this manual. |
AMENDMENT TO SECTION 4 - MAINTENANCE
Add Section 4 - 5. MOTOR COUPLING
A flexible coupling connects the motor and coolant pump. If coupling replacement becomes necessary, install new
coupling with longer portion onto motor shaft as shown in Figure 4-3 on this Errata Sheet.
IMPROPER COUPLING AND FAN INSTALLATION will damage components.
Add Fiaura 4 - 3, Flexible Coupling Installation
Retaining
в Washer
— ———— E
— © ©
pi
Flexible
Coupling
Install fan and coupling so that sufficient clearance is present between fan and internal components.
Markings Inside Fan
Hub Must Face Pump
Coolant
Pump
Motor
Position Fan With
Blade Pitch Angles
As Shown
TB-094 489
Figure 4 - 3. Flexible Coupling Installation
tem Part Replaced
No. No, With Description Quantity
4 081541 091 445 COUPLING, flexible 1/2 (Eff w/JE-Q) ....... co iii ii KE 1
9 081544 (093 557 STRIP, pump-adi support (Eff w/JD-47) ........ cc iii, 2
10 070931 091071 PUMP, coolant (Eff w/JD-30) .............e.eorceeverrecereecveca ces 1
31 081539 093 168 ANGLE, tank stop (Eff w/JD-47 thru JE-8) ............e....esveeerereco. 1
31 093 168 094 229 BRACKET, retainer-tank (Ef w/JE-9)........—..e_.erecesmesaravecorr ere. 1
36 086 352 093 169 COVER, coolanttank (Effw/JD-47) ........ iii iii e. 1
37 081 535 1093 170 TANK, coolant (Effw/JD-47) ........._....eesenrsorsorrecarocareore one. 1
026 837 Deleted (Eff w/JD-47)
093 556 BRACKET, support-pump (Eff w/JD-47) ..............o—eoerecorceroaen. 2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Es SECTION 1 - INTRODUCTION yim
Motor | Ampere
Input input | Motor
Model
Tank Overall Weight
Dimensions Net | Ship
Radiator 1 | 115V 5.5A 1725
Radiator 2 | 230V 2.8A rpm
Voltage | Full Load |Speed | Phase | Frequency | Capacity
Single | 50/60 Hz.
1.5 Height - 12-1/4"
Width - 12-1/4" 148 Ib. | 52 Ib.
Gallons | Depth - 19-1/4”
==
12-1/4"
TC-049 137-4
Figure 1-1. Specifications
1-1. GENERAL - This manual has been prepared
especially for use in familiarizing personnel with the
design, Installation, operation, maintenance, and
troubleshooting of this equipment. All information
presented herein and on various labels, tags, and plates
on the unit should be given careful consideration to
assure optimum performance of this equipment.
1-2. RECEIVING-HANDLING - Prior to installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill of
lading and freight bill will be furnished by the carrier on
request if occasion to file claim aríses.
When requesting information concerning this equip-
ment, it is essential that Model Description and Serial
(or Style) Numbers of the equipment be supplied.
1-3. DESCRIPTION - The coolant system consists of
an electric motor, stainless steel tank, radiator, fan, and
high pressure pump to circulate the coolant. The pump
discharge line is equipped with a by-pass vaive for
pressure relief,
The coolant system is designed and buiit to work in con-
junction with inert gas torches and other water-cooled
equipment to supply adequate coolant circulation to the
equipment and connecting cables.
1-4, SAFETY - Before the equipment is put into
operation, the safety section at the front of the welding
power source or welding generator manual should be
read completely. This will help avoid possible injury due
to misuse or improper welding applications. |
The foliowing definitions apply to CAUTION and IM-
PORTANT blocks fround throughout this manual.
Under this heading, installation,
operating, and maintenance procedures or practices will
be found that if not carefully followed may create a
hazard to personnel,
Under this heading, installation,
operating, and maintenance procedures or practices will
be found that if not carefully followed may result in
damage to equipment.
1-6. COOLANT SYSTEM RATINGS - The effec-
tiveness of the coolant system is dependent upon
severai factors: the coolant system design, coolant flow
`
`
%
\
\
5100 > BY-PASS CLOSED
y 80 |-
2
a 606
had
o +
40
Q
к 20
=
un | | 1 L |
о 1 2 3 4 5 6 7 8
FLOW (QTS. PER MIN) 8-049 272
Figure 1-2. Pump Performance With By-Pass
Valve Closed
OM-622 Page 1
rate, and torch design. To be effective, the coolant
systern must be able to circulate coolant through the
torch with a flow rate great enough to provide adequate
cooling of the torch and must effectively dissipate heat
to tower the coolant temperature.
A. Pump Performance
The pumping ability of the coolant system with the
pump by-pass valve closed.-is illustrated in Figure 1-2.
Operation of the pump with the by-pass valve closed is
pot normally recommended (see Section 3-1), Figure
1-3 illustrates the pumping ability of the coolant system
with the by-pass valve set for 50 psi. A by-pass valve
setting of 50 psi should provide adequate protection for
most torches. The apparent loss of flow when the by-
pass valve is opened is caused by a portion of the
coolant being diverted to the tank through the by-pass
valve.
The amount of water that will flow for a given by-pass
setting is determined by the resistance of the torch and
lines and can be illustrated by a resistance curve as
shown in Figure 1-3. The operating point for the system
will be where the torch resistance curve and pump per-
formance curve cross. As illustrated, the torch with low
resistance has a higher coolant flow rate.
o
o
BY-PASS SET AT 30 PSI
со
oO
1
>
TORCH RESISTANCE CURVES
A. HIGHLY RESTRICTIVE DESIGN
B. LOW RESTRICTIVE DESIGN
©
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©
bh
o
i | 1 Lo
o 1 2 3 4 5 6 7 8
FLOW (QTS. PER MIN)
STATIC PRESSURE PSI
B-049 278
Figure 1-3. Pump Performance With By-Pass
Valve Set At 50 PSI
B. Heat Dissipation Abilities
The actual performance of the coolant system is depen-
dent upon and will vary with individual torch design. For
each torch there is a maximum temperature the coolant
going into the torch can reach and still provide adequate
cooling. If this torch inlet temperature, along with the
corresponding torch outlet temperature is known,
Figure 1-4 can be used to determine the adequacy of
the total system if the flow rate is approximately 1 quart
per minute.
Page 2
1. Obtain the maximum coolant inlet and cor-
responding outlet temperatures in degrees
Fahrenheit from the torch manufacturer.
2. Multiply the difference in temperature by 125 to
obtain the heat extracted from the torch in
BTUs per hour.
3. Use the BTU's/hour obtained above and the
torch output temperature in degrees Centigrade
to locate a point on the Heat Dissipation Chart
Figure 1-4.
1000 BLU
æ
©
с
©
E
©
TORCH QUTPUT TEMP °С.
|
|
|
|
|
1
|
|
|
|
“2
©
N
"CURVE OBSTAINED ATA FLOW RATE
OF OME QUART FER MIN.
1600 38001
| | 1 J
1 | |
0 1900 1000 3000 4000 5000 4000 7000 BCCO
HEAT EXTRACTED (B.T.U./HR.) B-081 945-A
Figure 1-4. Heat Dissipation Chart
The heat dissipation ability of the coolant system must
be equal to or greater than the heat extracted from the
torch when ccmpared with the torch outlet
temperature,
Example: A torch manufacturer states that the max-
imum torch inlet temperature is 136°F. The torch outlet
temperature after system equilibrium is reached is
176°F. The flow rate is approximately 1 quart/ minute.
if the temperature difference, 40°F, is multiplied by
125, 5000 BTU’'s/hr is extracted by the coolant. The
torch outlet temperature is 80°C. Since the capability of
the coolant system at 80°C is greater than the 5000
BTU’'s/hr extracted from the torch (5800 vs 5000
BTU’s/ hr), the coolant system would be more than ade-
quate for that particular torch. In comparison, the
coolant system with a 40 gallon tank is rated for 3600
BTU’s/hr at 80°C. That coolant system would not have
sufficient heat dissipation ability once the system has
reached equilibrium. However, due to the, large tank
capacity, approximately 334 pounds of coolant, the
system could handle substantial overloads until such
time that system equilibrium is reached.
E SECTION 2 - INSTALLATION E
Dudo EF: 166 Do not block air flow through the
unit. Allow a minimum of 18 inches of unrestricted
space between the unit and the nearest obstruction.
2-1. PRIMARY CONNECTIONS - The coolant
system is designed to be operated from a single-phase,
60 or 60 Hertz, ac power supply which has a line
voltage rating that corresponds with the electrical input
voitage shown on the unit nameplate. Consult the local
electric utility if there is any question about the type of
electrical system available at the installation site or how
proper connections to the coolant system are to be
made.
Do not attempt to get 115 volts ac
power from the 230 volts primary terminals on the
welding power source. Use the external 115 volts
receptacle where furnished. If 115 or 230 volts ac
power is required and not available, an auxiliary power
source will have to be provided.
2-2. COOLANT CONNECTIONS (Figure
3-1) - Both the pump outlet and the return line are
5/8-18 female left hand adapters, which are standard
connections on most inert gas torches.
Coolant system connections should
be made directly to the gun water hoses. Do not con-
nect the coolant system to a water solenoid valve on the
wire feeder or welding power source. Failure to comply
may result in damage to the coolant pump and/or gun.
Coolant tank capacity of this unit is 1.5
gallons (5.7 liters); however, length of coolant hoses
will directly effect the amount of coolant needed in the
unit. Add coolant in sufficient amounts to compensate
for coolant in hoses. For 5/16 1.D. hose add approx-
imately 1.5 quarts (1.42 liters} per 100 ft. * (30.5 ml of
hose, For 3/8 1.D. hose add approximately 2.25 quarts
(2.13 liters) per 100 ft. * (30.5 m) of hose. *Combined
total of 50 ft. Coolant In and 50 ft. Coolant Out hose.
2-3. COOLANT - Normally, ordinary tap water can be
used as a coolant. However, because of wide dif-
ferences in water quality, it is recommended that the
water be analyzed for harmful mineral deposits and cor-
rosives, and if necessary, treated before being used in
the coolant system.
A mixture of tap water and ethylene glycol anti-freeze
can eliminate some of the problems associated with or-
dinary water,
Where freezing conditions may be encountered, perma-
nent type anti-freeze may be added to the coolant. Mix
coolant according to the anti-freeze manufacturers
recommendation for the ambient temperature en-
countered.
Lido EFE Do not use sealant type anti-freeze in
the coolant system as it may block torch coolant
passages.
Ensure that all coolant connections are air tight to pro-
vide maximum cooling efficiency.
Cs SECTION 3 - OPERATION (manana ss Ss
3-1. BY-PASS VALVE - A by-pass valve is installed
in the pump discharge line to help accomodate for dif-
ferences in torch design and to provide pressure relief in
case the discharge line should be closed for any reason.
Factory setting of the by-pass valve is 50 Ibs. of
pressure. This setting can be adjusted to follow the
torch manufacturer's recommended pressure.
If for normal operation the by-pass
valve is closed or set to a pressure higher than recom-
mended by the torch manufacturer, damage to the
torch will result. If the by-pass valve is set to a pressure
lower than recommended, the torch will not be properly
cooled and damage to the torch may result.
To adjust the by-pass valve pressure, remove the lock
nut and turn the pressure adjustment screw clockwise
to increase pressure. Replace lock nut to lock the
pressure adjustment screw at the desired pressure. The
higher the setting of the by-pass valve pressure, the
more coolant flows through the system per minute,
3-2. POWER SWITCH (Figure 3-1) - This coolant
system is equipped with a POWER switch which when
placed in the ON position will energize the coolant
systems motor and thereby permit coolant circulation,
Placing the POWER switch in the OFF position will shut
the coolant system down,
Coolant In Coolant Out
pl, LA
qe Power S» vitch
Flow
Indicator ~ | El — = Power Cord
|
Fill TA-049 138-A
Figure 3-1. Component Locations
OM-622 Page 3
Es SECTION 4 - MAINTENANCE ss
Periodically inspect the labels on this
unit for legibility. All labels must be maintained in a
clearly readable state and replaced when necessary.
See the Parts List for part number of labels.
4-1, CLEANING THE COOLANT SYSTEM - А
maintenance schedule for cleaning the coolant system
must be based on the type of coolant used.
A. Ordinary Tap Water As Coolant
Initially clean the coolant tank and fiiter at frequent in-
tervals to determine if mineral deposits are ac-
cumulating; and visually examine the system for corro-
sion. И the level of mineral deposition or corrosion is
high, appropriate water treatment or the use of a water
and anti-freeze mixture is required.
B. Water And Anti-freeze Mixture As Coolant
Check the anti-freeze solution every three months.
4-2. GENERAL - Keep the unit clean and free from
accumulated dust and dirt. The radiator fins" should be
cleaned occassionally by blowing them out with com-
pressed air. Wipe other surfaces with a clean, dry cloth.
The bearings of the motor should be oiled according to
the manufacturer's recommendations on the motor
nameplate.
4-3. FUSE PROTECTION - This unit is equipped with
a fuse F1, located behind the front panei. The fuse pro-
tects the motor from overheating if the coolant pump
fails. If the fuse opens, coolant recirculation ceases.
XII Disconnect input power to the coolant
system before attempting to change the fuse.
4-4, MOTOR MAINTENANCE - Every 6 months
reoil the bearings on the motor. Use 150 drops (approx-
imately 1 teaspoon) of SAE 20 motor oil in each bear-
ing. Continue to service motor regularly according to
manufacturer's recommendations on motor nameplate,
wr WHT
>
PLG 4
Circuit Diagram No. A-070 796
Figure 4-1. Circuit Diagram For 115 Volts Models
230V, GRA.
ac. € ° |!
- RED
“че
PLO1
Circuit Diagram No. A-070 797
Figure 4-2. Circuit Diagram For 230 Volts Models
Page 4
FORM: OM-622C :
March 1983
Effective With Style No. JD-13
MODEL
RADIATOR 1
RADIATOR 2
PARTS
LIST
19 14 13 20
EAT
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30
TD-049 135-E
Figure A - Complete Assembly
OM-622 Page 1
Quantity
Model
Item Dia. Part Radiator ) Radiator
No. Mkgs. No. Description 1 2
Figure A Complete Assembly
1 086 852 STRAINER, coolant ......... oii ieee ieee 1 1
2 086 412 SCREW, thumbbrass-knurled 10-32 x1 .......... cirri... 2 2
3 MOT 027 803 MOTOR, 1/4hp 115/230 voltsacb0/60Hz .................... 1 1
4 081 541 COUPLER, motor - shaft pump............... RAA 1 1
5 081 286 BLADE, fan 60 Hz 9 inch 5 wing 0.182 bore............0.000000 1 1
6 010 323 CLAMP, hose 1/4-5/8dia.............. cc iii iin, 1 1
7 081 646 FITTING, barbed M 3/8 TBGx 1/4NPT ...... iii. 3 3
8 010 378 GROMMET, rubber 9/16 x 3/4 mtg hole ....................... 2 2
9 081 544 BRACKET, anti - rotation pump ......._._..e_eceecesderreeooaron 2 2
10 070 931 PUMP, coolant ........ PP 1 1
070 916 KIT, repair - pump (as reg'd) ............o ee 0x9 90:00 RA 1 1
11 048 739 FITTING, brass - compression connector M 5/16 TBG x 1/4 NPT .., 1 1
12 048 808 TUBING, coolant - return pump by-pass ........._ee eeenrareeraa 1 1
13 046 510 HOSE, neoprene - braided No. 1x0.373IDx18 ................. 1 1
14 023 562 CLAMP, hose 5/16-7/8 dia ............ 000000000, reee 4 4
15 047 596 RADIATOR, water - coolant tank ..........—r—e_eoccrrerocorere 1 1
16 048 807 STRIP, mounting - radiator top. ...........o_eeee.ée.rereverereos 1 1
17 048 805 STRIP, mounting - radiatorbottom ................... cc. ch... 1 1
18 046 447 WRAPPER... i ee ee 1 1
19 081 543 FITTING, Water... oc. ee eevee na, 2 2
20 081 651 FITTING, plastic - compression M 3/8 TBGx 1/4 MPT ........... 1 1
21 — 070828 SHIELD, fuse ..... iii i ee 1 1
22 HH *085 874 FUSE, miniature-glassslo-blo10amp ......................... 1
22 Fl *(085 875 FUSE, miniature -glassslo-blobamp ........... LL. 1
23 012 571 HOLDER, fuse.............o_._.ee.rerx0oeazeorrererovrered, era 1 1
24 046 511 HOSE, neoprene - braided No. 1 x3/8I1IDx17 ................... 1 1
25 Si 011 609 SWITCH, toggle SPDT 15 amp 125 volts ............—.—.—em.erece.. 1
25 $1 011 611 SWITCH, toggle DPDT 15 amp 125 volts ............... ene... 1
26 046 694 PANEL, mounting - cOomponeNtS .. ea ae a aa 20e 1 1
27 NAMEPLATE {order by model and stylenumbers)................ 1 1
28 010 610 CONNECTOR, clamp -cable1/2inch............... ccc. 1 1
29 085 357 GAUGE, sight ............eeeerecceararorederereceaneorean e 1 1
30 086 896 CORD, power 10 ft... o eeeeseodearrerer ee nene. 1
30 086 897 CORD, power 10 ft... RER A. 1
31 081 539 STRIP, mounting - tank ..........._.._—.—eoeoeeecvecoreoecareare, 2 2
32 | 046 445 CASE SECTION, front/bottom/back .......................... 1 1
33 048 806 ANGLE, mounting - radiator ..........._..._.-eceeeeresrrenedereero 2 2
34 010 594 GROMMET, rubber1/2IDxtmtghole ........................ 1 1
35 015 713 GROMMET, rubber5/16 1D x1/2mtghole ..................... 1 1
36 086 352 COVER, tank cootant.........2242 1004 a 00 40e a a a a ane a a 0 4 41040 1 1
37 081 535 TANK, coolant .............eeeeeeeccecoccdororo rre ara 1 1
38 081 936 COVER, filter.........._....o0..e0recuarec.onadeoreneoev en. 1 1
39 603 115 WEATHERSTRIPPING, adhesive 1/8 x 3/8 (order by ft) .......... 5 ft 5
40 081 895 NUT, weil 10-32 blind fastener ..........—..eeecrrevorredere rre. 2 2
41 085 359 GROMMET, rubber 3/4 1D x 15/16 mtg hole ...................é. 1 1
026 837 INSULATOR, terminal - nylon .............eeoeeesrearercede ana» 2 4
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND STYLE NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-622 Page 2