Miller WATERMATE 1A Owner's Manual

OWNER’S MANUAL
August 1997
FORM: OM-627F
Effective With Serial No. KH469867
Watermate™ 1A
1.
Specifications
Recirculating Coolant System For Water-Cooled GTAW Torches And GMAW Guns
Use With Guns/Torches Rated Up To 500 Amperes
2 gal (7.6 L) Coolant Tank Capacity;
Maximum Cooling Capacity: 11,000 BTU/hr At 1.25 qt/min (1.2 L/min)
Dimensions: 9-1/4 in (235 mm) Long, 9-1/4 in (235 mm) Wide, 30-3/4 in (781 mm) High
Weight: 50 lb (23 kg)
Single-Phase Input Power, 115 VAC, 5.5 A, 50/60 Hz
ST-137 227-A
2.
Safety Symbol Definitions
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Have only trained and qualified persons install, operate,
or service this unit. Call your distributor if you do not understand the directions. For WELDING SAFETY and
EMF information, read wire feeder and welding power
source manuals.
Beware of electric shock from wiring.
Beware of moving parts.
Wear safety glasses with side shields.
Recycle or dispose of used coolant in an environmentally
safe way.
© 1997 MILLER Electric Mfg. Co.
3.
Preparing Cooling Unit For Use
Fittings have 5/8-18 left-hand
threads. Connect hoses with
proper fittings as shown.
Tools Needed:
1
2
11/16 in
2
Flow Indicator
Filler Cover
Use table to select proper coolant,
and fill tank. Keep coolant level full.
FLOW
INDICATOR
3
4
Power Switch
Coolant Out Fitting
5
Coolant In Fitting
3
1
FILL
4
5
GTAW Or Where
HF* Is Used
GMAW Or Where
HF* Is Not Used
Where Coolant Contacts
Aluminum Parts
MILLER Low Conductivity
Coolant No. 174 599**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
MILLER Low Conductivity
Coolant No. 174 599**; Or
MILLER Aluminum Protecting
Coolant No. 174 600**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
MILLER Aluminum
Protecting Coolant
No. 174 600**
Application
Coolant
*HF: High Frequency Current
**MILLER coolants protect to -37° F (-38°C) and resist algae growth.
Ref. ST-800 496 / Ref. ST-136 398 / Ref. ST-099 157-A
OM-627 Page 2
4.
Connections
To prevent overheating, make sure
cooling unit is positioned so airflow
is not restricted.
GTAW Connections
Y When using coolant system
with a welding power source
with a water valve, bypass
water valve on welding power source by connecting directly to torch/gun to avoid
overheating, or damage to
coolant system.
GMAW Connections
ST-800 481 / ST-800 482
OM-627 Page 3
5.
Coolant Maintenance And Oiling Motor
Turn Off and unplug unit.
1
Motor
Remove plugs and put about 15
drops of SAE 20 motor oil into each
oil port. Replace plugs, and reassemble unit.
2
3
Coolant Pump
Acorn Nut
Place cloth or suitable container under nut, and remove nut.
1
4
5
Rubber Washer
Strainer
Rinse strainer with clean water.
Reinstall parts. Remove cloth or
container, and reinstall wrapper.
. Relief valve is factory set at 60
psi (414 kPa), and normally
needs no adjustment: Only adjust if replacing motor.
6
7
6
Pressure Gauge
Relief Valve Adjustment
Screw
Connect gauge to Coolant Out fitting as shown. Block or plug any
output fitting on gauge.
Turn On power, and adjust pressure adjustment screw as needed.
Turn Off power. Disconnect gauge
and reinstall nut and wrapper.
2
5
7
4
Decrease
Increase
3
Tools Needed:
3/8 in
15/16, 3/4 in
OM-627 Page 4
Ref. ST-800 483-A
6.
Routine Maintenance
Y Turn Off all power and unplug unit before maintaining.
1 Month
Blow Out Heat
Exchanger Fins
Clean Coolant Filter
6 Months
Change
Coolant (If
Using Water)
Replace
Cracked
Hoses
Replace
Unreadable
Labels
12 Months
Change
Coolant (If
Using MILLER
Coolant)
Oil Motor
7.
Troubleshooting
Trouble
Coolant system does not work.
Remedy
Be sure input power cord is plugged in to energized receptacle.
Check line fuses or circuit breaker, and replace or reset if necessary.
Motor overheated. Unit starts running when motor has cooled.
Have Factory Authorized Service Agent check Power switch and motor.
Decreased or no coolant flow.
Add coolant.
Check for clogged hoses or coolant filter.
Disconnect pump, and check for sheared coupling. Replace coupling if necessary.
PLG1
BLK
S1
11
INPUT POWER
WHT
MOT
12
GRN/YEL
SA-135 796-D
Figure 7-1. Circuit Diagram For 115 And 230 Volts Models
OM-627 Page 5
8.
Parts List
6
5
1
4
7
8
9
3
2
10
11
13
12
14
19
18
17
30
16
15
20
29
24
21
22
25
23
26
27
28
ST-137 167-E
. Hardware is common and
not available unless listed.
Figure 9-1. Complete Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Complete Assembly
... 1 ..........
... 2 ..........
... 3 ..........
... 4 ..........
... 5 ..........
... 6 ..........
... 7 ..........
... 8 ..........
... 9 ..........
. . . 10 . . . . . . . . . .
. . . 11 . . . MOT .
. . . 12 . . . . . . . . . .
. . . 13 . . . . . . . . . .
. . . 14 . . . . . . . . . .
................
. . . 15 . . . . . . . . . .
. . . 16 . . . . . . . . . .
OM-627 Page 6
182 446
097 966
081 543
097 510
097 238
030 170
136 318
097 236
108 379
097 239
174 898
135 804
134 795
126 992
146 249
108 377
124 919
. . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RADIATOR, 8.000 x 8.750 x 4.187 .375 inlet/outlet . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, snap-in nyl .750z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLADE, fan 8 in 5wg 37deg .500 bore CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg motor/pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOTOR, 1/4hp 115VAC 50/60Hz 1425/1725RPM . . . . . . . . . . . . . . . . . . . . . . .
. . PUMP, coolant (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COUPLER, drive pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, hose brs barbed elb M 3/8tbg x 3/8NPT . . . . . . . . . . . . . . . . . . . . .
. . . . STRAINER, screen 100 x 90 mesh 2.215 lg . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SKID, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, PVC .375 ID x .675 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
2
1
1
2
1
1
1
1
1
1
1
2
1
1
2ft
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Complete Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
17
18
19
20
21
22
23
24
25
26
27
28
29
30
. . . . . . . . . . 175 429 . .
. . . . . . . . . . 081 936 . .
. . . . . . . . . . 153 202 . .
. . . . . . . . . . 086 412 . .
. . . . . . . . . . 177 400 . .
. . . . . . . . . . 010 913 . .
. . . . . . . . . . 081 895 . .
. . . . S1 . . 177 396 . .
. . . . . . . . . . 134 900 . .
. . . . . . . . . +108 378 . .
. . . . . . . . . . 180 663 . .
. . PLG1 . 135 794 . .
. . . . . . . . . . 175 776 . .
.....................
TANK, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER, filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBING, PVC .375 ID x .125 mtg wall (order by ft) . . . . . . . . . . . . . . . . . . . . . .
SCREW, thumb brs 10-32 x 1.000 knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, well 10-32 blind fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH, rocker DPST 15A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STRAIN RELIEF, cable flexible .270-.480 cable . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE, pwr 10ft 6 in 16ga 3/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, caution incorrect coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . .
1
1
3ft
2
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.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-627 Page 7