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OWNER’S MANUAL OM-180 231 March 1996 Watertank L (PU 301) 1. Specifications Recirculating Coolant System For Water-Cooled GTAW Torches And GMAW Guns Use With Guns/Torches Rated Up To 600 Amperes 3 gal (11.4 L) Coolant Tank Capacity; Maximum Cooling Capacity: 14,000 BTU/hr At 1.25 qt/min (1.2 L/min) Dimensions: 23 in (584 mm) Long, 12 in (305 mm) Wide, 13 13-1/4 1/4 in (337 mm) High Weight: 39 lb (18 kg) ST-801 189 2. 3. 115 Volt Models Use 5.9 Amperes, 50/60 Hertz, Single-Phase Input Power 230 Volt Models Use 3 Amperes, 50/60 Hertz, Single-Phase Input Power 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. Preparing Cooling Unit For Use 1 Coolant Out Hose 2 Coolant In Hose Fittings have 5/8-18 left-hand threads. Connect hoses with proper fittings as shown. 3 Coolant Tank Cap Use table to select proper coolant, and fill tank. Keep coolant level full. 4 Flow Indicator 5 Power Switch 1 2 Application 3 4 5 GTAW Or Where HF* Is Used GMAW Or Where Coolant Contacts Aluminum Parts Or Where HF* Not Used MILLER Low Conductivity Coolant No. 174 599** MILLER Aluminum Protecting Coolant No. 174 600**; Distilled Or Deionized Water OK Above 32° F (0° C) Coolant *HF: High Frequency Current **MILLER coolants protect to -37° F (-38°C) and resist algae growth. Tools Needed: 5/8 in ST-801 193-A © 1996 MILLER Electric Mfg. Co. 4. Connections 1 Lift -Eye If placing cooling unit on welding power source, slots are provided in bottom of unit so it fits over lift-eye. GTAW Connections 1 To prevent overheating, make sure cooling unit is positioned so airflow is not restricted. Y If welding power source has a water valve, do not connect hoses to water valve. Connect hoses as shown. Operation: Turn power switch On. Flow indicator spins to indicate that at least 0.53 qt/min (0.5 L/min) of coolant is flowing. GMAW Connections ST-801 190-A / ST-801 191-A OM-180 231 Page 2 5. 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 6. Coolant Maintenance And Oiling Motor 1 Coolant Filter Unscrew housing to clean filter. Changing coolant: Drain coolant by tipping unit forward. Fill with clean water and run for 10 minutes. Drain and refill. 2 1 Motor Remove plugs and put about 15 drops of SAE 20 motor oil into each oil port. Replace plugs. . If replacing hoses, use hoses compatible with ethylene glycol, such as buna-N, neoprene, or hypalon. 2 Tools Needed: 3/8 in ST-801 195-A / Ref. ST-801 194 OM-180 231 Page 3 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. INPUT POWER SA-135 796-A Figure 7-1. Circuit Diagram For 115 And 230 Volts Models OM-180 231 Page 4 Notes OM-180 231 Page 5 OM-180 231 Page 6 29 30 Figure 8-1. Complete Assembly * *Included in Item 19 28 31 25 24 22 23 1 18 27 17 2 26 8 15 21 16 20 19 13 22 8 17 4 3 5 14 16 15 6 13 8 9 7 12 8 11 10 8. Parts List ST-801 196-B Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-1. Complete Assembly ... 1 ... 2 ... 3 ... 4 ... 5 ... 6 ... 6 ... 7 ... 8 ... 9 . . . 10 . . . 11 . . . 12 . . . 13 . . . 14 . . . 15 . . . 16 . . . 17 . . . 18 . . . 19 . . . 20 . . . 21 . . . 22 . . . 23 . . . 24 . . . 25 . . . 26 . . . 27 . . . 28 . . . 29 . . . 30 . . . 30 . . . 31 . . . . . . . . . . +166 562 . . . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 327 . . . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 042 . . . . . PUMP COOLANT w/CLAMPS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 992 . . . . . . . FITTING, hose brs barbed elb M 3/8tbg x 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 795 . . . . . . . COUPLER, drive pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOT . . 173 264 . . . . . MOTOR, 1/4hp 230VAC 50/60Hz 1425/1725rpm (230V model) . . . . . . . . . . . MOT . . 173 263 . . . . . MOTOR, 1/4hp 115VAC 50/60Hz 1425/1725rpm (115V model) . . . . . . . . . . . . . . . . . . . 166 570 . . . . . BLADE, fan 9.000 5wg 38deg .500 bore cw (setscrew included) . . . . . . . . . . . . . . . . . . 174 044 . . . . . TUBING, PVC .375 x .625 OD X 18.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 746 . . . . . CLAMP, 1-ear type nom dim .656 x .275 wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 293 . . . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 569 . . . . . RADIATOR, heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 267 . . . . . TANK COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 043 . . . . . TUBING, PVC .375 ID x .625 OD x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 608 . . . . . CAP, tank screw-on w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 045 . . . . . TUBE, pick-up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 369 . . . . . TUBING, PVC .375 ID x .625 OD x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 248 . . . . . HOSE, nprn brd No. 1 x .375 ID x 4.000 black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 560 . . . . . RING, ring ext .500 shaft grv x .042thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 564 . . . . . FILTER, in-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 254 . . . . . CLIP, filter mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 047 . . . . . NUT, .250-20 special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 559 . . . . . INDICATOR, flow (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 568 . . . . . . . PADDLE, slow indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 566 . . . . . . . O-RING, 1.301 ID x .070CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 567 . . . . . . . LENS, flow indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1 . . . 177 396 . . . . . SWITCH, rocker DPST 15A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 399 . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 571 . . . . . FITTING, coolant barbed 3/8tbg 5/8-18 female . . . . . . . . . . . . . . . . . . . . . . . . PLG1 . . 136 038 . . . . . CABLE, power 16ga 3c (230V model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG1 . . 176 836 . . . . . CABLE, power 10ft 16ga (115V model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 042 . . . . . BUSHING, strain relief .270/.480 id x .804 mtg hol . . . . . . . . . . . . . . . . . . . 1 1 1 2 1 1 1 1 2 10 1 1 1 1 1 1 1 1 2 1 1 4 1 1 1 1 1 1 1 2 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-180 231 Page 7 Notes OM-180 231 Page 8
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