Miller LJ060042F Owner's manual

OWNER’S MANUAL

OM-231 313E

2008−01

Coolmate™ 3.5

1. Specifications

Recirculating Coolant System For Water-Cooled GTAW Torches And GMAW Guns

Use With Guns/Torches Rated Up To 600 Amperes

IP Rating: 23

3-1/2 gal (13.2 L) Coolant Tank Capacity;

Maximum Cooling Capacity: 15,000 BTU/hr At 1.25 qt/min (1.3 L/min)

Dimensions: 26 in (660 mm) Long, 15-3/4 in (400 mm) Wide, 11-3/4 in (298 mm) High

804 839

Dimensions: 26 in (660 mm) Long, 15 3/4 in (400 mm) Wide, 11 3/4 in (298 mm) High

Weight: 60 lb (27 kg)

839

115 Volt Models Use 3.1 Amperes, 50/60 Hertz, Single-Phase Input Power

2. Safety Symbol Definitions

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.

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.

Wear safety glasses with side shields.

Porter des lunettes de sécurité avec des protections laté-

rales.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible ha-

zards are shown in the adjoining symbols or explained in

the text.

Indique une situation dangereuse qui si on l’évite pas peut

donner la mort ou des blessures graves. Les dangers possi-

bles sont montrés par les symboles joints ou sont expliqués

dans le texte.

Have only trained and qualified persons install, operate,

or service this unit. Call your distributor if you do not un-

derstand the directions. For WELDING SAFETY and

EMF information, read owner’s manual(s).

L’installation, l’exploitation et l’entretien de cet appareil

doivent être confiés uniquement à des personnes quali-

fiées et convenablement formées. S’adresser à un distri-

buteur si l’on ne comprend pas les directives. Pour les

renseignements ayant trait à la SECURITE lors du sou-

dage et aux champs électromagnétiques, consulter les

manuels traitant les dévidoirs et les sources de courant

pour le soudage.

NOTICE

Indicates statements not related to personal injury.

Indique des déclarations pas en relation avec des blessu-

res personnelles.

Indicates special instructions.

Indique des instructions spécifiques.

Beware of moving parts. Keep guards and panels in

place, covers closed, and hands away from moving parts.

Attention aux pièces mobiles. Maintenir les dispositifs de

sécurité et les panneaux en place, les couvercles fermés

et garder les mains éloignées des pièces mobiles.

Beware of electric shock from wiring. Disconnect input

power before installing this kit. Reinstall all panels and

covers.

Prendre garde aux chocs électriques dus au câblage.

Avant d’installer cet ensemble, couper l’alimentation.

Réinstaller tous les panneaux et couvercles.

Recycle or dispose of used coolant in an environmentally

safe way.

Recycler ou éliminer tout liquide de refroidissement usé

conformément aux méthodes prescrites pour assurer la

protection de l’environnement.

dec_cooler_1/07

Declaration of Conformity for

European Community (CE) Products

. This information is provided for units with CE certification (see rating label on unit).

Manufacturer: European Contact:

Miller Electric Mg. Co. Mr. Danilo Fedolfi,

1635 W. Spencer St. Managing Director

Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.

Phone: (920) 734-9821 Via Privata Iseo 6/E

20098 San Giuliano

Milanese, Italy

Phone: 39(02)98290-1

Fax: 39(02)98290203

European Contact Signature:

Declares that the product: CoolmateE 3.5

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC, 2006/95/EC

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC, 2004/108/EC

Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC

Marking Directive: 93/68/EEC

Standards

Arc Welding Equipment − Part 2: Liquid Cooling Systems. IEC 60974-2 Ed. 1, 2202-06

Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10, Ed. 1.1, 2004-10

Degrees of Protection Provided By Enclosure (IP Code): IEC 60529 Ed. 2.1, 2001-02

Insulation Coordination For Equipment Within Low-Voltage Systems − Part 1: Principles, Requirements, And Tests.

IEC 60664-1 Ed. 1.1

The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.

OM-231 313 Page 1

3. Warning Labels

OM-231 313 Page 2

4. Warning Labels Continued

S-180 663

1 2 3 4 5

7 8 9

1 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 Moving parts, such as fans, can cut

fingers and hands and cause injury.

Keep away from moving parts.

5 Wear safety glasses with side shields.

6 Read the Owner’s Manual before

working on this machine.

7 Read the labels on the welding power

source, wire feeder, or other major

equipment for welding safety

information.

8 Recycle or dispose of used coolant in

an environmentally safe way.

9 Do not remove or paint over (cover)

the label.

S-178 910

043 810 (HF)

043 809 (AL)

100 h. std.

21 3

1 Warning! Watch Out! There are

possible hazards as shown by the

symbols.

2 Disconnect input plug or power before

working on machine.

3 Wear safety glasses with side shields.

4 Plugged filter or hoses cause

overheating and damage.

5 Read Owner’s Manual.

6 Check and clean filter every 100

hours; also check condition of hoses.

7 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.

OM-231 313 Page 3

5. Rating Label

S/N: KG085472

043007

COOLMATE 3

Hz50/60

IP 23

NRTL/C

LR5071

231 308-B

6. Symbols And Definitions

Hertz Input Power Power On Indicator

Water (Coolant)

Output

Water (Coolant) In-

put

Line Connection

Single-Phase

Alternating

Current

Primary Voltage

1max

Rated Maximum

Supply Current

Degree Of

Protection

max

Rated maximum

power

Pl/

min

Power liters per

minute

OM-231 313 Page 4

7. Coolant Chart

Low Conductivity Coolant No. 043 810**; Distilled Or Deionized Water OK Above 32° F (0° C)

GTAW Or Where

HF* Is Used

Application

*HF: High Frequency Current

**Coolant 043 810, a 50/50 solution, protects to -37° F (-38°C) and resist algae growth.

Coolant

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.).

Notes

OM-231 313 Page 5

8. GTAW Connections

804 846-A

Tools Needed:

5/8 in

To prevent overheating, make sure cooling

unit is positioned so airflow is not restricted.

NOTICE − If welding power source has a

water valve, do not connect hoses to water

valve. Connect hoses as shown.

1 Coolant Out Hose

2 Coolant In Hose

Fittings have 5/8-18 left-hand threads.

Connect hoses with proper fittings as

shown. Some power sources may require

a TIG block.

3 Coolant Tank Cap

4 115 Volt AC Grounded Receptacle

An individual branch circuit capable of car-

rying 15 amperes and protected by fuses

or circuit breakers is recommended. Rec-

ommended fuse or circuit breaker size is

15 amperes.

Operation:

Fill tank with proper coolant. Use table in

Section 7 to select proper coolant. Maintain

coolant level at approximately 1 in (25 mm)

below top of filler neck. Connect hoses as

shown. Unit turns on when plugged in.

OM-231 313 Page 6

9. GMAW Connections

804 845-A

Tools Needed:

5/8 in

To prevent overheating, make sure cooling

unit is positioned so airflow is not restricted.

NOTICE − If welding power source has a

water valve, do not connect hoses to water

valve. Connect hoses as shown.

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

4 115 Volt AC Grounded Receptacle

An individual branch circuit capable of car-

rying 15 amperes and protected by fuses

or circuit breakers is recommended. Rec-

ommended fuse or circuit breaker size is

15 amperes.

Operation:

Fill tank with proper coolant. Use table in

Section 7 to select proper coolant. Maintain

coolant level at approximately 1 in (25 mm)

below top of filler neck. Connect hoses as

shown. Unit turns on when plugged in.

OM-231 313 Page 7

10. Routine Maintenance

! Disconnect power

before maintaining.

n = Check Z = Change ~ = Clean Δ = Repair l = Replace

* To be done by Factory Authorized Service Agent

Every

Months

~Coolant Strainer,

di h i

~ Blow out heat exchanger fins.

nCheck coolant level. Top off with

~ ,

durning heavy service,

clean more frequently.

nCheck coolant level

Top off with

distilled or deionized water if necessary.

Every

Months

nlHoses

nl Labels

ZReplace coolant.

m30 Torx

Tools Needed:

11. Coolant Maintenance And Oiling Motor

804 649-A / Ref. 801 194

! Disconnect input power be-

fore maintaining.

1 Coolant Filter

Unscrew housing to clean filter.

Changing coolant: Drain coolant by

tipping unit to rear, or use suction

pump. Fill with clean water and run

for 10 minutes. Drain and refill with

coolant (see section 7).

. If replacing hoses, use hoses

compatible with ethylene gly-

col, such as Buna-n, Neo-

prene, or Hypalon. NOTE:

Oxy-acetylene hoses are not

compatible with any product

containing ethylene glycol.

Install cover if removed.

OM-231 313 Page 8

12. Troubleshooting

Trouble Remedy

Coolant system does not work. 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 S1 and motor (Mot).

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.

13. Circuit Diagram For Cooler

228 525-B

OM-231 313 Page 9

Notes

OM-231 313 Page 10

14. Parts List

804 838-C

Figure 13-1. Complete Assembly

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-1. Main Assembly

Quantity

1 230 156 Cover, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 +192 449 Label, warning/caution 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 228 551 Plug, W/Leads Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 226 965 Panel, Side Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 228 519 Hose, nprn brd no 1 X .250 ID X .455 OD X 9.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 228 508 Pump, Coolant W/Fittings (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 5523 Ftg, Hose Brs Barbed Elbow M 3/8 TBG X 3/8 NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 173 999 Pump, Coolant 100 Gph W/Clamps Cw Rotation 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 134 795 Coupler, Drive Pump 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 196 990 Ftg, Brs Barbed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 173 263 Motor, 1/4hp 115vac 50/60hz 1425/1725 Rpm Dual 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 226 966 Bracket, Motor Mount 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 166 608 Cap, Tank Screw−on W/Vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 226 932 Tank, Coolant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 228 529 Hose, .375 ID X .650 OD X 19.500 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 155 436 Label, Ground/Protective Earth 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 163 562 Light, Ind Wht Lens 125vac Snap−in Neon Non−relampa 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 231 308 Label, Rating Card CSA C US 300245 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 213 053 Panel, Louver Cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 230 151 Plate, Indicator Front Cooler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 226 940 Valve, Check Bidirectional Assy 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 230 155 Backet, Valve Mounting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 226 964 Panel, Side Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 226 931 Base, Cooler 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 232 424 Radiator, Heat Exchanger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 231 341 Plenum, Air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-231 313 Page 11

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 13-1. Main Assembly (continued)

Quantity

27 213 072 Fan, Muffin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 233 164 CABLE, Power 11 ft 4 in. 16 ga 3c 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 228 498 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 196 312 Guard, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 228 520 Filter, Assy W/Fittings (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 215 667 Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 228 532 Hose, .375 ID X .650 OD X 1.415 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 231 311 Ftg, Hose Nyl Elbow Barbed 3/8 X 3/8 90 Deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 226 967 Bracket, Mtg Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 236 084 Hose, .375 ID X .650 OD X 10.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 228 530 Hose, .375 ID X .650 OD X 8.375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 231 368 Elbow/Tubing Assy, Return 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 231 367 Elbow/Tubing Assy, Pick-up 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 231 284 Bushing, Tank Coolant 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 180 663 Label, Warning General Precautionary Static&wire Fe 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 178 910 Label, Caution Incorrect Coolant Wordless Intl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 219 178 Label, Caution Incorrect Coolant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

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.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

www.MillerWelds.com

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier to:

For Service

Owner’s Record

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.

Contact your Distributor for:

To locate a Distributor or Service Agency visit

Miller LJ060042F, Coolmate 3.5, LH360001F, LJ330001F Owner's manual

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