Miller LJ450119F Owner's manual

OWNER’S MANUAL

OM‐618 194 463F

2009−01

CE And Non-CE Models

Use above FORM number when ordering extra manuals.

Coolmate™ V3

1. Specifications

Ref. ST-802 367-A

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

Use With Guns/Torches Rated Up To 600 Amperes

IP Rating: 23 − Not Intended For Use In Heavy Rain, Or Near Splashing Water

3 gal (11.4 L) Coolant Tank Capacity;

Maximum Cooling Capacity: 3,820 W (13,000 BTU/hr) @ 4.2 qt/min (4.0 L/min)

IEC Cooling Capacity: 1,420 W (4,840 BTU/hr) @ 1.1 qt/min (1 L/min)

IEC Cooling Capacity States That The Water Inlet Temperature Can Not Exceed 40° C Above Ambient

Temperature At A 1l/ Min Flow Rate.

Dimensions: 12-1/4 in (311 mm) Deep, 9-3/4 in (248 mm) Wide, 33 in (838 mm) High

Weight: 50 lb (23 kg)

115 Volt, 5.9 Amperes 60 Hertz, 4.7 Amperes 50 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.

3. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the back panel. Use rating label to determine input power requirements and/or

rated output. For future reference, write serial number in space provided on cover of this manual.

OM-618 Page 2

4. Warning Label Definitions For CE Products

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.

4/96

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-618 Page 3

5. Symbols And Definitions

. Some symbols are found only on CE products.

Amperes Alternating Current Voltage Input

Circulating Unit

With Coolant Pump

Volts

Water (Coolant) In-

put

Water (Coolant)

Output

Line Connection

Protective Earth

(Ground)

Degree Of

Protection

Primary Current

Hertz

On Off

Primary Voltage Single Phase

6. WEEE Label (For Products Sold Within The EU)

Do not discard product (where ap-

plicable) with general waste.

Reuse or recycle Waste Electrical

and Electronic Equipment (WEEE)

by disposing at a designated collec-

tion facility.

Contact your local recycling office

or your local distributor for further

information.

7. Tipping

! Do not move or operate unit

where it could tip.

Ref ST-802 055

OM-618 Page 4

8. Preparing Cooling Unit For Use

Ref. ST-802 367-A

Fittings have 5/8-18 left-hand

threads. Connect hoses with

proper fittings as shown.

1 Flow Indicator

2 Filler Cover

Use table to select proper coolant,

and fill tank. Keep coolant level full.

3 Power Switch

4 Coolant In Fitting

5 Coolant Out Fitting

Tools Needed:

11/16 in

MILLER Low Conductivity

Coolant No. 043 810**;

Distilled Or Deionized Water

OK Above 32° F (0° C)

MILLER Low Conductivity

Coolant No. 043 810**; Or

MILLER Aluminum Protecting

Coolant No. 043 809**;

Distilled Or Deionized Water

OK Above 32° F (0° C)

GTAW Or Where

HF* Is Used

GMAW Or Where

HF* Is Not Used

Application

*HF: High Frequency Current

**MILLER coolants protect to -37° F (-38°C) and resist algae growth.

Coolant

MILLER Aluminum

Protecting Coolant

No. 043 809**

Where Coolant Contacts

Aluminum Parts

Some models have

Holes are provided in bottom edge of

wrapper for bolting unit (with 1/4 in, customer

supplied hardware) to a running gear or other

permanent location.

two labels instead of one

(see Parts List).

NOTICE − Use of any coolant other than those listed in the table voids the warranty on any parts that come in contact with the coolant

(pump, radiator, etc.).

OM-618 Page 5

9. Connections

ST-802 368

To prevent overheating, make sure

cooling unit is positioned so airflow

is not restricted.

NOTICE − When using coolant sys-

tem 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.

! To prevent tipping when

placing unit on uneven or tilt-

ing surfaces, properly se-

cure the coolant system to a

wall, stationary support, or

equivalent rigid structure.

GTAW Connections

GMAW Connections

OM-618 Page 6

Turn Off and unplug unit.

1 Coolant Pump

2 Filter Cap

Place cloth or suitable container un-

der nut, and remove nut.

3 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 ad-

just if replacing motor.

4 Pressure Gauge

5 Relief Valve Adjustment

Screw

Connect gauge to Coolant Out fit-

ting as shown. Block or plug any

output fitting on gauge.

Turn On power, and adjust pres-

sure adjustment screw as needed.

Turn Off power. Disconnect gauge

and reinstall nut and wrapper.

. If replacing hoses, use hoses

compatible with ethylene gly-

col, such as Buna-n, Neo-

prene, or Hypalon. Oxy-acety-

lene hoses are not compatible

with any product containing

ethylene glycol.

3/8 in

Tools Needed:

10. Coolant Maintenance

ST-802 369-A

15/16, 3/4 in

Decrease Increase

OM-618 Page 7

11. Routine Maintenance

! Turn Off all power and unplug unit before maintaining.

1 Month

Blow Out Heat

Exchanger Fins

NOTICE − Clean coolant strainer. Severe condi-

tions may require more frequent cleaning (contin-

uous use, high/low temperatures, dirty environ-

ment, etc.). Failure to properly clean coolant

strainer voids pump warranty.

6 Months

Replace

Cracked

Hoses

Replace

Unreadable

Labels

Change

Coolant (If

Using Water)

12 Months

Change

Coolant (If

Using MILLER

Coolant)

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 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.

SA-135 796-D

BLK

WHT

GRN/YEL

MOT

PLG1

INPUT POWER

Figure 11-1. Circuit Diagram

OM-618 Page 8

13. Parts List

802 364-D

. Hardware is common and

not available unless listed.

. Some models have two labels

instead of one (check your front

panel).

34/35

36/37

Figure 12-1. Complete Assembly

OM-618 Page 9

Description

Part

No.

Dia.

Mkgs.

043 009

Item

No.

Figure 12-1. Complete Assembly

Quantity

1 166 608 CAP, tank screw-on w/vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 194 179 TUBE, pick-up coolant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 192 852 TANK, reservoir 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4A,4B 194 174 TUBING, PVC .375 ID x .625 OD x 15.000 clear brd 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5A,5B 174 044 TUBING, PVC .375 ID x .625 OD x 18.000 clear brd 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 196 515 RADIATOR, heat exchanger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 197 361 PUMP, coolant (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 126 978 FITTING, hose brs barbed M 3/8tbg x 3/8NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 196 990 FITTING, hose brs barbed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 134 795 COUPLER, drive pump 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 194 173 HOSE, NPRN brd No. 1 x .375 ID x 21.000 black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 MOT 173 263 MOTOR, 1/4hp 115VAC 50/60Hz 1425/1725RPM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 166 570 BLADE, fan 9.000 5wg 38deg .500 bore CW AL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 192 848 BRACKET, mtg motor/pump 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 192 856 PLENUM, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 192 858 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 PLG1 192 457 CABLE, power 11ft 5 in 16ga 3/c 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 139 042 BUSHING, strain relief .270/.470 ID x .804mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 192 854 CASE SECTION, wrapper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 192 857 CASE SECTION, main 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 192 449 LABEL, warning/caution 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 166 564 FILTER, in-line low profile 100 screen 3/8 hose bar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 168 254 CLIP, filter mounting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 279 INDICATOR, flow (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 186 004 HOUSING, flow indicator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 215 270 PADDLE, flow indicator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 166 566 O-RING, 1.301 ID x .070 CS 70 Duro Buna−N1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 186 005 LENS, flow indicator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 166 560 RING, rtng ext .500 shaft x .042thk E style bowed 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 166 571 FITTING, coolant barbed 3/8tbg 5/8-18 female 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 193 710 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 S1 177 396 SWITCH, rocker DPST 15A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 +192 859 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 177 448 WEATHERSTRIPPING, adh .250 x .375 x 8.500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 134 327 LABEL, warning (with words) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 180 663 LABEL, warning general precautionary (wordless for CE) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 188 980 LABEL, caution incorrect coolant (with words) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 178 910 LABEL, caution incorrect coolant (wordless for CE) 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.

Notes

242093‐A

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:

Product Stock Number

COOLMATE V3 W/CE COMPLIANCE 043009012

Council Directives:

• 2006/95/EC Low Voltage

• 2004/108/EC Electromagnetic Compatibility

• 2006/42/EEC Machinery Directive

Standards:

• IEC 609741 Arc Welding Equipment  Welding Power Sources: edition 3, 200507.

• IEC 609742 Arc Welding Equipment  Liquid Cooling Systems: edition 1, 200206.

• IEC 6097410 Arc Welding Equipment  Electromagnetic Compatibility Requirements: edition 1.1,

200410.

US Signatory:

January 27, 2009

__________________________________________________________________________

David A. Werba

Date of Declaration

MANAGER, PRODUCT DESIGN COMPLIANCE

Notes

Miller LJ450119F, Coolmate V3 Owner's manual

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