Miller MH170329G Owner's manual

Category
Welding System
Type
Owner's manual
ProHeatt Heavy Duty
Induction Cooler (24 Volt)
CE
Processes
Description
Heavy Duty Induction Cooler
Induction Heating
OM-271973C 201609
File: Induction Heating
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Mil_Thank 200909
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1..................................
1-1. Symbol Usage 1........................................................................
1-2. Induction Heating Hazards 1.............................................................
1-3. Additional Symbols for Installation, Operation, and Maintenance 2..............................
1-4. California Proposition 65 Warnings 3.......................................................
1-5. Principal Safety Standards 3.............................................................
1-6. EMF Information 3......................................................................
SECTION 2 CONSIGNES DE SÉCURITÉ LIRE AVANT UTILISATION 4............................
2-1. Signification des symboles 4.............................................................
2-2. Dangers relatifs au soudage à l’arc 4......................................................
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 5......
2-4. Proposition californienne 65 Avertissements 6...............................................
2-5. Principales normes de sécurité 6..........................................................
2-6. Informations relatives aux CEM 6.........................................................
SECTION 3 DEFINITIONS 7...................................................................
3-1. Additional Safety Symbols And Definitions 7................................................
3-2. Miscellaneous Symbols And Definitions 8...................................................
SECTION 4 SPECIFICATIONS 9................................................................
4-1. Serial Number And Rating Label Location 9.................................................
4-2. Specifications 9........................................................................
4-3. Coolant Specifications 9.................................................................
4-4. Environmental Specifications 9...........................................................
SECTION 5 INSTALLATION 11..................................................................
5-1. Selecting A Location 11...................................................................
5-2. Installing Power Source To Cooler 12.......................................................
5-3. Coolant Hose Connections To Cooler 13.....................................................
5-4. Coolant Hose Connections To Single Output Cable 14.........................................
5-5. Coolant Hose Connections To Dual Output Cables 15.........................................
5-6. Installing Optional External Heat Exchanger 16...............................................
SECTION 6 MAINTENANCE 17.................................................................
6-1. Routine Maintenance 17..................................................................
6-2. Coolant Maintenance 17..................................................................
6-3. Flow Direction W/Single Accessory 18......................................................
6-4. Troubleshooting 19......................................................................
SECTION 7 ELECTRICAL DIAGRAM 21..........................................................
SECTION 8 PARTS LIST 22.....................................................................
WARRANTY
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
COOLER/PROHEAT HEAVY DUTY INDUCTION 24V
(CE)
301298
Council Directives:
2014/35/EU Low Voltage
2014/30/EU Electromagnetic Compatibility
2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
IEC 60974-1:2012 Arc welding equipment – Part 1: Welding power sources
IEC 60974-2:2013 Arc welding equipment – Part 2: Liquid cooling systems
IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
_____________________________________ ___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
July 13, 2015
272706A
OM-271973 Page 1
SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING
ihom _2016-08
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
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.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
NOTICE Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2. Induction Heating Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The power circuit and output bus
bars or connections are electrically live whenever
the output is on. The input power circuit and machine
internal circuits are also live when power is on. Incorrectly installed or
improperly grounded equipment is a hazard.
D Do not touch live electrical parts.
D Enclose any connecting bus bars and coolant fittings to prevent
unintentional contact.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats or
covers big enough to prevent any physical contact with the work or
ground.
D Additional safety precautions are required when any of the following
electrically hazardous conditions are present: in damp locations or
while wearing wet clothing; on metal structures such as floors, grat-
ings, or scaffolds; when in cramped positions such as sitting,
kneeling, or lying; or when there is a high risk of unavoidable or acci-
dental contact with the workpiece or ground. For these conditions,
see ANSI Z49.1 listed in Safety Standards. And, do not work alone!
D Disconnect input power before installing or servicing this equip-
ment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
D Use only nonconductive coolant hoses with a minimum length of 18
inches (457 mm) to provide isolation.
D Properly install, ground, and operate this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground check and be sure that input pow-
er cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly grounded
receptacle outlet.
D When making input connections, attach proper grounding
conductor first double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for dam-
age or bare wiring – replace immediately if damaged – bare wiring
can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D Do not touch power circuit if you are in contact with the work, ground,
or another power circuit from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Use GFCI protection when operating auxiliary equipment in damp or
wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any internal parts.
Induction Heating of certain materials, adhesives,
and fluxes can produce fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation to re-
move fumes and gases. The recommended way to determine
adequate ventilation is to sample for the composition and quantity of
fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the man-
ufacturers instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Always have a trained watchperson near-
by. Fumes and gases from heating can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is
safe.
D Do not heat in locations near degreasing, cleaning, or spraying oper-
ations. The heat can react with vapors to form highly toxic and
irritating gases.
D Do not overheat coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
heated area, the area is well ventilated, and while wearing an air-
supplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if overheated. See coating SDS
for temperature information.
OM-271973 Page 2
FIRE OR EXPLOSION hazard.
D Do not overheat parts.
D Watch for fire; keep extinguisher nearby.
D Keep flammables away from work area.
D Do not locate unit on, over, or near combustible surfaces.
D Do not install unit near flammables.
D Do not operate where the atmosphere can contain flammable
dust, gas, or liquid vapors (such as gasoline).
D After completion of work, inspect area to ensure it is free of
sparks, glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturers instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Wear body protection made from durable, flameresistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
INDUCTION HEATING can burn.
D Do not touch hot parts bare-handed.
D Allow cooling period before handling parts or
equipment.
D Do not touch or handle induction head/coil during operation un-
less the equipment is designed and intended to be used in this
manner as specified in the owner’s manual.
D Keep metal jewelry and other metal personal items away from
head/coil during operation.
D To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
1-3. Additional Symbols for Installation, Operation, and Maintenance
FALLING EQUIPMENT can injure.
D Use handle and have person of adequate
physical strength lift unit.
D Move unit with hand cart or similar device.
D For units without a handle, use equipment of adequate capacity to
lift and support unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94110) when manually
lifting heavy parts or equipment.
FLYING METAL OR DIRT can injure eyes.
D Wear approved safety glasses with side
shields or wear face shield.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
STEAM AND HOT COOLANT can burn.
Hose may rupture if coolant overheats.
D Never disconnect both ends of hose when in-
stalled on hot workpiece.
D If coolant flow stops, leave one end of hose connected to allow
coolant to return to cooler and relieve pressure.
D Remove hose from hot workpiece to prevent damage.
D Visually inspect condition of hoses, cords, and cables before
each use. Do not use damaged hoses, cords, or cables.
D Allow cooling period before working on equipment.
HIGH PRESSURE FLUIDS can injure or kill.
D Coolant can be under high pressure.
D Release pressure before working on cooler.
D If ANY fluid is injected into the skin or body seek medical help
immediately.
OVERUSE can cause OVERHEATING
D Allow cooling period.
D Reduce output or reduce duty cycle before
starting to heat again.
D Follow rated duty cycle.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
BATTERY EXPLOSION can injure.
D Do not use induction equipment to charge bat-
teries or jump start vehicles unless it has a bat-
tery charging feature designed for this purpose.
OM-271973 Page 3
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified person familiar with elec-
tronic equipment perform this installation.
D The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equip-
ment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut.
READ INSTRUCTIONS.
D Read and follow all labels and the Owners
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to the
state of California to cause cancer, birth defects, or other re-
productive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csa-international.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone
for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
Applications Manual for the Revised NIOSH Lifting Equation, The Na-
tional Institute for Occupational Safety and Health (NIOSH), 1600 Clifton
Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passersby or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the weld-
ing circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations. If
cleared by your doctor, then following the above procedures is recom-
mended.
OM-271973 Page 7
SECTION 3 DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 201205
Do not remove or paint over (cover) the label.
Safe20 201205
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 201205
Recycle or dispose of used coolant in an environmentally safe way.
Safe119 201505
Disconnect input plug or power before working on machine.
Safe30 201205
XXXXX
Use coolant suggested by the manufacturer.
Safe52 201205
Read the Owners Manual before working on this machine.
Safe70 201206
Safe50 201205
Plugged filter or hoses can cause overheating to the power source
and torch.
100 h. Std.
Safe51 201205
Every 100 hours, check and clean filter and check condition of hoses.
OM-271973 Page 8
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
A
Amperage
Alternating
Current
Voltage Input
Circulating Unit
With Coolant
Pump
V
Volts
Water (Coolant)
Input
Water (Coolant)
Output
Line Connection
Protective Earth
(Ground)
IP
Degree Of
Protection
I
1
Primary Current
Hz
Hertz
On
Off
U
1
Primary Voltage
Single Phase
U
2
Conventional
Load Voltage
or
Load voltage
I
2
Rated Current
Cooling
P
1
Rated Cooling
Power (Coolers)
p
max
Rated Maximum
Pressure
(Coolers)
Notes
OM-271973 Page 9
SECTION 4 SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the front . Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Specifications
Input Power
Overall Dimensions
Weight
Pump Motor Blower
Coolant Tank -
Empty
Coolant Tank -
Full
24 Volts DC Commutated 24 Volts DC
Length (A): 30 in.
(762 mm)
Width (B): 21-1/4 in.
(540 mm)
Height (C): 12-3/4 in.
(324 mm)
105 lb
(48 kg)
122 lb
(55 kg)
4-3. Coolant Specifications
Do not use conductive coolant.
Use Low Conductivity Coolant 043810.
Coolant 043810 protects to -37°F (-38°C) and resists algae growth.
NOTICE Use of any coolant other than that listed voids the warranty on any parts that come in contact with the coolant (pump, radiator, etc.).
4-4. Environmental Specifications
A. IP Rating
IP Rating
IP23C
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23C 201406
B. Information On Electromagnetic Compatibility (EMC)
! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con-
ducted as well as radiated disturbances.
ce-emc 3 2014-07
OM-271973 Page 10
C. Temperature Specifications
ProHeat Cooler Rolling Inductor Heating Cables
°C °F Storage Operation Storage Operation Storage Operation Storage Operation
60 140
Reduced
efficiencies
above 40°C
Reduced
efficiencies
above 40°C
55 131
50 122
45 113
40 104
35 95
30 86
25 77
20 68
15 59
10 50
5 41
0 32
5 23
10 14
15 5
Energize
system
frequently to
maintain
coolant
temperature
above 14°F
(10°C).
Energize
system
frequently to
maintain
coolant
temperature
above 14°F
(10°C).
Energize
system
frequently to
maintain
coolant
temperature
above 14°F
(10°C).
20 -4
25 -13
Store dry Store dry Store dry
30 -22
35 -31
40 -40
Not Recommended
With Qualifications
Normal Operation With Coolant
NOTICE The Miller ProHeat 35 Rolling Inductor is rated for operation between 14°F and 140°F (10°C to 60°C). For operation at -40°F to
14°F (40°C to -10°C), take the following precautions to prevent equipment damage:
Connect coolant lines to Rolling Inductor when dry, or when ambient temperature is above 4°F (20°C).
Operate ProHeat 35 Heavy Duty Induction Cooler only in temperatures between 14°F and 104°F (10°C to 40°C) while operating Rolling Inductor/Liq-
uid Cooled Cables.
Always use Miller Coolant (Miller Part Number 043810).
Coolant must flow continuously through the Rolling Inductor/liquid cooled cables, and power must be applied to the Rolling Inductor /liquid cooled
cables at regular intervals to maintain a coolant temperature of at least 14°F (10°C).
Store Rolling Inductor/liquid cooled cables dry. Dry unit by using compressed air at 40 psi (2.75 bar) max to blow coolant out of the Rolling Inductor
and power cable.
Store ProHeat 35 Heavy Duty Induction Cooler at a temperature between4°F and 131°F(20°C to 55°C).
. Coolant will not begin to flow until it is 14°F (105C).
NOTICE For colder storage, the cooler must be stored dry. Dry unit by using compressed air at 40 psi (2.75 bar) max to blow coolant out of coolant
lines, filter bowls, pump, flow indicator, and heat exchanger.
. The correction factor on the cooling power at an ambient temperature of 1045F (405C) is 0.625.
OM-271973 Page 11
SECTION 5 INSTALLATION
5-1. Selecting A Location
! Do not move or operate
unit where it could tip.
Loc_cooler 2016-08
Notes
OM-271973 Page 12
5-2. Installing Power Source To Cooler
272 546-B
! Turn off and disconnect input
power from power source.
1 Power Source
2 Lift -Eye
3 Cooler Connection Cable
4 Cooler
5 Screw 0.250-20 (8)
Remove screws from right side panel,
unplug case fan connector, and remove
right side panel from power source.
Remove snap-in blank from power source
base.
Locate and loosen cooler connection cable
from inside power source, and place
connectors through hole in base. Insert
snap-in grommet into hole.
Use lift-eye to suspend power source
above cooler and plug connection cable
into matching connectors in cooler top
cover.
! Keep hands and fingers away from
pinch points when lowering power
source onto cooler.
Slowly lower power source onto top cover
of cooler making sure connection cable is
not pinched between power source base
and cooler.
Install supplied screws 8 places to secure
power source to cooler.
Reconnect case fan and install power
source right side panel.
Tools Needed:
3/8 in.
1
3
4
5
2
OM-271973 Page 13
5-3. Coolant Hose Connections To Cooler
272 547-A
1 Power Source/Cooler Assembly
2 Coolant Hose
3 Coolant Out Fitting
4 Coolant In Fitting
5 Coolant Tank Cap
. Coolant hose fittings have left-hand
threads.
Connect coolant hoses to fittings on cooler.
See Fill tank as specified in Section 4-3.
Maintain coolant level at bottom of fill neck.
6 Flow Indicator/Sensor
Flow indicator/sensor spins to indicate
coolant is flowing in the system. If coolant
flow is reduced below 0.25 gal/min. (1.14
L/min.), the power source output will be
disabled.
6
1
2
2
3
4
5
OM-271973 Page 14
5-4. Coolant Hose Connections To Single Output Cable
272 548-A
1 Power Source/Cooler Assembly
2 Liquid-Cooled Output Cable
3 Protective Cap
4 Coolant Hose
Connect output cable to output #1 on power
source. Connect protective plug to power
source output #2.
Connect quick-connect fitting on both
coolant hoses from cooler to output cable
fittings by pushing coolant hose fitting onto
output cable fitting.
To remove coolant hoses, grasp black ring
on coolant hose fitting and pull away from
output cable fitting . Coolant hose fitting will
separate from output cable fitting.
. Fittings have spring loaded valves
inside that close when fitting is discon-
nected from an output cable fitting to
minimize coolant leaks.
1
2
2
3
3
4
4
Single Liquid-Cooled
Output Connection
To
Cooler
OM-271973 Page 15
5-5. Coolant Hose Connections To Dual Output Cables
272 549-A
1 Power Source/Cooler Assembly
2 Liquid-Cooled Output Cable
. Cables must be the same length: 10 ft
(3 m), 25 ft (7.6 m), or 50 ft (15.2 m).
3 Coolant Hose
4 Dual Output Cable Coolant Hose
Connect output cables to output #1 and
output #2 on power source.
Coolant hoses between output cables and
cooler must be connected in series for dual
output operation. Connect dual output
coolant hose between output cable #1 and
output cable #2 fittings by pushing coolant
hose fitting onto output cable fitting.
Connect quick-connect fitting on both
coolant hoses from cooler to remaining
output cable fittings.
To remove coolant hoses, grasp black ring
on coolant hose fitting and pull away from
output cable fitting . Coolant hose fitting will
separate from output cable fitting.
. Fittings have spring loaded valves
inside that close when fitting is discon-
nected from an output cable fitting to
minimize coolant leaks.
. Heating cables must be the same
length: 30ft (9.1 m), 50 ft (15.2 m), 80ft
(24.2 m), or 140 ft (42.7 m).
. Total length of heating and extension
cables must not exceed 360 ft (110 m).
The extension cable is counted twice
the length because it has a supply and
return hose.
2
1
2
2
3
3
4
2
3
3
4
Dual LiquidCooled
Output Connections
To
Cooler
OM-271973 Page 16
5-6. Installing Optional External Heat Exchanger
269 886-A
1 Base Screw
Remove two screws from base of
unit as shown. Save screws for in-
stalling heat exchanger.
2 Cooler Mounting Screw
Remove cooler mounting screw on
left side of unit. Discard screw.
3 Heat Exchanger
Align heat exchanger mounting
holes with holes in base. Secure
heat exchanger with screws re-
moved in previous step.
4 1/4-20 x 3/4 in. Self-Drilling
Screw
Secure bottom of heat exchanger
with self-drilling screw.
5 Hose
6 Cushion Clamp
7 1/4-20 x 3/4 in. Screw
Route hoses through supplied
cushion clamps.
Align clamps with vacated hole in
base and secure with supplied
screw.
Connect cooler hoses to acces-
sories as shown in image below.
8 Label (Notice)
Apply label to power source where
shown.
1
1
2
3
4
5
67
8
8
OM-271973 Page 17
SECTION 6 MAINTENANCE
6-1. Routine Maintenance
! Disconnect power
before maintaining.
3 Months
Blow Out Heat
Exchanger Fins
NOTICE Clean coolant strainer. Severe con-
ditions may require more frequent cleaning
(continuous use, high/low temperatures, dirty
environment, etc.). Failure to properly clean
coolant strainer voids pump warranty.
6 Months
Replace
Cracked
Hoses
Replace
Unreadable
Labels
12 Months
Change Coolant (use Coolant 043810)
. Use only non-anaerobic pipe sealant, tape, or silicone when replacing quick-disconnect coolant couplers.
6-2. Coolant Maintenance
272 550-A
1
1
! Disconnect cooler plug from
welding power source receptacle
before maintaining.
! Dispose of used coolant accord-
ing to national, state, and local
codes. Do not pour down drain.
1 Cooler Front Panel
2 Coolant Filter
Unscrew housing to clean filter and
housing. Rinse filter and housing.
Changing Coolant
Drain coolant by tipping unit forward. Fill
with clean water and run for 10 minutes.
Drain and refill.
NOTICE If replacing hoses, use origi-
nal equipment hoses compatible with
ethylene glycol, such as Buna-n, Neo-
prene, or Hypalon. Oxy-acetylene
hoses are not compatible with any prod-
uct containing ethylene glycol. See Sec-
tion 8.
OM-271973 Page 18
6-3. Flow Direction W/Single Accessory
A. Flow Direction With Single Accessory
Pump
Filter
Radiator
Flow
Indicator/Sensor
Tank
Induction
Coil
Bypass
Filter
B. Flow Direction With Two Accessories
Pump
Filter
Tank
Filter
Bypass
First
Induction
Coil
Second
Induction
Coil
Flow
Sensor
Heat
Exchanger
OM-271973 Page 19
C. Flow Direction With External Heat Exchanger
Pump
Filter
Tank
Filter
Bypass
First
Induction
Coil
Second
Induction
Coil
Flow
Sensor
External
Heat
Exchanger
Internal
Heat
Exchanger
6-4. Troubleshooting
Trouble Remedy
Coolant system does not work. Be sure cooler input power and communication cables from power source are connected to cooler
receptacles (see Section 5-2).
Check input power line fuses or circuit breaker, and replace or reset if necessary.
Have Factory Authorized Service Agent check motor.
Decreased or no coolant flow. Add coolant.
Check for clogged hoses or coolant filters. Clean filters or clean / replace hoses if necessary.
Disconnect pump, and check for sheared coupler. Replace coupler if necessary.
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Miller MH170329G Owner's manual

Category
Welding System
Type
Owner's manual

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