Miller PROHEAT HEAVY DUTY INDUCTION COOLER CE Owner's manual

Brand: Miller

Model: PROHEAT HEAVY DUTY INDUCTION COOLER CE

Category: Welding System

Type: Owner's manual

This manual is also suitable for

ProHeatt Heavy Duty

Induction Cooler (24 Volt)

Processes

Description

Heavy Duty Induction Cooler

Induction Heating

OM-271973C 2016−09

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 Owner’s 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 2009−09

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-

ufacturer’s 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

manufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

D Wear body protection made from durable, flame−resistant 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. 94−110) 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 Owner’s

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 passers−by 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.

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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 2012−05

Do not remove or paint over (cover) the label.

Safe20 2012−05

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 2012−05

Recycle or dispose of used coolant in an environmentally safe way.

Safe119 2015−05

Disconnect input plug or power before working on machine.

Safe30 2012−05

XXXXX

Use coolant suggested by the manufacturer.

Safe52 2012−05

Read the Owner’s Manual before working on this machine.

Safe70 2012−06

Safe50 2012−05

Plugged filter or hoses can cause overheating to the power source

and torch.

100 h. Std.

Safe51 2012−05

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.

Amperage

Alternating

Current

Voltage Input

Circulating Unit

With Coolant

Pump

Volts

Water (Coolant)

Input

Water (Coolant)

Output

Line Connection

Protective Earth

(Ground)

Degree Of

Protection

Primary Current

Hertz

Off

Primary Voltage

Single Phase

Conventional

Load Voltage

Load voltage

Rated Current

Cooling

Rated Cooling

Power (Coolers)

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 2014−06

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 between−4°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.

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.

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.

Single Liquid-Cooled

Output Connection

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.

Dual Liquid−Cooled

Output Connections

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.

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

! 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 PROHEAT HEAVY DUTY INDUCTION COOLER CE Owner's manual

Brand: Miller

Model: PROHEAT HEAVY DUTY INDUCTION COOLER CE

Category: Welding System

Type: Owner's manual

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