Miller PROHEAT HEAVY DUTY INDUCTION COOLER (24 VOLT) CE Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

ProHeatt Heavy Duty
Induction Cooler (24 Volt)
CE
Processes
Description
Heavy Duty Induction Cooler
Induction Heating
OM-271 973B 2015−09
File: Induction Heating
Visit our website at
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 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 7.........................................................
SECTION 3 − DEFINITIONS 8...................................................................
3-1. Additional Safety Symbols And Definitions 8................................................
3-2. Miscellaneous Symbols And Definitions 9...................................................
SECTION 4 − SPECIFICATIONS 10................................................................
4-1. Serial Number And Rating Label Location 10.................................................
4-2. Specifications 10........................................................................
4-3. Environmental Specifications 10...........................................................
4-4. Coolant Chart 10........................................................................
SECTION 5 − INSTALLATION 11..................................................................
5-1. Installing Power Source To Cooler 11.......................................................
5-2. Coolant Hose Connections To Cooler 12.....................................................
5-3. Coolant Hose Connections To Single Output Cable 13.........................................
5-4. Coolant Hose Connections To Dual Output Cables 14.........................................
5-5. Installing Optional External Heat Exchanger 15...............................................
SECTION 6 − MAINTENANCE 16.................................................................
6-1. Routine Maintenance 16..................................................................
6-2. Coolant Maintenance 16..................................................................
6-3. Flow Direction W/Single Accessory 17......................................................
6-4. Troubleshooting 18......................................................................
SECTION 7 − ELECTRICAL DIAGRAM 20..........................................................
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-271 973 Page 1
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
ihom _2013-09
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-271 973 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 may 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, 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 dur-
ing operation unless the equipment is designed
and intended to be used in this manner as spec-
ified 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 docto
r
and the device manufacturer before going near arc welding, spo
t
welding, gouging, plasma arc cutting, or induction heating
operations.
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.
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 maintenance and service according to the Owners
Manuals, industry standards, and national, state, and local
codes.
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-271 973 Page 3
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, 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.csa-international.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 30333 (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 may 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.
OM-271 973 Page 6
L’EMPLOI EXCESSIF peut SUR-
CHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement
D Réduire le courant de sortie ou le facteur de mar-
che avant de recommencer le chauffage.
D Respecter le cycle opératoire nominal.
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits im-
primés.
D Établir la connexion avec la barrette de terre
AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, -
placer ou expédier des cartes PC.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (HF) risque de provoquer
des interférences.
D Le rayonnement haute fréquence (HF) peut
provoquer des interférences avec les équipe-
ments de radio-navigation et de communication,
les services de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appa-
reil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
L’EXPLOSION DE LA BATTERIE pe
ut
provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pou
r
charger des batteries ou faire démarrer de
s
véhicules à l’aide de câbles de démarrage, sau
f
si l’appareil dispose d’une fonctionnalité d
e
charge de batterie destinée à cet usage.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des
malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants).
Ce produit contient des éléments chimiques, dont le plomb,
reconnus par l’État de Californie pour leur caractère
cancérogène ainsi que provoquant des malformations
congénitales ou autres problèmes de procréation. Se laver les
mains après toute manipulation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
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, 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.csa-international.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 30333 (phone: 1-800-232-4636, website: www.cdc.gov/
NIOSH).
OM-271 973 Page8
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 Owners 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-271 973 Page 9
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
Notes
OM-271 973 Page 10
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. Environmental Specifications
A. IP Rating
IP Rating Operating Temperature Range Storage Temperature Range
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.
14 to 104 °F (−10 to 40°C) W/Miller Coolant
043810 In Device.
-4 to 131 °F (-20 to 55°C) W/Miller Coolant
043810 In Device.
IP23 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
4-4. Coolant Chart
Low Conductivity Coolant No. 043 810*
*Coolant 043 810 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.).
OM-271 973 Page 11
SECTION 5 − INSTALLATION
5-1. 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-271 973 Page 12
5
-2. 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 4-4.
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-271 973 Page 13
5-3. 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-271 973 Page 14
5-4. 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 Liquid1−Cooled
Output Connections
To
Cooler
OM-271 973 Page 15
5-5. 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-271 973 Page 16
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 043 810)
. Use only non-anaerobic pipe sealant, tape, or silicone when replacing quick-disconnect coolant couplers.
6-2. Coolant Maintenance
272 550-A
1 Coolant Filter
Unscrew housing to clean filter.
Properly discard fluid in 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.
. If replacing hoses, use original
equipment hoses (see Parts
List Section 8).
1
1
OM-271 973 Page 17
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-271 973 Page 18
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 5-1).
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.
OM-271 973 Page 19
Notes
229895
MATERIAL THICKNESS GAUG
E
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Miller PROHEAT HEAVY DUTY INDUCTION COOLER (24 VOLT) CE Owner's manual

Category
Welding System
Type
Owner's manual
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