Miller Coolmate 4 Bedienungsanleitung

OWNER’S MANUAL OM-624 126 174P

2007−10

And Non-CE Models

Coolmate™4

1. Specifications

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

Use With Guns/Torches Rated Up To 600 Amperes

4 gal (15 L) Coolant Tank Capacity;

Maximum Cooling Capacity: 15,000 BTU/hr At 1.3 qt/min (1.2 L/min)

Dimensions: 18-3/4 in (476 mm) Long, 15-1/4 in (387 mm) Wide, 16-1/4 in (413 mm)

R f ST 1228 574 A

Dimensions: 18 3/4 in (476 mm) Long, 15 1/4 in (387 mm) Wide, 16 1/4 in (413 mm)

Weight: 44 lb (20 kg)

Ref. ST-1228 574-A 115 Volts, 5.2 Amperes, 50/60, Single-Phase Input Power

2. Safety Symbol Definitions

DANGER! −Indicates a hazardous situation which, if not

avoided, will result in death or serious injury. The possible

hazards are shown in the adjoining symbols or explained

in the text.

DANGER! −Indique une situation dangereuse qui si on

l’évite pas peut donner la mort ou des blessures graves. Les

dangers possibles sont montrés par les symboles joints ou

sont expliqués dans le texte.

Have only trained and qualified persons install, operate,

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

derstand the directions. For WELDING SAFETY and

EMF information, read wire feeder and welding power

source manuals.

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

doivent être confiés uniquement à des personnes

qualifiées et convenablement formées. S’adresser à un

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

des renseignements ayant trait à la SÉCURITÉ lors du

soudage et aux champs électromagnétiques, consulter

les manuels traitant les dévidoirs et les sources de

courant pour le soudage.

Beware of electric shock from wiring.

Attention! Risque d’électrocution due au contact avec des

fils.

Beware of moving parts.

Attention! Pièces en mouvement.

Wear safety glasses with side shields.

Porter des lunettes de sécurité avec protections

latérales.

Recycle or dispose of used coolant in an environmentally

safe way.

Recycler ou éliminer tout liquide de refroidissement usé

conformément aux méthodes prescrites pour assurer la

protection de l’environnement.

OM-624 Page 2

3. Warning Label Definitions For CE Products

S-180 663

1 2 3 4 5

67 8 9

1 Warning! Watch Out! There are

possible hazards as shown by the

symbols.

2 Electric shock from wiring can kill.

3 Disconnect input plug or power before

working on machine.

4 Moving parts, such as fans, can cut

fingers and hands and cause injury.

Keep away from moving parts.

5 Wear safety glasses with side shields.

6 Read the Owner’s Manual before

working on this machine.

7 Read the labels on the welding power

source, wire feeder, or other major

equipment for welding safety

information.

8 Recycle or dispose of used coolant in

an environmentally safe way.

9 Do not remove or paint over (cover)

the label.

4/96

S-178 910

043 810 (HF)

043 809 (AL)

100 h. std.

21 3

1 Warning! Watch Out! There are

possible hazards as shown by the

symbols.

2 Disconnect input plug or power before

working on machine.

3 Wear safety glasses with side shields.

4 Plugged filter or hoses cause

overheating and damage.

5 Read Owner’s Manual.

6 Check and clean filter every 100

hours; also check condition of hoses.

7 Use Low Conductivity Coolant No. 043

810 for High-Frequency assisted or

Gas Tungsten Arc Welding

applications. Use Aluminum Protecting

Coolant No. 043 809 where coolant

contacts aluminum parts or for Gas

Metal Arc Welding applications or

where High Frequency is not used.

OM-624 Page 3

1 Warning! Watch Out! There

are possible hazards as

shown by the symbols.

2 Moving parts, such as fans,

can cut fingers and hands and

cause injury. Keep away from

moving parts.

4/96

S-176 106

4. Rating Label

INPUT

NRTL/C

VOLTS

AMPERES

PHASE HERTZ

SERIAL NO.

STOCK NO.

EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY

KJ306576

042288

115VAC

5.2A

1 (Single) 50/60Hz

COOLMATE 4

LR5071

S-165 371

5. Symbols And Definitions

.Some symbols are found only on CE products.

AAmperes Alternating Current U1Primary Voltage Single Phase

VVolts Water (Coolant) In-

put Water (Coolant)

Output Line Connection

Hz Hertz IP Degree Of

Protection I1Primary Current

OM-624 Page 4

6. Preparing Cooling Unit For Use

137 378-A / 160 554

1 Coolant Out Fitting

2 Coolant In Fitting

Fittings have 5/8-18 left-hand

threads.

Use table to select proper coolant,

and fill tank. Maintain coolant level

at approximately 1 in (25 mm) from

filler neck.

Unit turns On when plugged in.

Tools Needed:

5/8 in

Low Conductivity Coolant

No. 043 810**;

Distilled Or Deionized Water

OK Above 32°F (0°C)

Low Conductivity Coolant

No. 043 810**; Or

Aluminum Protecting Coolant

No. 043 809**;

Distilled Or Deionized Water

OK Above 32°F (0°C)

GTAW Or Where

HF* Is Used GMAW Or Where

HF* Is Not Used

Application

*HF: High Frequency Current

**Coolants 043 810 and 043 809 protect to -37°F (-38°C) and resist algae growth.

Coolant

Aluminum Protecting

Coolant No. 043 809**

Where Coolant Contacts

Aluminum Parts

OM-624 Page 5

7. Connections

160 556 / 160 555-B

To prevent overheating, make sure

cooling unit is positioned so airflow

is not restricted.

NOTICE −If welding power source

has a water valve, do not connect

hoses to water valve. Connect

hoses as shown.

GTAW Connections

GMAW Connections

OM-624 Page 6

8. Routine Maintenance

!Disconnect power

before maintaining.

1 Month

Clean Coolant Filter Blow Out

Radiator Fins

6 Months

Replace

Cracked

Hoses

Replace

Unreadable

Labels

Change

Coolant (If

Using Water)

12 Months

Oil Motor

Change

Coolant (If

Using 043 810

Or 043 809

Coolant)

9. Coolant Maintenance

160 559

1 Coolant Filter

Remove nut to remove filter. Clean

filter and reinstall.

Changingcoolant: Drain coolant by

tippingunit. Fill with clean water and

run for 10 minutes. Drain and refill.

.If replacing hoses, use hoses

compatible with ethylene gly-

col, such as Buna-n, Neo-

prene, or Hypalon. NOTE:

Oxy-acetylene hoses are not

compatible with any product

containing ethylene glycol.

15/16 in

Tools Needed:

OM-624 Page 7

Tools Needed:

10. Oiling Motor

Ref. 160 557 / Ref. 801 195-A

1 Wire Form

2 Radiator

.Wear gloves when handling ra-

diator.

Remove wire form. Pull radiator out

far enough to turn it to the side as

shown.

3 Motor

Remove plugs and put about 15

drops of SAE 20 motor oil into each

oil port. Replace plugs, and reas-

semble unit.

7/16 in

Tools Needed:

11. Adjusting Relief Valve

160 558-A

.Relief valve is factory set at 60

psi (414 kPa), and normally

needs no adjustment: Only ad-

just if replacing motor.

1 Pressure gauge

2 Relief Valve Adjustment

Screw

Connect gauge to Coolant Out fit-

ting as shown. Block or plug any

output fitting on gauge.

Turn On power, and adjust pres-

sure adjustment screw as needed.

Turn Off power. Disconnect gauge

and reinstall nut.

3/4 in

IncreaseDecrease

OM-624 Page 8

12. Troubleshooting

Trouble Remedy

Coolant system does not work. Be sure input power cord is plugged in to energized receptacle.

Check line fuses or circuit breaker, and replace or reset if necessary.

Motor overheated. Unit starts running when motor has cooled.

Have Factory Authorized Service Agent check motor.

Decreased or no coolant flow. Add coolant.

Check for clogged hoses or coolant filter.

Disconnect pump, and check for sheared coupling. Replace coupling if necessary.

187 313

Figure 12-1. Circuit Diagram

OM-624 Page 9

13. Parts List

131 764-G

Includes

Items

10&11

15 17

10 11

18 20

Figure 13-1. Complete Assembly

OM-624 Page 10

Description Quantity

Part

No.

Figure 13-1. Complete Assembly

Item

No.

1 124 377 WIRE FORM, radiator end 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 127 904 RADIATOR, coolant tank w/weatherstripping (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124 374 RADIATOR, coolant tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

159 594 WEATHERSTRIPPING, adh .250 x .750 x 3ft 4 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 228 531 HOSE, rubber braided .375 ID X .650 OD X 12.000 SAE J20R3−CLASS D−2 2. . . . . . . . . . . . . .

4 236 084 HOSE, rubber braided .375 ID X .650 OD X 10.500 SAE J20R3−CLASS D−22. . . . . . . . . . . . . .

6 188 980 LABEL, caution incorrect coolant (non-CE and generic models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

6 178 910 LABEL, caution incorrect coolant (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 121 316 LABEL, warning general precautionary (non-CE and generic models) 1. . . . . . . . . . . . . . . . . . . . . .

7 180 663 LABEL, warning general precautionary (CE models only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 166 608 CAP, tank screw-on w/screw type vent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 +139 154 TANK, coolant (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 124 253 BUSHING, tank fuel 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 124 621 FITTING, hose brs barbed 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 130 633 INSULATOR, panel front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 601 881 NUT, stl hex jam .500-20 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 231 241 WASHER, tooth .512 ID x .900 OD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 137 378 PLATE, ident 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 149 356 FITTING, hose brs barbed elb M 3/8tbg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 173 263 MOTOR, 1/4HP 115VAC 50/60 Hz 1425/1725RPM dual sha 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

19 177 246 PUMP, coolant (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 5523 FITTING, hose brs barbed elb M 3/8tbg x 3/8NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 134 795 COUPLER, drive pump 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146 249 STRAINER, screen 100 x 90 mesh 2.125 lg x .687 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 144 649 CABLE, pwr 115V 16ga 3/c 13ft w/strain relief 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 194 099 BRACKET, mtg motor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .