OM-624 126174Z

2017−02
Processes
TIG (GTAW) Welding

MIG (GMAW) Welding

Description

Coolmatet4
CE And Non-CE

For product information, File: TIG (GTAW)

Owner’s Manual translations,
and more, visit
www.MillerWelds.com
 From Miller to You
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 Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
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
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard. particular model are also provided.

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.

Mil_Thank 2009−09
 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Cooling Equipment Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Dangers liés aux équipements de refroidissement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 3
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-3. Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5-1. Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6-2. Coolant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6-3. Adjusting Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WARRANTY
COMPLETE PARTS LIST − Available at www.MillerWelds.com
DECLARATION OF CONFORMITY
for European Community (CE marked) products.

MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

Coolmate 3 043007, 043008
Coolmate 3.5 300245
Coolmate 4 042288015

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 60974-2:2013 Arc welding equipment – Part 2: Liquid cooling systems
• IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements

Signatory:

December 02, 2015

_____________________________________ ___________________________________________
David A. Werba Date of Declaration

MANAGER, PRODUCT DESIGN COMPLIANCE

242094E

−4−
 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
coolers 2016-08
7

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 . Indicates special instructions.
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
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Cooling Equipment Hazards

The symbols shown below are used throughout this manual ELECTRIC SHOCK can kill.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions Touching live electrical parts can cause fatal shocks
or severe burns. The input power circuit and machine
to avoid the hazard. The safety information given below is
internal circuits are also live when power is on.
only a summary of the more complete safety information Incorrectly installed or improperly grounded equip-
found in the Safety Standards listed in Section 1-5. Read and ment is a hazard.
follow all Safety Standards.
D Do not touch live electrical parts.
Only qualified persons should install, operate, maintain, and
D Disconnect input power or stop engine before installing or
repair this unit.
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
During operation, keep everybody, especially children, away.
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
HOT PARTS can burn. D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
D Do not touch hot parts bare handed. disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D Allow cooling period before working on
equipment. D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns. D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
FLYING METAL or DIRT can injure eyes.
D Turn off all equipment when not in use.
D Wear approved safety glasses with side D Use only well-maintained equipment. Repair or replace damaged
shields even under your welding helmet. parts at once. Maintain unit according to manual.
D Keep all panels and covers securely in place.

1-3. Additional Symbols For Installation, Operation, And Maintenance

FALLING EQUIPMENT can injure. READ INSTRUCTIONS.

D Use equipment of adequate capacity to lift and D Read and follow all labels and the Owner’s
support unit. Manual carefully before installing, operating, or
D If using lift forks to move unit, be sure forks are servicing unit. Read the safety information at
long enough to extend beyond opposite side of the beginning of the manual and in each
unit. section.
D Keep equipment (cables and cords) away from moving vehicles D Use only genuine replacement parts from the manufacturer.
when working from an aerial location.
D Perform installation, maintenance, and service according to the
D Follow the guidelines in the Applications Manual for the Revised Owner’s Manuals, industry standards, and national, state, and
NIOSH Lifting Equation (Publication No. 94−110) when manu- local codes.
ally lifting heavy parts or equipment.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
OVERUSE can cause OVERHEATING consumables, coolants, degreasers, fluxes, and metals.

D Allow cooling period; follow rated duty cycle.

D Do not block or filter airflow to unit.

OM-624 Page 1
 STEAM AND HOT COOLANT can burn. MOVING PARTS can injure.

Hose may rupture if coolant overheats. D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
D Visually inspect condition of hoses before each closed and securely in place.
use. Do not use damaged hoses.
D Allow cooling period before working on equipment. D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
HIGH PRESSURE FLUIDS can injure or kill. D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
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.

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)

This product contains or produces a chemical known to the

state of California to cause cancer or birth defects (or other
reproductive harm). (California Health & Safety Code Section
25249.5 et seq.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied Processes, CSA Standard
is available as a free download from the American Welding Society at W117.2, from Canadian Standards Association, Standards Sales, 5060
http://www.aws.org or purchased from Global Engineering Documents Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 1-877-413-5184, website: www.global.ihs.com). (phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
Safe Practices for the Preparation of Containers and Piping for Welding tion, ANSI Standard Z87.1, from American National Standards Institute,
and Cutting, American Welding Society Standard AWS F4.1, from Glob- 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
al Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org).
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for Welding and Cutting Containers that have Held Com- Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
National Electrical Code, NFPA Standard 70, from National Fire Protec- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
www.nfpa.org and www. sparky.org). phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, Applications Manual for the Revised NIOSH Lifting Equation, The Na-
from Compressed Gas Association, 14501 George Carter Way, Suite tional Institute for Occupational Safety and Health (NIOSH), 1600
103, Chantilly, VA 20151 (phone: 703-788-2700, website: Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cganet.com). www.cdc.gov/NIOSH).

OM-624 Page 2
 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
Cooler 2016−08_fre

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
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.
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 Ce groupe de symboles veut dire Avertissement! Attention! DANGER
joints ou sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
AVIS − Indique des déclarations pas en relation avec des blessures
afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.

2-2. Dangers liés aux équipements de refroidissement

Les symboles représentés ci-dessous sont utilisés dans ce UNE DÉCHARGE ÉLECTRIQUE peut
manuel pour attirer l’attention et identifier les dangers possibles. entraîner la mort.
En présence de l’un de ces symboles, prendre garde et suivre Le contact d’organes électriques sous tension peut
les instructions afférentes pour éviter tout risque. Les provoquer des accidents mortels ou des brûlures
instructions en matière de sécurité indiquées ci-dessous ne graves. Le circuit d’alimentation et les circuits
constituent qu’un sommaire des instructions de sécurité plus internes de la machine sont également sous tension
complètes fournies dans les normes de sécurité énumérées lorsque l’alimentation est sur Marche. Un équipement installé ou mis
dans la Section 2-5. Lire et observer toutes les normes de à la terre de manière incorrecte ou impropre constitue un danger.
sécurité.
D Ne pas toucher aux pièces électriques sous tension.
Seul un personnel qualifié est autorisé à installer, faire D Couper l’alimentation ou arrêter le moteur avant de procéder
fonctionner, entretenir et réparer cet appareil. à l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
Pendant le fonctionnement, maintenir à distance toutes les 1910.147 (voir normes de sécurité).
personnes, notamment les enfants de l’appareil. D Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
LES PIÈCES CHAUDES peuvent nationales, gouvernementales et locales.
provoquer des brûlures. D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
D Ne pas toucher à mains nues les parties raccordé à la borne de terre du sectionneur ou que la fiche du
chaudes. cordon est raccordée à une prise correctement mise à la terre.
D Prévoir une période de refroidissement avant de
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
travailler à l’équipement. protégez−les contre les étincelles et les pièces métalliques
D Ne pas toucher aux pièces chaudes, utiliser les outils recomman- chaudes.
dés et porter des gants de soudage et des vêtements épais pour
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer
éviter les brûlures.
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
DES PIECES DE METAL ou DES D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
SALETES peuvent provoquer des D N’utiliser qu’un matériel en bon état. Réparer ou remplacer
blessures dans les yeux. sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
D Porter des lunettes de sécurité avec écrans D S’assurer que tous les panneaux et couvercles sont correctement
latéraux ou un écran facial. en place.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

LA CHUTE DE L’ÉQUIPEMENT peut L’EMPLOI EXCESSIF peut

provoquer des blessures. SURCHAUFFER L’ÉQUIPEMENT.
D Utiliser un équipement de levage de capacité D Prévoir une période de refroidissement ;
suffisante pour lever l’appareil. respecter le cycle opératoire nominal.
D En utilisant des fourches de levage pour D Ne pas obstruer les passages d’air du poste.
déplacer l’unité, s’assurer que les fourches
sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
OM-624 Page 3
 LA VAPEUR ET LE LIQUIDE DE
LIRE LES INSTRUCTIONS. REFROIDISSEMENT CHAUD peuvent
D Lire et appliquer les instructions sur les provoquer des brûlures.
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de Un tuyau peut se rompre lorsque le liquide de
l’appareil. Lire les informations de sécurité au refroidissement surchauffe.
début du manuel et dans chaque section. D Vérifiez visuellement l’état des tuyaux avant
D N’utiliser que les pièces de rechange recommandées par le chaque utilisation. N’utilisez pas de tuyaux
constructeur. endommagés.
D Effectuer l’installation, l’entretien et toute intervention selon les D Laissez refroidir avant d’intervenir sur l’équipement.
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
D Lire et comprendre les fiches de données de sécurité et les
instructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
LES LIQUIDES SOUS HAUTE PRESSION
Les PIÈCES MOBILES peuvent peuvent provoquer des blessures ou la
causer des blessures. mort.
D S’abstenir de toucher des organes mobiles tels D Liquide de refroidissement sous haute
que des ventilateurs. pression.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de D Libérez la pression avant d’intervenir sur le
protection. refroidisseur.
D Lorsque cela est nécessaire pour des travaux d’entretien et de D En cas d’injection d’un liquide QUELCONQUE dans la peau ou
dépannage, faire retirer les portes, panneaux, recouvrements le corps, consultez immédiatement un médecin.
ou dispositifs de protection uniquement par du personnel
qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

2-4. Proposition californienne 65 Avertissements

malformations de naissance (ou autre problèmes
Les équipements de soudage et de coupage produisent des reproductifs. (Code de santé et de sécurité de Californie,
fumées et des gaz qui contiennent des produits chimiques chapitre 25249.5 et suivants).
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 Ce produit contient des produits chimiques, notamment du
25249.5 et suivants) plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
Ce produit contient ou forme un produit chimique reconnu problèmes de procréation. Se laver les mains après
par l’état de Californie de provoquer le cancer ou utilisation.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied Processes, CSA Standard
is available as a free download from the American Welding Society at W117.2, from Canadian Standards Association, Standards Sales, 5060
http://www.aws.org or purchased from Global Engineering Documents Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 1-877-413-5184, website: www.global.ihs.com). (phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face
Safe Practices for the Preparation of Containers and Piping for Welding Protection, ANSI Standard Z87.1, from American National Standards
and Cutting, American Welding Society Standard AWS F4.1, from Institute, 25 West 43rd Street, New York, NY 10036 (phone:
Global Engineering Documents (phone: 1-877-413-5184, website: 212-642-4900, website: www.ansi.org).
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for Welding and Cutting Containers that have Held Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
Combustibles, American Welding Society Standard AWS A6.0, from
Global Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General
website: www.global.ihs.com). Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing
National Electrical Code, NFPA Standard 70, from National Fire Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional
website: www.nfpa.org and www. sparky.org). Offices—phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, Applications Manual for the Revised NIOSH Lifting Equation, The
from Compressed Gas Association, 14501 George Carter Way, Suite National Institute for Occupational Safety and Health (NIOSH), 1600
103, Chantilly, VA 20151 (phone: 703-788-2700, website: Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cganet.com). www.cdc.gov/NIOSH).

OM-624 Page 4
 . A complete Parts List is available at www.MillerWelds.com

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

Disconnect input plug or power before working on machine.

Safe30 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

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

Safe20 2012−05

Use coolant suggested by the manufacturer.

XXXXX
Safe52 2012−05

Recycle.

Safe103 2012−09

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

Safe70 2012−06

Read the labels on the welding power source, wire feeder, or other
major equipment for welding safety information.

Safe71 2012−06

Plugged filter or hoses can cause overheating to the power source

and torch.

Safe50 2012−05

100 h. Std.
Every 100 hours, check and clean filter and check condition of hoses.

Safe51 2012−05

OM-624 Page 5
 . A complete Parts List is available at www.MillerWelds.com

3-2. Miscellaneous Symbols And Definitions

. Some symbols are found only on CE products.

A Amperes
IP Degree Of
Protection
Line Connection

V Volts
U1 Primary Voltage Cooling

Hz Hertz Water (Coolant)

Output I1max Rated Maximum
Supply Current

Alternating Cur-
rent
I1 Primary Current
P1 Rated Cooling
Power
Water (Coolant)

pmax
Input Single Phase Rated Maximum
Pressure

Notes

OM-624 Page 6
 . A complete Parts List is available at www.MillerWelds.com

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the lower right side. Use rating label to determine input power requirements
and/or rated output. For future reference, write serial number in space provided on cover of this manual.

4-2. Specifications
. The correction factor on the cooling power at an ambient temperature of 1045F (405C) is 0.625.
Recirculating Coolant System For Water-Cooled GTAW Torches And GMAW Guns

Use With Guns/Torches Rated Up To 600 Amperes

Coolant Tank Capacity 4 gal (15 L)
Rated Cooling Power 1.78 kW at 1.1 qt/min at 77°F (6070 BTU/hr at 1 L/min at 25°C)
Maximum Cooling Power 5.5 kW at 5.9 qt/min at 77°F (18,000 BTU/hr at 5.6 L/min at 25°C)
Dimensions (Length x Width x Height) 18.75 x 15.25 x 16.25 in. (476 x 387 x 413 mm)
Weight 44 lb (20 kg)
Input Voltage 115 VAC, Single Phase, 50 or 60 Hz
Input Amperage 5.9 A 60 Hz
4.7 A 50 Hz

4-3. Coolant Specifications

Do not use conductive coolant.

Application Coolant
GTAW Or Where High Frequency Current Is Used Low Conductivity Coolant 043810*
Distilled Or Deionized Water Okay Above 32°F (0°C)
GMAW Or Where High Frequency Current Is Not Used Low Conductivity Coolant 043810*
Aluminum Protecting Coolant 043809*
Distilled Or Deionized Water Okay Above 32°F (0°C)
Where Coolant Contacts Aluminum Parts Aluminum Protecting Coolant 043809*
*Coolants 043810 and 043809 protect to -37°F (-38°C) and resist algae growth.
NOTICE − Use of any coolant other than those listed in the table voids the warranty on any parts that come in contact with the coolant (pump, radiator,
etc.).

4-4. Environmental Specifications

A. IP Rating
IP Rating
IP21
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP21 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.
This equipment complies with IEC 61000-3-11 and IEC 61000-3-12.
ce-emc 4 2014-07

C. Temperature Specifications
Operating Temperature Range Storage/Transportation Temperature Range

14 to 104 °F (-10 to 40°C) −4 to 131°F (−20 to 55°C)

Temp1_2016- 08

OM-624 Page 7
 . A complete Parts List is available at www.MillerWelds.com

SECTION 5 − INSTALLATION

5-1. Connections
! Do not move or operate unit
where it could tip.
To prevent overheating, make sure
GTAW Connections cooling unit is positioned so airflow
is not restricted.
NOTICE − If welding power source
has a water valve, do not connect
1 hoses to water valve. Connect
hoses as shown.
1 Filler Cover
4
2 Coolant Out
3 Coolant In
Fittings have 5/8-18 left-hand
threads.
See Section 4-3 to select proper
coolant, and fill tank. Maintain cool-
3 ant level at approximately 1 in. (25
mm) from filler neck.
2
4 115 Volt AC Grounded Re-
ceptacle
Unit turns On when plugged in.
An individual branch circuit capable
of carrying 15 amperes and pro-
tected by fuses or circuit breakers
is recommended. Recommended
fuse or circuit breaker size is 15
amperes.

GMAW Connections

1
4

Tools Needed:
5/8 in.
160 556-A / 160 555-C

OM-624 Page 8
 . A complete Parts List is available at www.MillerWelds.com

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance

! Turn Off all power and unplug unit before maintaining.

1 Month
NOTICE − Clean coolant strainer. Severe condi- Blow Out Heat
tions may require more frequent cleaning (contin- Exchanger Fins
uous use, high/low temperatures, dirty environ-
ment, etc.). Failure to properly clean coolant
strainer voids pump warranty.

6 Months

Replace Change Replace

Cracked Coolant (If Unreadable
Hoses Using Water) Labels

12 Months

Change
Coolant (If
Using Miller
Coolant)

6-2. Coolant Maintenance

! 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 Coolant Filter
Remove nut to remove filter. Clean filter
and reinstall.
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 hoses
compatible with ethylene glycol, such as
Buna-n, Neoprene, or Hypalon.
Oxy-acetylene hoses are not compati-
ble with any product containing ethylene
glycol.

Tools Needed:

15/16 in.

160 559-A

OM-624 Page 9
 . A complete Parts List is available at www.MillerWelds.com

6-3. Adjusting Relief Valve

. Relief valve is factory set at 60
psi (414 kPa), and normally
needs no adjustment: Only ad-
just if replacing motor.
1 Pressure gauge
1
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.
Decrease Increase

Tools Needed:

3/4 in.

160 558-B

6-4. 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.

OM-624 Page 10
 . A complete Parts List is available at www.MillerWelds.com

SECTION 7 − ELECTRICAL DIAGRAM

187 313

SECTION 8 − PARTS LIST

8-1. Recommended Spare Parts

Dia. Part
Mkgs. No. Description Quantity
Recommended Spare Parts

. . . . . . . . . . . . . . . . 146249 . . . . Strainer, Screen 100x90 Mesh 2.125 Lg X .687 Dia . . . . . . . . . . . . . . . . . 1

OM-624 Page 11
Notes
Notes
Notes
 Effective January 1, 2017
(Equipment with a serial number preface of MH or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective date of
1-800-4-A-MILLER this limited warranty is free of defects in material and workmanship at 6. 90 Days — Parts
* Accessory (Kits)
for your local the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, * Canvas Covers
Miller distributor. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND * Induction Heating Coils and Blankets, Cables, and
FITNESS. Non-Electronic Controls
Within the warranty periods listed below, Miller will repair or replace any * M-Guns
warranted parts or components that fail due to such defects in material * MIG Guns, Subarc (SAW) Torches, and External
Your distributor also gives or workmanship. Miller must be notified in writing within thirty (30) days Cladding Heads
you ... of such defect or failure, at which time Miller will provide instructions on
the warranty claim procedures to be followed. If notification is submitted * Remote Controls and RFCS-RJ45
Service as an online warranty claim, the claim must include a detailed * Replacement Parts (No labor)
You always get the fast, description of the fault and the troubleshooting steps taken to identify * Spoolmate Spoolguns
reliable response you failed components and the cause of their failure.
Miller’s True Blue® Limited Warranty shall not apply to:
need. Most replacement Miller shall honor warranty claims on warranted equipment listed below
parts can be in your 1. Consumable components; such as contact tips,
in the event of such a failure within the warranty time periods. All
hands in 24 hours. warranty time periods start on the delivery date of the equipment to the cutting nozzles, contactors, brushes, relays, work
original end-user purchaser, and not to exceed twelve months after the station table tops and welding curtains, or parts that
Support equipment is shipped to a North American distributor or eighteen fail due to normal wear. (Exception: brushes and
Need fast answers to the months after the equipment is shipped to an International distributor. relays are covered on all engine-driven products.)
tough welding questions? 1. 5 Years Parts — 3 Years Labor 2. Items furnished by Miller, but manufactured by others,
Contact your distributor. * Original Main Power Rectifiers Only to Include SCRs, such as engines or trade accessories. These items are
The expertise of the Diodes, and Discrete Rectifier Modules covered by the manufacturer’s warranty, if any.
distributor and Miller is 2. 3 Years — Parts and Labor 3. Equipment that has been modified by any party other than
there to help you, every * Auto-Darkening Helmet Lenses (Except Classic Miller, or equipment that has been improperly installed,
step of the way. Series) (No Labor) improperly operated or misused based upon industry
* Engine Driven Welder/Generators standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the and necessary maintenance, or equipment which has
Engine Manufacturer.) been used for operation outside of the specifications for
* Inverter Power Sources (Unless Otherwise Stated) the equipment.
* Plasma Arc Cutting Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Process Controllers USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Semi-Automatic and Automatic Wire Feeders
MAINTENANCE OF WELDING EQUIPMENT.
* Transformer/Rectifier Power Sources
In the event of a warranty claim covered by this warranty, the
3. 2 Years — Parts and Labor exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Auto-Darkening Helmet Lenses − Classic Series Only replacement; or, where authorized in writing by Miller in appropriate
(No Labor) cases, (3) the reasonable cost of repair or replacement at an
* Fume Extractors − Capture 5, Filtair 400 and Industrial authorized Miller service station; or (4) payment of or credit for the
Collector Series purchase price (less reasonable depreciation based upon actual
4. 1 Year — Parts and Labor Unless Specified use) upon return of the goods at customer’s risk and expense.
* AugmentedArc and LiveArc Welding Systems Miller’s option of repair or replacement will be F.O.B., Factory at
* Automatic Motion Devices Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
* Bernard BTB Air-Cooled MIG Guns (No Labor) reimbursement for transportation costs of any kind will be allowed.
* CoolBelt and CoolBand Blower Unit (No Labor)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Desiccant Air Dryer System PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* External Monitoring Equipment and Sensors REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Field Options DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
(NOTE: Field options are covered for the remaining CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
warranty period of the product they are installed in, WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
or for a minimum of one year — whichever is LEGAL THEORY.
greater.) ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* RFCS Foot Controls (Except RFCS-RJ45) IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
* Fume Extractors − Filtair 130, MWX and SWX Series TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* HF Units CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* ICE/XT Plasma Cutting Torches (No Labor)
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
* Induction Heating Power Sources, Coolers DEALING, INCLUDING ANY IMPLIED WARRANTY OF
(NOTE: Digital Recorders are Warranted MERCHANTABILITY OR FITNESS FOR PARTICULAR
Separately by the Manufacturer.) PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Load Banks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
* Motor-Driven Guns (except Spoolmate Spoolguns) MILLER.
* PAPR Blower Unit (No Labor) Some states in the U.S.A. do not allow limitations of how long an
* Positioners and Controllers implied warranty lasts, or the exclusion of incidental, indirect,
* Racks special or consequential damages, so the above limitation or
* Running Gear/Trailers exclusion may not apply to you. This warranty provides specific
* Spot Welders legal rights, and other rights may be available, but may vary from
state to state.
* Subarc Wire Drive Assemblies
* TIG Torches (No Labor) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
* Tregaskiss Guns (No Labor) to the extent that they may not be waived, the limitations and
* Water Cooling Systems exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province.
miller_warr 2017-01
 Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2017 Miller Electric Mfg. Co. 2017−01