Miller Hydracool 270 User Manual - Rapid Welding and Industrial
Contents
1. 1 Oath a ius ain J554396 Eabel Ground siria ito A ua ena te eee Donee Ded ewe dol S D eee 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 266 361 Page 15 Notes Notes Notes 72 Miller Effective January 1 2013 Equipment with a serial number preface of MD or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below ITW Welding Products Italy warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warr2. 8 34 SPECIICAONS ae nee arte neta sS face uet eee Se as suu ss 9 4 Environmental SpeeniealloLls xa lt k a uuruuu A Fee ia 3 92 Coolant Chat zeiten nee ehe SECTHIONZFINSTALLATION san ia A Nx 2Selecling a SOCQ OLT rs In ada Pee ter 4 2 Installing Unit On A STH 270 Welding Power Source And Connecting 400 VAC Input Power SECTION 5 OPERATION i 5 as ai 9 12 AS onttol Panels dea attt edendo a aha i ee ee e tier ee ee SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance uen met bra ape een 627 2 gt C00lant Maintenance ae 6 3 EIOW Direclion ze ee HHH BHHHBBMDBBBDMNBDBBDBDBHBHE MEDED 6 4 HoublesHoOlLig gt lt 5 555k H l co a M en ade X se heke Nek RES Dkey A n Ru quU SECTION 7 ELECTRICAL DIAGRAM 2 5 2 2 2 kk kk kk kak kak ka ak kk a a kk a a kk kk kk a a kk kk kk ka ka SEGTION S PARIS EIS ida dida a a ARES RARE a ay Ad AE LEE E RI UE Es WARRANTY CO OO O N SN Y Y Y 9 QI QI AO m h m m m m BAS 9 NN a OO DECLARATION OF CONFORMITY Q Miter for European Community CE marked products ITW Welding Italy S r l Via Privata Iseo 6 E 20098 San Giuliano M se MI Italy declares that the prod uct s identified in this declaration conform to the essential requirements and provisions of the stat ed Council Directive s and Standard s Product App
3. Turn off welding power source before maintaining Cooler Side Panel Coolant Level Indicator 3 Coolant Filter Unscrew housing to clean filter and housing Changing coolant Drain coolant by tipping unit forward Fill with clean water and run for 10 minutes Drain and refill r If replacing hoses use hoses compatible with ethylene glycol such as Buna n Neoprene or Hy palon Oxy acetylene hoses are not compatible with any product containing ethylene glycol 956172138_4 A OM 266 361 Page 11 6 3 Flow Direction gt e WEISS Outlet Flow Filter lt Blue TTS TT DI Inlet Flow gt Red SE Radiator 956172140 A 6 4 Troubleshooting E M Trouble Remedy Coolant system does not work Be sure cooler input power and communication cables from power source are connected to cooler receptacles 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 filter Clean filter or clean replace hoses if necessary Disconnect pump and check for sheared coupling Replace coupling if necessary OM 266 361 Page 12 SECTION 7 ELECTRICAL DIAGRAM 400VAC INPUT POWER 2 50VAC TEEN GRN YEL HUN si eo n es 10 asn GtIVZVH X90HS resul suos1ad payienb Ajuo
4. BABY e 31419373 DeAOUI8J SISAOI UUM ejeJedo jou od e Buraas 91099 u Bu dois 10 Jamod Indu P3uuoss q e syed eano eal y9no jou og e 9NINHVM Y 956172139_A OM 266 361 Page 13 SECTION 8 PARTS LIST Hardware is common and not available unless listed 956172138_5 A Figure 8 1 Main Assembly Hydracool 270 OM 266 361 Page 14 No Mkgs No Description Figure 8 1 Main Assembly Hydracool 1 e MC 110121128 52 WE ER ee ee ee usu Swa du uh 1 le ida 156005187 Bracket Mtg Welding Power Supply 2 RER eee 166564 Filter In Line Low Profile 100 Screen 3 8 Hose Bar 1 DELL en en 235419 22 Bracket FINCK A ee Capua 3 1 TUE MUERE 166608 Cap Tank S6IOW ike ere dne E A dy eb E d 1 TS PNE 251119 Tank Water 5L_ 1 7 MOT 057010060 Motor 170 W 230 VAC 1 EE Say O AR A 556049386 Connector Male 3 8 D 10 2 dd 556049419 Elbow Pipe Male Female 38 2 ied OA ct nan V57011071 24 PIT AS Sy aire yu un yu bce eae ae fine baka DN Qusan ese he aot 1 sings A 156005186 Mig Bracket Motor amp Transformer 1 12 T1 058021161 Transformer 400 230 VAC 1 ava al Betas 056082102 G Radiator ASSY gu uu ias unai een ea 1
5. TEE METRUM 11560051988 4 Fan SUDDO souci RR en ee X Dar e Oen s Ee Dons 1 15 FM 235504 Fan Assy Radiator Cooling 230 V 1 a Od gh A BED ma a 25 1125 Bezel Frnt Hear y uu unde Vetera are Det release 2 staat AAA 057014280 Cable Primary 400 VAC C W Strain Relief 1 suu REITER DER 756007013 Cover Switch 37 X 20 1 19 S1 056067251 Switch Power On Off 1 Mo s a Lu asna 656110013 Foot Rubber Mount 4 ee AA 116006132 Base 1 ra GB yan BSAS a Breaker Creul SR are rn era eur 1 RR CENE 556049410 Water Connection Quick Connect Blue 1 ED E 556049409 Water Connection Quick Connect Red 1 En O Ade 316029728 Nameplate Front Hydracool 270 1 26 PL1 056072084 Light Wht Lens 230 VAC Neon 1 2 c 156033034 Boot Rubber 1 wan IE 316029729 Nameplate Rear Hydracool 270 1 sch OO tnd db ded hla qubd 180663 Label Warning Primary Connections 2 mc TP 207290 Label Advisory Service 1 Mu PN UE 956142629 Label Warning Moving Parts
6. again e Do not block or filter airflow to unit FLYING SPARKS can injure e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire BATTERY EXPLOSION can injure e Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose MOVING PARTS can injure e Keep away from moving parts such as fans d lt e Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before insta
7. in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if required for the welding process e If AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or Iying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install ground and operate this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in r Indicates special instructions Ga 4A I This group of symbols means Warning Watch Out ELECTRIC SHOCK MO
8. warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at ITW Welding Products Group Europe or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCL
9. AIMED BY MILLER milan_warr 2013 01 RS QI 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 Country Zip Postal Code 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 Service and Repair Replacement Parts Owner s Manuals ITW Welding Italy S r l Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Contact the Delivering Carrier to File a claim for loss or damage during Phone 39 0 2982901 shipment Fax 39 0 298290 203 email miller itw welding it 72 Miller For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department ORIGINAL INSTRUCTIONS PRINTED IN USA 2013 Miller Electric Mfg Co 2013 01
10. IC FIELDS EMF can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e 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 NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise lev elis high CYLINDERS can explode if damaged Compressed gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct compressed gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Do not stand in front of or behind t
11. NS 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 Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent 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 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 4 Keep head and trunk as far away from the equipment in the welding 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 Implante
12. OM 266361A 2013 11 m Miller se TIG GTAW Welding MIG GMAW Welding Description Hydracool 270 CE Visit our website at 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 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 which exact part you may need to fix the problem Warranty and service informatio
13. Spoolguns Positioners and Controllers Powered Air Purifying Respirator PAPR Blower Unit No Labor Racks Running Gear and Trailers Subarc Wire Drive Assemblies Water Coolant Systems Non Integrated Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Systems EU Models USA Models 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets MIG Guns Remote Controls Replacement Parts No Labor Spoolmate Spoolguns Cables and Non Electronic Controls Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes switches slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a
14. VING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards disconnect box or that cord plug is connected to a properly groundedreceptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord and ground conductor for damage or bare wiring replace immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or repaired cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal obje
15. anty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date the equipment was delivered to the original retail purchaser or one year after the equipment is shipped to a European distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers only to include SCRs diodes and discrete rectifier modules with exclusion of STR Si STi STH and MPi series 2 3 Years Parts and Labor Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer Inverter Power Sources Unless Otherwise Stated Process Controllers Semi Automatic and Automatic Wire Feeders Transformer Rectifier Power Sources Water Coolant System Integrated 3 2 Years Parts Auto Darkening Helmet Lenses No Labor Migmatic 175 HF Units Water Coolant Non Integrated 4 1 Year Parts and Labor Unless Specified Automatic Motion Devices Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Induction Heating Power Sources Coolers and Electronic Controls Recorders Motor Driven Guns w exception of Spoolmate
16. aratus Identification Stock Number HYDRACOOL 270 028042107 Council Directives 2006 95 EC Low Voltage 2004 108 EC Electromagnetic Compatibility 2011 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equipment Standards IEC 60974 1 Arc Welding Equipment Welding Power Sources edition 3 2005 07 IEC 60974 2 Arc Welding Equipment Liquid Cooling Systems edition 2 0 2007 11 IEC 60974 10 Arc Welding Equipment Electromagnetic Compatibility Requirements edition 2 0 2007 08 EN 50445 2008 Product family standard to demonstrate compliance of equipment for resistance welding arc weld ing and allied processes with the basic restrictions related to human exposure to electromagnetic fields OHZ 300Hz EU Signatory Mood an d lt November 15th 2013 Massimigliano Lavarini Date of Declaration ELECTRONIC ENGINEER R amp D TECH SUPPORT 956 172 141 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 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 poss
17. ct e Do not connect more than one electrode or work cable to any single weld output terminal Disconnect cable for process not in use e Use GFCI protection when operating auxiliary equipment in damp or wet locations SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn e Do not touch hot parts bare handed e Allow cooling period before working on equip LA ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 266 361 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding 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 If ventilation is poor wear an approved air supplied respirator Read and understand the Safety Data Sheets SDSs and the manufacturers instructions for adhesives coatings cleaners consumables coolants degreasers fluxes and metals Work in a confined
18. d Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cuiting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 DEFINITIONS 2 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 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 Disconnect input plug or power before working on machine Safe5 2012 05 Do not remove or paint over cover the label Safe20 2012 05 Recycle Safe103 2012 09 Use coolant suggested by the manufacturer Safe52 2012 05 Please drain fluid according to instructions 2012 05 Read the labels on the welding power source wire feeder or other major equipment for welding safety information Safe71 2012 06 Read the Owner s Manual before working on this machine Safe70 2012 06 OM 266 361 Page 5 Plugged filter or hoses can cause overheating to the power source and torch Safe50 2012 05 100 h 100 n Sta Every 100 hours check and clea
19. ed Water O O TR OK Above 329 F 0 C HF High Frequency Current MILLER coolants 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 Ref 956142645 4 5 SECTION 4 INSTALLATION 4 1 Selecting a Location Position unit so air can circulate 956172138_1 A OM 266 361 Page 8 4 2 Installing Unit On A STH 270 Welding Power Source And Connecting 400 VAC Input Power 22 Cooling Suppl Circuit Board 1 Welding Power Source A Have only qualified persons make this installation A Disconnect and lockout tag out input power before con necting input conductors from unit Follow estab lished procedures regarding the installation and removal of lockout tagout devices Front Rear Bezel Mounting Brackets Screws Plastic Cap Wrapper 9 Ci W N Loosen screws and remove bezels Install cooling system on power source by checking that mounting holes match Reinstall bezels Do not fully tighten screws Remove wrapper from power source and plastic cap from power source rear panel 7 Strain Relief 8 Input Power Cord Insert strain relief into hole Route power cord through strain re lief and tighten strain relief A Always connect green or green yellow conductor to supply grounding terminal first and never to a
20. f Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 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 OM 266 361 Page 4 A This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use Spectrum Way Suite 100 Ontario Canada L4W 5
21. he regulator when opening the valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do nol install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit NEZ FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld
22. ible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding 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 electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output
23. line ter minal 9 Machine Grounding Terminal 10 Green Yellow Grounding Conductor 11 Input Conductors L1 L2 12 Device Line Terminals Secure grounding conductor to ma chine grounding terminal first Connect input conductors L1 L2 to device line terminals Reinstall wrapper Close and secure door on discon nect device Follow established lockout tagout procedures to put unit in service Tools Needed E BR Tor T20 956172138_2 A OM 266 361 Page 9 SECTION 5 OPERATION 5 1 Control Panel Tank Filler Neck Supplementary Protector CB1 Power On Off Light Quick Connect Water Out Quick Connect Water In Power On Off Switch 956172138_3 A OM 266 361 Page 10 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance Tal AX Disconnect power before maintaining D Y Check Change Clean Replace Reference To be done by Factory Authorized Service Agent Ever Y NOTICE Clean coolant filter Severe condi Months tions may require more frequent cleaning con tinuous use high low temperatures dirty envi ronment etc Failure to properly clean cool ant filter voids pump warranty Coolant Filter Every 6 Months N gt P Cracked Parts Change Coolant If Using Replace Unreadable Labels Water Every 12 Months SQ Change Coolant If Using B 050024004 6 2 Coolant Maintenance Z
24. lling operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equi
25. n filter and check condition of hoses Safe51 2012 05 2 2 Miscellaneous Symbols And Definitions AR Circulating Unit voltage Input With Coolant Pump Water Coolant Water Coolant i Output Line Connection Protective Earth Degree Of Primary Voltage Single Phase OM 266 361 Page 6 SECTION 3 SPECIFICATIONS 3 1 Important Information Regarding CE Products Sold Within The EU A This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding This equipment is built in accordance with EN 60974 1 and is intended to be used only in an occupational environment where the general public access Is prohibited or regulated in such a way as to be similar to occupational use by an expert or an instructed person Wire feeders and ancillary equipment such as torches liquid cooling systems and arc striking and stabilizing devices as part of the welding circuit may not be a major contributor to the EMF See the Owner s Manuals for all components of the welding circuit for additional EMF exposure information e The EMF assessment on this equipment was conducted at 0 5 meter e Ata distance of 1 meter the EMF exposure values were less than 20 of the permissible values ce emf 1 2010 10 3 2 Serial Number And Rating Label Location The serial number and rating information for this product is located on the back panel Use rating label to determine input power
26. n for your 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 catalog sheets RER Working as hard as you do every power source from Miller is backed by the most hassle free warranty in the business GQ Miller TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING SS A O NS FESD SEN TEN RE RENS SES RENSE RR 1 2 Are Welding Hazards ie hese Kod bub Essa we a aded duree isu us SS sa 1 3 Additional Symbols For Installation Operation And Maintenance 1 4 California Proposition 65 Warnings 1 5 Principal Safe standarde eses rentas ana a doe tau a a a 156 EMP IMIOniiallon s ni upip teten ea aaa SECTION 2 DEFINITIONS 333 x 944 8 2 2 AAA 2 1 Additional Safety Symbols And Definitions 2 2 Miscellaneous Symbols And Definitions SECTION 3 SPECIFICATIONS 3 usa ara a Quse D Ra kn d 3 1 Important Information Regarding CE Products Sold Within The EU 3 2 Serial Number And Rating Label Location
27. pment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 266 361 Page 3 1 4 California Proposition 65 Warnings A 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 amp Safety Code Section 25249 5 et seq 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 ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com 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 Safe Handling o
28. requirements and or rated output For future reference write serial number in space provided on cover of this manual 3 3 Specifications Coolant Tank Maximum Cooling Model Capacity Capacity Input Power Dimensions Weight Hydracool 270 5L 1470 Watts Three Phase Length 620 mm 23 2 kg 5020 BTU hr 400 VAC Height 320 mm 1 0 L min 50 60 Hz Width 227 mm 1 1 qt min 0 5 Amperes IEC Cooling Capacity States That The Water Inlet Temperature Can Not Exceed 40 C Above Ambient Temperature At A 11 Min Flow Rate Plug Is Customer Supplied Recirculating Coolant System For Water Cooled GTAW Torches And GMAW Guns Use With Guns Torches Rated Up To 280 Amperes 3 4 Environmental Specifications IP Rating Operating Temperature Range Storage Temperature Range Hydracool 270 IP23S This equipment is designed for outdoor use It 10 to 40 C 14 to 104 F 20 to 25 C 68 to 77 F may be stored but is not intended to be used outside during precipitation unless sheltered OM 266 361 Page 7 3 5 Coolant Chart Application GTAW Or Where GMAW Or Where Where Coolant Contacts pp HF Is Used HF Is Not Used Aluminum Parts MILLER Low Conductivity MILLER Low Conductivity MILLER Aluminum Coolant No 043 810 Coolant No 043 810 Or Protecting Coolant Distilled Or Deionized Water MILLER Aluminum Protecting No 043 809 OK Above 32 F 0 C Coolant No 043 809 Distilled Or Deioniz
29. s leather gloves heavy shirt cuffless trousers high shoes and a cap AIZ WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on containers that have held combustibles or on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unkno
30. space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld 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 welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear body protection made from durable flame resistant mate rial leather heavy cotton wool Body protection includes oil free clothing such a
31. wn paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes OM 266 361 Page 2 Remove stick electrode from holder or cut off welding wire at contact tip when not in use 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 Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby Read and understand the Safety Data Sheets SDSs and the manufacturers instructions for adhesives coatings cleaners consumables coolants degreasers fluxes and metals FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill e Shut off compressed gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNET
Download Pdf Manuals
Related Search