Miller Coolmate 3.5 CE, Coolmate 3.5 Non-CE Owner's Manual

OM-231313U 2018-06

Processes

TIG (GTAW) Welding

MIG (GMAW) Welding

Description

Coolmatet3.5

CE and Non-CE

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

File: TIG (GTAW)

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 the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

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 2017−06

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 4.....

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. Selecting A Location 8..................................................................

5-2. GTAW Connections 9...................................................................

5-3. GMAW Connections 10..................................................................

SECTION 6 − MAINTENANCE & TROUBLESHOOTING 11.........................................

6-1. Routine Maintenance 11.................................................................

6-2. Coolant Maintenance 11.................................................................

6-3. Troubleshooting 12......................................................................

SECTION 7 − ELECTRICAL DIAGRAM 12........................................................

7-1. Circuit Diagram For Cooler 12.............................................................

SECTION 8 − PARTS LIST 12...................................................................

8-1. Recommended Spare Parts 12............................................................

COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

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

Product/Apparatus Identification:

Product

Stock Number

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 60974-10:2014 Arc welding equipment – Part 10: Electromagnetic compatibility requirements

Signatory:

March 24, 2017

_____________________________________ ___________________________________________

David A. Werba

MANAGER, PRODUCT DESIGN COMPLIANCE

242094F

Date of Declaration

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

coolers 2018-01

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid the
hazards.

1-2. Cooling Equipment 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 equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, train­ing and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recog­nize and avoid the hazards involved.

During operation, keep everybody, especially children, away.

HOT PARTS can burn.

D Do not touch hot parts bare handed.
D Allow cooling period before working on

equipment.

D To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

D Wear approved safety glasses with side

shields even under your welding helmet.

D Do not touch live electrical parts.

D 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).

D Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare
wiring can kill.

D Turn off all equipment when not in use.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Keep all panels and covers securely in place.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The input power circuit and machine
internal circuits are also live when power is on.
Incorrectly installed or improperly grounded equip­ment is a hazard.

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

FALLING EQUIPMENT can injure.

D Use correct procedures and equipment of ade-

quate capacity to lift and support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of
unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu­ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.
D Do not block or filter airflow to unit.

OM-231313 Page 1

READ INSTRUCTIONS.

HIGH PRESSURE FLUIDS can injure or kill.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and
local codes.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

STEAM AND HOT COOLANT can burn.

Hose may rupture if coolant overheats.

D Visually inspect condition of hoses before each

use. Do not use damaged hoses.

D Allow cooling period before working on equipment.

1-4. California Proposition 65 Warnings

WARNING: This product can expose you to chemicals in­cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.

For more information, go to www.P65Warnings.ca.gov.

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.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

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: [phone], website: www.global.ihs.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: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02169 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:
www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: 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: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Govern­ment Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: [phone]) (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 Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

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