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OM-254203 Page 1

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

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE

 

 Indicates statements not related to personal injury.

.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. 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 unit.

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.

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 equip-

ment is a hazard.

ELECTRIC SHOCK can kill.

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.

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

FALLING EQUIPMENT can injure.

D

Use equipment of adequate 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 manu-

ally 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.

READ INSTRUCTIONS.

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.

Summary of Contents for 028042103

Page 1: ...NER S MANUAL Hydracool 1 Hydracool 2 CE Processes Description TIG GTAW Welding MIG GMAW Welding OM 254203E 2016 09 For product information Owner s Manual translations and more visit www MillerWelds co...

Page 2: ...ucts 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...

Page 3: ...ions 3 2 2 Miscellaneous Symbols And Definitions 4 SECTION 3 SPECIFICATIONS 5 3 1 Serial Number And Rating Label Location 5 3 2 Specifications 5 3 3 Coolant Specifications 5 3 4 Environmental Specific...

Page 4: ...5 HYDRACOOL 2 V 230 50 60HZ 028042106 Council Directives 2006 95 EC Low Voltage 2004 108 EC Electromagnetic Compatibility 2011 65 EU Restriction of the use of certain hazardous substances in electrica...

Page 5: ...can kill 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 Sa...

Page 6: ...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 tha...

Page 7: ...acility 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 pai...

Page 8: ...and clean filter and check condition of hoses 2 2 Miscellaneous Symbols And Definitions A Amperage Alternating Current Voltage Input Circulating Unit With Coolant Pump V Voltage Water Coolant Input Wa...

Page 9: ...tates That The Water Inlet Temperature Can Not Exceed 40 C Above Ambient Temperature At A 1l Min Flow Rate Plug Is Customer Supplied Recirculating Coolant System For Water Cooled GTAW Torches And GMAW...

Page 10: ...diated 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 10...

Page 11: ...4 Circuit Breaker CB1 5 Power On Off switch 6 Tank Filler Neck 7 Coolant level Indicator 1 2 3 4 5 956142899_2 A 6 7 5 2 Control Panel Hydracool 2 1 Flow Indicator 2 Power On Off switch 3 Circuit Bre...

Page 12: ...ange Coolant If Using Water lReplace Unreadable Labels Every 12 Months ZChange Coolant 6 2 Coolant Maintenance Ref coolmaint_2016 08 Disconnect cooler plug from welding power source receptacle before...

Page 13: ...tacle Check circuit breakers on cooler and welding power source and reset if necessary Motor overheated Unit starts running when motor has cooled Have Factory Authorized Service Agent check Power swit...

Page 14: ...OM 254203 Page 10 SECTION 7 ELECTRICAL DIAGRAM 956142901_B...

Page 15: ...03 Page 11 SECTION 8 PARTS LIST Hardware is common and not available unless listed 956142899_3 A 3 2 1 20 19 18 17 16 15 14 13 12 21 22 23 24 25 26 27 28 11 8 10 9 7 6 5 Figure 8 1 Main Assembly Hydra...

Page 16: ...Bar 1 15 CB1 083431 Breaker Circuit 5A 1 16 556049410 Water Connection Quick Connect Blue 1 17 215279 Indicator Flow 1 18 S1 056067251 Switch Power On Off 1 19 316029721 Nameplate Front Hydracool 1 1...

Page 17: ...OM 254203 Page 13 Hardware is common and not available unless listed Figure 8 2 Main Assembly Hydracool 2 956142900_3 A 1 2 3 4 12 11 10 9 8 7 6 5 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29...

Page 18: ...2 1 15 CB1 083431 Breaker Circuit 5A 1 16 027042002 Tank Water 8 L 1 17 116122306 Mounting Bracket Tank Assy 1 18 956142908 Nameplate Rear Water Terminals 1 19 556049410 Water Connection Quick Connec...

Page 19: ...ntrollers Powered Air Purifying Respirator PAPR Blower Unit No Labor Racks Running Gear and Trailers Subarc Wire Drive Assemblies Water Coolant Systems Work Stations Weld Tables No Labor 5 6 Months Pa...

Page 20: ...y Zip Postal Code Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Suppli...

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