Miller Electric Coolmate Coolmate 4 User manual

Processes
TIG (GTAW)
MIG (GMAW)
Plasma Cutting
Resistance Welding
Input Power Single-Phase
Input Voltage 115 VAC or 230 VAC, 50/60 Hz
Max. Cooling Capacity 9,700–18,000 BTU/hr
Light/Heavy Industrial Applications
Manufacturing
Aerospace
Automotive
Tube Mills
Automation
Coolmate™Series Coolant
Systems
Issued Oct. 2010 • Index No. AY/7.2
Closed-loop design with radiator reduces coolant temperatures and
prevents the system from overheating. Closed-loop design also
recirculates the coolant through a fan-cooled heat exchanger.
The Power of Blue® .
Rustproof coolant reservoir molded of polyethylene for durability and
corrosion resistance.
Standard inlet/outlet torch fittings are compatible with TIG and MIG
torches having standard 5/8-18 left-hand fittings.
10 ft (3 m) power cords with plugs are longer than most power cords in
the industry — providing the extra length when required.
Compatible with Miller coolants and are ideal for warm and cold
weather conditions, while providing HF or corrosion protection.
Coolmate 3
Coolant
Coolmate 1
Coolmate 3.5
Coolant systems are warranted for 1 year, parts and labor.
Quick
Specs
Coolmate 4
Coolmate V3
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
Equipment Sales US and Canada
Phone: [phone]
FAX: [phone]
International Phone: [phone]
International FAX: [phone]

Model
Coolmate 1
Coolmate 1 CE
Coolmate 3
Coolmate 3 CE
Coolmate V3
Coolmate V3 CE
Coolmate 3.5
Coolmate 4
Coolmate 4 CE
Coolmate 3X
Maximum
Current Draw
50 Hz 60 Hz
— 2.1 A
0.65 A 0.55 A
5.9 A 4.7 A
2.5 A 3.0 A
5.9 A 4.7 A
5.9 A 4.7 A
5.9 A 4.7 A
5.9 A 4.7 A
Rated
Cooling
Capacity**
1,210 W
(4,120 BTU/hr)
1.1 qt/min (1 L/min)
1,420 W
(4,840 BTU/hr)
1.1 qt/min (1 L/min)
1,420 W
(4,840 BTU/hr)
1.1 qt/min (1 L/min)
1,660 W
(5,660 BTU/hr)
1.1 qt/min (1 L/min)
1,780 W
(6,070 BTU/hr)
1.1 qt/min (1 L/min)
1,660 W
(5,660 BTU/hr)
1.1 qt/min (1 L/min)
Maximum
Cooling
Capacity*
2,850 W
(9,700 BTU/hr)
1.8 qt/min (1.7 L/min)
3,820 W
(13,000 BTU/hr)
4.2 qt/min (4.0 L/min)
3,820 W
(13,000 BTU/hr)
4.2 qt/min (4.0 L/min)
4,140 W
(14,000 BTU/hr)
5.0 qt/min (4.7 L/min)
5,500 W
(18,000 BTU/hr)
5.9 qt/min (5.6 L/min)
4.140 W
(14,000 BTU/hr)
5.0 qt/min (4.7 L/min)
Motor Input
Voltage 50/60 Hz
115 VAC, 60 Hz
230 VAC, 50/60 Hz
115 VAC
230 VAC
115 VAC
115 VAC
115 VAC
115 VAC
Tank
Capacity
1 gal
(3.8 L)
3 gal
(11.4 L)
3 gal
(11.4 L)
3.5 gal
(13.2 L)
4 gal
(15 L)
3 gal
(11.4 L)
Net
Shipping
Weight
29 lb
(13 kg)
43 lb
(20 kg)
54 lb
(24 kg)
70 lb
(32 kg)
40 lb
(18 kg)
158 lb
(72 kg)
Specifications (Subject to change without notice.)
Dimensions
H: 8 in (203 mm)
W: 7-1/2 in (191 mm)
D: 23-3/4 in (603 mm)
H: 13-1/4 in (337 mm)
W: 12-1/4 in (311 mm)
D: 23-1/4 in (584 mm)
H: 33 in (838 mm)
W: 9-1/4 in (235 mm)
D: 9-1/4 in (235 mm)
H: 11-3/4 in (298 mm)
W: 15-3/4 in (400 mm)
D: 26 in (660 mm)
H: 16-1/4 in (413 mm)
W: 15-1/4 in (387 mm)
D: 18-3/4 in (476 mm)
H: 17 in (432 mm)
W: 27 in (686 mm)***
D: 39 in (991 mm)
All CE models conform to the applicable parts of the IEC 60974 series of standards.
All models are certified by Canadian Standards Association to both the Canadian and U.S. Standards.
2
*Maximum cooling capacity is based on a 25°C (77°F) environment at maximum flow with a 65°C (149°F) coolant temperature rise.
**Rated IEC standard cooling capacity is based on a 25°C (77°F) environment at a flow of 1 L/min with a 40°C (104°F) coolant temperature rise.
***Width measurement includes rear wheels and axle. Cooler width without rear wheels and axle is 22-1/4 in (565 mm).
Coolmate™1
#300 360 115 VAC, 60 Hz
#300 360-00-1 115 VAC, 60 Hz CE
#300 459 230 VAC, 50/60 Hz
#300 459-00-1 230 VAC, 50/60 Hz CE
Light industrial, 1-gallon cooler designed for water-cooled
torches on power sources rated up to 200 A*.
• Designed to integrate with smaller Dynasty and Maxstar models
and Syncrowave 200
• Compact horizontal design allows stacking and convenient mounting
• Lightweight at 25 lb (11 kg) dry
• Equipped with lighted on/off power switch on front panel
• Filter and coolant filling spout are conveniently located for
easy access
• Fluid level sight window
• Polyethylene-molded coolant tank and filler spout are rustproof
• Thermally protected piston pump guards against overheating
• Stainless steel oscillating piston pump provides consistent
coolant flow and pressure rating with long pump-life expectancy
Coolmate™3
#043 007 115 VAC, 50/60 Hz
#043 007-01-2 115 VAC, 50/60 Hz CE
#043 008 230 VAC, 50/60 Hz
#043 008-01-2 230 VAC, 50/60 Hz CE
Economical, 3-gallon cooler designed for water-cooled torches
rated up to 500 A*.
• Compact horizontal design allows stacking and convenient mounting
• Midsize cooler weighs 40 lb (18 kg) dry
• On/off power switch, “paddle wheel” coolant flow indicator, filter
and coolant filling spout are all conveniently located on front panel
• Polyethylene-molded coolant tank, fan shroud and filler spout
are rustproof
• Factory-set pressure relief valve (55 PSI) maintains consistent
pressure during operation
• Thermally protected 1/4 HP motor guards against overheating
• Efficient fin and tube heat exchanger
• Brass-body, positive displacement rotary vane pump
provides consistent coolant flow and pressure rating with
long pump-life expectancy
Product Descriptions
*May vary with torch design and cable length.

Coolmate™V3
#043 009 115 VAC, 50/60 Hz
#043 009-01-2 115 VAC, 50/60 Hz CE
Vertical, 3-gallon cooler designed
for water-cooled torches rated up to
500 A*.
• Distinct, vertical design allows
mounting onto a power source
running gear or gas cylinder rack
•Weighs only 48 lb (22 kg) dry
• On/off power switch, “paddle wheel”
coolant flow indicator, filter and
coolant filling spout are all
conveniently located on front panel
• Polyethylene-molded coolant tank, fan
shroud and filler spout are rustproof
• Factory-set pressure relief valve
(55 PSI) maintains consistent
pressure during operation
• Thermally protected 1/4 HP motor guards against overheating
• Efficient fin and tube heat exchanger
• Brass-body, positive displacement rotary vane pump
provides consistent coolant flow and pressure rating with
long pump-life expectancy
Coolmate™3.5
#300 245 115 VAC, 50/60 Hz
Industrial, 3.5-gallon cooler designed for water-cooled torches
rated up to 600 A*.
• Designed to integrate with Dynasty 350/700 and Maxstar 350/700
• Horizontal design allows stacking or convenient mounting onto a
MIGRunner™cart
• Weighs only 64 lb (29 kg) dry
• Polyethylene-molded coolant tank, fan shroud and filler spout
are rustproof
• Factory-set pressure relief valve (55 PSI) maintains consistent
pressure during operation
• Thermally protected 1/4 HP motor guards against overheating
• Efficient fin and tube heat exchanger
• Equipped with internal check valves to prevent coolant flow when
torch is disconnected
• Brass-body, positive displacement rotary vane pump
provides consistent coolant flow and pressure rating with
long pump-life expectancy
Coolmate™4
#042 288
115 VAC, 50/60 Hz
#042 288-01-5
115 VAC, 50/60 Hz CE
The best performer in its class — industrial, 4-gallon cooler
designed for water-cooled torches rated up to 600 A*.
• Weighs only 38 lb (17 kg) dry
• Tough, one-piece case is portable and rustproof
• Convenient carrying handle and filler spout are molded into case
• Easily accessible coolant filter
• Factory-set pressure relief valve (60 PSI) maintains consistent
pressure during operation
• Thermally protected 1/4 HP motor guards against overheating
• Efficient fin and tube heat exchanger
• Coolant system has a constant flow of coolant inside to keep the
pump primed and to reduce algae buildup in the tank
• Brass-body, positive displacement rotary vane pump
provides consistent coolant flow and pressure rating with
long pump-life expectancy
Coolmate™3X
#300 419
115 VAC, 50/60 Hz
Industrial, 3-gallon cooler designed for water-cooled torches
rated up to 500 A*.
• Includes easy load dual cylinder rack, running gear and handles
for Syncrowave 250 DX/350 LX
• “Paddle wheel” coolant flow indicator, filter and coolant filling
spout are all conveniently located on front panel
• Polyethylene-molded coolant tank, fan shroud and filler spout
are rustproof
• Factory-set pressure relief valve (55 PSI) maintains consistent
pressure during operation
• Thermally protected 1/4 HP motor guards against overheating
• Efficient fin and tube heat exchanger
• Brass-body, positive displacement rotary vane pump
provides consistent coolant flow and pressure rating with
long pump-life expectancy
Product Descriptions
3
Includes
wheels and
handles.
*May vary with torch design and cable length.

4
Water-Cooled TIG Torch Adapters
50 mm Dinse with Water Return Line
#195 377
For Maxstar 200, 300 and 350, Dynasty
200, 300 and 350, and Syncrowave 250
and 350.
Used with (WP125, WP24W,
WP25, WP20, WP18, WP12, CS310,
CS410, WP22, WP27) water-cooled torch.
Order from Miller Service Parts.
50 mm Dinse Flow Thru #195 380
For Econotig and Syncrowave 180 and
200.
Used with (WP125, WP24W, WP25,
WP20) water-cooled torch. Order from
Miller Service Parts.
50 mm Thread Lock Style #225 028
For Dynasty 700 and Maxstar 700. Used
with (WP125, WP24W, WP25, WP20,
WP18, WP12, CS310, CS410, WP22, WP27)
water-cooled torch. Order from Miller
Service Parts.
Water-Cooled TIG
Block Adapter #45V11
For Miller power
sources with stud-type
output terminals.
Order from Miller
Service Parts.
Replacement Water Hose for
Dinse Adapter #222 809
18 in (457 mm). Order from Miller
Service Parts.
Water Hoses and Connectors
Water Hose Extension
#40V76R6 6 ft (1.8 m)
Hose with two male 5/8 in 18 LH thread
connections. Order from Miller Service Parts.
Water Coupler #057 020
Brass hose fitting with 5/8 in 18 LH thread.
Order from Miller Service Parts.
Coolants
Sold in multiples of four in 1-gallon
recyclable plastic bottles. Miller coolants
contain a base of ethylene glycol and
deionized water to protect against freezing
to -37°F (-38°C) or boiling to 227°F (108°C).
Low-Conductivity Coolant
(Clear, Pre-Mixed) #043 810
For TIG and MIG applications. NOT for use
in push-pull systems or systems where
aluminum is in coolant path/circuit.
Aluminum-Protecting Coolant
(Green, Pre-Mixed) #043 809
Primarily used in push-pull systems where
aluminum is in coolant path/circuit and
high frequency is NOT used.
Replacement Filter Assemblies
Filter Assemblies
#166 564
For Coolmate 1, 3, V3 and 3X
#215 667 For Coolmate 3.5
Order from Miller Service Parts.
Filter Strainer
#146 249 For Coolmate 4
Located inside pump assembly. See owner’s
manual. Order from Miller Service Parts.
Genuine Miller Accessories
#166 564
Filter #215 667
Filter
With gas and
water return
line

5
Genuine Miller Accessories
250 A with WP20 Water-Cooled Torch
#300 185
25 ft (7.6 m) Weldcraft®WP20 torch
Torch cable cover
AK4C torch accessory kit includes
shielding cups, collets, collet bodies
and 2% cerium tungsten electrodes
(1/16, 3/32 and 1/8 in)
Smith®regulator/flowmeter HM2051A-580
12 ft (3.7 m) rubber gas hose (regulator
to machine)
Water-cooled Dinse torch adapter
15 ft (4.6 m) 1/0 work cable with clamp
and Dinse connector
300 A with CS310 Water-Cooled Torch
#300 183
25 ft (7.6 m) Weldcraft®CS310 torch
Torch cable cover
CS310AKC torch accessory kit includes
shielding cups, collets, collet bodies
and 2% cerium tungsten electrodes
(1/16, 3/32 and 1/8 in)
Smith®regulator/flowmeter HM2051A-580
12 ft (3.7 m) rubber gas hose (regulator
to machine)
Water-cooled Dinse torch adapter
15 ft (4.6 m) 1/0 work cable with clamp
and Dinse connector
400 A with WP18SC Water-Cooled Torch
#300 186
25 ft (7.6 m) Weldcraft®WP18SC torch
Torch cable cover
AK18C torch accessory kit includes
shielding cups, collets, collet bodies
and 2% cerium tungsten electrodes
(3/32, 1/8 and 5/32 in)
Smith®regulator/flowmeter H1954D-580
12 ft (3.7 m) rubber gas hose (regulator
to machine)
Water-cooled thread lock torch adapters
12 ft (3.7 m) 4/0 work cable with clamp
Torch Kits
Typical Coolmate™Connections
MIG (GMAW) ConnectionsTIG (GTAW) Connections
Water
Coupler
Coolant Out
Coolant In
Coolant
In Water Coupler
Coolant Out
Coolant In