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OM-1500-3 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_7/02

1-1.

Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

Y

Marks a special safety message.

.

Means “Note”; not safety related.

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

1-2.

Arc Welding Hazards

Y

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 1-4. Read and follow all
Safety Standards.

Y

Only qualified persons should install, operate, maintain, and
repair this unit.

Y

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.

D

Do not touch live electrical parts.

D

Wear dry, hole-free insulating gloves and body protection.

D

Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.

D

Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.

D

Use AC output ONLY if required for the welding process.

D

If AC output is required, use remote output control if present on
unit.

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 and ground 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

When making input connections, attach proper grounding conduc-
tor first – double-check connections.

D

Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.

D

Turn off all equipment when not in use.

D

Do not use worn, damaged, undersized, or poorly spliced cables.

D

Do not drape cables over your body.

D

If earth grounding of the workpiece is required, ground it directly
with a separate cable.

D

Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.

D

Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.

D

Wear a safety harness if working above floor level.

D

Keep all panels and covers securely in place.

D

Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.

D

Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.

D

Do not connect more than one electrode or work cable to any
single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.

D

Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

FUMES AND GASES can be hazardous.

D

Keep your head out of the fumes. Do not breathe the fumes.

D

If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.

D

If ventilation is poor, use an approved air-supplied respirator.

D

Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.

D

Work in a confined 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.

D

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.

D

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 if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.

Содержание 3045 FC

Страница 1: ...Visit our website at www MillerWelds com 3045 FC And M 25 Gun OM 1500 3 203 580A August 2002 Processes Description Flux Cored FCAW Welding MIG GMAW Welding Wire Feeder...

Страница 2: ...ue 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...

Страница 3: ...And Drive Rolls 12 4 3 Connecting Weld Cable 12 4 4 Connecting Shielding Gas On Units With Optional Gas Solenoid 13 4 5 Installing Wire Spool And Adjusting Hub Tension 14 4 6 Threading Welding Wire 15...

Страница 4: ......

Страница 5: ...that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power...

Страница 6: ...elding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane ligh...

Страница 7: ...ry D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference D High frequency H F can interfere with radio...

Страница 8: ...r 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 1...

Страница 9: ...ntation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre D En effectuant les raccordements d entr e fixer d abord le condu...

Страница 10: ...er des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer t...

Страница 11: ...uvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences D Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de...

Страница 12: ...champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tel...

Страница 13: ...nput Welding Circuit Rating Wire Spool Capacity Overall Dimensions Weight 175 Amperes At 60 Duty Cycle 225 Amperes Maximum At 30 Duty Cycle 2 lb 0 9 kg 4 in 102 mm or 10 lb 4 5 kg 8 in 203 mm Length 1...

Страница 14: ...ng duty cycle can damage unit or gun and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 205 643 30 duty cycle at 225 amps 3 Minutes Welding 7 Minutes Resting 6 Minutes W...

Страница 15: ...802 967 800 797 C 1 Gun Securing Knob 2 Gun End 3 Gun Block Loosen knob Insert gun end through opening until it bottoms against gun block Tighten knob 4 Gun Trigger Plug 5 Gun Trigger Receptacle Inser...

Страница 16: ...drive roll The groove closest to the motor shaft is the proper groove to thread see Section 4 6 3 Retaining Pin To secure drive roll locate open slot and push drive roll completely over retaining pin...

Страница 17: ...inder 3 Valve 4 Flowmeter 5 Gas Fitting Optional Close valve on cylinder when fin ished welding See Sections 5 1 and 5 2 for weld parameters for Constant Current CC and Constant Voltage CV power sourc...

Страница 18: ...in Tools Needed 802 971 803 012 803 013 Installing 8 in 203 mm Wire Spool Installing 4 in 102 mm Wire Spool Use retaining ring with 8 in 203 mm spool only Use adapter with 8 in 203 mm spool only When...

Страница 19: ...lose and latch door Tools Needed 1 5 4 6 in 150 mm Pull and hold wire cut off end Tighten Remove gun nozzle and contact tip Open pressure assembly Push wire thru guides into gun continue to hold wire...

Страница 20: ...ding wire 6 Weld Cable Be sure cable is properly sized see welding power source owner s manual Determine polarity required by the welding wire DCEN or DCEP and connect cable to the correct output stud...

Страница 21: ...Select Switch Use Power Control switch to turn unit on and off Use Wire Speed control to adjust wire speed within range selected on power source Place CC CV switch in position that matches type of ou...

Страница 22: ...OM 1500 3 Page 18 5 2 Control Settings And Weld Parameters When Connected To Constant Current CC Power Sources...

Страница 23: ...eedrolls etc are selected to match the wire being used Set the voltage on the welding power source and the wire feed speed per the wire diameter gas thickness joint configurations and other parameters...

Страница 24: ...bles And Cords 6 Months Clean Drive Rolls Blow Out Or Vacuum Inside 6 2 Overload Protection 802 971 Y Turn Off wire feeder and weld ing power source Stop en gine on welding generator 1 Fuse F1 2 A 250...

Страница 25: ...eck and match wire size Head Tube Tools Needed 7 16 in Lay gun cable out straight before ins talling new liner Remove nozzle contact tip and adapter Unscrew and remove liner Blow out gun casing Cut of...

Страница 26: ...nto new head tube Hand tightenhead tube into cable connector Place head tube in vice and tighten until nuts are tight Remove from vice Reposition handle and install switch housing Secure with handle l...

Страница 27: ...roll liner and tip oversized tips may be needed for some wires Adjust drive roll pressure see Section 4 6 Readjust hub tension see Section 4 5 Clean or replace liner if dirty or plugged see Section 6...

Страница 28: ...tional gas solenoid only Connect weld cables so polarity DCEN or DCEP matches that required by welding wire Maintain correct distance between contact tip and work surface Difficult to weld thick mater...

Страница 29: ...OM 1500 3 Page 25 SECTION 7 ELECTRICAL DIAGRAM 203 039 B Figure 7 1 Circuit Diagram For Wire Feeder...

Страница 30: ...ON 8 PARTS LIST Hardware is common and not available unless listed 803 006 B 1 3 2 4 5 6 7 8 9 10 Figure 8 2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 F...

Страница 31: ...210530 Blank Snap in Nyl 1 250 Mtg Hole Black 1 27 605227 Nut 750 14 Knurled1 68dia 41h Included w Gas Valve Kit 194982 1 28 186621 Boot Generic Output Stud 1 29 180735 Washer Output Stud 1 30 181169...

Страница 32: ...1 8 197172 Screw Motor 3 9 204246 Knob Tee 1 10 203301 Lever Pressure 1 11 189915 Bearing Ball 1 12 M 202708 Motor Gear 1 13 202926 Roll Feed 045 030 035 1 14 203418 Spring Torsion 1 15 203567 Screw S...

Страница 33: ...OM 1500 3 Page 29 1 Ref 800 792 B 2 3 4 5 6 7 8 9 10 14 17 11 12 11 12 13 9 15 16 Figure 8 3 Gun Assembly...

Страница 34: ...ng Retaining 1 6 170 468 O ring 1 7 169 730 Washer Shock 1 8 169 731 Tube Head 1 9 169 738 Nut Locking Handle 2 10 194 523 Nut Jam 1 11 169 737 Handle 2 12 169 741 Strain Relief Cable 2 13 180 433 Cor...

Страница 35: ...ols Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles cont...

Страница 36: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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