Related Manuals for Miller 3045 FC
Summary of Contents for Miller 3045 FC
- Page 1 OM-1500-3 203 580A August 2002 Processes Flux Cored (FCAW) Welding MIG (GMAW) Welding Description Wire Feeder 3045 FC And M-25 Gun Visit our website at www.MillerWelds.com...
- Page 2 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.
-
Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1. -
Page 5: Section 1 - Safety Precautions - Read Before Using
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. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message. - Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
-
Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables. -
Page 8: Principal Safety Standards
1-4. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 800–463–6727 or in Toronto 416–747–4044, website: www.csa–in- from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 ternational.org). (phone: 305-443-9353, website: www.aws.org). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 Recommended Safe Practices for the Preparation for Welding and Cut- West 42nd Street, New York, NY 10036–8002 (phone: 212–642–4900,... -
Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité... - Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.
-
Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité... -
Page 12: Principales Normes De Sécurité
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. -
Page 13: Section 2 - Definitions
SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Output Input Amperes Volts Increase Wire Feed Percent Read Instructions Constant Current Constant Voltage Circuit Breaker Hertz (CC) (CV) SECTION 3 – INSTALLATION 3-1. Wire Feeder Specifications Type of Control Type of Weld Welding Power Wire Feed Wire Type And... -
Page 14: Duty Cycle And Overheating
3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit or gun and void warranty. 60% duty cycle at 175 amps 30% duty cycle at 225 amps 6 Minutes Welding 4 Minutes Resting... -
Page 15: Section 4 - Installation
SECTION 4 – INSTALLATION 4-1. Connecting Welding Gun Gun Securing Knob Gun End Gun Block Loosen knob. Insert gun end through opening until it bottoms against gun block. Tighten knob. Gun Trigger Plug Gun Trigger Receptacle Insert gun trigger plug into recep- tacle. -
Page 16: Installing Wire Guides And Drive Rolls
4-2. Installing Wire Guides And Drive Rolls Installing Wire Guide And Drive Rolls: Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place. -
Page 17: Connecting Shielding Gas On Units With Optional Gas Solenoid
4-4. Connecting Shielding Gas On Units With Optional Gas Solenoid Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) Shielding Gas Cylinder Valve Flowmeter Gas Fitting (Optional) Close valve on cylinder when fin- ished welding. See Sections 5-1 and 5-2 for weld parameters for Constant Rear View Current (CC) and Constant... -
Page 18: Installing Wire Spool And Adjusting Hub Tension
4-5. Installing Wire Spool And Adjusting Hub Tension Installing 4 in (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Installing 8 in (203 mm) Wire Spool Locating pin. Use adapter with 8 in. (203 mm) spool only. -
Page 19: Threading Welding Wire
4-6. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Tools Needed: Pressure Adjustment Knob Turn knob to increase or decrease drive roll pressure. Drive Roll Gun Conduit Cable Lay gun cable out straight. Thread wire as shown below. See Sections 5-1 and 5-2 for weld parameters for Constant Current (CC) and Constant... -
Page 20: Typical Set-Up
4-7. Typical Set-Up Use quick connector A 10 ft (3 m) gun (not supplied) to make (maximum) is weld connections more recommended for convenient. use with this wire feeder. Ref. 802 975 Work Cable And Clamp Power Source See Sections 5-2 and 5-3 for weld pa- Connect to either an engine-driven or static Be sure cable is properly sized (see welding rameters for Constant Current (CC) and... -
Page 21: Section 5 - Operation
SECTION 5 – OPERATION 5-1. Controls Power Control Switch Wire Speed Control CC/CV 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 output from power source. -
Page 22: Control Settings And Weld Parameters When Connected To Constant Current (Cc) Power Sources
5-2. Control Settings And Weld Parameters When Connected To Constant Current (CC) Power Sources OM-1500-3 Page 18... -
Page 23: Typical Configurations When Connected To Constant Voltage (Cv) Power Sources
5-3. Typical Configurations When Connected To Constant Voltage (CV) Power Sources Make sure the contact tips, liners, feedrolls, 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 required. -
Page 24: Section 6 - Maintenance & Troubleshooting
SECTION 6 – MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power Service unit more often if before performing used in severe conditions. maintenance. 3 Months Replace Damaged Or Replace Damaged Unreadable Gas Hose Labels Repair Or Replace Cracked Cables And Cords 6 Months Clean... -
Page 25: Removing Gun Nozzle, Contact Tip, Adapter, Liner, And Cleaning Gun Casing
6-3. Removing Gun Nozzle, Contact Tip, Adapter, Liner, And Cleaning Gun Casing Y Turn off welding power source/wire feeder. Nozzle Contact Tip Head Adapter Tube Wire size stamped on tip – check and match wire size. Remove nozzle, contact tip, and adapter. -
Page 26: Replacing Gun Switch And/Or Head Tube
6-4. Replacing Gun Switch And/Or Head Tube Y Turn Off welding power source /wire feeder and disconnect gun. Remove handle locking nut. Slide handle. Remove switch housing. Install new switch and connect leads (polarity is not important). Reas- semble in reverse order. If replacing head tube, continue to end of figure. -
Page 27: Troubleshooting
6-5. Troubleshooting Trouble Remedy Wire does not feed; open-circuit voltage Check fuse F1, and replace if open (see Section 6-2). available. Unit overheated. Turn Power switch Off and allow unit to cool. Check sensing lead connection. Check gun trigger plug connection. Check contact tip. - Page 28 Trouble Remedy Weld is porous or produces excessive Remove weld spatter buildup in nozzle. spatter. Make sure inner head tube is tight in cable connector. Check shielding gas flow/supply (units with optional 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.
-
Page 29: Section 7 - Electrical Diagram
SECTION 7 – ELECTRICAL DIAGRAM 203 039-B Figure 7-1. Circuit Diagram For Wire Feeder OM-1500-3 Page 25... -
Page 30: Section 8 - Parts List
SECTION 8 – PARTS LIST Hardware is common and not available unless listed. 803 006-B Figure 8-1. Main Assembly OM-1500-3 Page 26... - Page 31 Item Dia. Part Description Mkgs. Quantity Figure 8-1. Complete Assembly ....203041 Cable, Sensing 15ft ..........
- Page 32 Ref. 203 565 Figure 8-2. Wire Drive Feed Assembly Item Dia. Part Mkgs. Description Quantity Figure 8-2. Wire Feed Drive Assembly (Figure 8-1 Item 10) ....208401 Drive Assy, Wire (consisting of) .
- Page 33 Ref. 800 792-B Figure 8-3. Gun Assembly OM-1500-3 Page 29...
- Page 34 Item Part Description Figure 8-3. Gun Assembly ... 169 594 M-25 Gun, 10 Ft. .030 - .035 Wire (consisting of) ......
- Page 35 Effective January 1, 2002 (Equipment with a serial number preface of “LC” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...
-
Page 36: Options And Accessories
Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate 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...