Related Manuals for Miller Electric 625
Summary of Contents for Miller Electric 625
- Page 1 Visit our website at www.MillerWelds.com PowCon Arc Stud 625 Welding System OM-216 244J 2007−03 Process Stud (SW) Welding Description Arc Welding Power Source File: STUD WELDING (SW)
- Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2. -
Page 5: Section 1 − Safety Precautions - Read Before Using
DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. - Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. -
Page 8: Principal Safety Standards
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. - Page 10 LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique −... -
Page 12: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). -
Page 13: Section 3 − Introduction
1000 A at 36 VDC, 50−1000A 3-Phase 27% Duty Cycle *While idling **See Section 4-2 for additional information. 3-2. Duty Cycle And Overheating 0.750 0.625 0.500 0.375 0.250 0.125 0.000 .75 second Welding Overheating RMS Amps Input at Rated Load Output, 60 Hz 3-Phase at NEMA Max. -
Page 14: Section 4 − Installation - Power Source
SECTION 4 − INSTALLATION - POWER SOURCE 4-1. Selecting a Location Dimensions And Weight 73 lb (33.1 kg) Movement Location 18 in (460 mm) OM-216 244 Page 10 24 in (610 mm) 12-1/2 in (318 mm) Y Do not move or operate unit where it could tip. -
Page 15: Electrical Service Guide
4-2. Electrical Service Guide CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding pow- er source requires a CONTINUOUS supply of 60 Hz (+10%) power at +10% of rated input voltage. Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source. -
Page 16: Weld Output Receptacles And Selecting Cable Sizes
4-3. Weld Output Receptacles And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. -
Page 17: Connecting 3-Phase Input Power
4-4. Connecting 3-Phase Input Power Tools Needed: = GND/PE Earth Ground Y Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Y Disconnect and lockout/tagout in- put power before connecting input conductors from unit. Y Always connect green or green/ yellow conductor to supply grounding terminal first, and nev-... -
Page 18: Circuit Breaker
4-5. Circuit Breaker 4-6. 4 Pin Receptacle Information 4-7. Rack Mounting This unit is capable of being rack mounted (Contact your distributor). OM-216 244 Page 14 CONTROL Socket Output to control of gun solenoid; 90 volts dc. CONTROL Contact closure between 3 and 4 initiates weld cycle. -
Page 19: Section 5 − Installation - Stud Gun
SECTION 5 − INSTALLATION - STUD GUN 5-1. Chuck Installation Do not hammer or beat chuck into position. 5-2. Chuck Removal Y Disconnect gun from power source before installing or removing components. Chuck Chuck Adapter To install chuck, align chuck in front of chuck adapter. -
Page 20: Foot And Leg Setup
5-3. Foot and Leg Setup Make sure flat side of legs face outside ot gun body to ensure alignment with set screws. 5-4. Ferrule Grip / Spark Shield Removal and Installation OM-216 244 Page 16 Foot Installation Leg Screw Leg Washer Ferrule Grip Foot The foot is available in 3 different sizes... -
Page 21: Foot Alignment
5-5. Foot Alignment 5-6. Connecting Stud Gun and Work Clamp to Power Source Leg Screw Foot Ferrule Ferrule Grip Stud Alignment of the foot is very important, if the foot is not aligned properly it can create bad welds in the form of hang− ups. -
Page 22: Plunge Adjustment
A bit less for smaller studs, a bit more for larger studs. Stud Diameter Plunge 0 - .25 .094 .25 - .625 .125 .75 and up .188 Set Screw Plunge Depth To adjust plunge, loosen leg set screws on gun body. -
Page 23: Adjusting Stud Lift
5-8. Adjusting Stud Lift LIft Adjustment Table 1/16 in (1.6 mm) lift for studs up to 5/16 (7.9 mm) diameter 3/32 in (2.4 mm) lift for studs over 5/16 (7.9 mm) to 1/2 in (13 mm) diameter 1/8 in (3.2 mm) lift for studs over 1/2 (13 mm) diameter The lift controls the arc length and is a factor in controlling the heat of the welding process. -
Page 24: Section 6 − Operation - Power Source
SECTION 6 − OPERATION - POWER SOURCE 6-1. Front Panel Controls POWER OPTIONAL GAS OUT OPTIONAL WORK Power Switch Use switch to turn unit On/Off. Time Indicator Meter Amperage Indicator Meter OM-216 244 Page 20 Time (ms) Amperage COUNT RESET SELECT ADJUST Stud Count Indicator Light... - Page 25 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in)
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Page 26: Time/Amperage Control
6-2. Time/Amperage Control TIME (ms) SELECT Time/Amperage Select Button Depress button to select Time/Amperage control. Time Meter Amperage Meter OM-216 244 Page 22 AMPERAGE TIME/AMP ADJUSTMENT Time/Amp Adjustment Control Rotate knob clockwise to increase time/am- perage S Time - (5-1000 milliseconds) S Amperage - (50-1000 amps) Ref. - Page 27 Ready Amperage Adjustment - Push select button once. Returns to “Ready” dis- play in six seconds after adjustment. Time Adjustment - Push select but- ton twice. Returns to “Ready” display in six seconds after adjustment. Stud Count - Push select button three times.
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Page 28: Section 7 − Operation - Stud Gun
SECTION 7 − OPERATION - STUD GUN 7-1. Stud Gun Tool Functions 7-2. Stud Welding Procedures Position tool against work OM-216 244 Page 24 Ferrule Press tool towards work until ferrule is against work Y Disconnect gun from power source before installing or removing compo- nents. -
Page 29: Welding Sequence
7-3. Welding Sequence Chuck Stud Ferrule Gun is properely positioned and main gun spring is partially compressed. 7-4. Recommended Settings STANDARD TABLE Stud Size Current 1/4 Inch 300 Amps 5/16 Inch 410 Amps 3/8 Inch 520 Amps 1/2 Inch 750 Amps 5/8 Inch 980 Amps 3/4 Inch... -
Page 30: Section 8 − Maintenance & Troubleshooting
SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Replace Damaged Or Unreadable Labels 8-2. Blowing Out Inside Of Unit OM-216 244 Page 26 Y Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Cables 6 Months Blow Out Inside Maintain more often during severe conditions. - Page 31 Notes OM-216 244 Page 27...
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Page 32: Maintenance Procedures For Stud Gun
8-3. Maintenance Procedures for Stud Gun When is Maintenance Required? Maintenance requirements will vary with environment and usage. Dirty work areas or high volume stud welding will require more frequent main- tenance. There are three primary reasons for maintenance: Dirt - Dirt can enter the lifting mechanism and cause erratic lift and plunge operations. - Page 33 Chuck Adapter (2): Unscrew chuck adapter counter clockwise from cable clamp adapter. Important that chuck adapter is tight on cable clamp adapter to form a tight connection. An effective way of removing the adapter is to insert a round rod through two of the chuck eject holes.
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Page 34: Troubleshooting Help Aids
8-4. Troubleshooting Help Aids Front Panel Ready LED Status Error Indication Normal/None HELP 1 HELP 2 HELP 3 HELP 4 HELP 5 HELP 6 8-5. Troubleshooting - Power Source Trouble No weld output; unit completely inop- Place line disconnect switch in On position (see Section 4-2). erative. -
Page 35: Troubleshooting - Stud Gun
8-6. Troubleshooting - Stud Gun Trouble Hang up - Stud looks like it’s sitting on Check alignment of the foot. a pedestal with an hour glass shape a pedestal with an hour glass shape Service the gun to ensure lift/release actions are functioning properly. Too little plunge. - Page 36 Notes OM-216 244 Page 32...
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Page 37: Section 9 − Electrical Diagrams
SECTION 9 − ELECTRICAL DIAGRAMS 232 194-A Figure 9-1. Circuit Diagram For 460/575 Volt Models OM-216 244 Page 33... -
Page 38: Section 10 − Parts List For Power Source
SECTION 10 − PARTS LIST FOR POWER SOURCE Hardware is common and not available unless listed. Ref. 803 724-C Figure 10-1. Parts Assembly OM−216 244 Page 34... - Page 39 Item Dia. Part Mkgs....+224 966 ..... 178 551 .
- Page 40 Item Dia. Part Mkgs....207 725 ....216 229 .
- Page 41 7/16 in .4375 in 5/8 in 1/2 in .500 in 3/4 in 9/16 in .5625 in 7/8 in 5/8 in .625 in 15/16 in 3/4 in .750 in 1-1/8 in 7/8 in .875 in 1-5/16 in 1 in 1.000 in...
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Page 42: Section 11 − Parts List For Stud Gun
SECTION 11 − PARTS LIST FOR STUD GUN Hardware is common and not available unless listed. OM−216 244 Page 38 Figure 11-1. Parts Assembly 803 815-A... - Page 43 Item Dia. Part Mkgs....217 397 ....217 398 .
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Page 44: Section 12 − Options And Accessories
SECTION 12 − OPTIONS AND ACCESSORIES 12-1.Plunge Dampener The plunge dampener controls how fast the melted stud drops into the molten weld pool. There are three typical dampeners: S Soft (D rating) S Medium (E rating) S Hard (F rating) Hard dampeners are typically only used for large diameter, extremely heavy studs. - Page 45 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
- Page 46 Notes MATERIAL THICKNESS GAUGE...
- Page 47 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
- Page 48 File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...