Related Manuals for Miller Powcon Arc Stud 625
Summary of Contents for Miller Powcon Arc Stud 625
- Page 1 OM-216 244E March 2005 Process Stud (SW) Welding Description Arc Welding Power Source PowCon Arc Stud 625 Welding System 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.
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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 _8/03 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 visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.
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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. 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
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- (phone: 305-443-9353, website: www.aws.org). ternational.org). -
Page 9: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- lance. - Page 10 LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et D Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation.
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Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. D Ne pas placer l’appareil sur une surface inflam- D Se tenir à l’écart des organes mobiles comme les mable, ni au−dessus ou à... -
Page 12: Principales Normes De Sécurité
2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- (téléphone : (305) 443−9353, site Web : www.aws.org). -
Page 13: Section 3 − Introduction
SECTION 3 − INTRODUCTION 3-1. Specifications RMS Amps Input at Rated Load Output, 60 Hz 3-Phase at NEMA Amperage Max. Open- Load Voltages and Class I Rating Range in Range in Circuit Circuit 480 V 575 V Rated Welding Output CC Mode Voltage 1000 A at 36 VDC,... -
Page 14: Section 4 − Installation - Power Source
SECTION 4 − INSTALLATION - POWER SOURCE 4-1. Selecting a Location 24 in (610 mm) Dimensions And Weight 73 lb (33.1 kg) 17 in (432 mm) 12-1/2 in (318 mm) Y Special installation may be Movement required where gasoline or volatile liquids are present −... -
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. 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 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- = GND/PE Earth Ground... -
Page 18: Circuit Breaker
4-5. Circuit Breaker Circuit Breaker CB1 CB1 protects 60 volts ac portion of Remote 4 pin receptacle from overload. Press button to reset breaker. 803 619-A 4-6. 4 Pin Receptacle Information CONTROL Socket Socket Information 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 Y Disconnect gun from power source before installing or removing components. Chuck Chuck Adapter To install chuck, align chuck in front of chuck adapter. Tap firmly on the end of chuck to seat chuck into Do not hammer or beat adapter. -
Page 20: Foot And Leg Setup
5-3. Foot and Leg Setup Foot Installation Leg Screw Leg Washer Ferrule Grip Foot The foot is available in 3 different sizes (small, medium, and large) and 2 different configurations (closed and split). Typically, a split foot is only used when welding headed anchors and sheer connectors. -
Page 21: Foot Alignment
5-5. Foot Alignment 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. Place a stud into the chuck and a ferrule into the ferrule grip. -
Page 22: Plunge Adjustment
5-7. Plunge Adjustment Plunge Settings When Using Ferrules Plunge controls the amount of stud that is melted during the arc time. Too much plunge and the f illet will overf ill the ferrule or create excessive splatter when using a spark shield. -
Page 23: Adjusting Stud Lift
5-8. Adjusting Stud Lift The lift controls the arc length and is a factor in controlling the heat of the welding process. Lift should be set at 3/32 or .094 in (2.5 mm). Measuring LIft Y For safety from accidental activation, LIft Adjustment Table always disconnect the weld cable from the power source before making... -
Page 24: Section 6 − Operation - Power Source
SECTION 6 − OPERATION - POWER SOURCE 6-1. Front Panel Controls Time (ms) Amperage READY OUTPUT ON POWER SELECT ADJUST CONTROL WORK 216 221-A Time/Amperage Select Button (LED indicates when meter is active for READY to Weld Indicator Light adjusting) Power Switch OUTPUT ON Indicator LIght Amperage Indicator Meter... -
Page 25: Time/Amperage Control
6-2. Time/Amperage Control Time/Amperage Select Button TIME (ms) AMPERAGE Depress button to select Time/Am- perage control. Time Meter Amperage Meter Time/Amp Adjustment Control Rotate knob clockwise to increase time/amperage S Time - (50-999 milliseconds) S Amperage - (50-999 amps) Increase increments by units of 10. Decrease increments by units of 1. -
Page 26: Section 7 − Operation - Stud Gun
SECTION 7 − OPERATION - STUD GUN 7-1. Stud Gun Tool Functions Y Disconnect gun from power source before installing or removing compo- nents. The stud gun automates the stud welding process. Several key functions are: • Holds the ferrule, spark shield or gas de- livery system •... -
Page 27: Welding Sequence
7-3. Welding Sequence Chuck Stud Ferrule Gun is properely Trigger is pressed and the After arcing is complete, Gun is withdrawn positioned and main stud lifts off the work. An the main spring plunges from the welded stud. gun spring is partially arc is created and melts the the stud into the molten The ferrule is broken... -
Page 28: Section 8 − Maintenance & Troubleshooting
SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Y Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Repair Or Replace Replace Cracked Replace Damaged Or Stud Gun Body Cracked Unreadable Cables Labels Repair Or Replace Cracked Cables And Cords Clean... - Page 29 Notes OM-216 244 Page 25...
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Page 30: 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 31 Chuck Adapter (2): Unscrew chuck adapter counter clockwise from 13 Weld Cable (40): The weld cable can lift out of the gun body. Be cable clamp adapter. Important that chuck adapter is tight on cable careful unthreading the internal weld cable (9) from inside the body. clamp adapter to form a tight connection.
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Page 32: Troubleshooting Help Aids
8-4. Troubleshooting Help Aids Ready LED Output LED 803 618-A Front Panel Output LED Status Possible Symptom Remedy Error Indication Normal/None No problem HLP 1 Malfunction in the primary power cir- Contact a factory authorized service cuit. agent. HLP 2 Malfunction in the thermal protections Contact a factory authorized service circuitry. -
Page 33: Troubleshooting - Stud Gun
8-6. Troubleshooting - Stud Gun Trouble Remedy 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 34 Notes OM-216 244 Page 30...
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Page 35: Section 9 − Electrical Diagrams
SECTION 9 − ELECTRICAL DIAGRAMS 216 211-E Figure 9-1. Circuit Diagram For 460/575 Volt Models OM-216 244 Page 31... -
Page 36: 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-A Figure 10-1. Parts Assembly OM−216 244 Page 32... - Page 37 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Parts Assembly ....+224 018 Wrapper ............
- Page 38 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Parts Assembly (Continued) ....207 725 Heat Sink, Power Module ........
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Page 39: Section 11 − Parts List For Stud Gun
SECTION 11 − PARTS LIST FOR STUD GUN Hardware is common and not available unless listed. 803 815-A Figure 11-1. Parts Assembly OM-216 244 Page 35... - Page 40 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Parts Assembly ....217 397 Front Cover Jam Nut ..........
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Page 41: 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 42 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
- Page 43 Effective January 1, 2005 (Equipment with a serial number preface of “LF” 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 Induction Heating Coils and Blankets below, Miller Electric Mfg.
- Page 44 Contact the Delivering Carrier to: 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. © PRINTED IN USA 2005 Miller Electric Mfg. Co. 1/05...