Miller Electric 575Volt Owner's Manual

PowCon Arc Stud 625 Welding SystemRProcessDescriptionArc Welding Power SourceOM-216 244J2007−03Stud (SW) Welding™File: STUD WELDING (SW)Visit our webs

OM-216 244 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptib

OM-216 244 Page 72-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanceRisque D’INCENDIE OU D’EXPLO-SION.D

OM-216 244 Page 82-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Docume

OM-216 244 Page 9SECTION 3 − INTRODUCTION 3-1. SpecificationsAmperageRange inMax. Open-CircuitRMS Amps Input at Rated LoadOutput, 60 Hz 3-Phase at NEM

OM-216 244 Page 10SECTION 4 − INSTALLATION - POWER SOURCE 4-1. Selecting a Locationloc_2 3/96 - Ref. ST-151 556 / 803 618-BY Special installation may

OM-216 244 Page 11 4-2. Electrical Service GuideY CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding pow-er source requ

OM-216 244 Page 12 4-3. Weld Output Receptacles And Selecting Cable SizesY ARC WELDING can cause Electromagnetic Interference.To reduce possible inter

OM-216 244 Page 13 4-4. Connecting 3-Phase Input Power2/04 - Ref. 802 136-AY Installation must meet all Nationaland Local Codes − have only quali-fied

OM-216 244 Page 14803 619-B1 Circuit Breaker CB1CB1 protects 60 volts ac portionof Remote 4 pin receptacle fromoverload.Press button to reset breaker.

OM-216 244 Page 15SECTION 5 − INSTALLATION - STUD GUNY Disconnect gun from powersource before installing orremoving components.1 Chuck2 Chuck AdapterT

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-216 244 Page 16Foot Installation1 Leg Screw2 Leg Washer3 Ferrule Grip4 Foot5 LegThe foot is available in 3 different sizes(small, medium, and large

OM-216 244 Page 171 Leg Screw2 Foot3 Ferrule4 Ferrule Grip5 Stud. Alignment of the foot is very important,if the foot is not aligned properly it cancr

OM-216 244 Page 18Plunge Settings When Using FerrulesPlunge controls the amount of stud that ismelted during the arc time. Too much plungeand the fill

OM-216 244 Page 19The lift controls the arc length and is a factorin controlling the heat of the welding process.Lift should be set at 3/32 or .094 in

OM-216 244 Page 20SECTION 6 − OPERATION - POWER SOURCEAmperageTime (ms)POWERSELECTADJUSTOUTPUT ONREADYWORKSTUD GUNCONTROL 6-1. Front Panel Controls232

OM-216 244 Page 21Notes16 Gauge (.063 in)22 Gauge (.031 in)24 Gauge (.025 in)20 Gauge (.037 in)18 Gauge (.050 in)14 Gauge (.078 in)1/8 in (.125 in)3/1

OM-216 244 Page 22 6-2. Time/Amperage Control1 Time/Amperage Select ButtonDepress button to select Time/Amperagecontrol.2 Time Meter3 Amperage Meter4

OM-216 244 Page 23STUD COUNTREADYOUTPUT ONADJUSTSELECTTIME AMPERAGESTUD COUNTREADYOUTPUT ONADJUSTSELECTTIME AMPERAGESTUD COUNTREADYOUTPUT ONADJUSTSELE

OM-216 244 Page 24SECTION 7 − OPERATION - STUD GUNY Disconnect gun from power sourcebefore installing or removing compo-nents.The stud gun automates t

OM-216 244 Page 25 7-3. Welding SequenceGun is properelypositioned and maingun spring is partiallycompressed.Trigger is pressed and thestud lifts off

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbo

OM-216 244 Page 26SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine MaintenanceY Disconnect power before maintaining.. Maintain more oftendur

OM-216 244 Page 27Notes

OM-216 244 Page 28 8-3. Maintenance Procedures for Stud GunWhen is Maintenance Required?Maintenance requirements will vary with environment and usage.

OM-216 244 Page 294 Chuck Adapter (2): Unscrew chuck adapter counter clockwise fromcable clamp adapter. Important that chuck adapter is tight on cable

OM-216 244 Page 30 8-4. Troubleshooting Help Aids1 Stud Count LED2 Ready LED3 Output LED803 618-B231Front Panel Error IndicationReady LED Status Possi

OM-216 244 Page 31 8-6. Troubleshooting - Stud GunTrouble RemedyHang up - Stud looks like it’s sitting ona pedestal with an hour glass shapeCheck alig

OM-216 244 Page 32Notes

OM-216 244 Page 33SECTION 9 − ELECTRICAL DIAGRAMS232 194-AFigure 9-1. Circuit Diagram For 460/575 Volt Models

OM−216 244 Page 34SECTION 10 − PARTS LIST FOR POWER SOURCERef. 803 724-C. Hardware is common andnot available unless listed.Figure 10-1. Parts Assembl

OM-216 244 Page 35DescriptionPartNo.Dia.Mkgs.ItemNo. Figure 10-1. Parts AssemblyQuantity1 +224 966 Wrapper 1. . . . . . . . . . . . . . . .

OM−216 244 Page 36DescriptionPartNo.Dia.Mkgs.ItemNo. Figure 10-1. Parts Assembly (Continued)Quantity44 207 725 Heat Sink, Power Module 1. . .

OM-216 244 Page 37NotesSOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) SOCKET/WRENCH SELECTION TABLE(METRIC)Specifications Socket or Wrench Size Specif

OM−216 244 Page 38SECTION 11 − PARTS LIST FOR STUD GUN803 815-A. Hardware is common andnot available unless listed.12345687121314111023924425272629302

OM-216 244 Page 39DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 11-1. Parts AssemblyQuantity1 217 397 Front Cover Jam Nut 2. . . . . . . . . . . . . . . .

OM−216 244 Page 40SECTION 12 − OPTIONS AND ACCESSORIES12-1.Plunge DampenerThe plunge dampener controls how fast the melted stud drops into the molten

NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

Notes229895MATERIAL THICKNESS GAUGE

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

OM-216 244 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05Y Warning: Protect yourself and others from injury — read and follow these

OM-216 244 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sp

OM-216 244 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over,

OM-216 244 Page 41-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Document

OM-216 244 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONsom _3/05Y Avertissement : se protéger et protéger les autres contre le ris