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OM-216 244J
2007 −03
Process
Stud (SW) Welding
Description
Arc Welding Power Source
PowCon
™
Arc Stud 625
Welding System
Visit our website at
File: STUD WELDING (SW)
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Insta
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 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 Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessa
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Na
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 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. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier d’É
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet : ternet : www.global.ihs.com). www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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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 KVA KW 1000 A at 36 VDC, 50 −1000A 70 VDC 55 45 46 42 3-Phase (0.10*) (0.08*) (0.09*) (0.04*) 27% Duty Cycle *While idling **See Section 4-2 for additional information. 3-2. Duty Cycle And Overheating Exceeding duty cycle can damage unit and void warranty
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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) Special installation may be Movement required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Do not move or operate unit 1 Section 20. where it could tip. 1 Lifting Handles Use handles to lift unit. 2 Hand Cart 1 Use cart or similar device to move 2 unit. 3 Rating Label Use rating label to determine input power
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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. Actual input voltage should not exceed ± 10% of indicated required input
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4-3. Weld Output Receptacles And Selecting Cable Sizes 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. If interference still occurs, the user must take extra measures such as moving the welding machine, using sh
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4-4. Connecting 3-Phase Input Power Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Disconnect and lockout/tagout in- put power before connecting input 3 conductors from unit. Always connect green or green/ yellow conductor to supply grounding terminal first, and nev- = GND/PE Earth Ground er to a line terminal. 4 The Auto-Link circuitry in this unit au- tomatically adapts the power source to the primary voltage being applied.
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4-5. Circuit Breaker 1 Circuit Breaker CB1 CB1 protects 60 volts ac portion of Remote 4 pin receptacle from overload. Press button to reset breaker. 1 803 619-B 4-6. 4 Pin Receptacle Information CONTROL Socket Socket Information 4 4 3 1 Output to control of gun solenoid; 90 volts dc. GUN 2 CONTROL 2 3 Contact closure between 3 and 4 initiates weld cycle. 1 4 4-7. Rack Mounting This unit is capable of being rack mounted (Contact your distributor). OM-216 244 Page 14
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SECTION 5 − INSTALLATION - STUD GUN 5-1. Chuck Installation Disconnect gun from power source before installing or removing components. 1 Chuck 2 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. Not necessary to pound chuck into position. on the end of the chuck. This will da- mage the chuck. There is a unique chuck for ev- ery diameter of stud. Rectan- gular and other special shape studs m
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5-3. Foot and Leg Setup Foot Installation 1 Leg Screw 2 Leg Washer 3 Ferrule Grip 4 Foot 5 3 5 Leg 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. Foot Size Stud Range Part # 219670 Small Up to 1/2 in. Medium 5/8 to 3/4 in. 219671 4 1 2 The foot is installed on the ends of the legs. Unscrew the flat head screws from the ends of the legs.
