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Miller Electric 625 - page 1
PowCon Arc Stud 625 W elding System R Pro cess Descrip ti on Arc W elding Power Source OM -216 244J 2007 − 03 Stud (SW) W elding ™ File: STUD WELDING (SW) V isit our website at www.MillerWelds.com ...
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Miller Electric 625 - page 2
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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille ...
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Miller Electric 625 - page 3
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . ...
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Miller Electric 625 - page 4
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Miller Electric 625 - page 5
OM-216 244 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety me ...
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Miller Electric 625 - page 6
OM-216 244 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watchin ...
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Miller Electric 625 - page 7
OM-216 244 Page 3 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. ...
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Miller Electric 625 - page 8
OM-216 244 Page 4 1-5. Principal Safety Standards Safety i n W elding, 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 W elding and Cut- ting of Containers and Piping , American Welding Society Standard A W ...
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Miller Electric 625 - page 9
OM-216 244 Pag e 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les utili sés Sy mbole graphique d’av ertis s ement ! At tention ! Cette pro - cédur e c omporte des r is ques poss ...
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Miller Electric 625 - page 10
OM-216 244 Page 6 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. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe ...
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Miller Electric 625 - page 11
OM-216 244 Pag e 7 2-3 . Da ngers supplémenta ires en r e la tion avec l’insta lla tion, le f onc tionnem ent et l a maintenanc e 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 surcharg ...
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Miller Electric 625 - page 12
OM-216 244 Page 8 2-5. Princi pales norm es de sécur ité Safety in W elding, 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 fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W el ...
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Miller Electric 625 - page 13
OM-216 244 Page 9 SECTION 3 − INTRODUCTION 3-1. Specifications Amperage Range in Max. Open- Circuit RMS Amps Input at Rated Load Output, 60 Hz 3-Phase at NEMA Load V oltages and Class I Rating Rated Welding Output Range in CC Mode Circuit V oltage 480 V 575 V KV A KW 1000 A at 36 VDC, 3-Phase 27% Duty Cycle 50 − 1000A 70 VDC 55 (0.10*) 45 (0.08 ...
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Miller Electric 625 - page 14
OM-216 244 Page 10 SECTION 4 − INSTALLATION - POWER SOURCE 4-1. Selecting a Location loc_2 3/96 - Ref. ST-151 556 / 803 618-B Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 51 1 or CEC Section 20. 1 Lifting Handles Use handles to lift unit. 2 Hand Cart Use cart or similar device to move u ...
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Miller Electric 625 - page 15
OM-216 244 Page 1 1 4-2. Electrical Service Guide Y 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 de ...
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Miller Electric 625 - page 16
OM-216 244 Page 12 4-3. Weld Output Receptacles And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. T o 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 weldi ...
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Miller Electric 625 - page 17
OM-216 244 Page 13 4-4. Connecting 3-Phase Input Power 2/04 - Ref. 802 136-A Y Installation must meet all National an d 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 groundin ...
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Miller Electric 625 - page 18
OM-216 244 Page 14 803 619-B 1 Circuit Breaker CB1 CB1 protects 60 volts ac portion of Remote 4 pin receptacle from overload. Press button to reset breaker . 1 4-5. Circuit Breaker 4-6. 4 Pin Receptacle Information 4 CONTROL Socket Socket Information 3 4 GUN CONTROL 1 2 Output to control of gun solenoid; 90 volts dc. 2 1 3 4 Contact closure between ...
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Miller Electric 625 - page 19
OM-216 244 Page 15 SECTION 5 − INSTALLATION - STUD GUN Y 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 adapter. Not necessary to pound o n the end of the chuck. This will da- mage the chuc ...
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Miller Electric 625 - page 20
OM-216 244 Page 16 Foot Installation 1 Leg Screw 2 Leg W asher 3 Ferrule Grip 4 Foot 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. The foot is installed on the ends of the legs. Unsc ...
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Miller Electric 625 - page 21
OM-216 244 Page 17 1 Leg Screw 2 Foot 3 Ferrule 4 Ferrule Grip 5 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. The stud should sit perfectly in the center of the ferrule. If not, loosen the f l ...
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Miller Electric 625 - page 22
OM-216 244 Page 18 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. Too little plunge and there may be in- complete f illet formation. There should be approximately 1/8 of an in ...
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Miller Electric 625 - page 23
OM-216 244 Page 19 Th e 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 Fo r safety from accidental activation, always disconnect the weld cable from the power source before making any stud gun adjustments or per- forming any service on the ...
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Miller Electric 625 - page 24
OM-216 244 Page 20 SECTION 6 − OPERATION - POWER SOURCE Amperage Time (ms) POWER SELECT ADJUST OUTPUT ON READY WORK STUD GUN CONTROL 6-1. Front Panel Controls 232 187-A 1 1 Power Switch Use switch to turn unit On/Off. 2 Time Indicator Meter 3 Amperage Indicator Meter 4 Stud Count Indicator Light 5 READY to Weld Indicator Light 6 OUTPUT ON Indicat ...
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Miller Electric 625 - page 25
OM-216 244 Page 21 Notes 16 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) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MA TERIAL THICKNESS REFERENCE CHART ...
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Miller Electric 625 - page 26
OM-216 244 Page 22 6-2. Time/Amperage Control 1 T ime/Amperage Select Button Depress button to select T ime/Amperage control. 2 Time Meter 3 Amperage Meter 4 Time/Amp Adjustment Control Rotate knob clockwise to increase time/am- perage S Time - (5-1000 milliseconds) S Amperage - (50-1000 amps) Rotate knob counterclockwise to decrease time/amperage. ...
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Miller Electric 625 - page 27
OM-216 244 Page 23 STUD COUNT READY OUTPUT ON ADJUST SELECT TIME AMPERAGE STUD COUNT READY OUTPUT ON ADJUST SELECT TIME AMPERAGE STUD COUNT READY OUTPUT ON ADJUST SELECT TIME AMPERAGE STUD COUNT READY OUTPUT ON ADJUST SELECT TIME AMPERAGE Ready Amperage Adjustment - Push select button once. Returns to “Ready” dis- play in six seconds after adju ...
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Miller Electric 625 - page 28
OM-216 244 Page 24 SECTION 7 − OPERATION - STUD GUN 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 • Holds the stud • Strikes the arc • Establishes the arc length (lift dis ...
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Miller Electric 625 - page 29
OM-216 244 Page 25 7-3. W elding Sequence Gun is properely positioned and main gun spring is partially compressed. T rigger is pressed and the stud lifts off the work. An arc is created and melts the stud and parent material. After arcing is complete, the main spring plunges the stud into the molten pool of metal. Gun is withdrawn from the welded s ...
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Miller Electric 625 - page 30
OM-216 244 Page 26 SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace Damaged Or Unreadable Labels Replace Cracked Stud Gun Body Repair Or Replace Cracked Cables Repair Or Replace Cracked Cables And Cords Clean And Tighten W ...
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Miller Electric 625 - page 31
OM-216 244 Page 27 Notes ...
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Miller Electric 625 - page 32
OM-216 244 Page 28 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 err ...
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Miller Electric 625 - page 33
OM-216 244 Page 29 4 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. Replace chuck adapter if inside surface or threads ...
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Miller Electric 625 - page 34
OM-216 244 Page 30 8-4. T roubleshooting Help Aids 1 Stud Count LED 2 Ready LED 3 Output LED 803 618-B 2 3 1 Front Panel Error Indication Ready LED Status Possible Symptom Remedy Normal/None On No problem N/A HELP 1 Of f Malfunction in the primary power cir- cuit. Contact a factory authorized service agent. HELP 2 Of f Malfunction in the thermal pr ...
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Miller Electric 625 - page 35
OM-216 244 Page 31 8-6. T roubleshooting - Stud Gun T rouble Remedy Hang up - Stud looks like it’s sitting on a pedestal with an hour glass shape Check alignment of the foot. a pe d es t a l w ith an h our g l ass s h ape Service the gun to ensure lift/release actions are functioning properly . Undercutting or lack of fillet T oo little plunge. I ...
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Miller Electric 625 - page 36
OM-216 244 Page 32 Notes ...
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Miller Electric 625 - page 37
OM-216 244 Page 33 SECTION 9 − ELECTRICAL DIAGRAMS 232 194-A Figure 9-1. Circuit Diagram For 460/575 V olt Models ...
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Miller Electric 625 - page 38
OM − 216 244 Page 34 SECTION 10 − P ARTS LIST FOR POWER SOURCE Ref. 803 724-C . Hardware is common and not available unless listed. Figure 10-1. Parts Assembly ...
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Miller Electric 625 - page 39
OM-216 244 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Parts Assembly Quantity 1 +224 966 Wrapper 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 551 Insulator , Side Lh 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
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Miller Electric 625 - page 40
OM − 216 244 Page 36 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Parts Assembly (Continued) Quantity 44 207 725 Heat Sink, Power Module 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 T1 216 229 T ransformer , HF (480/575) 1 . . . . . . . . . . . . . . . . . . . ...
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Miller Electric 625 - page 41
OM-216 244 Page 37 Notes SOCKET/WRENCH SELECTION T ABLE (U.S. ST ANDARD) SOCKET/WRENCH SELECTION T ABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or W rench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.S. Decimal Equivalent Bolt Nut 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm 5/16 in .3125 in ...
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Miller Electric 625 - page 42
OM − 216 244 Page 38 SECTION 1 1 − P ARTS LIST FOR STUD GUN 803 815-A . Hardware is common and not available unless listed. 1 2 3 4 5 6 8 7 12 13 14 11 10 23 9 24 4 25 27 26 29 30 28 27 22 23 33 35 36 37 32 31 34 15 16 17 18 19 20 21 38 40 41 42 39 Figure 1 1-1. Parts Assembly ...
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Miller Electric 625 - page 43
OM-216 244 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Parts Assembly Quantity 1 217 397 Front Cover Jam Nut 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 217 398 Chuck Adapter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
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Miller Electric 625 - page 44
OM − 216 244 Page 40 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. Foot In ...
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Miller Electric 625 - page 45
Notes W or k l i k e a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this m anual. ...
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Miller Electric 625 - page 46
Notes 229895 MA TERIAL THICKNESS GAUGE ...
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Miller Electric 625 - page 47
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y ou r distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The exp ...
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Miller Electric 625 - page 48
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Comp any 1635 West Spenc er S treet Applet on, W I 54914 USA International He adquarter s − USA USA P hone: 920-735-4505 Aut o-At tended USA & C anada F AX : 920-735-4134 Int ernat ional FAX: 920-735-4125 European Headqua rters − U ...
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