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Miller Electric PowCon Arc Stud 625, Owner'S Manual

The Miller Electric PowCon Arc Stud 625 is a powerful welding machine designed for precision and durability. Ensure optimal performance by downloading the free Owner's Manual from manualshive.com. This comprehensive manual provides detailed instructions on how to operate and maintain your machine for long-lasting use.

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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

. . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

175 256

Insulator, Side Rh

1

. . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

2

195 585

Handle

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

3

138 442

Label, Caution Falling Equipment

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

4

HD1

216 178

Transducer, Current 600A

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG9

130 204

Connector & Pins

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

5

216 554

Bus Bar, Current Sensor

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

6

203 341

Bus Bar, Output Rectifier

4

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7

196 355

Insulator, Screw

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8

D1,2,3,4

201 531

Kit, Diode Power Module 

4

. . . 

. . . 

. . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

9

170 647

Bushing, Snap-In Nyl 1.312 Id X 1.500 Mtg Hole

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . 

10

R1, C5,6

. . . 

. . . 

R2, C10,11

232 296

Resistor/Capacitor Assy

2

. . . . . . . . 

. . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

11

RT1,2

173 632

Thermistor, Ntc 30K Ohm

2

. . . 

. . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

12

185 835

Label, Warning Exploding Parts

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

13

+216 227

Windtunnel, Lh

1

. . . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14

182 445

Nut, 1.000npt

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

15

CB1

161 078

Circuit Breaker, Man Reset 1p 7a 250VAC

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . 

16

+232 189

Panel, Rear

1

. . . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17

215 980

Bushing, Strain Relief .709/.984 Id X1.375 Mtg Hole

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . 

219 487

Cable, Power 12ft 8Ga 4C

1

. . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

18

232 190

Hole Layout, Plate Ident

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

19

196 002

Label, Warning Electric Shock Power Cord

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . 

20

217 392

Label, Caution Incorrect Voltage Will Damage Unit

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . 

21

216 355

Resistor, W/Terminals

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22

212 526

Capacitor, Elctlt 1500 Uf 100 VDC Can 1.40 Dia

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . 

23

CR1

110 386

Relay, Encl 24VAC Dpdt 5a/120VAC 8pin Flange Mtg

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . 

24

087 111

Clamp, Capacitor 1.375 Dia Clip

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

25

192 853

Bracket, Mtg Contactor/Capacitor/Pc Board

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . 

26

PC1

215 697

Circuit Card, Control (480/575)

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG2

131 056

Connector & Sockets (RC2)

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG3

130 203

Connector & Sockets (RC3)

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG4

115 094

Connector & Sockets (RC4)

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG5

115 091

Connector & Sockets (RC5)

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG7

115 093

Connector & Sockets (RC7)

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

27

RC10

166 679

Connector & Sockets

1

. . . 

. . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

28

T2

216 236

Transformer, Control (480/575)

1

. . . 

. . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

29

+216 232

Windtunnel, Rh

1

. . . 

. . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

30

153 403

Bushing, Snap-in Nyl .750 Id X 1.000mtg

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

31

025 248

Stand-Off, Insul .250

−

20 X 1.250 Lg X .437 Thd

4

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . 

32

177 547

Bushing, Snap-in Nyl 1.125mtg

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

33

185 214

Bus Bar, Interconnecting

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

34

CT1

175 199

Transformer, Current

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

35

C1,C2

188 446

Capacitor, Polyp Film .5 Uf 900 VAC 10%

2

. . . 

. . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . 

36

C3,4

193 738

Capacitor, Elctlt 1800uf 500Vdv (480/575)

2

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . 

37

PC2

+208 783

Circuit Card, Interconnect (480/575)

1

. . . 

. . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG13

131 204

Connector & Sockets (RC13)

1

. . . . . . . . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

PLG14,21

115 093

Connector & Sockets (RC14) (RC21)

2

. . . . . . . . 

. . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

126 026

Label, Warning Electric Shock

1

. . . . . . . . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

38

224 854

Bracket, Di/Dt

1

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

39

175 482

Coil, Di/Dt

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

40

109 056

Core

2

. . . 

. . . . . . . . . . . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

41

SR1

179 629

Kit Diode, Power Module

1

. . . 

. . . . . 

. . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

42

PM1,2

184 258

Kit, Transistor IGBT Module

1

. . . 

. . . . 

. . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

43

L1

173 563

Inductor, Input

1

. . . 

. . . . . . 

. . . . . . 

. . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required  when ordering parts from your local distributor.

Summary of Contents for PowCon Arc Stud 625

Page 1: ...PowCon Arc Stud 625 Welding System R Process Description Arc Welding Power Source OM 216 244J 2007 03 Stud SW Welding File STUD WELDING SW Visit our website at www MillerWelds com...

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...necting 3 Phase Input Power 13 4 5 Circuit Breaker 14 4 6 4 Pin Receptacle Information 14 4 7 Rack Mounting 14 SECTION 5 INSTALLATION STUD GUN 15 5 1 Chuck Installation 15 5 2 Chuck Removal 15 5 3 Foo...

Page 4: ......

Page 5: ...0 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that inpu...

Page 6: ...mbustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguishe...

Page 7: ...s computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt l...

Page 8: ...Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent...

Page 9: ...la norme OSHA 29 CFR 1910 147 voir normes de s curit D Installer le poste correctement et le mettre la terre convenablement selon les consignes du manuel de l op rateur et les normes nationales provin...

Page 10: ...es poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur p...

Page 11: ...ut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs D Demander seulement des personnes qualifi es familiaris es avec...

Page 12: ...bpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 31...

Page 13: ...3 00 seconds Resting 3 2 Duty Cycle And Overheating Y Exceeding duty cycle can damage unit and void warranty Percent duty cycle 1 7 times the number of 1 second 1000ms loads outputs per minute withou...

Page 14: ...CEC Section 20 1 Lifting Handles Use handles to lift unit 2 Hand Cart Use cart or similar device to move unit 3 Rating Label Use rating label to determine input power needs 4 Line Disconnect Device L...

Page 15: ...t Rated Output 55 45 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 Normal Operating 3 60 50 Min Input Conductor Size In AWG 4 10 10 Max Recommended Input Conductor Length In Feet Mete...

Page 16: ...shielded cables using line filters or shielding the work area 400 350 300 250 200 150 100 50 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2100 2 0 4 0 2 4 0 Use multi...

Page 17: ...in put power between 480 or 575 VAC without removing cover to relink the power source 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Yellow Grounding Conduct...

Page 18: ...s 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 c...

Page 19: ...of the chuck The depth stop should be adjusted so that you are retaining a good portion of the stud you are set ting up to weld Typically this is one third to one half of the length of the stud being...

Page 20: ...ainers Line up the flat side of the legs with set screws Tighten set screws securely 4 5 3 Foot and Leg Setup 5 1 2 3 Foot Size Stud Range Small Medium Up to 1 2 in 5 8 to 3 4 in 6 7 Make sure flat si...

Page 21: ...4 Perform the following procedures when connecting stud gun to power source Connect weld cable Connect control cable Use the same instructions provided if connecting to an extension cable Connecting W...

Page 22: ...foot towards gun or away from gun to increase or decrease plunge Plunge measurements are from end of stud and do not include the flux load These instructions are for standard fer rules For reduced fil...

Page 23: ...surements Adjusting Lift 2 Location of Core Set Screws To adjust lift remove the slotted screw hold ing the rear cap in place Remove rear cap Loosen the nylon tipped set screw that holds the adjustabl...

Page 24: ...r 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 Indicator LIght 7 Time Amperage Contr...

Page 25: ...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 MATERIAL THICKN...

Page 26: ...ge 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 The ac...

Page 27: ...RAGE 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 adjustment Time Adjustment Push select but...

Page 28: ...are due to improper gun set up or power set tings Welding Procedures Place stud to be welded into weld chuck Insert a ferrule into the ferrule grip this step is not necessary if using a spark shield P...

Page 29: ...Seconds 8 mm 420 Amps 310 Seconds 3 8 Inch 520 Amps 360 Seconds 10 mm 580 Amps 430 Seconds 1 2 Inch 750 Amps 450 Seconds 12 mm 720 Amps 500 Seconds 5 8 Inch 980 Amps 730 Seconds 14 mm 880 Amps 590 Se...

Page 30: ...s 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 Weld Connections 6 Months Blow Out In...

Page 31: ...OM 216 244 Page 27 Notes...

Page 32: ...ble the gun Inspect all parts for wear or damage Replace worn or damaged components Clean all components Reassemble components Adjust settings and test Disassembly Assembly Procedures Y To prevent acc...

Page 33: ...grease over the lift bearing and the lift bearing spring 12 Handle Covers 35 Remove 3 flat head screws 36 37 that retain the handle cover Inspect handle cover for breakage 13 Weld Cable 40 The weld c...

Page 34: ...ng load If problem persists contact a factory au thorized service agent HELP 6 Off Input voltage is either under low volt age or high over voltage DC bus voltage imbalance Unit has automatically shut...

Page 35: ...ort arc you may not be able to eliminate this condition To improve this situa tion shorten time and increase current If the results continue to be unsatisfactory then you may need to add a shielding g...

Page 36: ...OM 216 244 Page 32 Notes...

Page 37: ...OM 216 244 Page 33 SECTION 9 ELECTRICAL DIAGRAMS 232 194 A Figure 9 1 Circuit Diagram For 460 575 Volt Models...

Page 38: ...OM 216 244 Page 34 SECTION 10 PARTS LIST FOR POWER SOURCE Ref 803 724 C Hardware is common and not available unless listed Figure 10 1 Parts Assembly...

Page 39: ...1 375 Dia Clip 1 25 192 853 Bracket Mtg Contactor Capacitor Pc Board 1 26 PC1 215 697 Circuit Card Control 480 575 1 PLG2 131 056 Connector Sockets RC2 1 PLG3 130 203 Connector Sockets RC3 1 PLG4 115...

Page 40: ...Twlk Insul Fem 2 57 RC1 216 365 Receptacle W Leads Plug 1 216 592 Nut Conduit 0 500 Npt 1 135 Od X 180 Thk 1 58 232 188 Nameplate Order By Model And Serial Number 1 59 174 991 Knob Pointer 1 250 1 60...

Page 41: ...362 in 10 mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8 mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 16 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in...

Page 42: ...TS 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...

Page 43: ...n Spring 1 22 217 420 Gun Body 1 23 217 421 Leg Set Screw 2 24 217 422 Front Coil Yoke 1 25 217 423 Gun Coil 1 26 217 424 Rear Coil Yoke 1 27 217 425 Rear Coil Yoke Set Screws 2 28 217 426 Adjustable...

Page 44: ...4 12 2 Foot and Leg Setup 5 1 2 3 6 12 3 Table For Foot and Legs FOOT LEGS Foot Size Stud Range Part Number Length Part Number Small Up to 1 2 Inch 219670 9 Inch 219655 Medium 5 8 to 3 4 Inch 219671 1...

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 229895 MATERIAL THICKNESS GAUGE...

Page 47: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Page 48: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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