Miller Electric 625 manual Table of Contents

Page 3

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 Installation, Operation, And Maintenance

3

1-4. California Proposition 65 Warnings

3

1-5.

Principal Safety Standards

4

1-6.

EMF Information

4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

5

2-1.

Symboles utilisés

5

2-2.

Dangers relatifs au soudage à l’arc

5

2-3.

Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

7

2-4.

Proposition californienne 65 Avertissements

7

2-5.

Principales normes de sécurité

8

2-6.

Information EMF

8

SECTION 3 − INTRODUCTION

9

3-1.

Specifications

9

3-2. Duty Cycle And Overheating

9

SECTION 4 − INSTALLATION - POWER SOURCE

10

4-1.

Selecting a Location

10

4-2.

Electrical Service Guide

11

4-3.

Weld Output Receptacles And Selecting Cable Sizes

12

4-4.

Connecting 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. Foot and Leg Setup

16

5-4.

Ferrule Grip / Spark Shield Removal and Installation

16

5-5.

Foot Alignment

17

5-6.

Connecting Stud Gun and Work Clamp to Power Source

17

5-7.

Plunge Adjustment

18

5-8.

Adjusting Stud Lift

19

SECTION 6 − OPERATION - POWER SOURCE

20

6-1.

Front Panel Controls

20

6-2.

Time/Amperage Control

22

SECTION 7 − OPERATION - STUD GUN

24

7-1.

Stud Gun Tool Functions

24

7-2.

Stud Welding Procedures

24

7-3.

Welding Sequence

25

7-4.

Recommended Settings

25

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

26

8-1.

Routine Maintenance

26

8-2.

Blowing Out Inside Of Unit

26

8-3.

Maintenance Procedures for Stud Gun

28

8-4.

Troubleshooting Help Aids

30

8-5.

Troubleshooting - Power Source

30

8-6.

Troubleshooting - Stud Gun

31

SECTION 9 − ELECTRICAL DIAGRAMS

33

SECTION 10 − PARTS LIST FOR POWER SOURCE

34

SECTION 11 − PARTS LIST FOR STUD GUN

38

SECTION 12 − OPTIONS AND ACCESSORIES

40

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Contents File Stud Welding SW OM-216 244JProcess DescriptionFrom Miller to You Table of Contents Page Electric Shock can kill Symbol UsageMarks a special safety message Arc Welding HazardsBuildup of GAS can injure or kill ARC Rays can burn eyes and skinWelding can cause fire or explosion Flying Metal can injure eyesCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Pacemakers UNE Décharge Électrique peut entraîner la mort LES Fumées ET LES GAZ peuvent être dangereuxIndique un message de sécurité particulier DES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer unIncendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peut SUREn ce qui concerne les stimulateurs cardiaques Principales normes de sécuritéSpecifications − IntroductionDuty Cycle And Overheating Location − Installation Power SourceDimensions And Weight Selecting a LocationMin Grounding Conductor Size In AWG Electrical Service GuideHz Three Phase Input VoltageOutput Receptacles Turn off power before connecting to weld output terminalsWeld Output Receptacles And Selecting Cable Sizes ARC Welding can cause Electromagnetic Interference= GND/PE Earth Ground Tools Needed Connecting 3-Phase Input PowerSocket Information Circuit BreakerPin Receptacle Information Rack Mounting− Installation Stud GUN Chuck InstallationChuck Removal Leg Installation Foot and Leg SetupFerrule Grip / Spark Shield Removal and Installation Foot InstallationFoot Alignment Connecting Stud Gun and Work Clamp to Power SourceConnecting Weld Cable and Work Ground Cable Connecting Control CablePlunge Adjustment PlungeStud Welding Measuring LIft Adjusting Stud LiftLIft Adjustment Table Adjusting LiftFront Panel Controls − Operation Power SourceMaterial Thickness Reference Chart Time/Amperage Control Select TIME/AMP AdjustmentReady XxxxStud Welding Procedures − Operation Stud GUNStud Gun Tool Functions Welding Sequence Recommended Settings− Maintenance & Troubleshooting Do not remove case when blowing out inside of unitBlowing Out Inside Of Unit OM-216 244 Disassembly / Assembly Procedures Maintenance Procedures for Stud GunWhen is Maintenance Required? Maintenance StepsTools Needed OM-216 244 Troubleshooting Power Source Troubleshooting Help AidsTroubleshooting Stud Gun But no weldFree play OM-216 244 Circuit Diagram For 460/575 Volt Models − Electrical DiagramsParts Assembly − Parts List for Power SourceDia Part Description Quantity Mkgs 207 SOCKET/WRENCH Selection Table Standard Metric − Parts List for Stud GUN 217 Plunge Dampener Soft Standard W/Dampener Model Table For Chucks and Grips − Options and AccessoriesPlunge Dampener Table For Foot and LegsWork like a Pro Material Thickness Gauge Support ServiceMiller Electric Mfg. Co Owner’s Record
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