Miller ST 44 Series Wire Feeder, Owner'S Manual

Page 1: ...Processes Description MIG GMAW Welding Flux Cored FCAW Welding Wire Feeder OM 216 655G 2009 06 Effective with serial number 250 950 ST 44 Series Wire Feeder CE www MillerWelds com OWNER S MANUAL ...

Page 2: ...ducts Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The par...

Page 3: ...Products Sold Within The EU 6 2 4 Symbols and Definitions 6 SECTION 3 INSTALLATION 7 3 1 Serial Number And Rating Label Location 7 3 2 Specifications 7 3 3 Gun Recommendation Table 7 3 4 Equipment Connection Diagrams 7 3 5 14 Pin Plug Information 8 3 6 Connecting Welding Gun And Weld Cable 8 3 7 Installing Wire Guide And Drive Roll 9 SECTION 4 OPERATION 10 4 1 ST 44 Series Panel Controls 10 4 2 Ru...

Page 4: ...irectives 2006 95 EC Low Voltage 2004 108 EC Electromagnetic Compatibility 2006 42 EEC Machinery Directive Standards IEC 60974 1 Arc Welding Equipment Welding Power Sources edition 3 0 2005 07 IEC 60974 10 Arc Welding Equipment Electromagnetic Compatibility Requirements edition 2 0 2007 08 EU Signatory May 10 2009 __________________________________________________________________________ Mark Lowt...

Page 5: ...n cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire ...

Page 6: ...ss they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw fro...

Page 7: ...fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read Owner s Manual before using or servic ing unit D Use only genuine replacement parts from the man...

Page 8: ... York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and P...

Page 9: ...move the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Don t weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watch person ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use e...

Page 10: ...finitions Symbols found on product On Off Input Output A Amperes V Volts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Circuit Breaker Wire Feed Jog U1 Primary Voltage Gas Metal Arc Welding GMAW Gun Line Connection Purge Spot Weld Time Spot Weld Continuous Weld Burnback Time Preflow Time Postflow Time Read Instructions U2 Load Voltage I1 Primary Current I2 Rated Current U1 Prim...

Page 11: ... Volts AC Single Phase 5 Amperes 50 60 Hz Constant Voltage CV DC with 14 pin and Contactor Control 0 to 20 mpm 0 to 788 ipm 0 6 to 2 0 mm 0 23 to 5 64 in Max Spool Weight 15 kg 33 0 lb 100 Volts 500 Amperes 100 Duty Cycle Length 650 mm 25 5 in Width 220 mm 8 65 in Height 420 mm 16 5 in ST 44 Series ST Blu Fab 22 0 kg 48 lbs ST 44 Ultra Lite 15 0 kg 33 lbs 3 3 Gun Recommendation Table Process Gun G...

Page 12: ...control circuit common E 0 to 10 volts DC input command signal from remote control with respect to pin D H Voltage feedback 0 to 10 volts DC 1 V 10 arc volts The remaining pins are not used Ref S 0004 A 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob insert gun into block Position outlet wire guide as close as possible to drive rolls without touching Tighten knob 4 Gun Trigger ...

Page 13: ... wire brush Check general condition of drive rolls Aligning Wire Guide And Drive Rolls View is from top of drive rolls looking down with pressure assem bly open Turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assembly Repeat for remaining drive rolls un til all drive rolls line up with wire guides as shown 3 7 Installing Wire Guide And Drive Roll 802 310 A...

Page 14: ... Power ON OFF 6 Digital Voltmeter mpm 7 Remote Control Receptacle 8 Flowmeter 9 In Out Cooling System 10 Torch Connection 11 Panel Remote Control Switch 12 Wire Speed Control 13 Circuit Breaker 14 Gas In Connector 15 Control Cable Connection 16 Weld Cable Connection 17 In Out Cooling Connections 2 3 4 5 6 7 10 12 9 1 8 16 13 14 15 9 ...

Page 15: ...8 10 t Run In Control Use control to set wire feed speed before arc initiation After arc initiation wire feed speed is controlled by the wire feed speed control on the front control panel Burnback Control Control adjusts the time welding wire is energized after wire feed stops ...

Page 16: ...isconnect power before maintaining 3 Months Replace Unreadable Labels Clean And Tighten Weld Terminals Repair Or Replace Cracked Weld Cable 14 Pin Cord Gas Hose Gun Cable Replace Cracked Parts 6 Months Blow Out Or Vacuum Inside During Heavy Service Clean Monthly OR Clean Drive Rolls ...

Page 17: ...e feeds as soon as power is applied Check gun trigger See gun Owner s Manual Wire does not feed until trigger is pressed but continues to feed after trig ger is released Check for short between gun trigger leads and weld cable Repair or replace gun trigger leads Gas valve rattles loudly and wire feeds slowly or erratically Check for short between gun trigger leads and weld cable Repair or replace ...

Page 18: ...OM 216 655 Page 14 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 19: ...OM 216 655 Page 15 SECTION 6 ELECTRICAL DIAGRAM 956 142 484 ...

Page 20: ...OM 216 655 Page 16 SECTION 7 PARTS LIST Hardware is common and not available unless listed Figure 7 1 ST 44 Complete Assembly Optional Equipment Shown May 2009 ...

Page 21: ...ger latch 1 1 1 27 056067194 Switch power on off 1 1 1 28 316029689 Name Plate upper polycarbonate 1 1 1 29 056076180 Receptacle 7 pin 30 000207076 Knob pointer 3 4 4 31 058016019 Flowmeter gas 1 32 556049369 Quick Connector water blue 1 1 33 756005024 Flange euro adapter 1 1 1 34 556049368 Quick Connector water red 1 1 35 056067169 Switch remote 36 316029691 Name Plate lower polycarbonate 1 1 37 ...

Page 22: ...Lever mounting pressure gear 1 9 166 337 Housing adapter gun feeder 1 10 072 010 Washer insulated 2 11 108 943 Bolt adapter housing 2 12 173 618 Drive Gear central 2 13 602 239 Washer central drive gear shaft 1 14 174 609 Screw central drive gear shaft 1 15 602 009 Screw soc head hex 4 16 172 075 Carrier drive roll w component 24 pitch 4 17 601 872 Nut power stud 1 18 602 213 Washer plain power st...

Page 23: ...mm 0 045 in 0 045 in 046 782 053 697 V Grooved 056 193 056 207 1 6 mm 1 16 in 0 062 in 046 784 053 699 V Grooved 056 195 056 209 0 9 mm 0 035 in 0 035 in 044 750 072 000 U Grooved 056 192 056 206 1 2 mm 0 045 in 0 045 in 046 785 053 701 U Grooved 056 193 056 207 1 3 mm 0 052 in 0 052 in 046 786 053 702 U Grooved 056 193 056 207 1 6 mm 1 16 in 0 062 in 046 787 053 706 U Grooved 056 195 056 209 2 0 ...

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Page 27: ... 06 5 6 Months Batteries 6 90 Days Parts MIG Guns Induction Heating Coils and Blankets Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller bu...

Page 28: ...Country Zip Postal Code Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Service and Repair Replacement Parts Owner s Manuals Contact the Delivering Carrier to For Service File a claim for loss or damage during shipment For ...