Miller Electric ST 44 Series Owner'S Manual Download Page 1

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Processes

Description

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Wire Feeder

OM-216 655K

2012

−

ST 44 Series Wire Feeder

www.MillerWelds.com

OWNER’S MANUAL

Summary of Contents for ST 44 Series

Page 1: ...Processes Description MIG GMAW Welding Flux Cored FCAW Welding Wire Feeder OM 216 655K 2012 05 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: ...ymbols and Definitions 6 SECTION 3 INSTALLATION 7 3 1 Important Information Regarding CE Products Sold Within The EU 7 3 2 Serial Number And Rating Label Location 7 3 3 Specifications 7 3 4 Gun Recommendation Table 7 3 5 Equipment Connection Diagrams 7 3 6 14 Pin Plug Information 8 3 7 Connecting Welding Gun And Weld Cable 8 3 8 Installing Wire Guide And Drive Roll 9 SECTION 4 OPERATION 10 4 1 ST ...

Page 4: ...netic Compatibility Standards IEC 60974 1 Arc Welding Equipment Welding Power Sources edition 3 2005 07 IEC 60974 5 Arc Welding Equipment Wire Feeders edition 2 2007 11 IEC 60974 10 Arc Welding Equipment Electromagnetic Compatibility Requirements edition 2 0 2007 08 EN 50445 2008 Product family standard to demonstrate compliance of equipment for resistance welding arc welding and allied processes ...

Page 5: ...lds when in 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 vol...

Page 6: ...rums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 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 ...

Page 7: ...ING PARTS can injure D Keep away from moving parts such as 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 and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all la...

Page 8: ...ention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website 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 Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 P...

Page 9: ...alth 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove 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...

Page 10: ...g at a designated collec tion facility Contact your local recycling office or your local distributor for further information 2 4 Symbols and Definitions On Off Input Output A Amperes V Volts AlternatingCurrent 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 B...

Page 11: ...d Rating Label Location The serial number and rating information for this product is located on back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual Operating Temperature Range 14 F 10 C to 104 F 40 C Ratings were developed at an ambient temperature of 20 C to 25 C 3 3 Specifications ...

Page 12: ...ntrol 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 Re...

Page 13: ...e 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 8 Installing Wire Guide And Drive Roll 956142675_B T...

Page 14: ...ol 12 Circuit Breaker 13 Gas In Connector 14 Control Cable Connection 15 Weld Cable Connection 16 In Out Cooling Connections From Cooling System 16 10 2 3 4 5 6 7 9 11 1 15 12 13 14 8 4 2 Run In Control and Burnback Control 2 1 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 contr...

Page 15: ...onnect 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 Notes ...

Page 16: ...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 17: ...OM 216 655 Page 13 SECTION 6 ELECTRICAL DIAGRAM 956 142 484 C ...

Page 18: ...bly Optional Equipment Shown 956 142 672_B Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 25 24 16 15 14 13 12 11 58 17 18 19 26 27 20 21 22 23 Fig 7 2 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 57 56 55 54 53 52 51 50 49 48 47 46 45 43 44 59 40 ...

Page 19: ...393 Relay 2 2 30 PC2 057095012 Circuit Card digital meter board 1 31 000134201 Circuit Card spacer 4 4 32 PC1 057084124 Circuit Card control board 1 1 33 156005094 Circuit Card support 1 1 34 S3 056093022 Switch gas purge 1 1 35 S2 056093022 Switch wire jog 1 1 36 S4 056067260 Switch 2T 4T trigger latch 1 1 37 S1 056067194 Switch power on off 1 1 38 316029689 Nameplate front upper 1 1 39 056076180...

Page 20: ...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 When ordering a component originally displaying a precautionary label the label should also be ordered Euro torch models only Optional 956 142 674_B Hardware is common and not available unless listed 11 11 10 10 14 15 18...

Page 21: ...itch 4 17 601872 Nut 1 18 156009124 Washer D5 x 15 x 1 2 1 19 010224 Pin Spring CS 187 x 1 000 2 20 230691 Lever Mounting Pressure Gear 1 21 225718 Fastener Pinned 2 22 198080 Cup Spring 2 23 196897 Spring CPRSN 695 Od x 095 Wire x 1 500 2 24 196895 Knob Tension 2 25 203562 Screw 1 26 166072 Spacer Gear 4 27 151828 Pin Cotter Hair 042 x 750 2 28 079634 Pin Hinge 1 29 156019804 Screw 5 16 18 x 1 Al...

Page 22: ...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 ...

Page 23: ...ning Gear and Trailers Subarc Wire Drive Assemblies Water Coolant Systems USA Models Non Integrated Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets MIG Guns Remote Controls Replacement Parts No Labor Spoolmate Spoolguns Cables and Non Electronic Controls Miller s True Blue Limited Warranty shall not app...

Page 24: ...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 ...

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