background image

milan_warr 2012

01

Effective January 1, 2012

(Equipment with a serial number preface of MC or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY 

 Subject to the terms and conditions

below, ITW Welding Products Italy warrants to its original retail

purchaser that new Miller equipment sold after the effective date

of this limited warranty is free of defects in material and

workmanship at the time it is shipped by Miller. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or

replace any warranted parts or components that fail due to such

defects in material or workmanship. Miller must be notified in

writing within thirty (30) days of such defect or failure, at which

time Miller will provide instructions on the warranty claim

procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed

below in the event of such a failure within the warranty time

periods. All warranty time periods start on the date the

equipment was delivered to the original retail purchaser or one

year after the equipment is shipped to a European distributor or

eighteen months after the equipment is shipped to an

International distributor.
1.

5 Years Parts — 3 Years Labor

* Original main power rectifiers only to include SCRs,

diodes, and discrete rectifier modules with

exclusion of STR, Si, STi, STH and MPi series.

2.

3 Years — Parts and Labor

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated)
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
* Water Coolant System (Integrated)

3.

2 Years — Parts

* Auto-Darkening Helmet Lenses (No Labor)
* Migmatic 175
* HF Units
* Water Coolant Systems (EU Models,

Non-Integrated)

4.

1 Year — Parts and Labor Unless Specified

* Automatic Motion Devices
* Field Options

(NOTE: Field options are covered under True Blue

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)

* Induction Heating Power Sources, Coolers, and

Electronic Controls/Recorders

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Positioners and Controllers
* Powered Air Purifying Respirator (PAPR) Blower

Unit (No Labor)

* Racks
* Running 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 apply to:

1.

Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, switches, slip

rings, relays or parts that fail due to normal wear.

2.

Items furnished by Miller, but manufactured by others, such

as engines or trade accessories. These items are covered

by the manufacturer’s warranty, if any.

3.

Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,

improperly operated or misused based upon industry

standards, or equipment which has not had reasonable and

necessary maintenance, or equipment which has been

used for operation outside of the specifications for the

equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Miller’s option: (1) repair; or (2)

replacement; or, where authorized in writing by Miller in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Miller service station; or (4)

payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods at

customer’s risk and expense. Miller’s option of repair or

replacement will be F.O.B., Factory at ITW Welding Products

Group Europe or F.O.B. at a Miller authorized service facility as

determined by Miller. Therefore no compensation or

reimbursement for transportation costs of any kind will be

allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY

OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION

OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,

INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

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 ...

Reviews: