OM-216 655E
2007−03
Effective with serial number: 225 493
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
ST 44 Series and
ST Blu Fab
Wire Feeder
OWNER’S MANUAL
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TABLE OF CONTENTS
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Gun Recommendation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Equipment Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Connecting Welding Gun And Weld Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Installing Wire Guide And Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. ST 44 Series Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. ST Blu Fab Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Run-In Control and Burnback Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 5 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WARRANTY
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Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer:
European Contact:
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that this product:
ST 44 Series and ST Blu Fab
Wire Feeder
conforms to the following Directives and Standards:
Directives
Low Voltage: 73/23/EEC
Electromagnetic Compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37/EEC
And their amendments 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1, 1989
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1 (April 1995 - Draft revision)
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: December 1995
Degrees of Protection provided by Enclosures (IP code): IEC 529 : 1989
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_stat_Milan_6/05
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
Y
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
Y
Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
Y
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
Safety Standards.
D
D
D
D
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D
D
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Y
Y
Only qualified persons should install, operate, maintain, and
repair this unit.
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
During operation, keep everybody, especially children, away.
D
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
ELECTRIC SHOCK can kill.
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
groundedequipment is a hazard.
D
D
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
D
D
D
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
D
D
FUMES AND GASES can be hazardous.
D
Additionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; 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 voltage wire welder
is recommended. And, do not work alone!
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D
D
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
D
D
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
D
D
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
D
D
When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
OM-216 655 Page 1
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ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
D
D
Shut off shielding gas supply when not in use.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Always ventilate confined spaces or use
approved air-supplied respirator.
D
Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
D
D
D
Wear approved safety glasses with side shields under your
helmet.
D
D
Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
MAGNETIC FIELDS can affect pacemakers.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
D
D
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
NOISE can damage hearing.
D
D
D
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
damagehearing.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D
Wear approved ear protection if noise level is
high.
D
D
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
CYLINDERS can explode if damaged.
D
D
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
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
D
Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
D
D
Do not use welder to thaw frozen pipes.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
D
D
D
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D
D
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
FLYING METAL can injure eyes.
D
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D
D
Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
D
Wear approved safety glasses with side
shields even under your welding helmet.
OM-216 655 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D
Do not install or place unit on, over, or near
combustiblesurfaces.
D
D
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
D
Do not install unit near flammables.
D
D
Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
D
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
FALLING UNIT can cause injury.
D
D
D
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
READ INSTRUCTIONS.
Use equipment of adequate capacity to lift and
support unit.
D
D
Read Owner’s Manual before using or servic-
ing unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
Use only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
OVERUSE can cause OVERHEATING
D
D
Allow cooling period; follow rated duty cycle.
D
Have only qualified persons familiar with
electronic equipment perform this installation.
Reduce current or reduce duty cycle before
starting to weld again.
D
Do not block or filter airflow to unit.
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
If notified by the FCC about interference, stop using the
equipmentat once.
STATIC (ESD) can damage PC boards.
D
D
Have the installation regularly checked and maintained.
D
D
Put on grounded wrist strap BEFORE handling
boards or parts.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D
D
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
D
Be sure all equipment in the welding area is
electromagneticallycompatible.
D
D
D
D
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury.
D
D
Do not press gun trigger until instructed to do
so.
Be sure this welding machine is installed and grounded
according to this manual.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-216 655 Page 3
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1-5. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
ternational.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101(phone: 617−770−3000, website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-
site: www.cganet.com).
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-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-216 655 Page 4
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SECTION 2 − DEFINITIONS
2-1. Warning Label Definitions
A
B
C
A. Warning! Watch Out! There are possible
hazards as shown by the symbols.
B. Drive rolls can injure fingers.
C. Welding wire and drive parts are at
welding voltage during operation − keep
hands and metal objects clear.
1
Electric shock can kill.
1.1 Wear dry insulating gloves. Do not touch
electrode with bare hand. Do not wear
wet or damaged gloves.
1.2 Protect yourself from electric shock by
insulating yourself from work and ground.
1
2
1.1
2.1
3.1
4.1
1.2
1.3
1.3 Disconnect input plug or power before
working on machine.
2
Breathing welding fumes can be
hazardous to your health.
2.1 Keep your head out of the fumes.
2.2
2.3
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
4
5
3.2
3.3
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 ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
+ + +
5
Become trained and read the instructions
before working on the machine or
welding.
6
6
Do not remove or paint over (cover) the
label.
+
S-178 936
Do not discard this product with
general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec-
tion facility.
Contact your local recycling office
or your local distributor for further
information.
OM-216 655 Page 5
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1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
1
2
3
Drive rolls can injure fingers
Welding wire and drive parts
are at welding voltage during
operation − keep hands and
metal objects away.
2
3
2-2. Rating Label
ST WIRE FEEDER
Made In the EEC:2003
50/60 Hz
IP 23
24 V
1
3
A
2-3. Symbols and Definitions
Symbols found on product.
NOTE
On
Off
Input
Output
Amperes
Volts
AlternatingCurrent
Circuit Breaker
Duty Cycle
A
IP
V
Hz
U1
X
Degree Of
Protection
Hertz
Wire Feed
Gas Metal Arc
Welding (GMAW)
Gun
Jog
Primary Voltage
Line Connection
Purge
Spot Weld Time
Preflow Time
Spot Weld
Continuous Weld
Read Instructions
Burnback Time
Load Voltage
Postflow Time
Rated Current
Primary Current
Primary Voltage
U2
I1
I2
U1
Two Step Trigger
Operation (GTAW)
Four Step Trigger
Operation (GTAW)
Water (Coolant)
Input
Water (Coolant)
Output
Gas Flowmeter
Adjustment
Remote
Run−in Control
OM-216 655 Page 6
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SECTION 3 − INSTALLATION
3-1. Gun Recommendation Table
Process
Gun
GMAW − Hard or Corded Wires
FCAW − Self-Shielding Wires
M25 Or M40
GA-40GL
3-2. Equipment Connection Diagrams
1
2
CV Welding Power Source with
14 pin Amphenol Receptacle
Interconnecting Control Cord
(Required)
3
4
Weld Cable (Required)
Work
1
2
4
3
3-3. 14-Pin Plug Information
Pin*
Pin Information
A
B
G
C
D
E
H
24 volts ac with respect to pin G.
Contact closure to A completes 24 volts ac contactor control circuit.
Circuit common for 24 volts AC circuit.
J
A
E
K
I
B
N
L
C
H
+10 volts dc output to remote control with respect to pin D.
Remote control circuit common.
M
F
D
G
0 to +10 volts dc input command signal from remote control with respect to pin D.
Voltage feedback; 0 to 10 volts dc, 1 V/10 arc volts
*The remaining pins are not used.
Ref. S-0004-A
3-4. Specifications
Wire
Diameter
Range
Type of Input Welding Power
Power Source Type
Wire Feed
Speed Range
Welding
Circuit Rating
Overall
Dimensions
Weight
Length: 650 mm
(25.5 in)
100 Volts,
500 Amperes,
100%
ST 44 Series &
ST Blu Fab
(22.0 kg (48 lbs)
0.6 to 2.0 mm
(0.23 to 5/64 in)
24 Volts AC Single Constant Voltage
0 to 20 mpm
(0 to 788 ipm)
Width: 220 mm
(8.65 in)
Phase
5 Amperes 50/60
Hz
(CV) DC with 14
pin and Contactor
Control
Duty Cycle
Max Spool Weight:
15 kg (33.0 lb.)
ST 44 Ultra-Lite
15.0 kg (33 lbs)
Height: 420 mm
(16.5 in)
OM-216 655 Page 7
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3-5. Connecting Welding Gun And Weld Cable
1
2
3
Gun Securing Knob
Gun Block
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.
1
2
US Torch
3
4
5
Gun Trigger Receptacle
Gun Trigger Plug
4
1
5
2
Torch
Euro
802 308
3-6. Installing Wire Guide And Drive Roll
1
Inlet Wire Guide
1−2
2
Intermediate Wire Guide
Install and secure inlet wire guide,
and intermediate wire guide.
3
Drive Roll (4)
Install drive rolls and turn drive roll
nut one click.
During maintenance intervals,
remove drive rolls, and clean
grooves using a wire brush. Check
general condition of drive rolls.
3
Correct Alignment
1
Aligning Wire Guide And Drive
Rolls:
View is from top of drive rolls
looking down with pressure assem-
bly open.
3
Turn screw in or out until drive roll
groove lines up with wire guide.
2
Close pressure roll assembly.
Repeat for remaining drive rolls un-
til all drive rolls line up with wire
guides as shown.
Incorrect Alignment
Tools Needed:
3/8 in
802 310-A
OM-216 655 Page 8
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SECTION 4 − OPERATION
4-1. ST 44 Series Panel Controls
1
2
3
4
1
2
3
4
5
6
7
Voltage Control
Purge Control
Jog
2T−4T Switch
Power ON-OFF
Digital Voltmeter/mpm
5
6
13
Remote Control
Receptacle
8
9
Flowmeter
14
15
In-Out Cooling System
12
11
10 Torch Connection
11 Panel/Remote Control
Switch
12 Wire Speed Control
13 Circuit Breaker
7
16
17
14 Gas In Connector
15 Control Cable Connection
16 Weld Cable Connection
8
17 In-Out Cooling
Connections
10
9
4-2. ST Blu Fab Panel Controls
1
2
3
4
5
6
7
8
9
Voltage Control
Purge Control
Jog
1
2
3
4
5
2T−4T Switch
Power ON-OFF
Torch Connection
Circuit Breaker
Gas In Connector
Control Cable Connection
7
10 Weld Cable Connection
8
9
10
6
OM-216 655 Page 9
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4-3. Run-In Control and Burnback Control
Run-In Control
Use control to set wire feed speed
before arc initiation
6
4
After arc initiation, wire feed speed
is controlled by the wire feed speed
control on the front control panel.
2
8
Burnback Control
Control adjusts the time welding
wire is energized after wire feed
stops.
10
6
4
2
8
10
t
OM-216 655 Page 10
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SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
Y
Disconnect power before maintaining.
3 Months
Repair Or
Replace
Cracked
Clean And
Tighten
Weld
Replace
Unreadable
Labels
Weld Cable
Terminals
Replace Cracked Parts
14-Pin Cord
Gun Cable
Gas Hose
6 Months
Blow Out Or Vacuum Inside,
During Heavy Service, Clean
Monthly
Clean Drive Rolls
OR
OM-216 655 Page 11
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5-2. Troubleshooting
Problem
Solution
Check continuity of Power switch S1, and replace if necessary.
Reset circuit breaker CB1 if open.
Unit is completely inoperative.
Check input power source. See welding power source Technical Manual.
Turn Power switch On.
Wire does not feed, unit completely inop-
erative.
Check 14−pin receptacle connections.
Check input power or the CB
Wire does not feed.
Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s
Manual.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Readjust hub tension and drive roll pressure.
Wire feeds erratically.
Use correct size drive roll (see Parts List).
Clean or replace dirty or worn drive roll.
Remove weld spatter around nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Wire feeds when Jog switch is pressed Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s
but not when gun trigger is pressed.
Manual.
Check continuity of Jog button S3, and replace if necessary.
Check motor control board PC1 and connections, and replace if necessary
Realign drive rolls.
Wire does not feed with Jog button S2B
pressed.
Electrode wire feeding stops or feeds
erratically during welding.
Check hub assembly (see Parts List).
Wire feeds as soon as power is applied. Check gun trigger. See gun Owner’s Manual.
Wire does not feed until trigger is Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
pressed but continues to feed after trig-
ger is released.
Gas valve rattles loudly and wire feeds Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
slowly or erratically.
Gas does not flow; wire feeds.
Check gas valve and flowmeter.
Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.
Check continuity of Purge switch S2A, and replace if necessary.
Wire feeds, but gas does not flow with
gun trigger pressed.
Check continuity of Purge switch S2A, and replace if necessary.
Wire feeds, but gas does not flow with
Purge switch S2 pressed.
Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.
Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.
Clear blockage in gas hose or replace hose.
Wire feeds and electrode wire is ener-
gized, but gas flow is irregular.
Clear blockage in gun. See gun Owner’s Manual.
Motor runs at full speed.
Check motor control board PC1 and connections, and replace if necessary.
Check resistance and connections of active wire speed potentiometers and replace if necessary.
Wire drive motor coasts (no brake at trig- Check motor control board PC1 and connections, and replace if necessary.
ger release).
Meter does not work properly.
OM-216 655 Page 12
Check optional meter board PC2 and connections, and replace if necessary
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 7−1. ST 44 Complete Assembly
Qty
Basic Digital Ultra−Lite
. . . 1 . . . . . . . . . . . 000058427 . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 2 . . . . . . . . . . . 156032128 . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 3 . . . . . . . . . . . 156018033 . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 4 . . . . . . . . . . . 156009079 . . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 5 . . . . . . . . . . . 156032064 . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 6 . . . . . . . . . . . 156009075 . . Washer, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 7 . . . . . . . . . . . 000186435 . . Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 8 . . . . . . . . . . . 000186436 . . Washer, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 9 . . . . . . . . . . . 156005108 . . Support, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 11 . . . . . . . . . . . 056076216 . . Dinze Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 12 . . . . . . . . . . . 056076192 . . 14 Pin Panel Mounted Receptacle . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 13 . . . . . . . . . . . 056061042 . . Solenoid Valve, 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 14 . . . . . . . . . . . 056067188 . . Circuit Breaker, 5 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 15 . . . . . . . . . . . 116118168 . . Rear Panel, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . 15 . . . . . . . . . . . 116118170 . . Rear Panel, aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . 117060014 . . Baffle Plate, centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 17 . . . . . . . . . . . 156034005 . . Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . . . . 2
. . . 18 . . . . . . . . . . . 116122319 . . Side Panel, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . 18 . . . . . . . . . . . 116122320 . . Side Panel, aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . 156034004 . . Hinge, Polycarbonate . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . . . . 2
. . . 20 . . . . . . . . . . . 000208015 . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 21 . . . . . . . . . . +156121022 . . Cover, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . 21 . . . . . . . . . . +116121127 . . Cover, aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . 000006393 . . Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . . . . 2
. . . 23 . . . . . . . . . . . 057084124 . . Circuit Card, control board . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 24 . . . . . . . . . . . 056093022 . . Switch, gas purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 25 . . . . . . . . . . . 056093022 . . Switch, wire jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 26 . . . . . . . . . . . 056067169 . . Switch, 2T 4T trigger latch . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 27 . . . . . . . . . . . 056067247 . . 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 . . . . . . . . . . . 316029690 . . Name Plate, lower polycarbonate, w/flowmeter . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . 056059182 . . Potentiometer, voltage control . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . 39 . . . . . . . . . . . 056059182 . . Potentiometer, wire speed control . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 40 . . . . . . . . . . . 116005324 . . Motor Support, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . 40 . . . . . . . . . . . 116005325 . . Motor Support, aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . 056059277 . . Potentiometer 10.0k ohm . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . . . . 2
. . . 42 . . . . . . . . . . . +178-937A . . Label, electric chock and pinch . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 43 . . . . . . . . . . +116006130 . . Base, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . . 43 . . . . . . . . . . +116006131 . . Base, aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . *V57052030 . . Euro torch adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . Fig 7-2 . . Wire Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 46 . . . . . . . . . . . 057028067 . . US torch plug connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . . +S178-936 . . Label, general precautionary . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 48 . . . . . . . . . . . 656110012 . . Foot, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4 . . . . . . . . 4
. . . 49 . . . . . . . . . . . 057095012 . . Circuit Card, digital meter board . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . 1
. . . 50 . . . . . . . . . . . 027112275 . . Weld cable, w/lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . 1
. . . 51 . . . . . . . . . . . 000204326 . . Box, consummable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
* Euro torch models only.
** Optional
OM-216 655 Page 15
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. Hardware is common and
not available unless listed
Figure 7-2. 4 Roll Wire Drive Assembly (All Models)
Item
No.
Dia.
Mkgs.
Part
No.
Qty
Description
. . . 1 . . . . . . . . . . . 057010052 . . Drive Motor, 24 VDC, 60w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 601 966 . . Screw, housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 602 213 . . Washer, locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . 656005026 . . Insulator, bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 604 673 . . Screw, hex c/sunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 7 . . . . . . . . . . . . . 187 325 . . Insulator, drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 166 338 . . 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 stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 010 224 . . Pin, tension arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . 166 071 . . Lever, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 089 562 . . Tension arm, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . 085 244 . . Washer, cupped steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . 089 477 . . Spring, tension arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . 089 243 . . Knob, adjustment tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . 202 562 . . Power stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-216 655 Page 16
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Item
No.
Dia.
Mkgs.
Part
No.
Qty
Description
. . . 1 . . . . . . . . . . . 000058427 . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . 156032128 . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . 156018033 . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . 156009079 . . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . 156032064 . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . 156009075 . . Washer, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . 000186435 . . Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . 000186436 . . Washer, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . 156005108 . . Support spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . 056076216 . . Dinze Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . 056076192 . . Receptacle, 14 pin male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . 056061042 . . Gas Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . 000083432 . . CB1 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . 116118168 . . Rear Panel, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . 117060014 . . Plate, centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . 000151187 . . Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 18 . . . . . . . . . . . 116122319 . . Side Panel, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . 156034004 . . Hinge, Polycarbonate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . 000208015 . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . 156121022 . . Cover, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . 000204326 . . Compartment, accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . 057084124 . . Circuit Card, control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . 056093022 . . Switch, gas purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . 056093022 . . Switch, wire jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . 056067169 . . Switch, 2T 4T trigger latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . 056067194 . . Switch, power on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . 316029696 . . Nameplate, upper polycarbonate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . 000207076 . . Knob, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 30 . . . . . . . . . . *756005024 . . Flange, euro adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . 316029694 . . Nameplate, lower polycarbonate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . 116118167 . . Front Panel, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . 056059182 . . Potentiometer, wire speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . 156005097 . . Motor Support, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . 056059277 . . Potentiometer, 10.Kohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . +178−937A . . Label, electric shock and pinch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . +116006130 . . Base, steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . *057052032 . . Euro torch adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . Fig 7-4 . . Wire Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . Optional . . US torch plug connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . +S178−936 . . Label, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . 656110012 . . Foot, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . 027112275 . . Weld cable, w/lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . . . . . . . . . . Grommet, blanking plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . 057028075 . . PCB Run-In Control and Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . . 956142486 . . Label, Run-In and Burnback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* Optional, certain markets
OM-216 655 Page 18
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. Hardware is common and
not available unless listed
20
19
18
17
16
1
15
2
14
3
4
4
13
5
12
6
7
11
8
9
10
9/13/04
Figure 7-4. 2 Roll Wire Drive Assembly (All Models)
Item
No.
Dia.
Mkgs.
Part
No.
Qty
Description
. . . 1 . . . . . . . . . . . 057010052 . . Drive Motor, 24 VDC, 60w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 187 325 . . Insulator, drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . . . . . . Bolt, Power stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 602 213 . . Washer, locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . 656005029 . . Insulator, drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . 206219 . . Housing, adapter gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . 124778 . . Knob, T Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 604 673 . . Screw, hex c/sunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . 173 618 . . Drive Gear, central . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 602 239 . . Washer, central drive gear/shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 174 609 . . Screw, central drive gear/shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 602 009 . . Screw, soc head hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 601 872 . . Nut, power stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 602 213 . . Washer, plain, power stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 010 224 . . Pin, tension arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . 166971 . . Lever, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . 089562 . . Fastener, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 18 . . . . . . . . . . . . . . 196896 . . Cup, tension arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . 196897 . . Spring, tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . . 196895 . . Knob, adjustment tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-216 655 Page 19
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Table 7-1. Drive Roll And Wire Guide Kits (4 Drive Roll)
Base selection of drive rolls upon the following recommended usages:
1. V-Grooved rolls for hard wire.
NOTE
2. U-Grooved rolls for soft and soft shelled cored wires.
3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4. V-Knurled rolls for hard shelled cored wires.
5. Drive roll types may be mixed to suit particular requirements (example:
V-Knurled roll in combination with U-Grooved).
Wire Diameter
Fraction
Drive Roll
Type
Wire Guide
Inlet
Kit No.
Metric
0.6 mm
0.8 mm
0.9 mm
1.0/1.2 mm
1.0 mm
1.2 mm
1.6 mm
0.9 mm
1.2 mm
1.3 mm
1.6 mm
2.0 mm
0.9 mm
1.2 mm
1.3 mm
1.6 mm
1.8 mm
2.0 mm
1.2 mm
1.3 mm
1.6 mm
2.0 mm
Decimal
0.023/0.025 in
0.030 in
Part No.
087 130
053 695
053 700
189 285
053 696
053 697
053 699
072 000
053 701
053 702
053 706
053 704
132 958
132 957
132 956
132 955
132 959
132 960
083 489
083 490
053 708
053 710
Intermediate
056 206
056 206
056 206
056 207
056 206
056 207
056 209
056 206
056 207
056 207
056 209
056 209
056 206
056 207
056 207
056 209
056 209
056 209
056 207
056 207
056 209
056 209
0.023/0.025 in
0.030 in
0.035 in
0.035/0.045 in
0.040 in
0.045 in
1/16 in
087 132
046 780
046 781
N/A
V-Grooved
V-Grooved
V-Grooved
V-Grooved
V-Grooved
V-Grooved
V-Grooved
U-Grooved
U-Grooved
U-Grooved
U-Grooved
U-Grooved
V-Knurled
V-Knurled
V-Knurled
V-Knurled
V-Knurled
V-Knurled
U-Cogged
U-Cogged
U-Cogged
U-Cogged
056 192
056 192
056 192
156 193
056 192
056 193
056 195
056 192
056 193
056 193
056 195
056 195
056 192
056 193
056 193
056 195
056 195
056 195
056 193
056 193
056 195
056 195
0.035 in
0.035/0.045 in
0.040 in
191 917
046 782
046 784
044 750
046 785
046 786
046 787
046 788
046 782
046 793
046 794
046 795
089 985
046 796
083 319
083 320
046 800
046 801
0.045 in
0.062 in
0.035 in
0.045 in
0.052 in
1/16 in
0.035 in
0.045 in
0.052 in
0.062 in
5/64 in
0.079 in
0.035 in
0.045 in
0.052 in
1/16 in
0.035 in
0.045 in
0.052 in
0.062 in
0.068-0.072 in
5/64 in
0.068-0.072 in
0.079 in
0.045 in
0.052 in
1/16 in
0.045 in
0.052 in
0.062 in
5/64 in
0.079 in
OM-216 655 Page 20
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Notes
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Notes
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Effective January 1, 2007
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 S.r.l., 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.
*
*
*
*
*
*
APT Model Plasma Cutting Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas covers
Miller’s True Blue® Limited Warranty shall not apply to:
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.
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, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
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 that
the equipment was delivered to the original end-user
purchaser, and not to exceed one year after the equipment is
sent to a European distributor or eighteen months after the
equipment is sent to an International distributor.
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.
1. 5 Years Parts − 3 Years Labor
*
*
Original main power rectifiers
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.
Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (unless otherwise stated)
Water Coolant Systems (integrated)
Intellitig
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.
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3. 2 year − Parts and Labor (Panther only)
Hydramate 1&2 Water Cooling Unit
4. 1 year − Parts and Labor unless specified
*
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.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DC 253 & 403 Rectifier (April 06>)
Migmatic 171 (April 06>)
Motor Driven Guns (w/exception of Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
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.
IHPS Power Sources and Coolers
Water Coolant Systems (non−integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Spot Welders
Load Banks
Arc Stud power sources and Arc Stud guns
Running Gear/Trailers
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
Plasma Cutting Torches (except APT
Models)
&
SAF
*
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.)
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.
5
6 Months — Batteries
6. 90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction heating coils and blankets
milan_warr 1/06
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
Country
Zip/Postal Code
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Products Italy S.r.l.
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2007 Miller Electric Mfg. Co. 1/07
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