Miller Electric Welder ST 44 Series User Manual

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  
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  
the Safety Standards listed in Section 1-5. Read and follow all  
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  
committees 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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SECTION 6 − ELECTRICAL DIAGRAM  
OM-216 655 Page 13  
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SECTION 7 − PARTS LIST  
. Hardware is common and  
not available unless listed  
Figure 7-1. ST 44 Complete Assembly (Optional Equipment Shown)  
OM-216 655 Page 14  
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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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. Hardware is common and  
not available unless listed  
April 19, 2006  
Figure 7-3. ST Blu Fab Wire Feed Assembly  
OM-216 655 Page 17  
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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  
*
*
*
*
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*
*
*
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.  
*
*
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*
*
*
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*
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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