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Summary of Contents for Miller S-44GL
- Page 1 OM-1534 045 215G August 1998 Processes Flux Cored (FCAW) Welding Description Wire Feeder S-44GL Visit our website at www.MillerWelds.com...
- Page 2 Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.
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Page 3: Table Of Contents
TABLE OF CONTENTS Section No. Page No. SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. Introduction ..........1-2. -
Page 4: Section No
7-5. Brush Inspection And Replacement ......7-6. Troubleshooting ..........SECTION 8 –... -
Page 5: Section 1 - Safety Rules For Operation Of Arc Welding Power Source
SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. INTRODUCTION from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered. See 1-3A.2. We learn by experience. Learning safety through per- sonal experience, like a child touching a hot stove is Avoid oily or greasy clothing. - Page 6 atmosphere or where the radiant energy can penetrate ment as recommended in A6.0. Waterfilling just below to atmospheres containing even minute amounts of working level may substitute for inerting. trichloroethylene or perchloroethylene. A container with unknown contents should be cleaned (see preceding paragraph).
- Page 7 Locate or secure cylinders so they cannot be knocked outlet away from people and sources of ignition. Wipe over. with a clean lintless cloth. Match regulator to cylinder. Before connecting, check Passageways and work areas. Keep cylinders clear of that the regulator label and cylinder marking area, and areas where they may be struck.
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Page 8: Arc Welding
1-3. ARC WELDING Viewing the weld. Provide face shields for all persons who will be looking directly at the weld. Comply with precautions in 1-1, 1-2, and this section. Others working in area. See that all persons are wearing Arc Welding, properly done, is a safe process, but a flash goggles. -
Page 9: Standards Booklet Index
quate to carry ground currents safely. Equipment made ject in contact with the electrode circuit unless electrically HOT by stray current may shock, possibly the welding power source is off. fatally. Do NOT GROUND to electrical conduit, or to a b. -
Page 10: Section 2 - Safety Precautions And Signal Words
ANSI Standard Z41.1, STANDARD FOR MEN’S CGA Pamphlet P-1, SAFE HANDLING OF SAFETY-TOE FOOTWEAR obtainable from the COMPRESSED GASES IN CYLINDERS obtain- American National Standards Institute, 1430 able from the Compressed Gas Association, Broadway, New York, NY 10018. 1235 Jefferson Davis Highway, Suite 501, Ar- lington, VA 22202. -
Page 11: Section 3 - Specifications
SECTION 3 – SPECIFICATIONS Table 3-1. Specifications Max. Weld Weight Electrode Wire Speed Output @ 100% Diameter Capability Range Ship Duty Cycle Depends On 1/16 Thru 1/8 in. 100 Volts @ 115 lbs. 125 lbs. (1.6 Thru 3.2 mm) 750 Amperes (52 kg) (57 kg) Arc Voltage... -
Page 12: Wire Guide And Drive Roll Installation
4-3. WIRE GUIDE AND DRIVE ROLL INSTALLA- IMPORTANT: When the grooves become worn, re- TION (Figure 4-1) verse rolls to locate unused groove in position to feed wire. Upon initial installation, or as a result of changes in wire size and type, it is necessary to install the required drive rolls and wire guides. -
Page 13: Voltage Sensing Lead Connection
B. Shielding Gas (If Applicable) make shielding gas connection to control box. Proceed as follows: An integral gas input fitting is provided on the wire drive assembly for guns utilizing this type of connection. If the Install gas fitting onto one end of shielding gas gun requires a separate shielding gas connection, dis- hose. -
Page 14: Welding Wire Installation
Select and prepare weld cable according to information Pull lock and turn. Remove spanner nut from wire in welding power source Owner’s Manual. reel assembly. Remove wire retainer, and install wire onto wire For Electrode Positive/Reverse Polarity connections reel. Be sure wire feeds off bottom of reel. proceed as follows: Reinstall wire retainer. -
Page 15: Section 5 - Operator Controls
IMPORTANT: If the U-Cogged drive rolls do not align WARNING: ELECTRIC SHOCK can kill; TANGLED WELDING WIRE can touch case properly when the gear cover is closed, pivot the gear causing welding power source open-circuit cover away from the drive gear, and rotate pressure voltage to be present on case if JOG button gear one tooth (see Section 4-3). -
Page 16: Jog Button
5-2. JOG BUTTON (Figure 5-1) Place the POLARITY switch in the ELECTRODE POSI- TIVE position when the weld output cables are con- nected to the welding power source for electrode posi- tive welding. IMPORTANT: Be sure the weld cables from the welding power source are connected for the position of the PO- LARITY switch. -
Page 17: Section 6 - Sequence Of Operation
SECTION 6 – SEQUENCE OF OPERATION 6-1. FLUX CORE ARC WELDING (FCAW) AND Connect work clamp to clean, bare metal at work- GAS METAL ARC WELDING (GMAW) piece. Rotate the ARC LENGTH control to the desired WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause serious injury;... -
Page 18: Section 7 - Maintenance & Troubleshooting
SECTION 7 – MAINTENANCE & TROUBLESHOOTING 7-1. ROUTINE MAINTENANCE for the cleaning operation. If dirty or dusty conditions are present, clean the unit monthly. IMPORTANT: Every six months inspect the labels on B. Cleaning Of Drive Rolls this unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced WARNING: Read and follow safety informa- when necessary. -
Page 19: Reinstallation Of Hub Assembly
A. Horizontal Adjustment Remove hub assembly from hub support, and disassemble discarding worn or broken parts. Behind the motor gear are spring washers. Turn motor gear securing bolt in or out until motor gear is horizon- Slide the following items onto the hub support tally aligned with drive gears. -
Page 20: Brush Inspection And Replacement
Fuse F1 protects the unit from overload. If fuse F1 Open brush cap by sliding screwdriver under should open, the wire feeder would completely shut catch and lifting. Remove brush cap. down. To replace F1, proceed as follows: Grasp spring retaining bracket with long-nose pli- Depress and rotate fuse holder cover counter- ers. -
Page 21: Troubleshooting
7-6. TROUBLESHOOTING HOT SURFACES can cause severe burns. Allow cooling period before servicing. Troubleshooting to be performed only by quali- WARNING: ELECTRIC SHOCK can kill. fied persons. Do not touch live electrical parts. Shut down welding power source, and dis- It is assumed that the unit was properly installed accord- connect input power employing lockout/tag- ing to Section 4 of this manual, the operator is familiar... -
Page 22: Section 8 - Electrical Diagrams
SECTION 8 – ELECTRICAL DIAGRAMS Circuit Diagram No. SA-150 528-B Diagram 8-1. Circuit Diagram OM-1534 Page 18... - Page 23 Notes OM-1534 Page 19...
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Page 24: Section 9 - Parts List
SECTION 9 – PARTS LIST Hardware is common and not available unless listed. ST-045 406-H Figure 9-1. Main Assembly OM-1534 Page 20... - Page 25 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ... . . 058 427 RING, retaining spool ..........
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Page 26: Optional Equipment
Dia. Part Description Quantity Mkgs. Optional Equipment ....046 820 REMOTE WIRE INCHING CONTROL, (consisting of) .... -
Page 27: Figure 9-2. Switch, Magnetic Blowout
Item Dia. Part Mkgs. Description Quantity Figure 9-2. Switch, Magnetic Blowout (Fig 9-1 Item 30) ... . . 139 392 PIN, hinge ............ -
Page 28: Figure 9-3. Wire Drive & Gears
Item Part Description Quantity Figure 9-3. Wire Drive & Gears (Fig 9-1 Item 51) ... 096 359 DRIVE ASSEMBLY, (consisting of) ........ -
Page 29: Table 9-1. Drive Roll & Wire Guide Kits
Table 9-1. Drive Roll & Wire Guide Kits NOTE Base selection of drive rolls upon the following recommended usages: 1. V-Grooved rolls for hard wire. 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. - Page 30 Notes OM-1534 Page 26...
- Page 31 Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT & PLAZCUT Model Plasma Cutting below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold...
- Page 32 FAX: 44 (0) 1204-598066 www.MillerWelds.com Contact the Delivering Carrier for: 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 2000 Miller Electric Mfg. Co. 6/00...
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