Miller Blue Thunder Series, Owner'S Manual

Page 1: ...Processes Blue Thunder Series OM 233 381L 2015 06 Description Arc Welding Power Source Stick SMAW Welding Models 253 343 403 443 Visit our website at www MillerWelds com CE Models ...

Page 2: ...ducts Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The par...

Page 3: ...1 Serial Number And Rating Label Location 8 3 2 Specifications 8 3 3 Environmental Specifications 8 3 4 Volt Ampere Curves 9 3 5 Duty Cycle and Overheating 10 SECTION 4 INSTALLATION 11 4 1 Selecting A Location 11 4 2 Selecting Cable Sizes 12 4 3 Weld Output Terminals 12 4 4 Typical Connections For Stick SMAW Welding 12 4 5 Positioning Jumper Links 13 4 6 Electrical Service Guide 13 4 7 Connecting ...

Page 4: ...3 BLUE THUNDER 403 V 230 400 029016234 BLUE THUNDER 403 V 380 520 029016235 BLUE THUNDER 443 V 230 400 029016236 BLUE THUNDER 443 V 380 520 029016237 Council Directives 2006 95 EC Low Voltage 2004 108 EC Electromagnetic Compatibility 2011 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equipment Standards IEC 60974 1 2012 Arc Welding Equipment Part 1 Weldi...

Page 5: ...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 recommende...

Page 6: ...operly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline 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 Do not use welder to thaw frozen pip...

Page 7: ...G PARTS can injure Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS Read and follow all labels and the...

Page 8: ... NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 the...

Page 9: ...urself from work and ground Safe3 2012 05 Disconnect input plug or power before working on machine Safe5 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation or local exhaust to remove the fumes Safe8 2012 05 Use ventilating fan to remove fumes Safe10 2012 05 Keep flammables away from welding Do not weld near flammables Safe12 2012 05 Welding sparks can cause fires Have a f...

Page 10: ...nts and procedures Safe67 2012 06 V A Consult rating label for input power requirements Safe34 2012 05 3 1 Safe49 2012 05 Move jumper links as shown on inside label to match input voltage at job site Include extra length in grounding conductor and connect grounding conductor first Connect line input conductors as shown on inside label Double check all connections jumper link positions and input vo...

Page 11: ...rotective Earth Ground Supplementary Protector Off On V Volts Shielded Metal Arc Welding SMAW Input Remote Output Constant Current CC X Duty Cycle I1 Rated Supply Current Three Phase Transformer Rectifier U0 Rated No Load Voltage OCV U1 Rated Supply Voltage Fuse Line Connection Current Increase Scale Current Increase Decreas e Notes ...

Page 12: ...e EMF limits for the general public might be exceeded during welding This equipment is built in accordance with EN 60974 1 and is intended to be used only in an occupational environment where the general public access is prohibited or regulated in such a way as to be similar to occupational use by an expert or an instructed person Wire feeders and ancillary equipment such as torches liquid cooling...

Page 13: ... 403 80 60 40 20 0 0 50 100 150 200 250 300 350 400 450 80 60 40 20 0 0 50 100 150 200 250 300 350 400 450 DC VOLTS DC AMPERES 80 60 40 20 0 0 50 100 150 200 250 300 350 400 450 80 60 40 20 0 0 50 100 150 200 250 300 350 400 450 DC VOLTS DC AMPERES DC VOLTS DC AMPERES DC VOLTS DC AMPERES Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 14: ... Resting 3 5 Minutes Welding 6 5 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes 20 25 30 40 50 60 70 80 90100 35 250 200 150 100 50 Rated Output 300 20 25 30 40 50 60 70 80 90100 35 700 600 500 400 300 Rated Output 200 600 500 400 300 30 40 50 60 70 8090100 200 35 25 Rated Output 100 343 Model 443 45 Duty Cycle 600 500 400 300 30 40 50 60 70 80 90100 700 35 25 Rated Output 20...

Page 15: ...fting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Line Disconnect Device Locate unit near correct input power supply 4 1 Selecting A Location 3 18 in 460 mm 18 in 460 mm OR 1 2 Movement Location And Airflow loc_large 2015 04 804 961 a Do not move or operate unit where it could tip ...

Page 16: ...70 2 0 95 3 0 95 3 0 200 30 3 35 2 50 1 60 1 0 70 2 0 95 3 0 120 4 0 120 4 0 250 35 2 50 1 60 1 0 70 2 0 95 3 0 120 4 0 2x70 2x2 0 2x70 2x2 0 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere For distances longer tha...

Page 17: ...0 70 Time Delay Fuses 2 45 25 60 40 30 80 50 100 50 40 Normal Operating Fuses 3 50 30 80 48 35 110 60 125 70 50 Min Input Conductor Size In AWG 4 10 14 8 10 12 12 8 10 6 8 10 10 Max Recommended Input Conductor Length In Feet Meters 106 32 127 39 107 33 193 59 130 40 220 67 84 25 168 51 114 35 202 61 148 45 251 76 Min Grounding Conductor Size In AWG 4 10 14 8 10 12 12 8 10 6 8 10 10 Power cord supp...

Page 18: ...OM 233 381 Page 14 4 7 Connecting 3 Phase Input Power input2 2012 05 Ref 803 766 C GND PE Earth Ground L1 2 1 L2 L3 3 3 4 5 6 7 Tools Needed ...

Page 19: ...peration 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors L1 L2 And L3 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding ter minal first Connect input conductors L1 L2 and L3 to disconnect device line terminal...

Page 20: ...ing Current Indicator 2 Weld Current Control 3 Positive Weld Terminal 4 Negative Weld Terminal 5 Power On Off Switch 6 Power On Pilot Light 804 944 1 2 3 4 5 6 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 21: ...g movement of fan If fan does not run freely replace fan motor Erratic or improper weld output Clean and tighten all weld cable connections Check for proper size and type of cable see Section 4 2 Check for proper input and output connections see Sections 4 7 and or 4 4 Replace electrode Erratic arc with excessive spatter Use dry properly stored electrodes Shorten arc length Reduce amperage setting...

Page 22: ...OM 233 381 Page 18 SECTION 7 ELECTRICAL DIAGRAMS S9215019 Figure 7 1 Circuit Diagram For Blue Thunder 253 And 403 Models 230 400 V ...

Page 23: ...OM 233 381 Page 19 S9215020 Figure 7 2 Circuit Diagram For Blue Thunder 253 And 403 Models 380 520 V ...

Page 24: ...OM 233 381 Page 20 S9215023 Figure 7 3 Circuit Diagram For Blue Thunder 343 And 443 Models 230 400 V ...

Page 25: ...OM 233 381 Page 21 S9215018 Figure 7 4 Circuit Diagram For Blue Thunder 343 And 443 Models 380 520 V ...

Page 26: ... 22 SECTION 8 PARTS LIST Hardware is common and not available unless listed 9 8 7 6 5 32 30 27 4 3 1 28 25 24 23 22 21 20 19 38 18 17 37 36 16 14 15 33 34 12 11 10 35 13 804 964 26 2 29 31 Figure 8 1 Blue Thunder 253 ...

Page 27: ...76152 Dinse Socket 50 Sqmm Cx31 2 19 156012079 Axle 1 20 056054056 Wheel Rear Fixed 2 21 156023157 Wheel Retaining Clip 2 22 056054058 Pivoting Wheel 2 23 156118007 Base 1 24 256071008 Primary Input Cable 1 25 656089026 Cable Clamp Hole D 30 1 26 156118049 Panel Rear 1 27 FM 057035008 Fan Assembly 230 V 1 28 156122073 Panel Right Side 1 29 207291 Label Electric Shock Input 1 30 656062010 Scale Hol...

Page 28: ... 381 Page 24 Hardware is common and not available unless listed 9 8 7 6 5 31 32 33 4 27 3 1 34 26 25 24 23 22 21 20 19 39 18 17 38 37 16 13 14 15 30 28 12 11 10 36 29 804 963 2 35 Figure 8 2 Blue Thunder 343 ...

Page 29: ...inse Socket 50 Sqmm Cx31 2 19 156012079 Axle 1 20 056054056 Wheel Rear Fixed 2 21 156023157 Wheel Retaining Clip 2 22 056054058 Pivoting Wheel 2 23 156118007 Base 1 24 057014053 Primary Input Cable 4 x 4 0 mm 1 25 656089026 Cable Clamp Hole D 30 1 26 156118049 Panel Rear 1 27 FM 057035008 Fan Assembly 230 V 1 28 057098004 Choke 1 29 SR1 056050127 Rectifier 1 30 S1 056067210 Switch 1 31 057015076 P...

Page 30: ... 381 Page 26 Hardware is common and not available unless listed 804 963 9 8 7 6 5 31 32 33 4 27 3 1 34 26 25 24 23 22 21 20 19 39 18 17 38 37 16 13 14 15 30 28 12 11 10 36 29 2 35 Figure 8 3 Blue Thunder 403 ...

Page 31: ...ket 50 Sqmm Cx31 2 19 156012079 Axle 1 20 056054056 Wheel Rear Fixed 2 21 156023157 Wheel Retaining Clip 2 22 056054058 Pivoting Wheel 2 23 156118007 Base 1 24 057014054 Primary Input Cable 4 x 6 M4 1 25 656089026 Cable Clamp Hole D 30 1 26 156118049 Panel Rear 1 27 FM 057035009 Fan Assembly 230 V 1 28 057098016 Choke 1 29 SR1 056050140 Rectifier 1 30 S1 056067210 Switch 1 31 057015105 Central Pri...

Page 32: ... 381 Page 28 Hardware is common and not available unless listed 1 3 36 34 4 9 8 7 6 5 31 27 26 25 24 23 22 21 20 19 39 18 17 38 37 16 10 11 12 13 14 15 30 28 32 33 804 962 29 2 35 Figure 8 4 Blue Thunder 443 ...

Page 33: ... Dinse Socket 50 Sqmm Cx31 2 19 156012080 Axle D 25 L 619 1 20 056054057 Wheel Rear Fixed 2 21 156023156 Wheel Retaining Clip 2 22 056054059 Pivoting Wheel D 125 2 23 156118008 Base 1 24 057014054 Primary Input Cable 4 x 6 M4 1 25 656089026 Cable Clamp Hole D 30 1 26 156118051 Panel Rear 1 27 FM 057035009 Fan Assembly 230 V P 3 230 V 1 28 057098016 Choke Al D 9 5 Tube L 320 1 29 SR1 056050128 Rect...

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Page 35: ...ontrollers Powered Air Purifying Respirator PAPR Blower Unit No Labor Racks Running Gear and Trailers Subarc Wire Drive Assemblies Water Coolant Systems Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets MIG Guns Remote Controls Replacement Parts No Labor Spoolmate Spoolguns Cables and Non Electronic Contr...

Page 36: ...ry Zip Postal Code Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Service and Repair Replacement Parts Owner s Manuals Contact the Delivering Carrier to For Service File a claim for loss or damage during shipment For assis...