Miller Blue Thunder Series User Manual
Contents
1. 1 I emcee ie cece ae 057029003 lt 2 4 SHUNT YOKE iocis Sard a ee a ee ere ee 1 cT 056020044 Knob Pointer 1 au ES Deos 056072078 White Power On LED 1 mu 0m 756029008 Nameplate 1 x TO tr 056002010 Hand Wheel With Handle 1 NM 156118048 Front Panel 1 056076152 Dinse Socket 50 Sqmm Cx31 2 EM Lc 156012079 mide ecg tase 1 Set 056054056 Wheel Rear Fixed 2 Aa 156023157 Wheel Retaining Clip 2 eek hag el 056054058 Pivoting Wheel 2 T PPP 155119007 ve deuce 1 WU E 256071008 Primary Input 1 PE o M 656089026 Cable Clamp Hole 0 30 1 156118049 222 Panel Rear 2 1 EM 9 057035008 2 Fan Assembly 290 WV iuit AER e c E C m t 1 Io2. pM 0560592980 4 XUllb uncer ope 556019048 Regulation Screw I emcee ie cece ae 057029003 gt 22 4 SHUNT YOKE iocis bared a ee a ee ere ee cT 056020040 Knob Pointer Wr D Deos 056072078 White Power On LED mu 0m 756029010 Nameplate Front TO tr 056002010 Hand Wheel With Handle ee eee 156118048 Front Panel 056076152 Dinse Socket 50 Sqmm Cx31 EMEN SEEN 1560120479 AXI cle Ec m cte eee 056054056 Wheel Rear Fixed Aa 156023157 Wheel Retaining Clip Bela ce 056054058 Pivoting Wheel T PE 156T19007 vie 3 Rat mandet oda amen dua dance WU m 057014054 Primary Input Cable 4 6 4 PE o M 656089026 Cable Clamp Hole D 30 156118049 222 Pane
3. Ces Eiche 1 057035009 Fan Assembly 230 V 230 1 Too TE 057098016 Choke Al D 9 5 Tube L2320 1 29 suu ORL whee 056050128 Recifen PIS DD ues cedi Ba qa Rr oc a erc a 1 S iss 056067210 Switch 32 A 202 1 cp 057015079 Primary Winding 380 520 V 1 SN 176109020 lt gt REQUIATION INGOX 2 2m acier e deese nime tae des 1 DN Co PIS 656062010 Scale Holder 1 jus ee 2156122075 4 Panel Blant 9elgde x32 ence hed at ea cta ht ein db a gea e de a 1 Lid Duane teda ara 207291 Label Electric Shock 1 rco 156121010 s Handle ed re RC o rema dx ee ae eek 1 Lcid fet Severed deta 956142592 Negative Welding 1 DIC PRETENDE 956142590 Label Increase Decrease Weld Output 1 PE PES 956142591 Positive Welding 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Sugg
4. WH J aee X Un M OTEN AVA 7 7 j NN 9 804 964 Figure 7 1 Blue Thunder 253 OM 233 381 Page 20 Item Dia Part Mkgs No Description Quantity Figure 7 1 Blue Thunder 253 E ep 32156121092 Upper Panel eect speed geet dete T dob bee quie god a er ce teo rsen d 1 R PII 176254 Label General Precautionary Wordless 1 Tu pP 1560 T1019 2 25 EINNI BV ru e ted e ER Euh Cm aar hie rte 2 UL E 156122072 Panel Left Side Xa ema 1 aes unig 057015088 Secondary Winding 3 T ae eee ene 057015098 Primary Winding 230 400 2 Se ATE 057015102 Primary Winding 380 520 2 Tub EA 058021131 Transformer 3 Ph 230 400 V 1 TH EO 058021144 Transformer Ph 380 520 V 1 bh OF gen cmm 756069030 Primary Voltage Terminal Board 230 400 V 1 BE IPM 756069035 Primary Voltage Terminal Board 380 520 V 1 M aper 556070015 Primary Terminal Link 3 orc c P 05605926525 exister d aav dabit ute d un D D Rt bee od 2 ML MEER ERES 556019047 Regulation 5
5. Minutes Reduce Duty Cycle OM 233 381 Page 9 3 5 Selecting A Location 1 Lifting 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 pow er supply A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 804 961 139 445 E A Do not move or operate unit where it could tip 804 961 OM 233 381 Page 10 3 7 Weld Output Terminals and Selecting Cable Sizes NOTICE The Total Cable Length in Weld Circuit see table below is the combined length of both weld cables For example if the power source is 30 100 ft from the workpiece the total cable length in the weld circuit is 60 m 2 cables x 30 Use the 60 m 200 ft column to determine cable size Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding Weld Output Terminals Turn off power be fore connecting to weld output termi nals Do not use worn 30 m 100 ft or Less damaged under sized poorly spliced cables 45 m 60 m 70m 90 m 105 m 120 m 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 10 60 60 100 Welding Duty Duty 10 10096 Duty Cycle Amperes Cycle Cycle mm AWG mm AWG mm AWG 100 2
6. teed e 1 eel mete FM s 057035008 2 4 Fan Assembly 230 V aiser rmt s ew itte rd oe ct a 1 Ew T 057098004 des Sheek ed Bw Ex ne Ge Ip ba 1 MeO wee SELL unes 9505 T2 Z cxx RECUEI es Roe erar Greed dee cela ine pae aed 1 51 05600721TT 222 eiie dct eeu tase 1 Ecc 057015076 Primary Winding 380 520 V 1 176109019 Regulation INdEX 2 2i acta c hne atc e iim hrs Ree ewe les 1 DN Co PIS 656062010 Scale Holder 1 jus ee 21561220739 cn Panel Blant xd wi tie ebat e at ek 1 eee eee eee 207291 Label Electric Shock 1 rco 1560020191 2 Handle oae to ron ei Eee 1 Lcid fet Severed deta 956142592 Negative Welding 1 DIC PRETENDE 956142590 Label Increase Decrease Weld Output 1 PE PES 956142591 Positive Welding 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replaceme
7. ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit 400 230V 50 60Hz 51 rJ Lo m T L3 Le W T3 GND 9215020 Figure 6 2 Circuit Diagram For Blue Thunder 253 And 403 Models 380 520 V OM 233 381 Page 17 4 WARNING e Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZARD or service this unit 400 230V 50 60Hz 51 S L2 2a GND 250 400 59215023 Figure 6 3 Circuit Diagram For Blue Thunder 343 443 Models 230 400 V OM 233 381 Page 18 WARNING e Do not touch live electrical parts e e Disconnect input power or stop engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit C C O eI gt gt DI gt OIO 0O _ CN p LC O O oO mw m E NE Hr 0O OQO O X ZHO9 0S AOZS 08 9215018 Figure 6 4 Circuit Diagram For Blue Thunder 343 And 443 Models 380 520 V OM 233 381 Page 19 SECTION 7 PARTS LIST 5 Hardware is common not available unless listed LO NEN 72 N 5 5 oY 27
8. Electromagnetic Compatibility EMC Requirements IEC 60974 10 Ed 1 1 2004 10 Degrees of Protection Provided By Enclosures IP Code IEC 60529 Ed 2 1 2001 02 The product technical file is maintained by the responsible Business Unit s located at the manufacturing facility dec stat 1 07 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2009 08 Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text A Indicates a hazardous situation which if not avoided A DANGER Indicates a hazardous situation which if could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards The symbols shown below 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 Only qualified persons should install operate maintain and repair this unit During operation keep everybody e
9. Pr 1156122073 Panel Right Side 1 ee 207291 Label Electric Shock 1 een 656062010 Scale Holder 1 cum 057015103 Central Primary Winding 380 520 V 1 Lm 176109017 Hegulation Inde Ite more a Pee rhone s hm ied 1 La Oed S assis 055067221 2 e n e Brand eben a AE Beet 1 po dd uses SEI 225 0055050139 522 eiue di dro Apu o 1 ete dna itt s 156002019 lt z Handle ret tid e mde eur dier eui eso etie doma ee de eae 1 Peo ee 956142592 Negative Welding 1 e OU duae dat ed sieh i 956142590 Label Increase Decrease Weld Output 1 Yo M DIES 956142591 Positive Welding 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 233 381 Page 21 ER cd ce 9 lt A EN 255 pos
10. all weld cable connections Check for proper size and type of cable see Section 3 7 Check for proper input and output connections see Sections 3 7 and or 3 11 Replace electrode Erratic arc with excessive spatter Use dry properly stored electrodes Shorten arc length Reduce amperage setting Electrode freezing to work Increase amperage setting Increase arc length Use dry properly stored electrodes Low weld output with no control Check position of Amperage Control see Section 4 1 Limited output and low open circuit Check incoming power for correct voltage Replace line fuse if open See Section 3 11 voltage Check for proper input and output connections see Sections 3 7 and or 3 11 OM 233 381 Page 15 SECTION 6 ELECTRICAL DIAGRAMS 4 WARNING e Do not touch live electrical parts Disconnect input power stop engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit 400 230V 50 60Hz 51 R L1 U TI 5 12 Var 5 TS Ws GND 230V 400V S9215019 Figure 6 1 Circuit Diagram For Blue Thunder 253 And 403 Models 230 400 V OM 233 381 Page 16 WARNING e Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed
11. containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline e 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 e Do not use welder to thaw frozen pipes OM 233 381 Page 2 Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill Shut off shielding gas supply when not in use e Alwa
12. cycle before starting to weld again Do not block or filter airflow to unit FLYING SPARKS can injure Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away STATIC ESD can damage PC boards 3 Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards 2 em MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do 50 Do not point gun toward any part of the body other people or any metal when threading welding wire 2 3 MOVING PARTS can injure Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place se e Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the begi
13. of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label OM 233 381 Page 5 Warning Watch Out There possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Read the Owner s Manual before working on this machine 1 Consult rating label for input power requirements and check power available at the job site they must match Read Owner s Manual and inside labels for connection points and procedures Move jumper links as shown on inside label to match voltage at job site Having a loop of extra length connect grounding conductor first Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying power 207 291 2 2 WEEE Label For Products Sold Within The EU Do not discard product where ap plicable 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 233 381 Page 6 2 3 Symbols And Definitions Amperes Output Constant Current CC Rated No Load Voltage Average Negative Weld Output Terminal
14. 0 4 20 4 20 4 30 3 35 2 50 1 60 1 0 60 1 0 150 30 3 30 3 35 2 50 1 60 1 0 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 Negati Positive 2x70 2x70 2 250 35 2 50 1 60 1 0 70 2 0 95 3 0 120 4 0 5 2 m 804 944 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 4 volts or less drop or a current density of at least 300 circular mils per ampere For distances longer than those shown in this guide call a factory applications representative Milan Ref S 0007 G 2009 08 3 8 Typical Connections For Stick SMAW Welding 804 961 OM 233 381 Page 11 3 9 Positioning Jumper Links Check input voltage available at site 230 400 Volt Models 1 Jumper Links Access Remove side panel 2 Jumper Link Label Check label only one is on unit 3 Input Voltage Jumper Links Move jumper links to match input voltage Close and secure side panel 380 520 Volt Models 380 V 520 V Oe XO 3 10 Electrical Service Guide Ref S9215023 Ref S9215018 Failure to follow these fuse circuit breaker recommendations could create an electric shock or fire hazard These recommendationsare for a dedicated branch circuit that applies to the
15. 2 lt 4999 8M 4 not available unless listed Hardware is common Figure 7 2 Blue Thunder 343 OM 233 381 Page 22 Dia Part No Mkgs No Description Quantity Figure 7 2 Blue Thunder 343 E eve 1156121032 Upper Panel ces isse oh eae 1 176254 Label General Precautionary Wordless 1 T T 159601 T0 T9 23 BV 2 i2 m act pode e m ear ec Oe Ere ra c hei ctm rece Rime Co pb ees 2 DP 156122072 zu Panel Left Sid e oe SURE 1 Uu tuted 057015063 Secondary Winding 3 Gesu BA ERES 057015077 Primary Winding 380 520 2 CDM PETI 057015099 Primary Winding 230 400 2 IET y NM 058021097 Transformer Ph 380 520 V 1 v 058021132 Transformer Ph 230 400 V 1 756069035 Primary Voltage Terminal Board 380 520 V 1 TE DC 756069030 Primary Voltage Terminal Board 230 400 V 1 556070015 Primary Terminal Link 6 nie 056059266 IUE 69 6975 See 2 eed woot 556019048 Regulation Screw M
16. 24 L 245 1 TIRE 057029003 Shunt Yoke 1 TE PRI m 056020044 Knob aa uae he Saee ee Role ee o e BERS 1 14 PE s 056072078 White Power On LED 1 i ges deed 756029009 Nameplate 1 WO aed om stent 056002010 Hand Wheel 1 eee lu eee 156118048 Front Panel reier x am BE eee ee 1 de Stone sed ite Ya Roache wh 056076152 Dinse Socket 50 Sqmm Cx31 2 lt any ere em ES T9560 12079 ou ANG hie at Ernte acd Sev yd Sn 1 ey tpt 056054056 Wheel Rear Fixed 2 eV E 156023157 Wheel Retaining 2 Me 056054058 Pivoting Wheel 2 os 156119007 5 2 ns 1 Mu MR 057014053 Primary Input Cable 4 x 4 0 mm 1 Io 656089026 Cable Clamp Hole D 30 1 156118049 Panel ied Coa us aug ee
17. 6 2 9 69 X O9 Saxe esa Sep een 2 c 556019043 Regulation Screw M24 L 245 1 ius e nun ne fe 057029004 Shunt Yoke D 35 L2150 1 eode dito tot irent 056020044 Knob Pointer x sd ea oa tek cit e o Re us 1 14 PE s 056072078 White Power On LED 1 i MeO ges deii 756029011 Nameplate Fron 25 1 TU CORP 056002015 Hand Wheel 200 1 156113950 gt lt From Patel cedo re 1 ie Ds teo ee re 056076152 Dinse Socket 50 Sqmm Cx31 2 1560120805 14 60 25 E56 1 eye pee 056054057 Wheel Rear Fixed 2 E 156023156 Wheel Retaining Clip 2 Me 056054059 Pivoting Wheel 125 2 os 156118008 qwe re e 1 Mu MR 057014054 Primary Input Cable 4 x 6 4 1 Io 656089026 Cable Clamp Hole 0 30 1 ICE 156716057 s Panek Rear
18. 700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example access restrictions for passers by or individual risk assess ment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Donot place your body between welding cables Arrange cables to one side and away from the operator 3 not coil or drape cables around your body OM 233 381 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constit
19. JMESSOME Miller Processes Stick SMAW Welding Description Za EJ Arc Welding Power Source Blue Thunder Series CE Models Models 253 343 403 443 OWNER S MANUAL Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products 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 parts list will then help you to
20. Supplementary Protector Shielded Metal Arc Welding SMAW Duty Cycle Rated Supply Voltage Current Increase Scale Positive Weld Output Terminal Rated Supply Current Protective Earth Ground Remote Three Phase Transformer Rectifier 7 1 Line Connection Current Increase Decrease OM 233 381 Page 7 SECTION 3 INSTALLATION 3 1 Serial Number And Rating Label Location The serial number and rating information for this product is located on the back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 3 2 Specifications Rated Weldi Ampere Max Amperes Input at Dimensions Model I9 Range Open Circuit Ea Rated Load Output KVA KW Weight mm 230 V 380 V 400V 520 V 220 253 29 Volts DC 30 220 A 59 66 V 22 36A 21 14 6 12 80 kg 980 x 410 x 650 35 Duty Cycle 320 343 32 8 Volts DC 50 320 A 68 V 22 55A 32A 32A 23A 22 18 105 kg 980 x 410 x 650 35 Duty Cycle 400 A 403 36 Volts DC 60 400 A 66 73 V 22 7 42 28 23 115 kg 980 x 410 x 650 35 Duty Cycle 420 A 443 36 8 Volts DC 60 420 A 78M 22 47 47 34A 32 26 175 kg 1150 x 520 x 730 45 Duty Cycle 3 3 Volt Ampere Curves The volt ampere curves show the nor mal minimum an
21. Within The EU 6 2 9 Symbols And Definitions obs ERR RE LR ERA Geis Gans ae ey Fre dde eae ay 7 SECTION 3 INSTALLATION RES eee as a RR RE REIR EEDE NRA 8 3 1 Serial Number And Rating Label Location 8 3 2 SPECHICAlIONS scs eius oot de Re NI EE P XXI S eee ed ERE REDE 8 2 2 MOIBATRDOTG HEUS Us Edu quat adir e UL A d RO 8 3 4 Duty Cycle and Overheating a mg eg d se Eg a e d 9 25 5 gt 16 sem peri aree d eee Hed e O ed 10 Seo SIMON Ses oie ah 10 3 7 Weld Output Terminals and Selecting Cable Sizes 11 3 8 Typical Connections For Stick SMAW 0 11 3 9 POSITIONING Jumper bInKSs open ee ee ee ee eee eee aes 12 3 10 Electri al Service Gude Rina Kee RR 12 3 11 Connecting NHU FOWE e RR e Rae Ret E RE ERA ERES ERR IE NE EVE ae eee ak 13 SECTION 4 OPERATION iurare nro teed s 14 d GOLFO Sus crece Du aiat DEL RD Rn d Et D dera ae
22. cility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER milan_warr 2009 05 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address 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 Pr
23. d maximum voltage and amperage output capabilities of the unit Model 253 Model 343 O O DC VOLTS JI DC VOLTS JI NO O N O 50 100 150 200 250 300 350 400 450 J TRU MIGE ANE EAER DC AMPERES DC AMPERES Model 403 Model 443 80 DC VOLTS DC VOLTS B D NO O 50 100 150 200 250 300 350 400 450 50 100 150 200 250 300 350 400 450 DC AMPERES DC AMPERES OM 233 381 Page 8 3 4 Duty Cycle and Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty Model 253 35 Duty Cycle Model 343 35 Duty Cycle Rated Output LLI LLI or or LU LLI OW OW gt gt lt lt Z Z 20 25 30 3540 50 60 70 80 90100 25 30 3540 50 60 70 8090100 DUTY CYCLE DUTY CYCLE Model 403 35 Duty Cycle Model 443 45 Duty Cycle Rated Output 700 700 0 600 0 600 500 2 500 gt lt 400 5 gt 2 400 300 300 200 200 20 25 30 3540 50 60 708090100 25 30 3540 50 60 70 8090100 DUTY CYCLE 35 Duty Cycle 45 Duty Cycle 5462 A OE 3 5 Minutes Welding 6 5 Minutes Resting 4 5 Minutes Welding 5 5 Minutes Resting ew
24. decide which exact part you may need to fix the problem Warranty and service information for your particular model are also provided 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 Working as hard as you do every power source from Miller is backed by the most hassle free warranty in the business 2 Miller TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE 1 RACER one een ade taney 1 152 Are Welding Hazardo Ae See a uim deu ade a eee 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 06 4 1 5 Principal Safety Standards Dc rd c cae c o S co Dodo ate ND 4 156 MIATA B OTI uh gh an abe RAT i Rari t t at d cnc oat ae HE o cor ey pa 4 SECTION 2 DEFINITIONS ei ex ee ese Code E ous Fe eee eee oe 5 2 1 Warning Label Definitions For Wordless Labels 5 2 2 WEEE Label For Products Sold
25. ded according to this manual e lf 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 OM 233 381 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq 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 reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2
26. e Blue Limited Warranty shall not apply to 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 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Millers 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 fa
27. ested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 233 381 Page 27 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual Notes Notes 2 Miller Effective January 1 2009 This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below ITW Welding Products Italy warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date the equipment was delivered to the origi
28. hing these fumes and gases can be hazardous to your health 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 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 e 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 e 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 e Do not weld on coated metals such as galvanized lead or cadmium plated 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 ARC RAYS can burn eyes and skin 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 e Wear an approved welding helmet fitted with a
29. ivata Iseo 6 E 20098 San Giuliano Milanese Italy Contact the Delivering Carrier to File a claim for loss or damage during Phone 39 0 2982901 shipment Fax 39 0 298290 203 email miller itw welding it 2 Miller For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department ORIGINAL INSTRUCTIONS PRINTED IN USA 2009 Miller Electric Mfg Co 2009 01
30. l Rear ie ped ae tos edic eem cedit BRE fta EM 057035009 2 Fan Assembly 290 W uri th ARR e o E e oe t RB 057098016 CHOKE ao ORC dicitis bere 29 1 056050140 eve b eode s qas 590 2 Sls 056067210 OWC aeter Gs She del 057015105 Central Primary Winding 380 520 V Died yt 176109018024 Hegulation Inde iuo Send an a Pe e eros ee med 656062010 Scale Holder 2156122073 Panels dew aeu RN 207291 Label Electric Shock moo 156002019 Handle hore Ede ais 956142592 Negative Welding Terminal gt AA 956142590 Label Increase Decrease Weld Output o 956142591 Positive Welding Item Dia Part Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts fro
31. m your local distributor OM 233 381 Page 25 Hardware is common not available unless listed 24 N 4 YW LLL 804 962 21 Figure 7 4 Blue Thunder 443 OM 233 381 Page 26 Item Dia Part Mkgs No Description Quantity Figure 7 4 Blue Thunder 443 E eee eee ee 1156121033 Upper Panel osx eal dined 1 Sige alae cia i Rea ca 176254 Label General Precautionary Wordless 1 TU T 15601 T0 19 2 2 EYG 2 Ere rhe ctm uem eo 2 PE 155122074 Panel Left Side ues Seek MUERE ewe oe ERU SUR Ea 1 PE S Tested TEE 057015065 Secondary Winding 70 X 115 1 2 057015080 Primary Winding 380 520 2 be o soe 057015091 Primary Winding 230 400 V 70 115 3 ee ee 058021098 Transformer Ph 380 520 V 70 X 115 Al 1 hans E MET 058021114 Transformer Ph MMA 230 400 V 70 X 115 AI 1 756069035 Primary Voltage Terminal Board 380 520 V 1 PD C 756069030 Primary Voltage Terminal Board 230 400 V 1 ET 556070015 Primary Terminal Link 6 p o anes Sch 05605925
32. n a plar 14 SECTION 5 MAINTENANCE AND TROUBLESHOOTING 15 5 12 MAMENANG vs daa os ecd cete th ri rod e Ra as n ei 15 5 2 JMOHDIGSIOOHFTQ s aereo oa ecrire Rd pene o ara grad 15 SECTION 6 ELECTRICAL DIAGRAMS 225055 Ex nave dea EE ACRES EE 16 SECTION 7 PARTS LIST it RD 3G RR IRRERESRIRG ERR 20 WARRANTY Declaration of Conformity for European Community CE Products t This information is provided for units with CE certification see rating label on unit Manufacturer European Contact ITW Welding Products Italy S r l Mr Danilo Fedolfi Via Privata Iseo 6 E Managing Director 20098 San Giuliano ITW Welding Products Italy S r l Milanese Italy Via Privata Iseo 6 E Phone 39 02 98290 1 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 Sb European Contact Signature Declares that this product B r 253 343 403 443 conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC 2006 95 EC Electromagnetic Compatibility Directives 89 336 EEC 92 31 EEC 2004 108 EC Machinery Directives 98 37EEC 91 368 EEC 92 31 EEC 133 04 93 68 EEC CE Marking Directive 93 68 EEC Standards Arc Welding Equipment Part 1 Welding Power Sources IEC 60974 1 Ed 3 2005 07 Arc Welding Equipment Part 10
33. nal retail purchaser not to exceed eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers limited to only include SCRs diodes and discrete rectifier components where applicable 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 Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 2 Years Parts and Labor Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers RFCS Foot Controls IHPS Power Sources and Coolers Water Coolant Systems Non Integrated HF Units Running Gear Trailers 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 4 1 Year Parts and Labor Unless Specified DC 253 amp 403 Rectifier April 062 Migmatic 171 April 06 gt 5 6 Months Batteries 6 90 Days Parts MIG Guns Induction Heating Coils and Blankets Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns QCanvas Covers Millers Tru
34. nductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 233 381 Page 12 3 11 Connecting Input Power A Installation must meet all Na tional and Local Codes have only qualified persons make this installation A Disconnect and lockout tag out input power before con necting input conductors from unit EZ A Always connect green or green yellow conductor to 2 GND PE supply grounding terminal first and never toa line ter 1 minal A Make input power connec tions to the welding power source first de ESTA 2 Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC L1 U Section 20 d NOTICE Verify j link Verify jumper links GND PE L3 W match input voltage see Section Connect First 3 9 See rating label on unit and check input voltage available at site 1 Disconnect Device switch shown in OFF position 2 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding terminal first 3 Disconnect Device Line Terminals Connect input conductors L1 U L2 V And L3 W to disconnect device line terminals 4 Overcurrent Protection Select t
35. nning of the manual and in each section e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained 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 ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots Be sure all equipment in the welding area is electromagnetically compatible 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 e Be sure this welding machine is installed and groun
36. nt Parts Model and serial number required when ordering parts from your local distributor OM 233 381 Page 23 not available unless listed Hardware is common co 24 co CN LO N N N N y A OD Y 422 4 Wr o Mie gt 7 CL CT gt 7 WE d A an Figure 7 3 Blue Thunder 403 OM 233 381 Page 24 Mkgs No Description Quantity Figure 7 3 Blue Thunder 403 TE Merc 32156121092 Upper Panel uda it pde ewe oce tee D qum nn 176254 Label General Precautionary Wordless T DX RTT 1560 T1019 EINNI EYS 3L dedo ru dae uh eh aar oie rte T MT E 156122072 Panel Left Side 22552204 ema 057015100 Secondary Winding DE ohare coon 057015101 Primary Winding 230 400 057015104 Primary Winding 380 520 TW PES 058021142 Transformer 3 Ph 230 400 V Wu IE aen 058021145 Transformer Ph 380 520 V TL Rv Mc 756069030 Primary Voltage Terminal Board 230 400 TE TI 756069035 Primary Voltage Terminal Board 380 520 T 556070015 Primary Terminal Link
37. proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection FRA WELDING can cause fire or explosion 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 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 e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e 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 e Do not weld on closed
38. rated output and duty cycle of the welding power source 253 343 403 443 Input Voltage V 230 400 230 380 400 520 230 400 230 380 400 520 Input Amperes A At Rated Output 36 21 55 32 32 23 73 42 80 47 47 36 Max Recommended Standard Fuse Rating In Amperes Time Delay Fuses 2 45 25 60 40 40 30 80 50 100 60 50 40 Normal Operating Fuses 3 50 30 80 50 48 35 110 60 125 70 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 106 127 107 193 130 220 84 168 114 202 148 251 In Feet Meters 32 39 83 59 40 67 25 51 85 61 45 76 Min Grounding Conductor Size In AWG 4 10 14 8 10 12 12 8 10 6 8 10 10 Power cord supplied with the unit is sized for 230V operation Larger power cord may be required for cable lengths greater than 3 meters onsult national and local regulations Reference 2008 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class 65 amps and above 4 Conductor data in this section specifies co
39. rn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when oylinder is in use or connected for use 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 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit NEZ FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit Keep equipment cables and cords away from moving vehicles when working from an aerial location Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty
40. semiautomatic DC 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 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 5 Indicates special instructions a 4 This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards 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 grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over yo
41. specially children away ELECTRIC SHOCK can kill 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 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 grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground 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 unit Additional safety 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
42. uents are known to the State of California to cause cancer birth defects and other reproductive harm 25 West 48rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CPSC gOV Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Donot weld whilst carrying the welding power source or wire feeder Abo
43. ur body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of inputpower e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 233 381 Page 1 FUMES AND GASES be hazardous Welding produces fumes and gases Breat
44. ut Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 DEFINITIONS 2 1 Warning Label Definitions For Wordless Labels Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring 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 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 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 Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson 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
45. ype and size of overcurrent protection using Section 3 10 fused disconnect switch shown Close and secure door on line dis connect device Remove lockout tagout device and place switch in the On position 804 961 801 721 OM 233 381 Page 13 SECTION 4 OPERATION 4 1 Controls Welding Current Indicator Weld Current Control Positive Weld Terminal Negative Weld Terminal Power On Off Switch Power On Pilot Light 0000000000000000000 2 25 325 4 5 40 90 130 180 20 3 H 804 944 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 233 381 Page 14 SECTION 5 MAINTENANCE AND TROUBLESHOOTING 5 1 Routine Maintenance Check Change Clean x Replace To be done by Factory Authorized Service Agent Every 3 Months Damaged Or Cracked Weld cables Q Weld Connections Unreadable Labels Every 6 Months Inside Unit 5 2 Troubleshooting Trouble Remedy No weld output fan does not run sure Power switch is On see Section 4 1 Be sure line disconnect switch is in On position Check and replace line fuses if open Reset breakers if necessary Fan does not run weld output okay Be sure nothing is blocking movement of fan If fan does not run freely replace fan motor Erratic or improper weld output Clean and tighten
46. ys ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect ImplantedMedical Devices Wearers of Pacemakers and other Implanted Medical Devices should keep away Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high CYLINDERS can explode if damaged 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 Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Tu
Download Pdf Manuals
Related Search