Blue Thunder 253 PDF

OM-233 381C 2007−09
Processes
Stick (SMAW) Welding
Description
Arc Welding Power Source
Blue Thunder Series
Models: 253, 343, 403, 443
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www.MillerWelds.com
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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 Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
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
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. 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 specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2005−04

TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Warning Label Definitions (For Wordless Labels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-3. Manufacturer’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-4. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-3. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-5. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-6. Weld Output Terminals and Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-7. Typical Connections For Stick (SMAW) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-8. Positioning Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-10. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WARRANTY

Declaration of Conformity for
European Community (CE) Products
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
European Contact Signature:
Declares that this product: Blue Thunder 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: 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_milan1/07
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2007−04
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex- SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text. bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.
1-2. Arc Welding Hazards
Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and Frequently inspect input power cord for damage or bare wiring −
repair this unit. replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
During operation, keep everybody, especially children, away. Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
ELECTRIC SHOCK can kill. If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Touching live electrical parts can cause fatal shocks Do not touch electrode if you are in contact with the work, ground,
or severe burns. The electrode and work circuit is or another electrode from a different machine.
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also Do not touch electrode holders connected to two welding ma-
live when power is on. In semiautomatic or automatic wire welding, the chines at the same time since double open-circuit voltage will be
wire, wire reel, drive roll housing, and all metal parts touching the present.
welding wire are electrically live. Incorrectly installed or improperly Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
Do not touch live electrical parts. Wear a safety harness if working above floor level.
Wear dry, hole-free insulating gloves and body protection.
Keep all panels and covers securely in place.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work Clamp work cable with good metal-to-metal contact to workpiece
or ground. or worktable as near the weld as practical.
Do not use AC output in damp areas, if movement is confined, or if Insulate work clamp when not connected to workpiece to prevent
there is a danger of falling. contact with any metal object.
Use AC output ONLY if required for the welding process. Do not connect more than one electrode or work cable to any
If AC output is required, use remote output control if present on single weld output terminal.
unit.
Additional safety precautions are required when any of the follow-
SIGNIFICANT DC VOLTAGE exists in inverter-type
ing electrically hazardous conditions are present: in damp welding power sources after removal of input
locations or while wearing wet clothing; on metal structures such power.
as floors, gratings, or scaffolds; when in cramped positions such Turn Off inverter, disconnect input power, and discharge input
as sitting, kneeling, or lying; or when there is a high risk of unavoid- capacitors according to instructions in Maintenance Section
able or accidental contact with the workpiece or ground. For these before touching any parts.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt- HOT PARTS can cause severe burns.
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone! Do not touch hot parts bare handed.
Disconnect input power or stop engine before installing or Allow cooling period before working on gun or
servicing this equipment. Lockout/tagout input power according to torch.
OSHA 29 CFR 1910.147 (see Safety Standards). To handle hot parts, use proper tools and/or
Properly install and ground this equipment according to its wear heavy, insulated welding gloves and
Owner’s Manual and national, state, and local codes. clothing to prevent burns.
OM-233 381 Page 1

Do not use welder to thaw frozen pipes.
FUMES AND GASES can be hazardous.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your Wear oil-free protective garments such as leather gloves, heavy
health. shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
Keep your head out of the fumes. Do not breathe the fumes. from your person before doing any welding.
If inside, ventilate the area and/or use local forced ventilation at the After completion of work, inspect area to ensure it is free of sparks,
arc to remove welding fumes and gases. glowing embers, and flames.
If ventilation is poor, wear an approved air-supplied respirator. Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables, Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
coatings, cleaners, and degreasers. for hot work and have a fire watcher and extinguisher nearby.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
FLYING METAL or DIRT can injure eyes.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
ing air is safe.
they can throw off slag.
Do not weld in locations near degreasing, cleaning, or spraying op-
Wear approved safety glasses with side
erations. The heat and rays of the arc can react with vapors to form
shields even under your welding helmet.
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
BUILDUP OF GAS can injure or kill.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements Shut off shielding gas supply when not in use.
can give off toxic fumes if welded. Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.

MAGNETIC FIELDS can affect Implanted
Arc rays from the welding process produce intense Medical Devices.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the Wearers of Pacemakers and other Implanted
weld.
Medical Devices should keep away.
Wear an approved welding helmet fitted with a proper shade of fil- Implanted Medical Device wearers should consult their doctor
ter lenses to protect your face and eyes when welding or watching and the device manufacturer before going near arc welding, spot
(see ANSI Z49.1 and Z87.1 listed in Safety Standards). welding, gouging, plasma arc cutting, or induction heating
Wear approved safety glasses with side shields under your operations.
helmet.
Use protective screens or barriers to protect others from flash, NOISE can damage hearing.
glare and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant mate- Noise from some processes or equipment can
rial (leather, heavy cotton, or wool) and foot protection. damage hearing.
Wear approved ear protection if noise level is
WELDING can cause fire or explosion. high.
Welding on closed containers, such as tanks, CYLINDERS can explode if damaged.

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 Shielding gas cylinders contain gas under high
burns. Accidental contact of electrode to metal objects can cause pressure. If damaged, a cylinder can explode. Since
sparks, explosion, overheating, or fire. Check and be sure the area is gas cylinders are normally part of the welding
safe before doing any welding. process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechani-
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
cal shocks, physical damage, slag, open flames, sparks, and arcs.
this is not possible, tightly cover them with approved covers.
Install cylinders in an upright position by securing to a stationary
Do not weld where flying sparks can strike flammable material. support or cylinder rack to prevent falling or tipping.
Protect yourself and others from flying sparks and hot metal. Keep cylinders away from any welding or other electrical circuits.
Be alert that welding sparks and hot materials from welding can Never drape a welding torch over a gas cylinder.
easily go through small cracks and openings to adjacent areas. Never allow a welding electrode to touch any cylinder.
Watch for fire, and keep a fire extinguisher nearby. Never weld on a pressurized cylinder − explosion will result.
Be aware that welding on a ceiling, floor, bulkhead, or partition can Use only correct shielding gas cylinders, regulators, hoses, and fit-
cause fire on the hidden side. tings designed for the specific application; maintain them and
Do not weld on closed containers such as tanks, drums, or pipes, associated parts in good condition.
unless they are properly prepared according to AWS F4.1 (see Turn face away from valve outlet when opening cylinder valve.
Safety Standards). Keep protective cap in place over valve except when cylinder is in
Do not weld where the atmosphere may contain flammable dust, use or connected for use.
gas, or liquid vapors (such as gasoline). Use the right equipment, correct procedures, and sufficient num-
Connect work cable to the work as close to the welding area as ber of persons to lift and move cylinders.
practical to prevent welding current from traveling long, possibly Read and follow instructions on compressed gas cylinders,
unknown paths and causing electric shock, sparks, and fire associated equipment, and Compressed Gas Association (CGA)
hazards. publication P-1 listed in Safety Standards.
OM-233 381 Page 2

1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

Do not install or place unit on, over, or near Keep away from moving parts such as fans.
combustible surfaces. Keep all doors, panels, covers, and guards
Do not install unit near flammables. closed and securely in place.
Do not overload building wiring − be sure power supply system is Have only qualified persons remove doors, panels, covers, or
properly sized, rated, and protected to handle this unit. guards for maintenance as necessary.
Reinstall doors, panels, covers, or guards when maintenance is
FALLING UNIT can cause injury. finished and before reconnecting input power.
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. Read Owner’s Manual before using or servic-
If using lift forks to move unit, be sure forks are ing unit.
long enough to extend beyond opposite side of Use only genuine replacement parts from the
unit. manufacturer.
OVERUSE can cause OVERHEATING

H.F. RADIATION can cause interference.
Allow cooling period; follow rated duty cycle.
High-frequency (H.F.) can interfere with radio
Reduce current or reduce duty cycle before navigation, safety services, computers, and
starting to weld again. communications equipment.
Do not block or filter airflow to unit. Have only qualified persons familiar with
electronic equipment perform this installation.
FLYING SPARKS can cause injury. The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
Wear a face shield to protect eyes and face. tion.
Shape tungsten electrode only on grinder with If notified by the FCC about interference, stop using the
proper guards in a safe location wearing proper equipment at once.
face, hand, and body protection. Have the installation regularly checked and maintained.
Sparks can cause fires — keep flammables away. Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
STATIC (ESD) can damage PC boards. minimize the possibility of interference.
Put on grounded wrist strap BEFORE handling

boards or parts. ARC WELDING can cause interference.
Use proper static-proof bags and boxes to
store, move, or ship PC boards. Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
MOVING PARTS can cause injury. such as robots.
Be sure all equipment in the welding area is
Keep away from moving parts.
electromagnetically compatible.
Keep away from pinch points such as drive
rolls. 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-
WELDING WIRE can cause injury. tronic equipment.
Be sure this welding machine is installed and grounded
Do not press gun trigger until instructed to do
according to this manual.
so.
If interference still occurs, the user must take extra measures
Do not point gun toward any part of the body,
such as moving the welding machine, using shielded cables,
other people, or any metal when threading
using line filters, or shielding the work area.
welding wire.
OM-233 381 Page 3

1-4. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling. defects, and other reproductive harm.
1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
from Global Engineering Documents (phone: 1-877-413-5184, website: 416-747-4044, website: www.csa-international.org).
www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec-
Recommended Safe Practices for the Preparation for Welding and Cut- tion, ANSI Standard Z87.1, from American National Standards Institute,
ting of Containers and Piping, American Welding Society Standard 25 West 43rd Street, New York, NY 10036–8002 (phone:
AWS F4.1, from Global Engineering Documents (phone: 212-642-4900, website: www.ansi.org).
1-877-413-5184, website: www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
National Electrical Code, NFPA Standard 70, from National Fire Protec- Work, NFPA Standard 51B, from National Fire Protection Association,
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone: P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-
617-770-3000, website: www.nfpa.org and www. sparky.org). site: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
from Compressed Gas Association, 4221 Walney Road, 5th Floor, and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
Code for Safety in Welding and Cutting, CSA Standard W117.2, from (phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Canadian Standards Association, Standards Sales, 5060 Mississauga, Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them, or using a
Electric And Magnetic Fields cable cover.
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from opera-
Research Council concluded that: “The body of evidence, in the tor as practical.
committee’s judgment, has not demonstrated that exposure to power-
5. Connect work clamp to workpiece as close to the weld as possi-
frequency electric and magnetic fields is a human-health hazard.”
ble.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you About Implanted Medical Devices:
may wish to minimize your exposure to electromagnetic fields when Implanted Medical Device wearers should consult their doctor and the
welding or cutting. device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
To reduce magnetic fields in the workplace, use the following If cleared by your doctor, then following the above procedures is recom-
procedures: mended.
OM-233 381 Page 4

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 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 are
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.
2 Read Owner’s Manual and
inside labels for connection
points and procedures.
3 Move jumper links as shown
on inside label to match
voltage at job site.
4 Having a loop of extra length,
connect grounding conductor
first.
5 Connect line input conductors
as shown on inside label −
double-check all connections,
jumper link positions, and
input voltage before applying
power.
1/96
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. Manufacturer’s Rating Label
OM-233 381 Page 7

2-4. Symbols And Definitions
A Amperes
Negative Weld
Output Terminal
Positive Weld
Output Terminal
Protective Earth
(Ground)
Supplementary
Output Off On
Protector
V Volts
Shielded Metal Arc
Welding (SMAW)
Input Remote
Three Phase
Constant Current
(CC) X Duty Cycle
I1 Rated Supply
Current
Transformer
Rectifier
U0 Rated No-Load
Voltage (Average) U1 Rated Supply
Voltage
Fuse Line Connection
Current Increase Current Increase/

Scale Decrease
OM-233 381 Page 8

SECTION 3 − INSTALLATION
3-1. Specifications
Ampere Max Amperes Input at Dimensions

Rated Welding IP Rated Load Output,
Model Range Open-Circuit KVA/KW Weight (mm)
Output Rating 50/60 Hz, Three-Phase
DC Voltage DC LxWxH
230 V 380 V 400 V 520 V
220 A @
253 29 Volts DC, 30-220 A 59-66 V IP22 36 A −− 21 A −− 14.6/12 80 kg 980 x 410 x 650
35% Duty Cycle
320 A @
343 32.8 Volts DC, 50-320 A 68 V IP22 55 A 32 A 32 A 23 A 22/18 105 kg 980 x 410 x 650
35% Duty Cycle
400 A @
403 36 Volts DC, 60-400 A 66-73 V IP22 73 A −− 42 A −− 28/23 115 kg 980 x 410 x 650
35% Duty Cycle
420 A @
443 36.8 Volts DC, 60-420 A 78 V IP22 80 A 47 A 47 A 34 A 32/26 175 kg 1150 x 520 x 730
45% Duty Cycle
3-2. Volt-Ampere Curves

The volt-ampere curves show the
normal minimum and maximum
voltage and amperage output capa-
bilities of the unit.
Model 253 Model 343

80 80
60 60
DC AMPERES
DC AMPERES
40 40
20 20
0 0
0 50 100 150 200 250 300 350 400 450
0 50 100 150 200 250 300 350 400 450
DC VOLTS
DC VOLTS
Model 403 Model 443

80 80
DC AMPERES
60 60
DC AMPERES
40 40
20 20
0 0
0 50 100 150 200 250 300 350 400 450
0 50 100 150 200 250 300 350 400 450
DC VOLTS DC VOLTS
OM-233 381 Page 9

3-3. 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 Rated Output
300
250 600
WELDING AMPERES
WELDING AMPERES
200 500
150
400
100
300
50
200
343
100
20 25 30 35 40 50 60 70 80 90 100 25 30 35 40 50 60 70 80 90100
% DUTY CYCLE % DUTY CYCLE
Model 403 − 35% Duty Cycle Model 443 − 45% Duty Cycle
Rated Output
Rated Output
700 700
600 600
WELDING AMPERES
WELDING AMPERES
500
500
400
400
300
300
443
200 200
20 25 30 35 40 50 60 70 80 90 100 25 30 35 40 50 60 70 80 90100
% DUTY CYCLE % DUTY CYCLE
35% Duty Cycle 45% Duty Cycle
3.5 Minutes Welding 6.5 Minutes Resting 4.5 Minutes Welding 5.5 Minutes Resting
Overheating
0 A or V
15
OR
Minutes Reduce Duty Cycle
OM-233 381 Page 10

3-4. Selecting A Location
1 Lifting Eye
2 Lifting Forks
Use lifting eye or lifting forks to
Movement move unit.
If using lifting forks, extend forks
1 beyond opposite side of unit.
3 Rating Label
OR Use rating label to determine input
power needs.
2 4 Line Disconnect Device
Locate unit near correct input pow-
er supply.
! Special installation may be
required where gasoline or
Location And Airflow 4 volatile liquids are present −
see NEC Article 511 or CEC
3 Section 20.
18 in
(460 mm)
18 in
(460 mm) 804 961 / 139 445-E
3-5. Tipping
! Do not move or operate unit
where it could tip.
804 961
OM-233 381 Page 11

3-6. Weld Output Terminals and Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
Weld Output 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

100 ft (30 m) Or Less
Terminals (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
! Turn off power before

connecting to weld out-
put terminals. 10 − 60%
Welding 60 − 100%
Duty 10 − 100% Duty Cycle
! Do not use worn, dam- Amperes Duty Cycle
Cycle
aged, undersized, or
poorly spliced cables.
100 20 20 20 25 35 50 50 50
150 25 25 35 50 50 70 90 90
200 25 35 50 50 70 90 90 90
Negative Positive
Terminal Terminal 250 35 35 50 70 90 90 120 120
804 944
Weld cable size (mm2) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Ref. S-0007-D
3-7. Typical Connections For Stick (SMAW) Welding
804 961
OM-233 381 Page 12

3-8. Positioning Jumper Links
Check input voltage available at
site.
230/400 Volt Models 1 Jumper Links Access
230 V 400 V 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
Ref. S9215023 / Ref S9215018
3-9. Electrical Service Guide

Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.
253 343 403 443

Input Voltage 230 400 230 380 400 520 230 400 230 380 400 520
Input Amperes At Rated Output 36 21 55 32 32 23 73 42 80 47 47 36
Max Recommended Standard Fuse Rating In
Amperes 1
Time-Delay 2 45 25 60 40 40 30 80 50 100 60 50 40
Normal Operating 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) (33) (59) (40) (67) (25) (51) (35) (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. C
onsult national and local regulations.
Reference: 2005 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” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor 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 13

3-10. Connecting Input Power
! Installation must meet all Na-
tional and Local Codes −
have only qualified persons
make this installation.
! Disconnect and lockout/tag-
out input power before con-
necting input conductors
from unit.
! Always connect green or
green/yellow conductor to
2 GND/PE supply grounding terminal
first, and never to a line ter-
1 minal.
! Make input power connec-
tions to the welding power
source first.
4
! Special installation may be
required where gasoline or
3 volatile liquids are present −
see NEC Article 511 or CEC
L1 (U) Section 20.
L2 (V)
NOTICE − Verify jumper links
GND/PE L3 (W) match input voltage (see Section
Connect First 3-8).
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 type and size of overcurrent
protection using Section 3-9 (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 14

SECTION 4 − OPERATION
4-1. Controls
1 Welding Current Indicator
2 Weld Current Control
3 + Positive Weld Terminal
4 − Negative Weld Terminal
6
5 Power On-Off Switch
6 Power On Pilot Light
5
1
4 3
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 15

SECTION 5 − MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
! Disconnect power
before maintaining.
= Check = Change = Clean = Replace

* To be done by Factory Authorized Service Agent
Every
3
Months
Damaged Or Cracked Weld cables Weld Connections

Unreadable Labels
Every OR
6
Months
Inside Unit
5-2. Troubleshooting
Trouble Remedy
No weld output; fan does not run. Be 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 all weld cable connections.
Check for proper size and type of cable (see Section 3-6).
Check for proper input and output connections (see Sections 3-6 and/or 3-10).
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 3-10).
voltage.
Check for proper input and output connections (see Sections 3-6 and/or 3-10).
OM-233 381 Page 16

SECTION 6 − ELECTRICAL DIAGRAMS
S9215019
Figure 6-1. Circuit Diagram For Blue Thunder 253

OM-233 381 Page 17
S9215018
Figure 6-2. Circuit Diagram For Blue Thunder 343 And 443 Models (380/520 V)
OM-233 381 Page 18

S9215023
Figure 6-3. Circuit Diagram For Blue Thunder 343 And 443 Models (230/400 V)
OM-233 381 Page 19

S9215020
Figure 6-4. Circuit Diagram For Blue Thunder 403
OM-233 381 Page 20

Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-233 381 Page 21

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

OM-233 381 Page 22
Item Dia. Part
No. Mkgs. No. Description Quantity
... 1 . . . . . . . . . . . . . +156121032 ... Upper Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . . . . . 176254 ... Label, General Precautionaly Wordless . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . 156011019 ... Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . . . . . . . . . . 156122072 ... Panel, Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . 057015088 ... Secondary Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 6 . . . . . . . . . . . . . . 057015098 ... Primary Winding, 230/400 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 7 . . . . . T1 . . . . . 058021131 ... Transformer, 3hp, 230/400 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . . 756069030 ... Primary Voltage Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . 556070015 ... Primary Terminal Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 10 . . . . . . . . . . . . . . 056059265 ... Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 . . . . . . . . . . . . . . 556019047 ... Regulation Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . 057029003 ... Shunt Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . 056020044 ... Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . PL . . . . . 056072078 ... White “Power On” LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . . 756029008 ... Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . . . . . . . . . . . 056002010 ... Hand Wheel With Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . . . . . . . . . . 156118048 ... Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . . . . . . . . . . 056076152 ... 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 Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 176109017 ... Regulation Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 32 . . . . . S1 . . . . . 056067221 ... Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 33 . . . . SR1 . . . . 056050139 ... Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 34 . . . . . . . . . . . . . . 156002019 ... Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 35 . . . . . . . . . . . . . . 956142592 ... Negative Welding Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 36 . . . . . . . . . . . . . . 956142590 ... Label, Increase/Decrease Weld Output . . . . . . . . . . . . . . . . . . . . . . . . 1
... 37 . . . . . . . . . . . . . . 956142591 ... Positive Welding Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 23

1
2
3
36
35
34
6
7 5
8
31 32
33
27
10
30 28 26
11
12 15
14
13
25
29 24
23
22
16 37
38
17
18
39
19
20
21 804 963
OM-233 381 Page 24

Item Dia. Part
... 1 . . . . . . . . . . . . . +156121032 ... Upper Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . . . . . 176254 ... Label, General Precautionaly Wordless . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . 156011019 ... Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . . . . . . . . . . 156122072 ... Panel, Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . T1 . . . . . 058021132 ... Transformer, 3hp, MMA, 230/400 V . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . . 756069035 ... Primary Voltage Terminal Board, 380/520 V . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . 056059266 ... Shunt, 65 X 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 . . . . . . . . . . . . . . 556019048 ... Regulation Screw, M24, L=245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . 057029003 ... Shunt Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . 056020044 ... Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . . 756029009 ... Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . . . . . . . . . . . 056002010 ... Hand Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . . . . . . . . . . 156118048 ... Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . . . . . . . . . . . 156012079 ... Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 . . . . . . . . . . . . . . 056054056 ... Wheel, Rear Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 22 . . . . . . . . . . . . . . 056054058 ... Pivoting Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 23 . . . . . . . . . . . . . . 156118007 ... Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . . . . . . . . . . . . 057014053 ... Primary Input Cable 4 x 4.0 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . 056067211 ... Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 057015076 ... Primary Winding 380/520 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 33 . . . . . . . . . . . . . . 656062010 ... Scale Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 34 . . . . . . . . . . . . . +156122073 ... Panel, Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 36 . . . . . . . . . . . . . . 156002019 ... Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-233 381 Page 25

1
2
3
35
34
6 5 33
7
8
31 31
32
27
10
30 28 26
11
12 15
14
13
25
29 24
23
22
16 36
37
17
18
38
19
20
21 804 963
OM-233 381 Page 26

Item Dia. Part
... 1 . . . . . . . . . . . . . +156121032 ... Upper Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 3 . . . . . . . . . . . . . . 156011019 ... Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . . . . . . . . . . 156122072 ... Panel, Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . . 756069030 ... Primary Voltage Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . 056059280 ... Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 . . . . . . . . . . . . . . 556019048 ... Regulation Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . 057029003 ... Shunt Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . 056020040 ... Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . . 756029010 ... Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . . . . . . . . . . . 056002010 ... Hand Wheel With Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . . . . . . . . . . 156118048 ... Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . . . . . . . . . . . 156012079 ... Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 . . . . . . . . . . . . . . 056054056 ... Wheel, Rear Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 22 . . . . . . . . . . . . . . 056054058 ... Pivoting Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 23 . . . . . . . . . . . . . . 156118007 ... Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . . . . . . . . . . . . 057014054 ... Primary Input Cable 4 x 6, M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
... 32 . . . . . . . . . . . . . . 656062010 ... Scale Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 33 . . . . . . . . . . . . . +156122073 ... Panel, Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 35 . . . . . . . . . . . . . . 156002019 ... Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-233 381 Page 27

1
2
3
36
35
6
7 5 34
8
31 32
33
27
10
30 26
28
11
12 15
14
13
25
29 24
23
22
16
37
38
17
18
39
19
20
21 804 962
OM-233 381 Page 28

Item Dia. Part
... 1 . . . . . . . . . . . . . +156121033 ... Upper Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 3 . . . . . . . . . . . . . . 156011019 ... Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 4 . . . . . . . . . . . . . . 156122074 ... Panel, Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . 057015065 ... Secondary Winding, 70 X 115 Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 6 . . . . . . . . . . . . . . 057015091 ... Primary Winding, 230/400 V, 70 X 115 Al . . . . . . . . . . . . . . . . . . . . . . 3
... 7 . . . . . T1 . . . . . 058021098 ... Transformer, 3hp, MMA, 380/520 V, 70 X 115 Al . . . . . . . . . . . . . . . . 1
... 7 . . . . . T1 . . . . . . 058021114 ... Transformer, 3hp, MMA, 230/400 V, 70 X 115 Al . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . 056059256 ... Shunt, 65 X 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 11 . . . . . . . . . . . . . . 556019043 ... Regulation Screw, M24, L=245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . 057029004 ... Shunt Yoke, D.35, L=150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . 056020044 ... Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . . 756029011 ... Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 . . . . . . . . . . . . . . 056002015 ... Hand Wheel, D.200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 . . . . . . . . . . . . . . 156118050 ... Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . . . . . . . . . . . 156012080 ... Axle, D.25, L=619 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 . . . . . . . . . . . . . . 056054057 ... Wheel, Rear Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 22 . . . . . . . . . . . . . . 056054059 ... Pivoting Wheel, D.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 23 . . . . . . . . . . . . . . 156118008 ... Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . . . . . . . . . . . . 057014054 ... Primary Input Cable 4 x 6, M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 ... Rectifier, Pts 550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 30 . . . . . S1 . . . . . 056067210 ... Switch, 32 A, A 3202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 . . . . . . . . . . . . . . 057015079 ... Primary Winding 380/520 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 33 . . . . . . . . . . . . . . 656062010 ... Scale Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 34 . . . . . . . . . . . . . +156122075 ... Panel, Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 36 . . . . . . . . . . . . . . 156121010 ... Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-233 381 Page 29

Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

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 4. 1 Year — Parts and Labor Unless Specified
below, ITW Welding Products Italy warrants to its original retail * DC 253 & 403 Rectifier (April 06>)
purchaser that new Miller equipment sold after the effective date
of this limited warranty is free of defects in material and * Migmatic 171 (April 06>)
workmanship at the time it is shipped by Miller. THIS 5. 6 Months — Batteries
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE 6. 90 Days — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS. * MIG Guns/TIG Torches
Within the warranty periods listed below, Miller will repair or * Induction Heating Coils and Blankets
replace any warranted parts or components that fail due to such * APT Model Plasma Cutting Torches
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which * Remote Controls
time Miller will provide instructions on the warranty claim * Accessory (Kits)
procedures to be followed.
* Replacement Parts (No labor)
Miller shall honor warranty claims on warranted equipment listed * Spoolmate Spoolguns
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date the * Canvas Covers
equipment was delivered to the original retail purchaser or one Miller’s True Blue® Limited Warranty shall not apply to:
year after the equipment is sent to a European distributor or
eighteen months after the equipment is shipped to an 1. Consumable components; such as contact tips,
International distributor. cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear.
1. 5 Years Parts — 3 Years Labor
2. Items furnished by Miller, but manufactured by others, such
* Original main power rectifiers as engines or trade accessories. These items are covered
* Inverters (Input and Output Rectifiers Only) by the manufacturer’s warranty, if any.
2. 3 Years — Parts and Labor 3. Equipment that has been modified by any party other than
* Transformer/Rectifier Power Sources Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
* Plasma Arc Cutting Power Sources standards, or equipment which has not had reasonable and
* Semi-Automatic and Automatic Wire Feeders necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
* Inverter Power Sources (Unless Otherwise Stated) equipment.
* Water Coolant Systems (Integrated)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Intellitig USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
* Maxstar 150 TRAINED AND EXPERIENCED IN THE USE AND
* Engine Driven Welding Generators except Panther MAINTENANCE OF WELDING EQUIPMENT.
(NOTE: Engines are warranted separately by the In the event of a warranty claim covered by this warranty, the
engine manufacturer.) exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
3. 2 Years — Parts and Labor
appropriate cases, (3) the reasonable cost of repair or
* Hydramate 1 & 2 Water Cooling Unit replacement at an authorized Miller service station; or (4)
* Motor Driven Guns (w/exception of Spoolmate payment of or credit for the purchase price (less reasonable
Spoolguns) depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
* Process Controllers replacement will be F.O.B., Factory at ITW Welding Products
* Positioners and Controllers Group Europe or F.O.B. at a Miller authorized service facility as
* Automatic Motion Devices determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
* RFCS Foot Controls allowed.
* IHPS Power Sources and Coolers TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Water Coolant Systems (Non-Integrated) PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Flowgauge and Flowmeter Regulators (No Labor) REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* HF Units, Including HFP-14 Pendant CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Grids PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* Spot Welders OTHER LEGAL THEORY.
* Load Banks ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
* Arc Stud Power Sources & Arc Stud Guns REPRESENTATION AS TO PERFORMANCE, AND ANY
* Running Gear/Trailers REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Plasma Cutting Torches (except APT & SAF OTHER LEGAL THEORY WHICH, BUT FOR THIS
Models) PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
* Field Options INCLUDING ANY IMPLIED WARRANTY OF
(NOTE: Field options are covered under True Blue® MERCHANTABILITY OR FITNESS FOR PARTICULAR
for the remaining warranty period of the product they PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
are installed in, or for a minimum of one year — FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
whichever is greater.) BY MILLER.
milan_warr 2007−01

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 Privata 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
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 1/07


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OM-233 381C 2007−09

Arc Welding Power Source

Blue Thunder Series

Models: 253, 343, 403, 443

Visit our website at

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Miller Electric manufactures a full line

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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Manufacturer: European Contact:

European Contact Signature:

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

Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

1-2. Arc Welding Hazards

OM-233 381 Page 1

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ARC RAYS can burn eyes and skin.

Welding on closed containers, such as tanks, CYLINDERS can explode if damaged.

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FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

Use lifting eye to lift unit only, NOT running

OVERUSE can cause OVERHEATING

Put on grounded wrist strap BEFORE handling

OM-233 381 Page 3

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1-5. Principal Safety Standards

1-6. EMF Information

OM-233 381 Page 4

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OM-233 381 Page 5

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Electric shock from wiring can kill.

Disconnect input plug or power

2-2. WEEE Label (For Products Sold Within The EU)

Do not discard product (where ap-

OM-233 381 Page 6

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OM-233 381 Page 7

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Current Increase Current Increase/

OM-233 381 Page 8

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Ampere Max Amperes Input at Dimensions

3-2. Volt-Ampere Curves

Model 253 Model 343

Model 403 Model 443

OM-233 381 Page 9

35% Duty Cycle 45% Duty Cycle

OM-233 381 Page 10

OM-233 381 Page 11

Total Cable (Copper) Length In Weld Circuit Not Exceeding

Weld Output 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft

! Turn off power before

= Check = Change = Clean = Replace

Damaged Or Cracked Weld cables Weld Connections