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Miller Electric 440 manual

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Table of contents for the manual

  • Page 1

    Processes Bluthunder 340/440 OM-193 696A September 2001 Effective with serial number : 153 421 Description Arc Welding Power Source Stick (SMA W) W elding Visit our website at www.MillerWelds.com[...]

  • Page 2

    Thank you and congratulations on choosing Miller . Now you can get the job done and get it done right. W e 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 af f[...]

  • Page 3

    T ABLE 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[...]

  • Page 4

    dec_con 5/97 Declaration of Conformity Manufacturer ’s Name: MILLER Europe S.r .l. Manufacturer ’s Address: Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy Declares that this product: Bluthunder 340/440 Conforms to the following Directives and Standards: Directives Electromagnetic Compatibility Directives: 89/336/EEC, 92/31/EEC Compati[...]

  • Page 5

    OM-193 696 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “ Note ” ; not safety related. This group of symbols means W arning! [...]

  • Page 6

    OM-193 696 Page 2 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. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and[...]

  • Page 7

    OM-193 696 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 8

    OM-193 696 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However , after examining more than 500 studies spanning 17 yea[...]

  • Page 9

    OM-193 696 Page 5 SECTION 2 – INST ALLA TION 2-1. Specifications Rated Output Max. Open Rated Input Amperage at Rated Output Model 100% 60% 45% 35% Circuit V oltage 230 V 380 V 400 V 520 V Dimension (mm) W eight (kg) 340 190 A 27.6 V 245 A 29.8 V - - 320 A 32.8 V 68 55 A 32 A 32 A 23 A 510 x 650 x 1010 105 440 290 A 31.6 V 375 A 35 V 420 A 36.8 V[...]

  • Page 10

    OM-193 696 Page 6 2-3. V olt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capa- bilities of the unit. Bluthunder 340 Bluthunder 440 2-4. Positioning Jumper Links Check input voltage available at site. 1 Jumper Links Access Remove side panel. 2 Jumper Link Label Check label – only one is on u[...]

  • Page 11

    OM-193 696 Page 7 2-5. Electrical Service Guide 340 440 Input V oltage 230 400 520 230 400 520 Input Amperes at Rated Output 55 32 25 79 46 25 Max Recommended Standard Fuse or Circuit Breaker Rating in Amperes 55 32 25 79 46 25 ** Input Conductor Size in mm 2 6 6 6 6 6 6 ** Grounding Conductor Size in mm 2 6 6 6 6 6 6 ** Power cord supplied with th[...]

  • Page 12

    OM-193 696 Page 8 SECTION 3 – OPERA TION 3-1. Controls 1 Range 2 Output Amperage Control 3 + Positive Weld T erminal 4 – Negative W eld T erminal 5 Power On Pilot Light 6 Power Switch 5 4 2 1.6 2.5 100 60 30 Amp. 220 160 1 2 3 4 5 6 3 2 6 4 5 60 30 1.6 4 2 2.5 100 160 5 Amp. 220 1 OFF ON ON OFF[...]

  • Page 13

    OM-193 696 Page 9 SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace un readable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service clean monthly . OR 4-2. T roubleshooting T rouble Remedy[...]

  • Page 14

    OM-193 696 Page 10 SECTION 5 – ELECTRICAL DIAGRAM 5-1. Bluthunder 340/440 230V - 400V GND 400/230V 50Hz M1 H1 + – U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 S1 L1 L2 L3 GN W2 U2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 230V 400V C.T . SCH3203 32A C.T .[...]

  • Page 15

    OM-193 696 Page 1 1 5-2. Bluthunder 340/440 400V - 520V VR SR1 Z + – PRI. BOARD FM PL GND 400/520 V 50/60Hz U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 S1 L1 L2 L3 400V 520V C1 0 1[...]

  • Page 16

    OM-193 696 Page 12 SECTION 6 – P ARTS LIST 8 23 24 26 27 28 4 5 6 29 12 17 15 19 21 18 7 30 13 – 14 16 22 25 10 11 9 20 1.6 30 100 2 160 2.5 4 5 220 Amp. 60 3 2 1 33 34 31 32 OFF ON 6-1. Main Assembly (340)[...]

  • Page 17

    OM-193 696 Page 13 Item Dia Ref. Code Qty . Dwg 1 156121009 ZL.0.0.6 1 2 15601 1019 UZ.0.0.14 2 3 156122027 ZL.0.0.4 1 4 SEC. WIND. 057150063 UZ.1.2 3 5 PRIM. WIND. 057015099 UZ.3.1 3 6 058021 132 UZ.3 7 PRI. BOARD 756069030 Zl.0.0.10 1 8 556070015 V A.0.0.15 6 9 056059255 UZ.1.1.1 2 10 556019042 UZ.0.0.16 1 1 1 057029003 UZ.1.1 1 12 056020037 UZ.0[...]

  • Page 18

    OM-193 696 Page 14 6-2. Main Assembly (440) 8 23 24 26 27 28 4 5 6 29 12 17 15 19 21 18 7 30 13 – 14 16 22 25 10 11 9 20 31 32 2 33 1 34 3 1.6 30 100 2 2.5 160 220 5 4 Amp. 60 OFF ON[...]

  • Page 19

    OM-193 696 Page 15 Item Dia Ref. Code Qty . Dwg 1 156121010 V A.0.0.20 1 2 15601 1019 UZ.0.0.14 2 3 156122032 V A.0.0.19 1 4 PRI. WIND. 057015091 V A.3.1 3 230/400 5 SEC. WIND 057015065 V A.1.2 3 6 T1 230/400 058021 1 14 V A.3 1 50/60 Hz 7 PRI. BOARD 756069030 ZL.0.0.10 1 8 556070015 V A.0.0.15 6 9 056059256 V A.1.1.1 2 10 556019043 V A.0.0.12 1 1 [...]

  • Page 20

    Notes[...]

  • Page 21

    Notes[...]

  • Page 22

    Notes[...]

  • Page 23

    Effective January 1, 2000 This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED W ARRANTY – Subject to the terms and conditions below , Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment s[...]

  • Page 24

    PRINTED IN USA  2001 Miller Electric Mfg. Co. 1/01 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarters – US A Phone: 414-735-4505 USA & C anada F A X: 920-735-4134 Int ernational F AX : 9 20-735-4125 European Headquarte rs – United K ingdom Phone:[...]