Miller Electric Blue Star 145 manual Troubleshooting, Welding, Generator Power, Trouble Remedy

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. Complete Parts List available at www.MillerWelds.com

SECTION 9 − TROUBLESHOOTING

9-1. Troubleshooting

A. Welding

Trouble	Remedy

No weld output or generator power out-	Be sure all equipment is disconnected from receptacles when starting unit.
put at ac receptacles.

	Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier
	SR2, and Weld Output control R1.

No weld output; generator power out-	Check Weld Output control setting.
put okay at ac receptacles.

	Check weld connections.

	Have Factory Authorized Service Agent check Weld Output control R1, stator, integrated rectifier
	SR2, stabilizer DC-Z, main rectifier SR1, and reactor AC-Z

Low weld output.	Check Weld Output control setting.

	Check engine speed, and adjust if necessary (see Section 8-3or 8-4).

	Service engine air cleaner.

	Check weld cable size and length.

	Have Factory Authorized Service Agent check Weld Output control R1, stator, integrated rectifier
	SR2, stabilizer DC-Z, main rectifier SR1, and reactor AC-Z

High weld output.	Check Weld Output control setting.

	Check engine speed, and adjust if necessary (see Section 8-3or 8-4).

Erratic weld output.	Check Weld Output control setting.

	Tighten and clean connections to electrode and workpiece.

	Use dry, properly-stored electrodes for Stick welding.

	Remove excessive coils from weld cables.

	Clean and tighten connections both inside and outside welding generator.

	Check engine speed, and adjust if necessary (see Section 8-3or 8-4).

	Check throttle/governor linkage for smooth, non-binding operation.

B. Generator Power

Trouble	Remedy

No output at generator power ac re-	Be sure all equipment is disconnected from receptacles when starting unit.
ceptacles; no weld output.

	Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier
	SR2, and Weld Output control R1.

No output at generator power ac re-	Reset and check supplementary protector (see Section 7-1).
ceptacles; weld output okay.

	Check receptacle wiring and connections.

	Have Factory Authorized Service Agent check stator windings and connections at terminal block 1T.

High output at generator power ac	Check engine speed, and adjust if necessary (see Section 8-3or 8-4).
receptacles.

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Contents Processes OM-4417210 403FDescription File Engine DriveFrom Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionCompressed Air Hazards Engine HazardsHOT Parts can cause burns and injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peuDES Organes Mobiles peuvent pro voquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion DES Organes Mobiles peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF Symbol Definitions − SpecificationsWeld, Power, And Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles DimensionsVolt-Ampere Curves Fuel Consumption Duty Cycle Generator Power Curve100% Duty Cycle at 80 Amperes CC/DC Minutes WeldingInstalling Welding Generator − InstallationMovement HazardsGrounding Generator When Supplying Building Systems Engine Prestart Checks − Standard ModelOil Engine Prestart Checks − DX Model Connecting The Battery DX Models OnlySelecting Weld Cable Sizes Connecting To Weld Output Terminals45 m 60 m 70 m 90 m 105 m 120 m 10 − Put terminalsControls Standard Models See Section − Operating the Welding GeneratorDescription Of Controls Standard Models See Section Stop engine and add oil if light goes on see SectionTo Start Controls DX Models See Section Description Of Controls DX Models See Section Generator Power Panel Receptacles − Operating Auxiliary EquipmentAC Receptacle RC1 Routine Maintenance − MaintenancePrecleaner Paper Element Servicing Air CleanerStop engine Standard Model ShownStop Engine Close Adjusting Engine Speed Standard Models OnlyValve Tools NeededAdjusting Engine Speed DX Models Only Weld/Power Speed AdjustmentIdle Speed Adjustment Troubleshooting − TroubleshootingGenerator Power WeldingEngine − Parts List Recommended Spare PartsRecommended Spare Parts Circuit Diagram For Standard Models − Electrical DiagramsCircuit Diagram for DX Models − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Cord Lengths for 120 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCurrent Load Watts Amperes Cord Lengths for 240 Volt Loads− Stick Welding Smaw Guidelines Stick Welding ProcedureElectrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleElectrode Movement During Welding Conditions That Affect Weld Bead ShapeLap Joint Butt JointsTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective ActionsTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Service Your distributor also givesSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s