Miller Electric Blue Star 3500 manual Specifications, Symbol Definitions

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SECTION 3 − DEFINITIONS

3-1. Symbol Definitions

 

Engine Choke

 

Read Operator’s

A

Amperes

V

Volts

 

 

Manual

 

 

 

 

 

 

Engine Oil

 

Fuel

 

Battery (Engine)

 

Engine

 

Positive

 

Negative

 

Alternating Current

 

Output

 

 

 

(AC)

 

 

 

 

 

 

 

 

h

Hours

s

Seconds

 

Time

 

Protective Earth

 

 

(Ground)

 

 

 

 

 

 

 

 

 

 

 

Circuit Breaker

Temperature

SECTION 4 − SPECIFICATIONS

NOTE

This unit uses either a Kohler or a Honda engine. Differences between models are noted throughout this manual.

4-1. Weld, Power, And Engine Specifications

Welding

Weld

Rated

Maximum

Generator

Fuel

 

Output

Open Circuit

Engine

Mode

Welding Output

Power Rating

Capacity

Range

Voltage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Kohler CS8.5TG

 

 

 

 

 

 

Air-Cooled,

 

 

 

 

 

 

One-Cylinder,

 

 

140 A, 25 V,

 

 

Kohler:

Four-Cycle,

 

 

30% Duty Cycle

 

Single-Phase,

1.8 gal (6.9 L)

8.5 HP (300 CC),

CC/DC

40 − 140 A

100 A, 25 V,

70

3.5 kVA/kW

Tank

Gasoline Engine

60% Duty Cycle

30/15 A,

Honda:

OR

 

 

 

120/240 V AC,

Honda GX270

 

 

80 A, 25 V

 

1.6 gal (6 L)

 

 

 

60 Hz

Air-Cooled,

 

 

100% Duty Cycle

 

 

Tank

One-Cylinder,

 

 

 

 

 

 

Four-Cycle,

 

 

 

 

 

 

9 HP (270 CC),

 

 

 

 

 

 

Gasoline Engine

 

 

 

 

 

 

 

Return To Table Of Contents

OM-498 Page 9

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Contents Processes OM-498Description From Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessuresInformation sur les champs électromagnétiques Principales normes de sécuritéSymbol Definitions − SpecificationsWeld, Power, And Engine Specifications − DefinitionsFuel Consumption Kohler-Powered Units Dimensions, Weights, And Operating AnglesDimensions Weight Kohler-Powered UnitsExceeding duty cycle can damage unit and void warranty Fuel Consumption Honda-Powered UnitsDuty Cycle 100% Duty Cycle at 80 Amperes CC/DCVolt-Ampere Curves Generator Power CurveInstalling Welding Generator − InstallationGrounding Generator To Truck Or Trailer Frame Use ground device as stated in electrical codes Grounding Generator When Supplying Building SystemsConnecting The Battery Honda Electric-Start Models Only Engine Prestart Checks Honda-Powered Units+ − OilSelecting Weld Cable Sizes Connecting To Weld Output Terminals− Operating the Welding Generator Controls Kohler-Powered Units60 Hz Choke Control LeverRecoil-Start 2Electric-Start Controls Honda-Powered Units See SectionWork like a Pro Description Of Controls Honda-Powered Units See Section− Operating Auxiliary Equipment Generator Power Panel 495 218 USA120 V x 10 a + 240 V x 9 a = 3.5 kVA/ KW OM-498 Generator Power Panel 495 Optional Generator Power PanelsCanada South Africa South America Australia Europe AsiaIt exceeds 3500W Generator Power Panel RatingsWire Load Plug Wired For 120/240Plex receptacle shares a load with One half of the 240 V receptacle− Maintenance Overload Protection Honda-Powered Units Only Maintenance LabelWeld/Power Speed Adjustment Adjusting Engine Speed Kohler-Powered UnitsTop View Idle Speed Adjustment Stop engine. Close fuel valve Top ViewThrottle Control Lever Adjustment Screw Adjusting Engine Speed Honda-Powered UnitsStop engine. Close fuel valve Tools Needed 3/8Troubleshooting − TroubleshootingGenerator Power WeldingViscosity oil for operating temperature Check battery voltage Honda electric-start models onlyEngine Make starting difficultCircuit Diagram For Welding Generator − Electrical DiagramsWiring Diagram For Generator Power Panels 1 Wiring Diagram For Generator Power Panels 2 Selecting Equipment − Generator Power GuidelinesOM-491 How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Volts 115 Amps Resistive LoadApproximate 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 xTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleWeld current starts when electrode touches work- piece Stick Welding Procedure− Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking 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 1.6 mm Tack WeldsTroubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective ActionsTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion 31−Fig − Parts ListDia Part Generator Power Panel 495 South Africa Australia Generator Power Panel 495 Generator Power Panel 495 315 USACanada Europe AmericaGenerator Power Panel 495 279 Canada Generator Power Panel 495 218 USAGenerator Power Panel 495 253 South Africa Generator Power Panel 495 289 AustraliaWork like a Pro Page TM-188 304 Invision 354MP Material Thickness Reference ChartYour distributor also gives ServiceSupport For assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department