Miller Electric Blue Star 3500 manual From Miller to You

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Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

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 decide the 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. 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 7/03

Working as hard as you do

every power source from Miller is backed by the most hassle-free warranty in the business.

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Contents Description OM-498Processes From Miller to You Table of Contents Page Symbol Usage Arc Welding HazardsEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures ’AIR Comprimé peut provoque r des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesWeld, Power, And Engine Specifications − SpecificationsSymbol Definitions − DefinitionsDimensions Dimensions, Weights, And Operating AnglesFuel Consumption Kohler-Powered Units Weight Kohler-Powered UnitsDuty Cycle Fuel Consumption Honda-Powered UnitsExceeding duty cycle can damage unit and void warranty 100% Duty Cycle at 80 Amperes CC/DCGenerator Power Curve Volt-Ampere CurvesGrounding Generator To Truck Or Trailer Frame − InstallationInstalling Welding Generator Grounding Generator When Supplying Building Systems Use ground device as stated in electrical codes+ − Engine Prestart Checks Honda-Powered UnitsConnecting The Battery Honda Electric-Start Models Only OilConnecting To Weld Output Terminals Selecting Weld Cable Sizes60 Hz Controls Kohler-Powered Units− Operating the Welding Generator Choke Control LeverControls Honda-Powered Units See Section Recoil-Start 2Electric-StartDescription Of Controls Honda-Powered Units See Section Work like a Pro120 V x 10 a + 240 V x 9 a = 3.5 kVA/ KW OM-498 Generator Power Panel 495 218 USA− Operating Auxiliary Equipment Canada South Africa South America Optional Generator Power PanelsGenerator Power Panel 495 Australia Europe AsiaGenerator Power Panel Ratings It exceeds 3500WPlex receptacle shares a load with Plug Wired For 120/240Wire Load One half of the 240 V receptacle− Maintenance Maintenance Label Overload Protection Honda-Powered Units OnlyTop View Idle Speed Adjustment Adjusting Engine Speed Kohler-Powered UnitsWeld/Power Speed Adjustment Stop engine. Close fuel valve Top ViewStop engine. Close fuel valve Adjusting Engine Speed Honda-Powered UnitsThrottle Control Lever Adjustment Screw Tools Needed 3/8Generator Power − TroubleshootingTroubleshooting WeldingEngine Check battery voltage Honda electric-start models onlyViscosity oil for operating temperature Make starting difficult− Electrical Diagrams Circuit Diagram For Welding GeneratorWiring Diagram For Generator Power Panels 1 Wiring Diagram For Generator Power Panels 2 OM-491 − Generator Power GuidelinesSelecting Equipment Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Volts 115 Amps Resistive LoadIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP xTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes− Stick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Positioning Electrode Holder Poor Weld Bead CharacteristicsGood Weld Bead Characteristics 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingTee Joint Butt JointsLap Joint 16 in 1.6 mm Tack WeldsWeld Test Troubleshooting − PorosityTroubleshooting − Excessive Spatter Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead − Parts List 31−FigDia Part Canada Generator Power Panel 495 Generator Power Panel 495 315 USAGenerator Power Panel 495 South Africa Australia Europe AmericaGenerator Power Panel 495 253 South Africa Generator Power Panel 495 218 USAGenerator Power Panel 495 279 Canada Generator Power Panel 495 289 AustraliaWork like a Pro Page Material Thickness Reference Chart TM-188 304 Invision 354MPSupport ServiceYour distributor also gives Your distributor and/or equipment manufacturer’s Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Transportation Department