Miller Electric Blue Star 3500 manual Work like a Pro

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6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2)

.Weld and generator power output stops if generator overheats or engine speed is too low.

1 Engine Switch

On models with recoil-start, use switch to open ignition circuit, and to stop engine.

On models with electric-start, use switch to open ignition circuit, and to start and stop en- gine.

2 Throttle Control Lever

Use lever to select engine speed. Move lever to idle position (far right) for idle speed. Move lever to Run position (far left) for weld/power speed.

.Always place lever in Run position (far left) for generator power and for maxi- mum weld output.

3 Choke Control Lever

Use lever to change engine air/fuel mix. Move

lever to left if starting a cold engine. Move le- ver to right if starting a warm engine.

4Starter Handle (Recoil-Start Models Only)

To Start (Recoil): open fuel valve, turn engine switch to On, move throttle lever to Idle, set choke, and pull starter handle. Open choke as engine warms.

To Start (Electric): open fuel valve, move throttle lever to Idle, set choke, and turn en- gine switch to Start position. Open choke as engine warms.

YIf the engine does not start, let engine come to a complete stop before at- tempting restart.

To Stop: turn engine switch to Off.

.Always close fuel valve after stopping unit. Moving unit with fuel valve open may cause carburetor flooding and make starting difficult.

5 Welding Range Label

Use label to determine correct weld amper- age based on electrode size, type, and mate- rial thickness.

6 Current Control

Use control to select weld amperage. Control may be adjusted while welding.

To Set Current Control: Use label to deter- mine correct size electrode for material thick- ness. Select electrode type and set current control to corresponding amperage range on nameplate. Adjust control within selected range to obtain desired weld performance.

EXAMPLE:

Material Thickness: 1/8 to 1/4 in

Electrode Diameter: 1/8

Electrode Type: E-6013

Current Control Setting: 90 − 120 A

Notes

Work like a Pro!

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

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Contents Description OM-498Processes From Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageEngine Hazards Compressed Air Hazards Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationLES Fumées ET LES GAZ peuvent être dangereux Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves’AIR Comprimé peut provoque r des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieInformation sur les champs électromagnétiques Principales normes de sécurité− Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsWeight Kohler-Powered Units Dimensions, Weights, And Operating AnglesFuel Consumption Kohler-Powered Units Dimensions100% Duty Cycle at 80 Amperes CC/DC Fuel Consumption Honda-Powered UnitsExceeding duty cycle can damage unit and void warranty Duty CycleVolt-Ampere Curves Generator Power CurveGrounding Generator To Truck Or Trailer Frame − InstallationInstalling Welding Generator Use ground device as stated in electrical codes Grounding Generator When Supplying Building SystemsOil Engine Prestart Checks Honda-Powered UnitsConnecting The Battery Honda Electric-Start Models Only + −Selecting Weld Cable Sizes Connecting To Weld Output TerminalsChoke Control Lever Controls Kohler-Powered Units− Operating the Welding Generator 60 HzRecoil-Start 2Electric-Start Controls Honda-Powered Units See SectionWork like a Pro Description Of Controls Honda-Powered Units See Section120 V x 10 a + 240 V x 9 a = 3.5 kVA/ KW OM-498 Generator Power Panel 495 218 USA− Operating Auxiliary Equipment Australia Europe Asia Optional Generator Power PanelsGenerator Power Panel 495 Canada South Africa South AmericaIt exceeds 3500W Generator Power Panel RatingsOne half of the 240 V receptacle Plug Wired For 120/240Wire Load Plex receptacle shares a load with− Maintenance Overload Protection Honda-Powered Units Only Maintenance LabelStop engine. Close fuel valve Top View Adjusting Engine Speed Kohler-Powered UnitsWeld/Power Speed Adjustment Top View Idle Speed AdjustmentTools Needed 3/8 Adjusting Engine Speed Honda-Powered UnitsThrottle Control Lever Adjustment Screw Stop engine. Close fuel valveWelding − TroubleshootingTroubleshooting Generator PowerMake starting difficult Check battery voltage Honda electric-start models onlyViscosity oil for operating temperature EngineCircuit Diagram For Welding Generator − Electrical DiagramsWiring Diagram For Generator Power Panels 1 Wiring Diagram For Generator Power Panels 2 OM-491 − Generator Power GuidelinesSelecting Equipment Volts 115 Amps Resistive Load Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible− 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 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderElectrode Movement During Welding Conditions That Affect Weld Bead Shape16 in 1.6 mm Tack Welds Butt JointsLap Joint Tee JointPossible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld TestTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead 31−Fig − Parts ListDia Part Europe America Generator Power Panel 495 Generator Power Panel 495 315 USAGenerator Power Panel 495 South Africa Australia CanadaGenerator Power Panel 495 289 Australia Generator Power Panel 495 218 USAGenerator Power Panel 495 279 Canada Generator Power Panel 495 253 South AfricaWork like a Pro Page TM-188 304 Invision 354MP Material Thickness Reference ChartSupport ServiceYour distributor also gives Transportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s