Miller Electric Blue Star 3500 manual Generator Power Guidelines, Selecting Equipment, OM-491

Page 37

SECTION 11 − GENERATOR POWER GUIDELINES

NOTE

The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.

11-1. Selecting Equipment

1 Generator Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

Y Do not use 2-prong plug un- less equipment is double in- sulated.

1

2

 

3

OR

Be sure equipment

has this symbol

 

 

and/or wording.

gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577

11-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE2

3

Electrically bond generator frame to vehicle frame by metal-to-metal contact.

YBed liners, shipping skids, and some running gear insulate the welding generator from the ve- hicle frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown.

YAlways ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards.

1Equipment Grounding Terminal (On Front Panel)

2Grounding Cable (Not Supplied)

3Metal Vehicle Frame

Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insulated copper wire.

YIf unit does not have GFCI re- ceptacles, use GFCI-pro- tected extension cord.

S-0854

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OM-491 Page 33

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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