Miller Electric Blue Star 3500 Troubleshooting − Burn-Through, Troubleshooting − Waviness Of Bead

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12-19. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes	Corrective Actions

Excessive heat input.	Select lower amperage. Use smaller electrode.

	Increase and/or maintain steady travel speed.

12-20. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes	Corrective Actions

Unsteady hand.	Use two hands. Practice technique.

12-21. Troubleshooting − Distortion

			Distortion − contraction of weld met-
			al during welding that forces base
			metal to move.
		Base metal moves
		Base metal moves
		in the direction of
		in the direction of
		the weld bead.

Possible Causes			Corrective Actions

Excessive heat input.			Use restraint (clamp) to hold base metal in position.

			Make tack welds along joint before starting welding operation.

			Select lower amperage for electrode.

			Increase travel speed.

			Weld in small segments and allow cooling between welds.

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OM-498 Page 47

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Contents OM-498 ProcessesDescription 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 Curve− Installation Installing Welding GeneratorGrounding Generator To Truck Or Trailer Frame 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 SectionGenerator Power Panel 495 218 USA − Operating Auxiliary Equipment120 V x 10 a + 240 V x 9 a = 3.5 kVA/ KW OM-498 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 − Generator Power Guidelines Selecting EquipmentOM-491 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 PossibleStick Welding Procedure Weld current starts when electrode touches work- piece− Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping 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 Shape 16 in 1.6 mm Tack Welds Butt Joints Lap Joint Tee JointPossible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld TestTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion 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 ChartService Your distributor also givesSupport Transportation Department Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s