Miller Electric Blue Star 3500 manual Work like a Pro

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Notes

Work like a Pro!

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

OM-498 Page 52

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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 Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiques− Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles Fuel Consumption Kohler-Powered UnitsDimensions Weight Kohler-Powered UnitsFuel Consumption Honda-Powered Units Exceeding duty cycle can damage unit and void warrantyDuty Cycle 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 codesEngine Prestart Checks Honda-Powered Units Connecting The Battery Honda Electric-Start Models Only+ − OilConnecting To Weld Output Terminals Selecting Weld Cable SizesControls Kohler-Powered Units − Operating the Welding Generator60 Hz 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 Optional Generator Power Panels Generator Power Panel 495Canada South Africa South America Australia Europe AsiaGenerator Power Panel Ratings It exceeds 3500WPlug Wired For 120/240 Wire LoadPlex receptacle shares a load with One half of the 240 V receptacle− Maintenance Maintenance Label Overload Protection Honda-Powered Units OnlyAdjusting Engine Speed Kohler-Powered Units Weld/Power Speed AdjustmentTop View Idle Speed Adjustment Stop engine. Close fuel valve Top ViewAdjusting Engine Speed Honda-Powered Units Throttle Control Lever Adjustment ScrewStop engine. Close fuel valve Tools Needed 3/8− Troubleshooting TroubleshootingGenerator Power WeldingCheck battery voltage Honda electric-start models only Viscosity oil for operating temperatureEngine 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 Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Volts 115 Amps Resistive LoadApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements 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 Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 1.6 mm Tack WeldsTroubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test 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 Generator Power Panel 495 Generator Power Panel 495 315 USA Generator Power Panel 495 South Africa AustraliaCanada Europe AmericaGenerator Power Panel 495 218 USA Generator Power Panel 495 279 CanadaGenerator Power Panel 495 253 South Africa Generator Power Panel 495 289 AustraliaWork like a Pro Page Material Thickness Reference Chart TM-188 304 Invision 354MPSupport ServiceYour distributor also gives Miller Electric Mfg. Co For assistance in filing or settling claims, contactYour distributor and/or equipment manufacturer’s Transportation Department