Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Blue Star 145 manual Positioning Electrode Holder, Poor Weld Bead Characteristics

Models: 145 DXR, 145 Blue Star 145

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13-5. Positioning Electrode Holder

10°-30°

90°90°

End View of Work Angle	Side View of Electrode Angle
GROOVE WELDS
45°	10°-30°
45°
45°
End View of Work Angle	Side View of Electrode Angle
FILLET WELDS	S-0060

13-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

2 3 4

5	S-0053-A

13-7. Good Weld Bead Characteristics

1Fine Spatter

2Uniform Bead

3Moderate Crater During Welding

Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded.

4No Overlap

5Good Penetration into Base Metal

S-0052-B

OM-4417 Page 43

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Contents

File Engine Drive OM-4417210 403FProcesses DescriptionFrom Miller to You Table of Contents Page HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité − Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsVolt-Ampere Curves Dimensions, Weights, And Operating AnglesDimensions Fuel Consumption Minutes Welding Generator Power CurveDuty Cycle 100% Duty Cycle at 80 Amperes CC/DCHazards − InstallationInstalling Welding Generator MovementOil Grounding Generator When Supplying Building SystemsEngine Prestart Checks − Standard Model Engine Prestart Checks − DX Model Connecting The Battery DX Models OnlyPut terminals Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 45 m 60 m 70 m 90 m 105 m 120 m 10 −Controls Standard Models See Section − Operating the Welding GeneratorTo Start Description Of Controls Standard Models See SectionStop engine and add oil if light goes on see Section Controls DX Models See Section Description Of Controls DX Models See Section AC Receptacle RC1 Generator Power Panel Receptacles− Operating Auxiliary Equipment Routine Maintenance − MaintenanceStandard Model Shown Servicing Air CleanerPrecleaner Paper Element Stop engineTools Needed Adjusting Engine Speed Standard Models OnlyStop Engine Close ValveIdle Speed Adjustment Adjusting Engine Speed DX Models OnlyWeld/Power Speed Adjustment Welding − TroubleshootingTroubleshooting Generator PowerEngine Recommended Spare Parts − Parts ListRecommended Spare Parts Circuit Diagram For Standard Models − Electrical DiagramsCircuit Diagram for DX Models Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment How Much Power Does Equipment Require? Grounding When Supplying Building SystemsFarm/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 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Cord Lengths for 240 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Current Load Watts Amperes− Stick Welding Smaw Guidelines Stick Welding ProcedureStriking 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 30 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 Support ServiceYour distributor also gives Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact