Miller Electric 6000 manual

Blue Star 6000

Processes

Description

Stick (SMAW) Welding

Engine Driven Welding Generator

OM-499 197 850H

March 2004

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Contents

Main Blue Star 6000 From Miller to You TABLE OF CONTENTS Page OM-499 Page 1 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING Warning: Protect yourself and others from injury read and follow these precautions. 1-1. Symbol Usage Marks a special safety message. 1-2. Arc Welding Hazards 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. OM-499 Page 3 1-4. Compressed Air Hazards cause serious injury or death. COMPRESSED AIR can cause injury HOSES can cause injury. HOT METAL from air arc cutting and gouging can cause fire or explosion. 1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards 1-8. EMF Information OM-499 Page 5 Revenez la table des matires SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions. 2-1. Signification des symboles Identifie un message de scurit particulier. 2-2. Dangers relatifs au soudage larc 2-3. Dangers existant en relation avec le moteur LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort. LACIDE DE LA BATTERIE peut pro- voquer des brlures dans les YEUX et sur la PEAU. OM-499 Page 7 Revenez la table des matires LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. 2-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro voquer des blessures graves ou cause la mort. LAIR COMPRIM peut provoque 2-6. Principales normes de scurit 2-7. Information sur les champs lectromagntiques SECTION 3 DEFINITIONS 3-1. Symbol Definitions h s SECTION 4 SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications 4-2. Dimensions, Weights, And Operating Angles 4-3. Fuel Consumption (Kohler-Powered Units) Page OM-499 Page 12 Return To Table Of Contents 4-6. Generator Power Curves The generator power curves show the ac power available in amperes at the receptacles. B. 50 Hz Model A. 60 Hz Model 4-7. Volt-Ampere Curves A. 60 Hz Model MID MAX MIN B. 50 Hz Model SECTION 5 INSTALLATION 5-1. Installing Welding Generator 5-2. Grounding Generator To Truck Or Trailer Frame 5-3. Grounding Generator When Supplying Building Systems 5 -4. Engine Prestart Checks (Kohler-Powered Units) 5 -5. Engine Prestart Checks (Honda-Powered Units) + 5-6. Connecting The Battery (Electric-Start Models Only) 5-7. Connecting To Weld Output Terminals 5-8. Selecting Weld Cable Sizes* SECTION 6 OPERATING THE WELDING GENERATOR 6-1. Controls (Kohler-Powered Units) 6-2. Controls (Honda-Powered Units) (See Section 6-3) 6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2) Notes SECTION 7 OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Panel 495 218 (USA) 7-2. Optional Generator Power Panels OM-499 Page 23 7-3. Generator Power Panel Ratings Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles. Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz) It exceeds 5500W. 7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) SECTION 8 MAINTENANCE 200 h 50 h 8-1. Maintenance Label ENGINE MAINTENANCE 8-2. Routine Maintenance 8 h 20 h 50 h 100 h 200 h 8-3. Overload Protection (Honda-Powered Units) 8-4. Adjusting Engine Speed (Kohler-Powered Units) 8-5. Adjusting Engine Speed (Honda-Powered Units) SECTION 9 TROUBLESHOOTING 9-1. Troubleshooting A. Welding B. Generator Power C. Engine Page Page Page Page SECTION 11 GENERATOR POWER GUIDELINES 1 11-1. Selecting Equipment 1-2. Grounding Generator To Truck Or Trailer Frame 11-3. Grounding When Supplying Building Systems 11-4. How Much Power Does Equipment Require? 11-5. Approximate Power Requirements For Industrial Motors 11-6. Approximate Power Requirements For Farm/Home Equipment 11-7. Approximate Power Requirements For Contractor Equipment 11-8. Power Required To Start Motor 11-9. How Much Power Can Generator Supply? 11-10.Typical Connections To Supply Standby Power Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. 11-11.Selecting Extension Cord (Use Shortest Cord Possible) SECTION 12 STICK WELDING (SMAW) GUIDELINES 12-1. Stick Welding Procedure OM-499 Page 42 Return To Table Of Contents 12-2. Electrode and Amperage Selection Chart 2 3 12-3. Striking an Arc Scratch Start Technique 1 2 3 12-5. Positioning Electrode Holder 12-6. Poor Weld Bead Characteristics 12-7. Good Weld Bead Characteristics 12-8. Conditions That Affect Weld Bead Shape 12-9. Electrode Movement During Welding 12-10.Butt Joints 12-11.Lap Joint 12-12.Tee Joint 12-13.Weld Test 12-14.Troubleshooting Porosity 12-15.Troubleshooting Excessive Spatter 12-16.Troubleshooting Incomplete Fusion 12-17.Troubleshooting Lack Of Penetration 12-18.Troubleshooting Excessive Penetration 12-19.Troubleshooting Burn-Through 12-20.Troubleshooting Waviness Of Bead 12-21.Troubleshooting Distortion SECTION 13 PARTS LIST Figure 13-1. Main Assembly Page Page Page Page Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2003 (Equipment with a serial number preface of LC or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Owners Record