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Miller Electric
Blue Star 3500 manual
1
1
60
60
Download
60 pages, 1.83 Mb
Blue
Star
3500
Processes
Description
Stick
(SMAW)
W
elding
Engine Driven Welding Generator
OM-498
197 849F
March 2004
Visit our website at
www.MillerWelds.com
Contents
Main
Blue Star 3500
From Miller to You
TABLE OF CONTENTS
Page
OM-498 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-498 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-498 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 d e s brlures dans les YEUX et sur la PEAU.
OM-498 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
h Hours s
3-1. Symbol Definitions
SECTION 4 SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
4-2. Dimensions, Weights, And Operating Angles
4-3. Fuel Consumption (Kohler-Powered Units)
4-4. Fuel Consumption (Honda-Powered Units)
4-5. Duty Cycle
4-6. Generator Power Curve
4-7. Volt-Ampere Curves
MIN MID MAX
SECTION 5 INSTALLATION
5-1. Installing W elding 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 (Honda 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 )
SECTION 7 OPERATING AUXILIARY EQUIPMENT
7-1. Generator Power Panel 495 218 (USA)
7-2. Optional Generator Power Panels
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 3500 Watts (60 Hz)
7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)
SECTION 8 MAINTENANCE
8-1. Routine Maintenance
8 h 20 h
50 h
100 h
8-2. Maintenance Label
ENGINE MAINTENANCE
8-3. Overload Protection (Honda-Powered Units Only)
200 h
50 h
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
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
11-11. Selecting Extension Cord (Use Shortest Cord Possible)
SECTION 12 STICK WELDING (SMAW) GUIDELINES
12-1. Stick Welding Procedure
OM-498 Page 41
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
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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