OM-498, Processes | Miller Electric Blue Star 3500 instruction

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OM-498

197 849F

March 2004

Processes

Stick (SMAW) Welding

Description

Engine Driven Welding Generator

Blue StarR 3500

Image 1

Miller Electric Blue Star 3500 manual OM-498, Processes, Description

Contents

Processes OM-498Description From Miller to You Table of Contents Page Arc Welding Hazards Symbol Usage Engine Hazards Compressed Air Hazards California Proposition 65 Warnings Principal Safety StandardsEMF Information Radiation can cause interference − Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux DES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe DES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessures Information sur les champs électromagnétiques Principales normes de sécurité Symbol Definitions − SpecificationsWeld, Power, And Engine Specifications − Definitions Fuel Consumption Kohler-Powered Units Dimensions, Weights, And Operating AnglesDimensions Weight Kohler-Powered Units Exceeding duty cycle can damage unit and void warranty Fuel Consumption Honda-Powered UnitsDuty Cycle 100% Duty Cycle at 80 Amperes CC/DC Volt-Ampere Curves Generator Power Curve Installing Welding Generator − InstallationGrounding Generator To Truck Or Trailer Frame Use ground device as stated in electrical codes Grounding Generator When Supplying Building Systems Connecting The Battery Honda Electric-Start Models Only Engine Prestart Checks Honda-Powered Units+ − Oil Selecting Weld Cable Sizes Connecting To Weld Output Terminals − Operating the Welding Generator Controls Kohler-Powered Units60 Hz Choke Control Lever Recoil-Start 2Electric-Start Controls Honda-Powered Units See Section Work like a Pro Description Of Controls Honda-Powered Units See Section − Operating Auxiliary Equipment Generator Power Panel 495 218 USA120 V x 10 a + 240 V x 9 a = 3.5 kVA/ KW OM-498 Generator Power Panel 495 Optional Generator Power PanelsCanada South Africa South America Australia Europe Asia It exceeds 3500W Generator Power Panel Ratings Wire Load Plug Wired For 120/240Plex receptacle shares a load with One half of the 240 V receptacle − Maintenance Overload Protection Honda-Powered Units Only Maintenance Label Weld/Power Speed Adjustment Adjusting Engine Speed Kohler-Powered UnitsTop View Idle Speed Adjustment Stop engine. Close fuel valve Top View Throttle Control Lever Adjustment Screw Adjusting Engine Speed Honda-Powered UnitsStop engine. Close fuel valve Tools Needed 3/8 Troubleshooting − TroubleshootingGenerator Power Welding Viscosity oil for operating temperature Check battery voltage Honda electric-start models onlyEngine Make starting difficult Circuit Diagram For Welding Generator − Electrical Diagrams Wiring Diagram For Generator Power Panels 1 Wiring Diagram For Generator Power Panels 2 Selecting Equipment − Generator Power GuidelinesOM-491 How Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Volts 115 Amps Resistive Load Approximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment How Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x Typical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord Possible Weld current starts when electrode touches work- piece Stick Welding Procedure− Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work Angle Electrode Movement During Welding Conditions That Affect Weld Bead Shape Lap Joint Butt JointsTee Joint 16 in 1.6 mm Tack Welds Troubleshooting − Excessive Spatter Troubleshooting − PorosityWeld Test Possible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion 31−Fig − Parts List Dia Part Generator Power Panel 495 South Africa Australia Generator Power Panel 495 Generator Power Panel 495 315 USACanada Europe America Generator Power Panel 495 279 Canada Generator Power Panel 495 218 USAGenerator Power Panel 495 253 South Africa Generator Power Panel 495 289 Australia Work like a Pro Page TM-188 304 Invision 354MP Material Thickness Reference Chart Your distributor also gives ServiceSupport For assistance in filing or settling claims, contact Miller Electric Mfg. CoYour distributor and/or equipment manufacturer’s Transportation Department