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Miller Electric Blue Star 3500 4-4. Fuel Consumption (Honda-Powered Units), 4-5. Duty Cycle

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OM-498 Page 11

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4-4. Fuel Consumption (Honda-Powered Units)

802 121

Continuous Welding

4-5. Duty Cycle

802 092

Duty cycle is the percentage of 10

minutes that unit can weld at rated

load without overheating.

Exceeding duty cycle can

damage unit and void

warranty.

100% Duty Cycle at 80 Amperes CC/DC

3 Minutes Welding 7 Minutes Resting

30% Duty Cycle at 140 Amperes CC/DC

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 Page 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