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Miller Electric Blue Star 3500 7-3. Generator Power Panel Ratings

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7-3. Generator Power Panel Ratings

Unless otherwise stated, the rating of duplex outlets is the combined load of all

receptacles.

NOTE

Total power from generator NOT to exceed 3500 Watts (60 Hz)

Receptacle Protected

By

Panel

495 218

(USA)

Panel

495 315

(USA)

Panel

495 298

(USA)

Panel

495 279

(Canada-

CSA)

Panel

495 253

(S. Africa)

Panel

495 288

(South

America)

Panel

495 289

(Australia)

Panel

495 290

(Europe)

Panel

495 283

(S.E. Asia)

60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz

240 V

Twist Lock CB1,2 30A/

3600W

240 V

Duplex CB1,2

15A/

3500W

See

Note 2

15A/

3500W

240 V

Duplex CB3,4 15A/

3500W

230 V

Single CB1 15A/

3500W 15A/

3500W 15A/

3500W

230 V

Single CB2 15A/

3500W 15A/

3500W 15A/

3500W

230 V

Single CB1,2 15A/

3500W

230 V

Single CB3,4 15A/

3500W

120 V

Twist Lock CB1 30A/

3500W 30A/

3500W

120 V

Duplex CB1,2

CB1,3 30A/

3500W

120 V

Duplex CB2 20A/

2400W

120 V

Duplex CB3 20A/

2400W

20A/

2400W

See

Note 3

20A/

2400W

120 V

Duplex CB4

20A/

2400W

See

Note 3

20A/

2400W

Total

Power NOT

to exceed 3500W 3500W 3500W 3500W 3500W 3500W 3500W 3500W 3500W

For example, for the 495 218 Generator Power Panel,

120V, 1500W heater 1500W

120V, 10A chain saw 1200W

120V, 500W halogen lamp 500W

Total 3200W This loading is OK.

120V, 1500W heater 1500W

120V, 10A chain saw 1200W

120V, 5A router 600W

120V, 500W halogen lamp 500W

Total 3800W This loading is not OK

.

It exceeds 3500W.

Notes: 1. Each receptacle of the duplex can provide 15A/1800W. Do not parallel the two 120V duplex receptacles.

2. Do not parallel the two 120V circuits.

3. Do not parallel the two duplex outlets.

Calculating total power provided by generator.

(See Section 11 − Generator Power Guidelines)

Each receptacle can provide the watts or amps as shown

above. However, the total power can not exceed 3500W.

The rating plate on electrical apparatus will contain the watts

consumed or the rated input amps. Watts may be calculated by

multiplying the rated voltage by the rated input amps.

watts = volts x amps

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