Work like a Pro | Miller Electric Blue Star 3500 instruction

Notes

Work like a Pro!

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

OM-498 Page 52

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Miller Electric Blue Star 3500 manual Work like a Pro

Contents

Description OM-498Processes From Miller to You Table of Contents Page Symbol Usage Arc Welding Hazards Engine Hazards Compressed Air Hazards Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux LE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoque r des blessures Principales normes de sécurité Information sur les champs électromagnétiques − Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − Definitions Dimensions, Weights, And Operating Angles Fuel Consumption Kohler-Powered UnitsDimensions Weight Kohler-Powered Units Fuel Consumption Honda-Powered Units Exceeding duty cycle can damage unit and void warrantyDuty Cycle 100% Duty Cycle at 80 Amperes CC/DC Generator Power Curve Volt-Ampere Curves Grounding Generator To Truck Or Trailer Frame − InstallationInstalling Welding Generator Grounding Generator When Supplying Building Systems Use ground device as stated in electrical codes Engine Prestart Checks Honda-Powered Units Connecting The Battery Honda Electric-Start Models Only+ − Oil Connecting To Weld Output Terminals Selecting Weld Cable Sizes Controls Kohler-Powered Units − Operating the Welding Generator60 Hz Choke Control Lever Controls Honda-Powered Units See Section Recoil-Start 2Electric-Start Description Of Controls Honda-Powered Units See Section Work like a Pro 120 V x 10 a + 240 V x 9 a = 3.5 kVA/ KW OM-498 Generator Power Panel 495 218 USA− Operating Auxiliary Equipment Optional Generator Power Panels Generator Power Panel 495Canada South Africa South America Australia Europe Asia Generator Power Panel Ratings It exceeds 3500W Plug Wired For 120/240 Wire LoadPlex receptacle shares a load with One half of the 240 V receptacle − Maintenance Maintenance Label Overload Protection Honda-Powered Units Only Adjusting Engine Speed Kohler-Powered Units Weld/Power Speed AdjustmentTop View Idle Speed Adjustment Stop engine. Close fuel valve Top View Adjusting Engine Speed Honda-Powered Units Throttle Control Lever Adjustment ScrewStop engine. Close fuel valve Tools Needed 3/8 − Troubleshooting TroubleshootingGenerator Power Welding Check battery voltage Honda electric-start models only Viscosity oil for operating temperatureEngine Make starting difficult − Electrical Diagrams Circuit Diagram For Welding Generator Wiring Diagram For Generator Power Panels 1 Wiring Diagram For Generator Power Panels 2 OM-491 − Generator Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Volts 115 Amps Resistive Load Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Current Load Watts Amperes − Stick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work Angle Conditions That Affect Weld Bead Shape Electrode Movement During Welding Butt Joints Lap JointTee Joint 16 in 1.6 mm Tack Welds Troubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective Actions Troubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead − Parts List 31−Fig Dia Part Generator Power Panel 495 Generator Power Panel 495 315 USA Generator Power Panel 495 South Africa AustraliaCanada Europe America Generator Power Panel 495 218 USA Generator Power Panel 495 279 CanadaGenerator Power Panel 495 253 South Africa Generator Power Panel 495 289 Australia Work like a Pro Page Material Thickness Reference Chart TM-188 304 Invision 354MP Support ServiceYour distributor also gives Miller Electric Mfg. Co For assistance in filing or settling claims, contactYour distributor and/or equipment manufacturer’s Transportation Department