Miller Electric 145 DXR, 145 manual

Blue Star 145 Processes Description Stick (SMAW) W elding Engine Driven Welding Generator OM-4417 210 403F 2007 − 05  Blue Star 145 DX  File: Engine Drive V isit our website at www.MillerWelds.com ESP AÑOL ENGLISH[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . [...]

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OM-4417 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or [...]

OM-4417 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.  If ventilation is [...]

OM-4417 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery .  Stop engine before disconnecting or connect- ing battery cables or servicing battery .  Do not allow tools to cause sparks when working on a battery .  Do not use welder to cha[...]

OM-4417 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury .  Do not touch hot compressor or air system parts.  Let system cool down before touching or ser- vicing. READ INSTRUCTIONS.  [...]

OM-4417 Page 5 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  The user is responsible for having a qualified electrician promptly corre[...]

OM-4417 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des ble[...]

OM-4417 Page 7 Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation.  Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.  Ne pas to[...]

OM-4417 Page 8  Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et N FPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affe c l’ouïe.  Porter des protections approuvés pour les or e les si le niveau sonore [...]

OM-4417 Page 9  Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES.  Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.  JAMAIS utiliser dan[...]

OM-4417 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant d e démarrer ou d’a rrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager le moteur électrique à cause d’une tension et d’une fré - quence trop faibles.  N e pas b[...]

OM-4417 Page 1 1 2-6. P r oposition californienne 65 A vertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de [...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Engine Choke Read Operator ’s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine Positive Negative Alternating Current (AC) Output h Hours s Seconds T ime Protective Earth (Ground) Circuit Protector T emperat[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 13 4-2. Dimensions, Weights, And Operating Angles Dimensions Height 22-3/4 in (578 mm) D Width 22-3/4 in (577 mm) D Depth 31-5/8 in (803 mm) ! Do not exceed tilt angles or engine could A 31-5/8 in (803 mm) B ! Do not exceed tilt angles or engine could be dama g ed or unit could[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 14 4-4. Fuel Consumption 220 637 DC WELD AMPERES A T RA TED DUTY CYCLE US Gal./Hr . 0 25 50 75 100 125 150 175 200 0.00 0.20 0.40 0.60 0.80 1.00 IDLE AUXILIARY POWER KW A T 100% DUTY CYCLE US Gal./Hr . 0 12 345 6 0.00 0.20 0.40 0.60 0.80 1.00 IDLE[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 15 Continuous W elding 4-5. Duty Cycle 220 625 − A Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle ca n damage unit and void warranty . 100% Duty Cycle at 80 Amperes CC/DC 20% Duty Cycle at 145 A[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 16 SECTION 5 − INST ALLA TION 5-1. Installing W elding Generator Ref 151 556 / Ref. 800 652 / 803 597-B / S-0854 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR Movement Airflow Clearance Location Do not install unit where air flow is restricted [...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 17 5-2. Grounding Generator When Supplying Building Systems GND/PE 1 2 2 3 800 576-B ! Ground generator to sys- tem earth ground if supply- ing power to a premises (home, shop, farm) wiring system. 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulate[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 18 5-4. Engine Prestart Checks − DX Model 803 595-B Full Gasoline 1/2 in (13 mm) Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. 1 Fuel V alve Open valve.  Close fuel valve before moving unit or carburetor may flo[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 19 5-6. Connecting T o W eld Output T erminals 803 596 − B / 803 778-A 1 Positive (+) W eld Output T erminal 2 Negative ( − ) Weld Output T erminal For Direct Current Electrode Posi- tive (DCEP), connect work cable to Negative ( − ) terminal and electrode holder to Positi[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 20 SECTION 6 − OPERA TING THE WELDING GENERA TOR 6-1. Controls (Standard Models) (See Section 6-2) 803 956 − B / 803 594 − B / 218 610 4 1 6 3 5 2[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 21 6-2. Description Of Controls (Standard Models) (See Section 6-1 ) 1 Engine Switch Use switch to control ignition circuit. T urn switch to On position when starting engine. Turn switch to Off position to stop engine. En- gine cannot be started with switch in the Off position.[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 22 6-3. Controls (DX Models) (See Section 6-4) 803 596 − A / 803 595 − A / 218 610 1 8 7 3 5 4 6 2[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 23 6-4. Description Of Controls (DX Models) (See Section 6-3 ) 1 Engine Switch Use switch to control ignition circuit. T urn switch t o Start position for electric start. Turn switch to On position to start engine using starter ha ndle (recoil). T urn switch to Off posi- tion t[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 24 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT Set Current control to maximum for full generator power output at AC receptacles. NOTE ! If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord.  Generator power decreases as weld current increases . 1 2[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 25 SECTION 8 − MAINTENANCE  Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. 8-1. Routine Maintenance ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, serv[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 26 8-2. Servicing Air Cleaner aircleaner6 9/00 − 803 404 ! Stop engine. NOTICE − Do not run engine with- ou t air cleaner or with dirty element. 1 Precleaner 2 Paper Element  Do not wash paper element or clean with compressed air. Remove cover . Was h precleaner with soa[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 27 8-3. Adjusting Engine Speed (Standard Models Only) 803 594-B T ools Needed: 3750 ± 30 rpm (62 Hz) After tuning engine, check engine speed. See table for proper no load speed. If necessary , adjust speed as follows: Start engine and run until warm. 1 Adjustment Screw T o inc[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 28 8-4. Adjusting Engine Speed (DX Models Only) 803 595 − B 2500 ± 100 rpm (42 Hz) 3750 ± 30 rpm (62 Hz) T ools Needed: After tuning engine, check engine speed. See table for proper no load speed. If necessary , adjust speed as follows: Start engine and run until warm. Set [...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 29 SECTION 9 − TROUBLESHOOTING 9-1. T roubleshooting A. Welding T rouble Remedy No weld output or generator power out- put at ac receptacles. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip r[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 30 T rouble Remedy Low output at generator power ac receptacles. Check W eld Output control setting. Check engine speed, and adjust if necessary (see Section 8-3 or 8-4). Open circuit voltage is reduced as engine speed drops. Erratic output at generator power ac receptacles Che[...]

 Complete Parts List available at www .MillerW elds.com OM-4417 Page 31 SECTION 10 − P ARTS LIST 10-1. Recommended Spare Parts Description Part No. Recommended Spare Parts Quantity 221581 T une − up & Filter Kit, Kohler CS 10 Recoil (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203960 Spark Pl[...]

OM-4417 Page 32 SECTION 1 1 − ELECTRICAL DIAGRAMS 226 737-A Figure 1 1-1. Circuit Diagram For Standard Models[...]

OM-4417 Page 33 226 738-A Figure 1 1-2. Circuit Diagram for DX Models[...]

OM-4417 Page 34 SECTION 12 − GENERA TOR POWER GUIDELINES  The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 12-1. Selecting Equipment gen_pwr 2007 − 04 − Ref. ST -159 730 / ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Pro[...]

OM-4417 Page 35 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Us e ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. A[...]

OM-4417 Page 36 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starti ng W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 285[...]

OM-4417 Page 37 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in 3[...]

OM-4417 Page 38 12-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not li[...]

OM-4417 Page 39 12-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install and ground this equip[...]

OM-4417 Page 40 12-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 840 4[...]

OM-4417 Page 41 SECTION 13 − STICK WELDING (SMA W) GUIDELINES 13-1. Stick Welding Procedure stick 2007 − 04 − ST-151 593 1 W orkpiece Make sure workpiece is clean be- fore welding. 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one. Fol- low electrode manufacturer’ s instructions when setting weld am-[...]

OM-4417 Page 42 13-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELECTR[...]

OM-4417 Page 43 13-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End V iew of Work Angle Sid e V iew of Electrode Angle End V iew of Work Angle S ide View of Electrode Angle 10 ° -30 ° 13-6. Poor W eld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crate[...]

OM-4417 Page 44 13-8. Conditions That Affect Weld Bead Shape  W eld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. S-0061 ELECTRODE ANGLE ARC LENGTH TRA VEL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo Small Angle T oo Large Correct Angle 13-9. Electro[...]

OM-4417 Page 45 13-10. Butt Joints S-0662 1 T ack Welds Prevent ed ge s o f j oint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 Single V -Groove Weld Good for materials 3/16 − 3/4 in (5-19 mm) thick. Cut bevel with oxy-[...]

OM-4417 Page 46 13-13. W eld T est S-0057-B 1 V ise 2 Weld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in 1/4 in 3 2 1 2 T o 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 13-14. T roubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets i n weld metal. Possib[...]

OM-4417 Page 47 13-16. T roubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insuf ficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in prop[...]

OM-4417 Page 48 13-19. T roubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 13-20. T roubleshooting − W avine[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y o ur distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The exp[...]

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Co mpan y 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarte rs − USA USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters −[...]