Miller Electric Blue Star 3500 manual

Blue Star 3500 Processes Description Stick (SMAW) W elding Engine Driven Welding Generator OM-498 197 849F March 2004  Visit our website at www.MillerWelds.com[...]

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 catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

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-498 Page 1 Return T o T able Of Contents SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining sym[...]

OM-498 Page 2 Return T o T able Of Contents W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly of f from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or f[...]

OM-498 Page 3 Return T o T able Of Contents STEAM AN D H O T C OOLANT can burn.  If possible, check coolant level when engine is cold to avoid scalding.  Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).  If the engine is warm, checking is[...]

OM-498 Page 4 Return T o T able Of Contents READ INSTRUCTIONS.  Use only genuine MILLER/Hobart replacement parts.  Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F . RADIA TION can cause interference.  High-frequency (H.F .) can [...]

OM-498 Page 5 Revenez à la table des matières SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 8/03  A vertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de dang[...]

OM-498 Page 6 Revenez à la table des matières LES ACCUMULA TIONS DE GAZ ris- quent de provoquer des blessures ou même la mort.  Fermer l’alimentation du gaz protecteur en cas de non utilisation.  V eiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l?[...]

OM-498 Page 7 Revenez à la table des matières L ’EXPLOSION DE LA BA TTERIE peut RENDRE A VEUGLE.  T oujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie.  Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.  Eviter de provoquer[...]

OM-498 Page 8 Revenez à la table des matières LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence t[...]

OM-498 Page 9 Return T o T able Of Contents 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 Breaker T emperature SECTION 4 − SPECIFICA TIONS [...]

OM-498 Page 10 Return T o T able Of Contents 4-2. Dimensions, W eights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) D Width 22-3/4 in (577 mm) D Depth 31-1/4 in (793 mm)  Do not exceed tilt angles or engine could A 31-1/4 in (793 mm) B  Do not exceed tilt angles or engine could be damaged or unit could tip. B 10-1/2 in (268 mm) [...]

OM-498 Page 1 1 Return T o T able Of Contents 4-4. Fuel Consumption (Honda-Powered Units) 802 121 Continuous W elding 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 W el[...]

OM-498 Page 12 Return T o T able Of Contents 4-6. Generator Power Curve 802 129 The ac generator power curves show the generator power available in amperes at the receptacles. 4-7. V olt-Ampere Curves 198 453 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities o f th e welding generator . Curves of al l oth[...]

OM-498 Page 13 Return T o T able Of Contents SECTION 5 − INST ALLA TION 5-1. Installing Welding Generator install1 5/02 − 802 512-A / Ref. 151 556 / 158 936-A / 800 652-A / 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 5-2. Grounding Generator T o T ruck Or T railer Fram[...]

OM-498 Page 14 Return T o T able Of Contents 5-3. Grounding Generator When Supplying Building Systems GND/PE 1 2 Use ground device as stated in electrical codes. 2 3 800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to sys- tem earth ground if supply- ing p[...]

OM-498 Page 15 Return T o T able Of Contents 5 -5. Engine Prestart Checks (Honda-Powered Units) Ref. 802 099-A Full Full Gasoline 1/2 i n (13 mm) Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil level gets too low . 1 Fuel V alve Open valve.  Close fuel valve before m[...]

OM-498 Page 16 Return T o T able Of Contents 5-7. Connecting T o Weld Output T erminals 196 921 / 495 179 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 Positive (+) terminal. For Direct Current Electr[...]

OM-498 Page 17 Return T o T able Of Contents SECTION 6 − OPERA TING THE WELDING GENERA TOR 6-1. Controls (Kohler-Powered Units) 802 512-A / 495 179 5 2 60 Hz 3 4  Weld and generator power output stops i f generator overheats or engine speed is too low . 1 Engine Switch Us e switch to open ignition circuit, and to stop engine. 2 Throttle Contro[...]

OM-498 Page 18 Return T o T able Of Contents 6-2. Controls (Honda-Powered Units) (See Section 6-3) 802 099-A / 802 100-A / 953T-5-4 Recoil-Start Electric-Start 60 Hz 1 4 3 6 2 1 5[...]

OM-498 Page 19 Return T o T able Of Contents 6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2 )  Weld and generator power output stops i f generator overheats or engine speed is too low . 1 Engine Switch On models with recoil-start, use switch to open ignition circuit, and to stop engine. On models with electric-start, use swi[...]

OM-498 Page 20 Return T o T able Of Contents SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT The welding generator provides power while welding and with the Current control in any position. However , under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations. It is recommended that on[...]

OM-498 Page 21 Return T o T able Of Contents 7-2. Optional Generator Power Panels Ref. ST-802 124 / H-495 290 / H-495 283 Generator Power Panel 495 315 (USA) Generator Power Panel 495 279 (Canada) Generator Power Panel 495 253 (South Africa) Generator Power Panel 495 289 (Australia)  If unit does not have GFCI recep- tacles, use GFCI-protected e[...]

OM-498 Page 22 Return T o T able Of Contents 7-3. Generator Power Panel Ratings Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles. NOTE T otal 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- CS[...]

OM-498 Page 23 Return T o T able Of Contents 7-4. Wiring Instructions For Optional 120/240 V olt T wistlock Plug (NEMA L14-30P) plug3-1 1/99 − 802 527 1 Plug Wired For 120/240 V , 3-Wire Load When wired for 120 V loads, each d u - plex receptacle shares a load with one half of the 240 V receptacle. 2 Neutral (Silver) T erminal 3 Load 1 (Brass) T [...]

OM-498 Page 24 Return T o T able Of Contents SECTION 8 − MAINTENANCE 8-1. Routine Maintenance Recycle engine fluids.  Stop engine before maintaining.  See Engine Manual and Maintenance Label. Service more often if used in severe conditions. * T o be done by Factory Authorized Service Agent. 8 h 20 h Wipe up spills. Check fluid levels. See S[...]

OM-498 Page 25 Return T o T able Of Contents Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. NOTE 8-2. Maintenance Label Ref. S-175 679-A ENGINE MAINTENANCE 8 h 1.1 l (1.2 US qt, 1.94 lmp qt) Unleaded 86 + Octane 6.5 l (1.7 US Gal, 1 1.4 lmp pt) 50 h 100 h 10W -30 ° F +32 +59 +86 +[...]

OM-498 Page 26 Return T o T able Of Contents 8-4. Adjusting Engine Speed (Kohler-Powered Units) 802 512-A / Kohler Dwg. After tuning engine, check engine speeds. See table for proper no load speeds. If necessary , adjust speeds as follows: Start engine and run until warm. W eld/Power Speed Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move[...]

OM-498 Page 27 Return T o T able Of Contents 8-5. Adjusting Engine Speed (Honda-Powered Units) 802 101-A After tuning engine, check engine speeds. See table for proper no load speeds. If necessary , adjust speeds as follows: Start engine and run until warm. W eld/Power Speed Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move lever to Run ([...]

OM-498 Page 28 Return T o T able Of Contents SECTION 9 − TROUBLESHOOTING 9-1. T roubleshooting A. Welding T rouble Remedy No weld output. Check Amperage control setting. Check weld connections. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, rotor , stator[...]

OM-498 Page 29 Return T o T able Of Contents T rouble Remedy Erratic output at generator power ac receptacles. Check fuel level. Check receptacle wiring and connections. Check throttle/governor linkage for smooth, non-binding operation. Service air cleaner according to engine manual. Check engine speed, and adjust if necessary (see Section 8-4 or 8[...]

OM-498 Page 30 Return T o T able Of Contents SECTION 10 − ELECTRICAL DIAGRAMS SC-495 297 198 016-D Figure 10-1. Circuit Diagram For Welding Generator[...]

OM-498 Page 31 Return T o T able Of Contents 201 026-A Figure 10-2. Wiring Diagram For Generator Power Panels (1 Of 2)[...]

OM-498 Page 32 Return T o T able Of Contents 201 026-A Figure 10-3. Wiring Diagram For Generator Power Panels (2 Of 2)[...]

OM-491 Page 33 Return T o T able Of Contents SECTION 1 1 − 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. NOTE 1 1-1. Selecting Equipment gen_pwr 1 1/02 − Ref. ST-159 730 / ST -800 577 1 Generator Power Receptacle s − Neut[...]

OM-491 Page 34 Return T o T able Of Contents 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e grou[...]

OM-491 Page 35 Return T o T able Of Contents 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting 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/[...]

OM-491 Page 36 Return T o T able Of Contents 1 1-7. 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 Benc[...]

OM-491 Page 37 Return T o T able Of Contents 1 1-8. Power Required T o Start Motor 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 listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts[...]

OM-491 Page 38 Return T o T able Of Contents 1 1-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner ’ s Manual and national, state, and local codes.  Customer -[...]

OM-491 Page 39 Return T o T able Of Contents 1 1-1 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) [...]

OM-498 Page 40 Return T o T able Of Contents SECTION 12 − STICK WELDING (SMA W) GUIDELINES 12-1. Stick W elding Procedure stick 12/96 − ST-151 593  W eld current starts when electrode touches work- piece.  W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. P lace work clamp a[...]

OM-498 Page 41 Return T o T able Of Contents 12-2. 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 2[...]

OM-498 Page 42 Return T o T able Of Contents 12-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End View of W ork Angle Side V iew of Electrode Angle End View of W ork Angle Side V iew of Electrode Angle 10 ° -30 ° 12-6. Poor W eld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough[...]

OM-498 Page 43 Return T o T able Of Contents 12-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. NOTE 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 S mall Angle T oo Lar[...]

OM-498 Page 44 Return T o T able Of Contents 12-10. Butt Joints S-0662 1 T ack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. 2 Square Groove W eld 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) [...]

OM-498 Page 45 Return T o T able Of Contents 12-13. W eld T est S-0057-B 1 V ise 2 W eld 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) 12-14. T roubleshooting − Porosity Porosity − small cavities or holes resulting from gas [...]

OM-498 Page 46 Return T o T able Of Contents 12-16. 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[...]

OM-498 Page 47 Return T o T able Of Contents 12-19. 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. 12-20.[...]

OM-498 Page 48 Return T o T able Of Contents SECTION 13 − P ARTS LIST  Hardware is common and not available unless listed. 802 513-A / 802 153-B 19 25 29 22 23 28 26 27 21 32 33 30 31−Fig 13-2 34 35 36 1 6 24 3 5 4 7 8 18 17 16 15 14 13 12 9 11 10 38 39 40 41 42 43 44 Figure 13-1. Main Assembly[...]

OM-498 Page 49 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quanti ty 1 +495 247 TOP , control box (specify color) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-498 Page 50 Return T o T able Of Contents  Hardware is common and not available unless listed. 196 921 25 3 4 Generator Power Panel 495 315 (USA) Generator Power Panel 495 218 (USA) Generator Power Panel 495 279 (Canada) Generator Power Panel 495 253 (South Africa) Generator Power Panel 495 289 (Australia) 6 7 8 9 10 11 12 13 14 15 16 18 17 1[...]

OM-498 Page 51 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 13-2. Generator Power Panels (Figure 13-1, Item 31) Quanti ty Generator Power Panel 495 298 (USA) 1 495 220 P ANEL, generator power assembly 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CB1, CB2 4[...]

OM-498 Page 52 Return T o T able Of Contents Notes W o rk l i ke a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginning of this manual .[...]

Notes[...]

TM-188 304 Page 54 Invision 354MP Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MA TERIAL THICKNESS REFERENCE CHART[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 8/03 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 expertise [...]

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarte rs− USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X: 920-735-4134 Int ernational F A X : 9 20-735-4125 European He adqua rt ers −[...]