Miller Electric Blue Star 3500, Owner'S Manual

Page 1: ...Blue Star 3500 Processes Description Stick SMAW Welding Engine Driven Welding Generator OM 498 197 849F March 2004 Visit our website at www MillerWelds com ...

Page 2: ...nue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation q...

Page 3: ...STALLATION 13 5 1 Installing Welding Generator 13 5 2 Grounding Generator To Truck Or Trailer Frame 13 5 3 Grounding Generator When Supplying Building Systems 14 5 4 Engine Prestart Checks Kohler Powered Units 14 5 5 Engine Prestart Checks Honda Powered Units 15 5 6 Connecting The Battery Honda Electric Start Models Only 15 5 7 Connecting To Weld Output Terminals 16 5 8 Selecting Weld Cable Sizes ...

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Page 5: ...ox or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conductor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape...

Page 6: ...Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully CYLINDERS can explode if damaged Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or ...

Page 7: ...l fill cap HOT METAL from air arc cutting and gouging can cause fire or explosion Do not cut or gouge near flammables Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury Do not touch hot compressor or air system parts Let system cool down before touching or servicing READ INSTRUCTIONS Read Owner s Manual before using or servicing unit Stop engine and release air pressure b...

Page 8: ... American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pa...

Page 9: ...à l installation à la réparation ou à l entretien de l appareil Déverrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité Installer et mettre à la terre correctement cet appareil conformément à son manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cord...

Page 10: ...ourd des pantalons sans revers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi mité DES PARTICULES VOLANTES peuvent blesser les yeux Le soudage l éca...

Page 11: ...ns le vase d ex pansion si présent et non dans le radiateur sauf si précisé autrement dans la section maintenance du manuel du moteur Si le moteur est chaud et que le liquide doit être vérifié opérer comme sui vant Mettre des lunettes de sécurité et des gants placer un torchon sur le bou chon du radiateur Dévisser le bouchon légèrement et laisser la vapeur s échapper avant d enlever le bouchon LA ...

Page 12: ...re des mesures supplémentaires telles que le déplacement du poste l utilisation de câbles blindés l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail 2 6 Principales normes de sécurité Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 télé phone 305 443 9353 site Web www aws org Recommend...

Page 13: ...fferences between models are noted throughout this manual NOTE 4 1 Weld Power And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Generator Power Rating Fuel Capacity Engine CC DC 40 140 A 140 A 25 V 30 Duty Cycle 100 A 25 V 60 Duty Cycle 80 A 25 V 100 Duty Cycle 70 Single Phase 3 5 kVA kW 30 15 A 120 240 V AC 60 Hz Kohler 1 8 gal 6 9 L Tank H...

Page 14: ...unit could tip Do not move or operate unit where it could tip C 13 45 64 in 348 mm could tip D 22 3 4 in 577 mm A E 1 3 4 in 44 mm A C F 19 1 2 in 495 mm C G 13 32 in 10 mm Dia Weight Kohler Powered Units G 15 15 222 lb 101 kg 4 Holes G 15 15 Weight Honda Powered Units 4 Holes 15 F Electric Start Model 226 lb 103 kg 802 096 Engine End F E 802 512 A Recoil Start Model 201 lb 91 kg 802 096 Engine En...

Page 15: ...ntinuous 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 ...

Page 16: ...ailable in amperes at the receptacles 4 7 Volt Ampere Curves 198 453 The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 0 10 20 30 40 50 60 70 80 0 25 50 75 100 125 150 175 200 LOAD AMPS LOAD VOLTS MIN MID MAX ...

Page 17: ...n 5 2 Grounding Generator To Truck Or Trailer Frame install1 5 02 Ref 151 556 S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Metal Vehicle Frame 2 Equipment Grounding Terminal 3 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI receptacles use GFCI protected extension cord Electrically bond gener...

Page 18: ...as a low oil level shut down switch However some conditions may cause engine damage before the engine shuts down Check oil level often and do not use the oil level shutdown system to monitor oil level 1 Fuel Valve Open valve by turning lever to verti cal position Close fuel valve before moving unit or carburetor may flood and make starting difficult Fuel Add fresh fuel before starting engine the f...

Page 19: ... time see mainte nance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Check fuel level on a cold engine before use each day Oil After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see main tenance label To improve cold weather starting Keep battery in good condition Store battery in warm area off conc...

Page 20: ...gine before connectingto weld out put terminals Do not use worn dam aged undersized or poorly spliced cables Welding Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 ...

Page 21: ... a warm engine 4 Starter Handle To Start open fuel valve see Section 5 4 turn engine switch to On move throttle lever to Idle set choke and pull starter handle Open choke as engine warms To Stop turn engine switch to Off Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult 5 Welding Range Label Use label to determine...

Page 22: ...OM 498 Page 18 Return To Table 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 ...

Page 23: ... and pull starter handle Open choke as engine warms To Start Electric open fuel valve move throttle lever to Idle set choke and turn en gine switch to Start position Open choke as engine warms If the engine does not start let engine come to a complete stop before at tempting restart To Stop turn engine switch to Off Always close fuel valve after stopping unit Moving unit with fuel valve open may c...

Page 24: ...V AC Twistlock Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 3 5 kVA kW 2 120 V 20 A AC Duplex Receptacle RC2 3 120 V 20 A AC Duplex Receptacle RC3 RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum output from RC2 or RC3 is 2 4 kVA kW Each receptacle of the duplex can pro vide 15A 1800W Do not parallel the two 120V duplex receptacl...

Page 25: ...e when a circuit breaker trips Unplug power cord before attempt ing to service accessories or tools Generator power decreases as weld current increases Set Amperage control at max for full generator power Place throttle lever in Run position far right for generator power Circuit breakers protect the generator from overload Press button to reset circuit breaker If breaker continues to open contact ...

Page 26: ...0W 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...

Page 27: ... Neutral Silver Terminal 3 Load 1 Brass Terminal 4 Load 2 Brass Terminal 5 Ground Green Terminal 6 Cord Grip Strip cord jacket back enough to sep arate conductors Strip conductors enough to make good contact with plug terminals Make plug connections and reinstall outer shell and cord grip Tighten assembly screws onto shell Do not overtighten 1 3 2 4 Tools Needed 5 6 120 V 240 V 120V Notes Work lik...

Page 28: ...arrestor screen See engine manual 50 h Clean and tighten weld terminals Service air cleaner element See engine manual 100 h Change oil See engine manual and maintenancelabel Check spark plugs Clean and tighten battery connections Electric Start models only Clean Fuel sediment cup 200 h Replace unreadable labels Clean fuel tank and strainer 300 h Check valve clearance 500 h Repair or replace cracke...

Page 29: ...F 32 59 86 30 20 10 0 40 C 104 10 10 15 20 200 h 0 7 0 8 mm 0 028 0 031 in SG SF CC CD 8 3 Overload Protection Honda Powered Units Only 1 Ignition Circuit Breaker Electric Start Models Only The circuit breaker protects the en gine battery charging circuit A short circuit or a battery connected in reverse polarity will trip the circuit breaker Press button to reset breaker If a switch or breaker op...

Page 30: ...hrottle Control Lever 2 Adjustment Screw Move lever to Run far right posi tion To increase speed turn screw out counterclockwise while lightly pushing lever to the right To de crease speed turn screw in clock wise Idle Speed Adjustment 3 Adjustment Screw Move lever to idle far left position To increase idle speed turn screw in clockwise To decrease idle speed turn screw out counter clockwise Stop ...

Page 31: ...1 Throttle Control Lever 2 Adjustment Screw Move lever to Run far left position Turn screw and move lever until en gine runs at weld power speed Idle Speed Adjustment 3 Pilot Screw 4 Throttle Stop Screw Move lever to idle far right posi tion Turn pilot screw until engine runs at highest idle speed Turn stop screw until engine runs at rated idle speed normally about 2 1 4 turns out Stop engine Clos...

Page 32: ...weld output Check Amperage control setting Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes for Stick welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside welding generator Check engine speed and adjust if necessary see Section 8 4 or 8 5 Check throttle governor linkage for smooth non binding operation B Ge...

Page 33: ... Honda electric start models only Check battery connections and tighten if necessary Honda electric start models only Check oil level see Section 5 4 or 5 5 Engine stops if oil level is too low Refill crankcase with proper viscosity oil for operating temperature Have Factory Authorized Service Agent check low oil level shutdown switch Engine stopped during normal operation Check fuel level see Sec...

Page 34: ...OM 498 Page 30 Return To Table Of Contents SECTION 10 ELECTRICAL DIAGRAMS SC 495 297 198 016 D Figure 10 1 Circuit Diagram For Welding Generator ...

Page 35: ...OM 498 Page 31 Return To Table Of Contents 201 026 A Figure 10 2 Wiring Diagram For Generator Power Panels 1 Of 2 ...

Page 36: ...OM 498 Page 32 Return To Table Of Contents 201 026 A Figure 10 3 Wiring Diagram For Generator Power Panels 2 Of 2 ...

Page 37: ... 2 Grounding Generator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire If unit does not have GFCI re...

Page 38: ...power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 11 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment VOLTS 115 4 5 60 AMPS Hz 1 2 3 3 EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5 ...

Page 39: ...quipment Farm Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 1...

Page 40: ...P 3000 1000 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900...

Page 41: ...Induction Motor Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Starting the motor requires 12 2 amperes 11 2 x 1 4 x 1000 230 12 2 A kVA HP x HP x 1000 VOLTS STARTING AMPERAGE Volts 230 HP 1 4 Using Table Code M results in kVA HP 11 2 11 9 How Mu...

Page 42: ...omer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed...

Page 43: ...25 38 75 23 50 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 ...

Page 44: ...ure 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 perage see Section 12 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a ...

Page 45: ... FLAT HORIZ FILLET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER 12 3 Striking an Arc Scratch Start Technique S 0049 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc...

Page 46: ...de Angle 10 30 12 6 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 12 7 Good Weld Bead Characteristics S 0052 B 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration ...

Page 47: ...gle Too Large Correct Angle 12 9 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better NOTE S 0054 A 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns...

Page 48: ... 16 in 1 6 mm 3 4 12 11 Lap Joint S 0063 S 0064 1 Electrode 2 Single LayerFillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength 30 Or Less Single Layer Fillet Weld Multi Layer Fillet Weld 30 Or Less 1 1 2 3 12 12 Tee Joint S 0060 S 0058 ...

Page 49: ...metal Possible Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 12 15 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amper...

Page 50: ...tings slag and dirt from work surface before welding 12 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge ...

Page 51: ...hat is not parallel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 12 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move Base metal moves in the direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold ...

Page 52: ... SECTION 13 PARTS 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 ...

Page 53: ...7 CARRIER bearing 1 18 495 348 SCREW 5 16 24 HWH 1 19 494 628 PANEL end generator 1 20 Deleted 21 495 257 MOUNT shock w bushing 2 22 495 256 MOUNT shock generator 1 23 194 504 FRAME mtg assembly Kohler 1 23 495 132 FRAME mtg assembly Honda 1 24 PC1 148 608 BOARD PC filter CSA only 1 25 494 613 TERMINAL output 2 26 R1 494 618 RHEOSTAT 35 ohm 100W 1 27 495 214 SEAL air duct 1 28 495 255 DUCT air 1 2...

Page 54: ...8 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 17 19 19 20 21 22 23 Generator Power Panel 495 290 Europe Generator Power Panel 495 288 S America Generator Power Panel 495 283 S E Asia 24 25 Generator Power Panel 495 298 USA 1 Figure 13 2 Generator Power Panels ...

Page 55: ...CB1 495 183 CIRCUIT BREAKER 30A 1 15 CB2 CB3 495 246 CIRCUIT BREAKER 20A 2 Generator Power Panel 495 253 South Africa 16 495 252 PANEL generator power assembly 1 17 CB1 CB2 495 245 CIRCUIT BREAKER 15A 2 Generator Power Panel 495 289 Australia 18 495 254 PANEL generator power assembly 1 19 CB1 CB4 495 245 CIRCUIT BREAKER 15A 4 Generator Power Panel 495 290 Europe 20 495 282 PANEL generator power as...

Page 56: ...OM 498 Page 52 Return To Table Of Contents Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 57: ...Notes ...

Page 58: ...n 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 MATERIAL THICKNESS REFERENCE CHART ...

Page 59: ...trols Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but man...

Page 60: ... complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Informati...