Miller Electric Blue Star 6000 Owner's Manual

Blue Star 6000(Honda-Powered)ProcessesDescriptionStick (SMAW) WeldingEngine Driven Welding GeneratorOM-488 495 371BJanuary 2000Visit our website atww

OM-488 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étince

OM-488 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvemen

OM-488 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des int

OM-488 Page 9SECTION 2 – DEFINITIONS2-1. Symbol DefinitionsEngine ChokeRead Operator’sManual AAmperesVVoltsEngine Oil Fuel Battery (Engine) EnginePosi

OM-488 Page 103-3. Fuel ConsumptionST-802 122Continuous Welding3-4. Duty CycleST-802 093Duty cycle is the percentage of 10minutes that unit can weld a

OM-488 Page 113-5. Auxiliary Power CurvesST-802 125 / ST-802 126The ac auxiliary power curvesshow the auxiliary power availablein amperes at the recep

OM-488 Page 123-6. Volt-Ampere CurvesST-802 127 / ST-802 128The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities

OM-488 Page 13SECTION 4 – INSTALLATION4-1. Installing Welding Generatorinstall1 1/97 – ST-802 095 / Ref. ST-151 556 / ST-158 936-A / S-085418 in(460 m

OM-488 Page 144-3. Grounding Generator When Supplying Building SystemsGND/PE1 2Use ground device asstated in electrical codes.23ST-800 576-B1 Equipmen

OM-488 Page 154-5. Connecting the Battery (Electric-Start Models Only)ST-802 095 / Ref. S-0756-D3/8, 1/2 inTools Needed:+– Connect negative (–)cable

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-488 Page 16SECTION 5 – OPERATING THE WELDING GENERATOR5-1. Controls (See Section 5-2)ST-802 094 / ST-802 095 / 495 1875Recoil-StartElectric-Start60

OM-488 Page 175-2. Description Of Controls (See Section 5-1)Weld and auxiliary power output stops ifgenerator overheats or engine speed istoo low.1 E

OM-488 Page 18SECTION 6 – OPERATING AUXILIARY EQUIPMENTThe welding generator provides power while welding and with the Current controlin any position.

OM-488 Page 196-2. Optional Receptacle Panel Ratings Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles.Un

OM-488 Page 20SECTION 7 – MAINTENANCE7-1. Routine MaintenanceRecycleenginefluids. Stop engine before maintaining. See Engine Manual and Maintenance

OM-488 Page 21Follow the storage procedure in the engine owner’s manual if the unit will not beused for an extended period.NOTE7-2. Maintenance LabelR

OM-488 Page 227-4. Adjusting Engine SpeedST-802 097After tuning engine, check enginespeeds. See table for proper noload speeds. If necessary, adjustsp

OM-488 Page 23SECTION 8 – TROUBLESHOOTING8-1. TroubleshootingA. WeldingTrouble RemedyNo weld output. Check Amperage control setting.Check weld connect

OM-488 Page 24Trouble RemedyLow power output. Check Amperage control setting.Check engine speed, and adjust if necessary (see Section 7-4). Output sto

OM-488 Page 25SECTION 9 – ELECTRICAL DIAGRAMSSC-495 296-AFigure 9-1. Circuit Diagram For Welding Generator

The following terms areused interchangeablythroughout this manual:TIG = GTAWStick = SMAWMIG = GMAWThe engine exhaust fromthis product containschemical

OM-488 Page 26Figure 9-2. Wiring Diagram For Welding Generator (1 Of 3)

OM-488 Page 27SC-495 296-AFigure 9-3. Wiring Diagram For Welding Generator (2 Of 3)

OM-488 Page 28SC-495 296-AFigure 9-4. Wiring Diagram For Welding Generator (3 Of 3)

OM-488 Page 29SECTION 10 – AUXILIARY POWER GUIDELINES10-1. Selecting Equipmentaux_pwr 2/99 – Ref. ST-159 730 / ST-800 5771 Auxiliary Power Receptacles

OM-488 Page 3010-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulated

OM-488 Page 3110-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 30

OM-488 Page 3210-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-488 Page 3310-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-488 Page 3410-10. Typical Connections To Supply Standby PowerS-0405-A1 Power Company ServiceMeter2 Main and Branch OvercurrentProtection3 Double-Po

OM-488 Page 3510-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, us

OM-488 Page 36SECTION 11 – STICK WELDING (SMAW) GUIDELINES11-1. Stick Welding Procedurestick 12/96 – ST-151 593 Weld current starts whenelectrode tou

OM-488 Page 3711-2. Electrode and Amperage Selection ChartRef. S-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/321/43/321/85/323/167/321/43/

OM-488 Page 3811-5. Positioning Electrode HolderS-006090° 90°10°-30°45°45°GROOVE WELDSFILLET WELDSEnd View of Work Angle Side View of Electrode AngleE

OM-488 Page 3911-8. Conditions That Affect Weld Bead ShapeWeld bead shape is affected by electrode angle, arc length, travel speed, andthickness of

OM-488 Page 4011-10. Butt JointsS-06621 Tack WeldsPrevent edges of joint from drawingtogether ahead of electrode by tackwelding the materials in posit

OM-488 Page 4111-13. Weld TestS-0057-B1 Vise2 Weld Joint3 HammerStrike weld joint in direction shown.A good weld bends over but doesnot break.2 To 3 i

OM-488 Page 4211-16. Troubleshooting – Incomplete FusionIncomplete Fusion – failure of weld metal to fuse completely withbase metal or a preceeding we

OM-488 Page 4311-19. Troubleshooting – Burn-ThroughBurn-Through – weld metal melting completely through base metal resultingin holes where no metal re

OM-488 Page 44SECTION 12 – PARTS LISTST-802 118-A123456789101112131415161718192021222324252627282930313233343536373839404142434445464748 Hardware is

OM-488 Page 45DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 +495 247 TOP, control box (specify color) 1. . . . . . . . . . .

OM-488 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_11/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-488 Page 46 Hardware is common andnot available unless listed.Ref. ST-802 124 / H-495 290 / H-495 283USA-1USA-2USA-3CANADA (CSA)S. AMERICAEUROPEAU

OM-488 Page 47DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Auxiliary Power PanelQuantityPANEL, aux power assembly (USA-1) 1. . . . . . . . . . . . .

OM-488 Page 48Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 1/00Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2000 Miller Electric Mfg. Co. 1/00Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-488 Page 2Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flyin

OM-488 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in

OM-488 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunic

OM-488 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom _nd_fre 11/981-1. Signification des symbolesSignifie Mise en garde ! Soyez