Miller-electric Blue Star 3500 User Manual

Blue Star 3500ProcessesDescriptionStick (SMAW) WeldingEngine Driven Welding GeneratorOM-498 197 849FMarch 2004Visit our website atwww.MillerWelds.com

OM-498 Page 6Revenez à la table des matièresLES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du ga

OM-498 Page 7Revenez à la table des matièresL’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutc

OM-498 Page 8Revenez à la table des matièresLE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-

OM-498 Page 9Return To Table Of ContentsSECTION 3 − DEFINITIONS3-1. Symbol DefinitionsEngine ChokeRead Operator’sManual AAmperesVVoltsEngine Oil Fuel

OM-498 Page 10Return To Table Of Contents4-2. Dimensions, Weights, And Operating AnglesDimensionsHeight 20-3/4 in (527 mm)DWidth 22-3/4 in (577 mm)DDe

OM-498 Page 11Return To Table Of Contents4-4. Fuel Consumption (Honda-Powered Units)802 121Continuous Welding4-5. Duty Cycle802 092Duty cycle is the p

OM-498 Page 12Return To Table Of Contents4-6. Generator Power Curve802 129The ac generator power curvesshow the generator power availablein amperes at

OM-498 Page 13Return To Table Of ContentsSECTION 5 − INSTALLATION5-1. Installing Welding Generatorinstall1 5/02 − 802 512-A / Ref. 151 556 / 158 936-A

OM-498 Page 14Return To Table Of Contents5-3. Grounding Generator When Supplying Building SystemsGND/PE1 2Use ground device asstated in electrical cod

OM-498 Page 15Return To Table Of Contents5-5. Engine Prestart Checks (Honda-Powered Units)Ref. 802 099-AFullFullGasoline1/2 in(13 mm)Check all fluids

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

OM-498 Page 16Return To Table Of Contents5-7. Connecting To Weld Output Terminals196 921 / 495 1791 Positive (+) Weld OutputTerminal2 Negative (−) Wel

OM-498 Page 17Return To Table Of ContentsSECTION 6 − OPERATING THE WELDING GENERATOR6-1. Controls (Kohler-Powered Units)802 512-A / 495 1795260 Hz34

OM-498 Page 18Return To Table Of Contents6-2. Controls (Honda-Powered Units) (See Section 6-3)802 099-A / 802 100-A / 953T-5-4Recoil-StartElectric-Sta

OM-498 Page 19Return To Table Of Contents6-3. Description Of Controls (Honda-Powered Units) (See Section 6-2) Weld and generator power output stops i

OM-498 Page 20Return To Table Of ContentsSECTION 7 − OPERATING AUXILIARY EQUIPMENTThe welding generator provides power while welding and with the Curr

OM-498 Page 21Return To Table Of Contents7-2. Optional Generator Power PanelsRef. ST-802 124 / H-495 290 / H-495 283Generator Power Panel 495 315(USA)

OM-498 Page 22Return To Table Of Contents7-3. Generator Power Panel RatingsUnless otherwise stated, the rating of duplex outlets is the combined load

OM-498 Page 23Return To Table Of Contents7-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)plug3-11/99 − 802 5271 Plug W

OM-498 Page 24Return To Table Of ContentsSECTION 8 − MAINTENANCE8-1. Routine MaintenanceRecycleenginefluids. Stop engine before maintaining. See Eng

OM-498 Page 25Return To Table Of ContentsFollow the storage procedure in the engine owner’s manual if the unit will not beused for an extended period.

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-498 Page 26Return To Table Of Contents8-4. Adjusting Engine Speed (Kohler-Powered Units)802 512-A / Kohler Dwg.After tuning engine, check enginespe

OM-498 Page 27Return To Table Of Contents8-5. Adjusting Engine Speed (Honda-Powered Units)802 101-AAfter tuning engine, check enginespeeds. See table

OM-498 Page 28Return To Table Of ContentsSECTION 9 − TROUBLESHOOTING9-1. TroubleshootingA. WeldingTrouble RemedyNo weld output. Check Amperage control

OM-498 Page 29Return To Table Of ContentsTrouble RemedyErratic output at generator power acreceptacles.Check fuel level.Check receptacle wiring and co

OM-498 Page 30Return To Table Of ContentsSECTION 10 − ELECTRICAL DIAGRAMSSC-495 297198 016-DFigure 10-1. Circuit Diagram For Welding Generator

OM-498 Page 31Return To Table Of Contents201 026-AFigure 10-2. Wiring Diagram For Generator Power Panels (1 Of 2)

OM-498 Page 32Return To Table Of Contents201 026-AFigure 10-3. Wiring Diagram For Generator Power Panels (2 Of 2)

OM-491 Page 33Return To Table Of ContentsSECTION 11 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all eng

OM-491 Page 34Return To Table Of Contents11-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse

OM-491 Page 35Return To Table Of Contents11-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Wat

OM-491 Page 36Return To Table Of Contents11-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHa

OM-491 Page 37Return To Table Of Contents11-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find

OM-491 Page 38Return To Table Of Contents11-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections acco

OM-491 Page 39Return To Table Of Contents11-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does no

OM-498 Page 40Return To Table Of ContentsSECTION 12 − STICK WELDING (SMAW) GUIDELINES12-1. Stick Welding Procedurestick 12/96 − ST-151 593 Weld curre

OM-498 Page 41Return To Table Of Contents12-2. Electrode and Amperage Selection ChartRef. S-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/32

OM-498 Page 42Return To Table Of Contents12-5. Positioning Electrode HolderS-006090° 90°10°-30°45°45°GROOVE WELDSFILLET WELDSEnd View of Work Angle Si

OM-498 Page 43Return To Table Of Contents12-8. Conditions That Affect Weld Bead ShapeWeld bead shape is affected by electrode angle, arc length, tr

OM-498 Page 44Return To Table Of Contents12-10. Butt JointsS-06621 Tack WeldsPrevent edges of joint from drawingtogether ahead of electrode by tackwel

OM-498 Page 45Return To Table Of Contents12-13. Weld TestS-0057-B1 Vise2 Weld Joint3 HammerStrike weld joint in direction shown.A good weld bends over

OM-498 Page 1Return To Table Of ContentsSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_8/03 Warning: Protect yourself and others from inju

OM-498 Page 46Return To Table Of Contents12-16. Troubleshooting − Incomplete FusionIncomplete Fusion − failure of weld metal to fuse completely withba

OM-498 Page 47Return To Table Of Contents12-19. Troubleshooting − Burn-ThroughBurn-Through − weld metal melting completely through base metal resultin

OM-498 Page 48Return To Table Of ContentsSECTION 13 − PARTS LIST Hardware is common andnot available unless listed.802 513-A / 802 153-B1925292223282

OM-498 Page 49Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main AssemblyQuantity1 +495 247 TOP, control box (specify colo

OM-498 Page 50Return To Table Of Contents Hardware is common and not available unless listed.196 9212534Generator Power Panel 495 315 (USA)Generator

OM-498 Page 51Return To Table Of ContentsDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-2. Generator Power Panels (Figure 13-1, Item 31)QuantityGenerator

OM-498 Page 52Return To Table Of ContentsNotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

Notes

TM-188 304 Page 54Invision 354MPNotes16 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 i

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 8/03Your distributor also givesyou ...ServiceYou always get the fa

OM-498 Page 2Return To Table Of ContentsWelding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off fro

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-498 Page 3Return To Table Of ContentsSTEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Alway

OM-498 Page 4Return To Table Of ContentsREAD INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if ap

OM-498 Page 5Revenez à la table des matièresSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et le