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OM-4417 210 403C
2005 −10
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Blue Star 145
Blue Star 145 DX
File: Engine Drive
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Engine Hazards . . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for nece
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WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Do not touch hot parts bare handed. Welding on closed containers, such as tanks, drums, or Allow cooling period before working on equipment. pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot To handle hot parts, use proper tools and/or wear equipment can cause fires and burns. Accidental contact of electrode to metal heavy, insulated welding gloves and c
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BATTERY ACID can BURN SKIN and EYES. STEAM AND HOT COOLANT can burn. Do not tip battery. If possible, check coolant level when engine is cold to avoid scalding. Replace damaged battery. Always check coolant level at overflow tank, if pres- Flush eyes and skin immediately with water. ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). If the engine is warm, checking is needed, and there is no overflow tank, ENGINE HEAT can cause fire. foll
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READ INSTRUCTIONS. ARC WELDING can cause interference. Use only genuine MILLER/Hobart replacement Electromagnetic energy can interfere with sensitive parts. electronic equipment such as microprocessors, computers, and computer-driven equipment such as Perform engine and air compressor (if applicable) robots. maintenance and service according to this manual and the engine/air compressor (if applicable) manu- Be sure all equipment in the welding area is electro- als. magnetically compatibl
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 3/05 Avertissement: 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 Ce groupe de symboles signi- présente des risques de danger ! Ceux-ci sont identifiés fie Mise en garde ! Soyez vigi- par des symboles adjacents aux directives. lant ! Il y a des risques de dan- ger reliés aux CHOCS ÉLEC- Identifie un messag
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LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. Ne pas toucher à mains nues les parties chaudes. Le soudage effectué sur des conteneurs fermés tels que des Prévoir une période de refroidissement avant de travailler à réservoirs, tambours ou des conduites peut provoquer leur l’équipement. éclatement. Des étincelles peuvent être projetées de l’arc de Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et por-
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Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. LA CHALEUR DU MOTEUR peut pro- Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. voquer un incendie. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- Ne pas placer l’appareil sur, au-dessus ou à proximité de ver le bouchon. surfaces inflammables. LES ACCUMULATIONS DE GAZ ris- Tenir à distance les produits inflammables de l’échappement.
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LIRE LES INSTRUCTIONS. LE SOUDAGE À L’ARC risque de Utiliser seulement les pièces de rechange d’origine. provoquer des interférences. Effectuer la maintenance du moteur et du compresseur L’énergie électromagnétique risque de provoquer des in- (si applicable) suivant ce manuel et le manuel du moteur/ terférences pour l’équipement électronique sensible tel compresseur (si applicable). que les ordinateurs et l’équipement commandé par ordi- nateur tel que les robots. Veiller à ce que tout l’
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SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Read Operator’s Engine Choke Amperes Volts Manual A V Engine Oil Fuel Battery (Engine) Engine Alternating Current Positive Negative Output (AC) Protective Earth Hours Seconds Time (Ground) s h Circuit Protector Temperature SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Weld Maximum Welding Rated Generator Fuel Output Open Circuit Engine Mode Welding Output Power Rating Capacity Range Voltage Kohler CS10 Single-Phase, 145 A,
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4-2. Dimensions, Weights, And Operating Angles Dimensions Height 22-3/4 in (578 mm) D D Width 22-3/4 in (577 mm) Depth 31-5/8 in (803 mm) D Do o not exceed tilt angles or engine could not exceed tilt angles or engine could B A 31-5/8 in (803 mm) be damaged or unit could tip. Do not move or operate unit where it B 10-9/16 in (268 mm) could could ti tip. p C 13-25/64 in (340 mm) D 22-3/4 in (577 mm) A A E 1-9/16 in (40 mm) C C F 19-5/8 in (498 mm) G 13/32 in (10 mm) Dia. 15° 15° Weight G G 1
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4-4. Fuel Consumption 1.00 0.80 0.60 0.40 0.20 IDLE 0.00 0 25 50 75 100 125 150 175 200 DC WELD AMPERES AT RATED DUTY CYCLE 1.00 0.80 0.60 0.40 0.20 IDLE 0.00 0 1 2 345 6 AUXILIARY POWER KW AT 100% DUTY CYCLE 220 637 OM-4417 Page 11 US Gal./Hr. US Gal./Hr.
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4-5. Duty Cycle 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. Continuous Welding 100% Duty Cycle at 80 Amperes CC/DC 2 Minutes Welding 8 Minutes Resting 20% Duty Cycle at 145 Amperes CC/DC 160 140 120 100 80 60 40 20 0 0 10 20 30 40 50 60 70 80 90 100 % DUTY CYCLE 220 625 −A 4-6. Generator Power Curve The ac generator power curves show the generator power available in amperes at the recep
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SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Airflow Clearance 18 in (460 mm) 18 in 18 in (460 mm) (460 mm) 18 in 18 in (460 mm) (460 mm) Always securely fasten welding generator Location onto transport vehicle or trailer and comply with all DOT and other applicable codes. Shown with OR optional running gear. Ref 151 556 / Ref. 800 652 / 803 594-B / S-0854 5-2. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to pre- vent el
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5-3. Grounding Generator When Supplying Building Systems 1 Equipment Grounding 1 2 GND/PE Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to sys- tem earth ground if supply- Use ground device as ing power to a premises stated in electrical codes. (home, shop, farm) wiring system. 2 3 800 576-B 5-4. Engine Prestart Checks − Standard Model Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine
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5-5. Engine Prestart Checks − DX Model Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. 1/2 in 1 Fuel Valve (13 mm) Full Open valve. Close fuel valve before moving unit or carburetor may flood Gasoline and make starting difficult. Fuel Add fresh fuel before starting 1 engine the first time (see engine manual 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
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5-7. Connecting To Weld Output Terminals 1 Positive (+) Weld Output Terminal 2 Negative ( −) Weld Output Terminal For Direct Current Electrode Posi- tive (DCEP), connect work cable to Negative ( −) terminal and electrode 1 2 holder to Positive (+) terminal. For Direct Current Electrode nega- tive (DCEN), reverse cable con- nections. Failure to properly connect weld cables may cause ex- cessive heat and start a fire, or damage your machine. 3 Weld Output Terminal 4 Supplied Weld Output Termina
