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OM-499 197 850H
March 2004
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Blue Star 6000
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_8/03 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. Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or Wear protective gloves and clothing when working on pipes, can cause them to blow up. Sparks can fly off from the a hot engine. welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal Do not touch hot engine parts or just-welded parts objects can cau
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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 8/03 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 si- présente des risques de danger ! Ceux-ci sont identifiés par gnifie Mise en garde ! des symboles adjacents aux directives. Soyez vigilant ! Il y a des risques de danger reliés Identifie un message de sécurité partic
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Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B LES ACCUMULATIONS DE GAZ ris- pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi- quent de provoquer des blessures ou mité. même la mort. DES PARTICULES VOLANTES peuvent blesser les yeux. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Le soudage, l’écaillement, le passage de la pièce Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adducti
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Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, L’EXPLOSION DE LA BATTERIE peut débrancher le câble négatif (−) de batterie de la borne. RENDRE AVEUGLE. Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga- nes mobiles. Toujours porter une protection faciale, des gants en Remettre en place les panneaux ou les dipositifs de protection et fermer les caoutchouc et vêtements de protection lors d’une in- portes à la fin des travaux d’entretien et a
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LE SURCHAUFFEMENT peut endom- LIRE LES INSTRUCTIONS. mager le moteur électrique. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compres- Arrêter ou déconnecter l’équipement avant de dé- seur (si applicable) suivant ce manuel et le manuel du marrer ou d’arrêter le moteur. moteur/compresseur (si applicable). Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence tr
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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 Breaker Temperature SECTION 4 − SPECIFICATIONS This unit uses either a Kohler or a Honda engine. Differences between models are NOTE noted throughout this manual. 4-1. Weld, Power, And Engine Specifications Rated Maximum Welding Weld Output Generator
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4-2. Dimensions, Weights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) D D Width 22-3/4 in (577 mm) Depth 31-1/4 in (793 mm) Do not exceed tilt angles or engine could B B b be e damaged or unit could tip. damaged or unit could tip. A 31-1/4 in (793 mm) Do Do not move or operate unit where it not move or operate unit where it B 10-1/2 in (268 mm) could tip. C 13-45/64 in (348 mm) A A D 22-3/4 in (577 mm) C C E 1-3/4 in (44 mm) F 19-1/2 in (495 mm) G 13/32 in (10 mm) Dia. 15 15°
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4-4. Fuel Consumption (Honda-Powered Units) 802 122 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 100 Amperes CC/DC 802 093 Return To Table Of Contents OM-499 Page 11
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4-6. Generator Power Curves The generator power curves show the ac power available in amperes at the receptacles. A. 60 Hz Model 250 225 200 175 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 LOAD AMPS B. 50 Hz Model 250 225 200 175 150 125 100 75 50 25 0 0 5 10 15 20 25 30 35 LOAD AMPS 198 570 Return To Table Of Contents OM-499 Page 12 LOAD VOLTS LOAD VOLTS
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4-7. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all A. 60 Hz Model other settings fall between the curves shown. 80 70 60 50 40 MAX 30 MID 20 MIN 10 0 0 25 50 75 100 125 150 175 200 225 250 LOAD AMPS B. 50 Hz Model 80 70 60 50 40 MAX 30 MID 20 MIN 10 0 0 25 50 75 100 125 150 175 200 225 250 LOAD AMPS 198 570 Return To Table Of Contents OM-499 Page 13 LOAD VOLTS LOAD VOLTS
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SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. Movement Airflow Clearance 18 in (460 mm) 18 in 18 in (460 mm) (460 mm) 18 in 18 in (460 mm) (460 mm) Location OR install1 10/00*− 802 524-A / Ref. 151 556 / 158 936-A / S-0854 5-2. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to pre- vent electric shock and sta
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5-3. Grounding Generator When Supplying Building Systems 1 Equipment Grounding Terminal 1 2 GND/PE 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to sys- tem earth ground if supply- ing power to a premises Use ground device as (home, shop, farm) wiring stated in electrical codes. system. 2 3 800 576-B 5-4. Engine Prestart Checks (Kohler-Powered Units) Follow run-in procedure in engine manual. Check all fluids daily. Engine must be 1/2 in cold
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5-5. Engine Prestart Checks (Honda-Powered Units) 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. 1/2 in (13 mm) Follow run-in procedure in en- Full gine manual. 1 Fuel Valve Open valve. Gasoline Close fuel valve before moving unit or carburetor may flood and make starting difficult. Fuel Add fresh fuel before starting engine the first time (see mainte- nance label for specifications). Fill fue
