209 416F 2007−05 Processes Stick (SMAW) Welding ENGLISH OM-4415 Engine Driven Welding Generator Blue Star 185 Blue Star 185 DX File: Engine Drive Visit our website at www.MillerWelds.
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.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. If ventilation is poor, wear an approved air-supplied respirator.
1-3. Engine Hazards BATTERY EXPLOSION can BLIND. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connecting battery cables or servicing battery. Do not allow tools to cause sparks when working on a battery. Do not use welder to charge batteries or jump start vehicles. Observe correct polarity (+ and −) on batteries. Disconnect negative (−) cable first and connect it last. FUEL can cause fire or explosion.
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. READ INSTRUCTIONS. Read Owner’s Manual before using or servicing unit. Stop engine and release air pressure before servicing. Use only genuine replacement parts from the manufacturer. Do not touch hot compressor or air system parts. Let system cool down before touching or servicing. 1-5.
H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_2007−04fre Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation. Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Ne pas toucher à mains nues les parties chaudes. Prévoir une période de refroidissement avant de travailler à l’équipement.
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 proximité. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut affec l’ouïe. Porter des protections approuvés pour les ore les si le niveau sonore est trop élevé. LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre implants médicaux, rester à distance.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. L’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Les fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisible et inodore. JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes. Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et bouches aération.
UNE REMORQUE QUI BASCULE peut entraîner des blessures. LE SURCHAUFFEMENT peut endommager le moteur électrique. Utiliser les supports de la remorque ou des blocs pour soutenir le poids. Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant. Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur.
2-6. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.
. Complete Parts List available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Symbol Definitions A V Engine Choke Read Operator’s Manual Engine Oil Fuel Battery (Engine) Engine Positive Negative Alternating Current (AC) Output Seconds Time Protective Earth (Ground) h Hours s Circuit Protector Amperes Volts Temperature SECTION 4 − SPECIFICATIONS 4-1.
. Complete Parts List available at www.MillerWelds.com 4-2. Dimensions, Weights, And Operating Angles Dimensions Height 22-3/4 in (578 mm) Width 22-3/4 in (577 mm) Depth 31-5/8 in (803 mm) A 31-5/8 in (803 mm) B 10-9/16 in (268 mm) C 13-25/64 in (340 mm) D 22-3/4 in (577 mm) E 1-9/16 in (40 mm) F 19-5/8 in (498 mm) G 13/32 in (10 mm) Dia. D Do not move or operate unit where it could tip. B Do not exceed tilt angles or engine could be damaged or unit could tip.
. Complete Parts List available at www.MillerWelds.com 4-4. Volt-Ampere Curves 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. A. Standard Model (Honda Engine) 80 70 60 VOLTS 50 40 MAX MIN 30 MID 20 10 0 0 50 100 150 AMPERES 200 250 300 B.
. Complete Parts List available at www.MillerWelds.com 4-5. Fuel Consumption Curves 1.00 0.80 0.60 0.40 0.20 0.00 B. Weld Output DX Model (Kohler Engine) U.S. Gal./Hr. U.S. Gal./Hr. 1.00 A. Weld Output Standard Model (Honda Engine) 0 25 50 75 100 125 150 175 200 DC Weld Amperes At Rated Duty Cycle 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 1.20 C. Auxiliary Power Standard Model (Honda Engine) U.S. Gal./Hr. 1.00 0.80 0.60 0.40 0.20 0.
. Complete Parts List available at www.MillerWelds.com 4-6. Generator Power Curves The ac generator power curves show the generator power available in amperes at the receptacles. A. Power Output Standard Model (Honda Engine) 300 250 200 VOLTS 240 VOLT 150 100 120 VOLT 50 0 0 10 20 30 40 AMPERES 50 60 70 80 B.
. Complete Parts List available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement Airflow Clearance 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) Location Do not install unit where air flow is restricted or engine may overheat.
. Complete Parts List available at www.MillerWelds.com 5-2. Grounding Generator When Supplying Building Systems 1 GND/PE 2 Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 2 Ground Device . Use ground device as stated 3 in electrical codes. 800 576-B 5-3. Engine Prestart Checks − Standard Model 1/2 in (13 mm) Check all fluids daily.
. Complete Parts List available at www.MillerWelds.com 5-4. Engine Prestart Checks − DX Model 1/2 in (13 mm) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. 1 Fuel Valve Open valve. Full . Close fuel valve before moving unit or carburetor may flood and make starting difficult. Gasoline Fuel Add fresh fuel before starting engine the first time (see engine manual for specifications). Fill fuel tank up to 1/2 in.
. Complete Parts List available at www.MillerWelds.com 5-6. Connecting To Weld Output Terminals 1 Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal 2 For Direct Current Electrode Positive (DCEP), connect work cable to Negative (−) terminal and electrode holder to Positive (+) terminal. 1 2 For Direct Current Electrode negative (DCEN), reverse cable connections. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.
. Complete Parts List available at www.MillerWelds.
. Complete Parts List available at www.MillerWelds.com SECTION 6 − OPERATING THE WELDING GENERATOR 6-1.
. Complete Parts List available at www.MillerWelds.com 6-2. Description Of Controls (Standard Models) (See Section 6-1) 1 Engine Switch Use switch to control ignition circuit. Turn switch to On position when starting engine. Turn switch to Off position to stop engine. Engine cannot be started with switch in the Off position. Engine stops if oil level is too low. Engine cannot be restarted until sufficient oil is added. 2 Starter Handle 3 Choke Control Use control to change engine air/fuel mix.
. Complete Parts List available at www.MillerWelds.com 6-3.
. Complete Parts List available at www.MillerWelds.com 6-4. Description Of Controls (DX Models) (See Section 6-3) 1 Engine Switch Use switch to control ignition circuit. Turn switch to Start position for electric start. Turn switch to On position to start engine using starter handle (recoil). Turn switch to Off position to stop engine. 2 Low Oil Level Light Light goes on and engine stops if engine oil level is too low. Engine cannot be restarted until sufficient oil is added.
. Complete Parts List available at www.MillerWelds.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Panel Receptacles 5 4 1 2 3 218 611−B If unit does not have GFCI receptacles, use GFCI-protected extension cord. . Generator power decreases as weld 1 120 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. current increases.
. Complete Parts List available at www.MillerWelds.com SECTION 8 − MAINTENANCE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. 8-1. Routine Maintenance Recycle engine fluids. = Check = Change = Clean * To be done by Factory Authorized Service Agent Stop engine before maintaining. Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. .
. Complete Parts List available at www.MillerWelds.com 8-2. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. 1 Precleaner 2 Paper Element . Do not wash paper element or clean with compressed air. Remove cover. Wash precleaner with soap and water solution. Allow precleaner to air dry completely. 1 Dip precleaner in clean engine oil. Squeeze out excess oil. The engine will smoke if precleaner contains too much oil.
. Complete Parts List available at www.MillerWelds.com 8-3. Adjusting Engine Speed (Honda-Powered Units) 1400 ± 150 rpm 3750 ± 30 rpm (62 Hz) After tuning engine, check engine speeds. See table for proper no load speeds. If necessary, adjust speeds as follows: Start engine and run until warm. Weld/Power Speed Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move lever to Run (far left) position. Turn screw and move lever until engine runs at weld/power speed.
. Complete Parts List available at www.MillerWelds.com 8-4. Adjusting Engine Speed (Kohler−Powered Units) 2500 ± 100 rpm (42 Hz) 3750 ± 30 rpm (62Hz) After tuning engine, check engine speed. See table for proper no load speed. If necessary, adjust speed as follows: Start engine and run until warm. Set Weld Output Control to Max. Weld/Power Speed Adjustment 1 Adjustment Screw To increase speed, turn screw out (counterclockwise). To decrease speed, turn screw in (clockwise).
. Complete Parts List available at www.MillerWelds.com SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting A. Welding Trouble No weld output or generator power output at ac receptacles. Remedy Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier SR2, and Weld Output control R1. No weld output; generator power output okay at ac receptacles. Check Weld Output control setting.
. Complete Parts List available at www.MillerWelds.com Trouble Remedy Low output at generator power ac Check Weld Output control setting. receptacles. Check engine speed, and adjust if necessary (see Section 8-3 or 8-4). Open circuit voltage is reduced as engine speed drops. Erratic output at generator power ac Check fuel level. receptacles receptacles. Have Factory Authorized Service Agent check connections at terminal block 1T. Check receptacle supplementary protector(s), wiring, and connections.
. Complete Parts List available at www.MillerWelds.com SECTION 10 − PARTS LIST 10-1. Recommended Spare Parts Dia. Mkgs. Part No. Description Quantity Recommended Spare Parts . . . . . . . . . . . . . . . . . . . 220305 . . . . . . . . . . . . . . . . . . . 190108 . . . . . . . . . . . . . . . . . . . 220303 . . . . . . . . . . . . . . . . . . . 220304 . . . . . . . . . . . . . . . . . . . 221584 . . . . . . . . . . . . . . . . . . . 203960 . . . . . . . . . . . . . . . . . . . 221582 . . . . . . . . .
SECTION 11 − ELECTRICAL DIAGRAMS 226 737-A Figure 11-1.
226 738-A Figure 11-2.
SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 12-1. Selecting Equipment 1 2 3 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Be sure equipment has double insulated symbol and/or wording on it. 1 2 Do not use 2-prong plug unless equipment is double insulated.
12-3. Grounding When Supplying Building Systems 1 1 2 2 GND/PE Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. 2 Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators. 3 ST-800 576-B 12-4.
12-5.
12-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec.
12-8. Power Required To Start Motor Single-Phase 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 4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 1 2 3 4 2 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage. Step 2: Find Motor HP and Volts.
12-10. Typical Connections To Supply Standby Power 1 2 Utility Electrical Service 4 3 Transfer Switch Have only qualified persons perform these connections according to all applicable codes and safety practices. Fused Disconnect Switch (If Required) Welding Generator Output Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.
12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
SECTION 13 − STICK WELDING (SMAW) GUIDELINES 13-1. Stick Welding Procedure Weld current starts when electrode touches workpiece. Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. 1 5 2 3 4 2 Work Clamp Electrode A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 13-2).
7014 7018 7024 Ni-Cl 308L ALL DEEP EP ALL DEEP 6013 EP,EN ALL LOW GENERAL 7014 EP,EN ALL MED 7018 EP ALL LOW SMOOTH, EASY, FAST LOW HYDROGEN, STRONG 7024 EP,EN NI-CL EP FLAT HORIZ FILLET ALL 308L EP ALL USAGE PENETRATION EP 6011 AC 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 DC* 450 400 350 300 AMPERAGE RANGE 250 200 150 POSI
13-5. Positioning Electrode Holder 10°-30° 90° 90° End View of Work Angle Side View of Electrode Angle GROOVE WELDS 10°-30° 45° 45° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 13-6. Poor Weld Bead Characteristics 1 2 3 4 5 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 1 2 4 3 5 S-0053-A 13-7.
13-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Angle Too Small Correct Angle 10° - 30° Angle Too Large Drag ELECTRODE ANGLE Spatter Normal Too Short Too Long ARC LENGTH Normal Slow Fast TRAVEL SPEED S-0061 13-9.
13-10. Butt Joints 1 1 2 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 1/16 in (1.6 mm) Single V-Groove Weld Good for materials 3/16 − 3/4 in (5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels.
13-13. Weld Test 1 2 3 3 Strike weld joint in direction shown. A good weld bends over but does not break. 3 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) Vise Weld Joint Hammer 2 To 3 in (51-76 mm) 2 2 1 1 S-0057-B 13-14. Troubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty.
13-16. Troubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding. Adjust work angle or widen groove to access bottom during welding.
13-19. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Excessive heat input. Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 13-20. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. Possible Causes Unsteady hand. Corrective Actions Use two hands.
Effective January 1, 2007 (Equipment with a serial number preface of “LH” or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co.
