OM-4417 210 403A September 2004 Processes Stick (SMAW) Welding Description Engine Driven Welding Generator Blue Star 145 Blue Star 145 DX 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 _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. Marks a special safety message. Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Protect yourself and others from flying sparks and hot metal.
STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold to avoid scalding. Always check coolant level at overflow tank, if present 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, follow the next two statements. Wear safety glasses and gloves and put a rag over radiator cap.
READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacement parts. Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manuals. H.F. RADIATION can cause interference. ARC WELDING can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
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 présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Identifie un message de sécurité particulier. Signifie NOTA ; n’est pas relatif à la sécurité.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. 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. DES PARTICULES VOLANTES peuvent blesser les yeux.
L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. Toujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie. Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie. Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie. Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide.
LE SURCHAUFFEMENT peut endommager le moteur électrique. LIRE LES INSTRUCTIONS. Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur. Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles. Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a lieu. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences.
SECTION 3 − DEFINITIONS 3-1. Symbol Definitions h 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) s Hours Circuit Breaker Amperes Volts Temperature SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Generator Power Rating Fuel Capacity 80 Single-Phase, 4.
4-3. Fuel Consumption 1.00 US Gal./Hr. 0.80 0.60 0.40 0.20 0.00 IDLE 0 25 50 75 100 125 150 175 200 DC WELD AMPERES AT RATED DUTY CYCLE 220 637 4-4. 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.
4-5. Generator Power Curve The ac generator power curves show the generator power available in amperes at the receptacles. 300 250 VOLTS 200 240 Volt 150 100 120 Volt 50 0 0 10 20 30 40 50 60 70 80 AMPERES 220 581 4-6. 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.
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) Location 18 in (460 mm) Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. Shown with optional running gear. OR install1 11/02 − 802 512-A / Ref. 151 556 / 158 936-A / 800 652-A / S-0854 / 803 594−A 5-2.
5-3. Grounding Generator When Supplying Building Systems 1 GND/PE 2 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Use ground device as stated in electrical codes. 2 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. 3 800 576-B 5-4. Engine Prestart Checks − Standard Model Check all fluids daily. Engine must be cold and on a level surface.
5-5. 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. (13 mm) from top to allow room for expansion.
5-7. 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. For Direct Current Electrode negative (DCEN), reverse cable connections. 2 1 Tools Needed: 3/4 in 803 596−A 5-8.
SECTION 6 − OPERATING THE WELDING GENERATOR 6-1.
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 Low Oil Pressure Light Light goes on and engine stops if engine oil level is too low.
6-3.
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. Stop engine and add oil if light goes on (see Section 5-5).
SECTION 7 − OPERATING AUXILIARY EQUIPMENT NOTE Set Current control to maximum for full generator power output at AC receptacles. 7-1. Generator Power Panel Receptacles 4 1 2 3 218 610−B If unit does not have GFCI receptacles, use GFCI-protected extension cord. 3 120 V 20 A AC Duplex Receptacle RC3 Generator power decreases as weld RC2 and RC3 supply 60 Hz single-phase power at weld/power speed. Maximum output from RC2 or RC3 is 2.4 kVA/kW.
SECTION 8 − MAINTENANCE NOTE 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 Stop engine before maintaining. Recycle engine fluids. See Engine Manual for important start-up, service, and storage information. Service more often if used in severe conditions. * To be done by Factory Authorized Service Agent. 8h Check fluid levels. See Section 5-5. Wipe up spills.
8-2. Servicing Air Cleaner Stop engine. 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. Replace paper element if dirty, oily, or damaged.
8-3. Adjusting Engine Speed (Standard Models Only) After tuning engine, check engine speed. See table for proper no load speed. If necessary, adjust speed as follows: 3750 ± 30 rpm (62 Hz) Start engine and run until warm. 1 Adjustment Screw To increase speed, turn screw in (clockwise). To decrease speed, turn screw out (counterclockwise). Stop engine. Close fuel valve.
8-4. Adjusting Engine Speed (DX Models Only) 2500 ± 100 rpm (42 Hz) 3750 ± 30 rpm (62 Hz) 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. Weld/Power Speed Adjustment 1 Adjustment Screw To increase speed, turn screw in (clockwise). To decrease speed, turn screw out (counterclockwise). Idle Speed Adjustment 2 3 Throttle Solenoid TS1 Adjustment Screw Loosen four screws on side of throttle solenoid TS1.
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. Check weld connections.
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 circuit breaker(s), wiring, and connections. Check throttle linkage for smooth, non-binding operation.
SECTION 10 − ELECTRICAL DIAGRAMS 218 706−B Figure 10-1.
SECTION 11 − GENERATOR POWER GUIDELINES NOTE The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 11-1. 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 Do not use 2-prong plug unless equipment is double insulated. 1 2 3 Be sure equipment has this symbol and/or wording. OR gen_pwr 11/02 − Ref.
11-3. Grounding When Supplying Building Systems 1 1 2 Equipment Grounding Terminal Grounding Cable 2 GND/PE Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. 2 Use ground device as stated in electrical codes. 3 ST-800 576-B 11-4. How Much Power Does Equipment Require? 1 3 2 1 VOLTS 115 AMPS 4.
11-5.
11-7. 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.
11-8. Power Required To Start Motor 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. Step 3: Determine starting amperage (see example). Welding generator amperage output must be at least twice the motor’s running amperage.
11-10. Typical Connections To Supply Standby Power Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. 1 2 Utility Electrical Service 3 Transfer Switch 4 Fused Disconnect Switch (If Required) Welding Generator Output 5 Essential Loads Have only qualified persons perform these connections according to all applicable codes and safety practices. Switch transfers the electrical load from electric utility service to the generator.
11-11. 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 12 − STICK WELDING (SMAW) GUIDELINES 12-1. 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 12-2).
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
12-5. 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 12-6. 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 12-7.
12-8. Conditions That Affect Weld Bead Shape NOTE 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 12-9.
12-10. 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.
12-13. 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 12-14. 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.
12-16. 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.
12-19. 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. 12-20. 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.
Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.
SECTION 13 − PARTS LIST Hardware is common and not available unless listed. 5 1 6 7 11 8 10 9 4 2 3 29 39 38 30 31 32 28 27 37 35 2 34 36 33 12 26 25 24 15 16 17 13 14 18 19 20 21 23 22 803 795−A Figure 13-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 13-1. Main Assembly (Standard Model) 1 . . . . . . AC−Z . . . . 218767 . . 2 . . . . . . . . . . . . . . . . . 099255 . . 3 . . . . . . . . . . . . . . . . . 217125 . . 4 . . . . . . . CB1 . . . . . 218782 . . 5 . . . . . . . RC1 . . . . . 218772 . . 6 . . . . . . . . 1T . . . . . 172661 . . 7 . . . . . . . . . . . . . . . . . 173734 . . 8 . . . . RC2, RC3 . . 141432 . . 8 . . GFCI2, GFCI3♦151981 . . 9 . . . . . . . . . . . . . . . . . 154408 . .
Hardware is common and not available unless listed. 16 15 10 11 9 4 57 59 2 1 3 5 14 13 12 6 7 17 18 8 50 58 43 44 45 46 47 48 56 19 42 41 20 55 21 40 52 54 50 51 49 38 53 23 39 25 27 30 24 22 26 28 29 31 32 35 37 33 36 34 803 797−A Figure 13-2. Main Assembly DX Model Item No. Dia. Mkgs. Part No. Description Quantity Figure 13-2. Main Assembly (DX Model) 1 . . . . . . . CB1 . . . . . 218782 2 . . . . . . . RC1 . . . . . 218772 3 . . . . . . . . 1T . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 13-2. Main Assembly (Continued) 11 . . . . . . . . . . . . . . . . 087341 . . Bumper,Door 1.000 Od X .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . . . 221007 . . Bracket,Support Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . 221038 . . Insulation,Thermal Fuel Tank Upper . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Effective January 1, 2004 (Equipment with a serial number preface of “LE” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. 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.
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 Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number.
