Miller Electric Blue Star 145 User Manual Download

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OM-4417 Page 44

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.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before

welding.

12-17. Troubleshooting

−

Lack Of Penetration

Lack Of Penetration

−

shallow fusion between weld metal and

base metal.

Lack of Penetration

Good Penetration

Possible Causes

Corrective Actions

Improper joint preparation.

Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique.

Keep arc on leading edge of weld puddle.

Insufficient heat input.

Increase amperage. Select larger electrode and increase amperage.

Reduce travel speed.

12-18. Troubleshooting

−

Excessive Penetration

Good Penetration

Excessive Penetration

−

weld metal melting through base metal and

hanging underneath weld.

Excessive Penetration

Possible Causes

Corrective Actions

Excessive heat input.

Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

Summary of Contents for Blue Star 145

Page 1: ...Blue Star 145 Processes Description Stick SMAW Welding Engine Driven Welding Generator OM 4417 210 403C 2005 10 Blue Star 145 DX File Engine Drive Visit our website at www MillerWelds com ...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operatio...

Page 3: ...onsumption 11 4 5 Duty Cycle 12 4 6 Generator Power Curve 12 SECTION 5 INSTALLATION 13 5 1 Installing Welding Generator 13 5 2 Grounding Generator To Truck Or Trailer Frame 13 5 3 Grounding Generator When Supplying Building Systems 14 5 4 Engine Prestart Checks Standard Model 14 5 5 Engine Prestart Checks DX Model 15 5 6 Connecting The Battery DX Models Only 15 5 7 Connecting To Weld Output Termin...

Page 4: ......

Page 5: ...ach proper grounding conductor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a sep arate c...

Page 6: ...to treat them carefully CYLINDERS can explode if damaged Protect compressed gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over ...

Page 7: ...e fire or explosion Do not cut or gouge near flammables Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury Do not touch hot compressor or air system parts Let system cool down before touching or servicing READ INSTRUCTIONS Read Owner s Manual before using or servicing unit Stop engine and release air pressure before servicing Use only genuine Miller Hobart replacement par...

Page 8: ...y Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 173...

Page 9: ... vérifier les connexions Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endom magé ou dénudé remplacer le cordon immédiatement s il est endommagé un câble dénudé peut provoquer une électrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des câbles usés endommagés de grosseur insuffisante ou mal épissés Ne pas enrouler les câbles autour du corp...

Page 10: ... de gaz font normalement partie du procédé de soudage les manipuler avec précaution Protéger les bouteilles de gaz comprimé d une chaleur excessive des chocs mécaniques des dommages physiques du laitier des flammes ouvertes des étincelles et des arcs Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les empêcher de tomber ou de se renverser Te...

Page 11: ... avant de toucher ou d effectuer la mainte nance LIRE LES INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arrêter le moteur et relâcher la pression avant d ef fectuer la maintenance Utiliser uniquement des pièces de rechange Miller Hobart 2 5 Dangers supplémentaires en relation avec l installation le fonctionnement et la maintenance LA CHUTE DE L APP...

Page 12: ...es ANSI Standard Z49 1 de Global Engineering Documents téléphone 1 877 413 5184 site In ternet www global ihs com RecommendedSafe Practices for the Preparation for Welding and Cutting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents téléphone 1 877 413 5184 site In ternet www global ihs com National Electrical Code NFPA Standard 70 de National Fir...

Page 13: ...IONS 4 1 Weld Power And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Generator Power Rating Fuel Capacity Engine CC DC 40 145 A 145 A 25 V 20 Duty Cycle 100 A 25 V 60 Duty Cycle 80 A 25 V 100 Duty Cycle 80 Single Phase 4 5 kVA kW Peak 4 kVA kW Continuous 34 17 A 120 240 V AC 60 Hz Standard Model 1 8 gal 6 9 L Tank DX Model 5 gal 19 L Tank K...

Page 14: ... 340 mm could tip D 22 3 4 in 577 mm A E 1 9 16 in 40 mm A C F 19 5 8 in 498 mm C G 13 32 in 10 mm Dia Weight G 15 15 DX Model 309 lb 140 kg 4 H l G 15 15 Standard Model 263 lb 119 kg Holes 15 F Optional Lifting Eye Weight Rating 803 403 Engine End F E 803 594 B 430 lb 195 kg 4 3 Volt Ampere Curves 220 602 The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities...

Page 15: ...Consumption 220 637 DC WELD AMPERES AT RATED DUTY CYCLE US Gal Hr 0 25 50 75 100 125 150 175 200 0 00 0 20 0 40 0 60 0 80 1 00 IDLE AUXILIARY POWER KW AT 100 DUTY CYCLE US Gal Hr 0 1 2 3 4 5 6 0 00 0 20 0 40 0 60 0 80 1 00 IDLE ...

Page 16: ...nty 100 Duty Cycle at 80 Amperes CC DC 20 Duty Cycle at 145 Amperes CC DC DUTY CYCLE WELD AMPERES 0 0 10 20 20 30 40 40 50 60 60 70 80 80 90 100 100 120 140 160 2 Minutes Welding 8 Minutes Resting 4 6 Generator Power Curve 220 581 The ac generator power curves show the generator power available in amperes at the receptacles AMPERES 0 0 10 20 30 40 50 60 70 80 50 100 150 200 250 300 240 Volt 120 Vo...

Page 17: ...l1 11 02 Ref 151 556 S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Metal Vehicle Frame 2 Equipment Grounding Terminal 3 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI receptacles use GFCI protected extension cord Electrically bond generator frame to vehicle frame by metal to metal contact GND...

Page 18: ...ine oil 1 Fuel Valve Open valve 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 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 before use each day Oil After fueling check oil with unit on level surface If oi...

Page 19: ...e use each day Oil After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see en gine manual Unit stops if oil level is too low Unit cannot be restarted until sufficient oil is added To improve cold weather starting Keep battery in good condition Store battery in warm area off concrete surface Use correct grade oil for cold weather Full Fuel valve is s...

Page 20: ...al and copper bar 1 2 5 8 Selecting Weld Cable Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 100 ft 30 m or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m W ld O t t Welding Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle Weld Output Terminals 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 Terminals Turn off power be...

Page 21: ...otes 16 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 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 5 in MATERIAL THICKNESS REFERENCE CHART ...

Page 22: ...OM 4417 Page 18 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Controls Standard Models See Section 6 2 803 956 B 803 594 B 218 610 4 1 6 3 5 2 ...

Page 23: ...n Set choke Pull starter handle Open choke as en gine warms If the engine does not start let engine come to a complete stop before at tempting restart To Stop Turn Engine switch to Off Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult 5 Welding Range Table Use table to determine correct weld amper age based on ele...

Page 24: ...OM 4417 Page 20 6 3 Controls DX Models See Section 6 4 803 596 A 803 595 A 218 610 1 8 7 3 5 4 6 2 ...

Page 25: ...le until engine starts Open choke as engine warms If the engine does not start let engine come to a complete stop before at tempting restart To Stop Turn Engine switch to Off Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult 5 Welding Range Table Use table to determine correct weld amper age based on electrode siz...

Page 26: ...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 Do not parallel the two 120V duplex receptacles 4 Supplementary Protector CB1 CB1 protects the receptacles from over load If CB1 opens the receptacles do not work Move switch to the On position to re set If supplementary protector continues to open contact Factory Authorized ...

Page 27: ...uids Check Change Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 4 5 5 Fuel Level Oil Level Oil Fuel Spills Every 25 Hours Section 8 2 Air Cleaner Precleaner Every 50 Hours Weld Terminals Every 100 Hours Engine Manual Section 8 2 Oil Air Cleaner Element Cooling System Spark Plug Gap Battery Terminals DX Models Spark Arrestor Screen Optional on DX Mod...

Page 28: ...aper Element Do not wash paper element or clean with compressed air Remove cover Wash precleaner with soap and wa ter solution Allow precleaner to air dry completely 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 oil Standard Model Shown 1 2 ...

Page 29: ... 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 1 Adjustment Screw To increase speed turn screw in clockwise To decrease speed turn screw out counterclockwise Stop engine Close fuel valve 1 ...

Page 30: ...Output Control to Max 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 Throttle Solenoid TS1 3 Adjustment Screw Loosen two screws on side of throttle solenoid TS1 Adjust TS1 until idle speed is approximately 2500 rpm Use adjustment screw to fine tune idle speed Be sure TS1 plunger bott...

Page 31: ...eck Weld Output control setting Check engine speed and adjust if necessary see Section 8 3 or 8 4 Erratic weld output Check Weld Output control setting Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes for Stick welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside welding generator Check engine speed and adj...

Page 32: ...fuel valve see Section 5 5 Close fuel valve before moving unit or carburetor may flood and make starting difficult Check battery voltage DX models only Check battery connections and tighten if necessary DX models only Check oil level see Section 5 5 Engine stops if oil level is too low Refill crankcase with proper viscosity oil for operating temperature Have Factory Authorized Service Agent check ...

Page 33: ...OM 4417 Page 29 SECTION 10 ELECTRICAL DIAGRAMS 226 737 A Figure 10 1 Circuit Diagram For Standard Models ...

Page 34: ...OM 4417 Page 30 226 738 A Figure 10 2 Circuit Diagram for DX Models ...

Page 35: ...un less equipment is double in sulated OR 2 Be sure equipment has this symbol and or wording 3 1 11 2 Grounding Generator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground termi...

Page 36: ...sistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 11 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment VOLTS 115 4 5 60 AMPS Hz 1 2 3 3 EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5 A x 115 V 520 ...

Page 37: ... Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 H...

Page 38: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 F...

Page 39: ...or 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 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Starting the motor requires 12 2 amperes 11 2 x 1 4 x 1000 230 12 2 A kVA HP x HP x 1000 VOLTS STARTING AMPERAGE Volts 230 HP 1 4 Using Table Code M results in kVA HP 11 2 11 9 How Much Power Can ...

Page 40: ...if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes ...

Page 41: ...0 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 20...

Page 42: ...is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 12 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp cracklin...

Page 43: ...LLET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER 12 3 Striking an Arc Scratch Start Technique S 0049 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out elec...

Page 44: ... 12 6 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 12 7 Good Weld Bead Characteristics S 0052 B 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Meta...

Page 45: ...Correct Angle 12 9 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better NOTE S 0054 A 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wi...

Page 46: ... 3 4 12 11 Lap Joint S 0063 S 0064 1 Electrode 2 Single LayerFillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength 30 Or Less Single Layer Fillet Weld Multi Layer Fillet Weld 30 Or Less 1 1 2 3 12 12 Tee Joint S 0060 S 0058 A S 0061 1 El...

Page 47: ...e Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 12 15 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high ...

Page 48: ...d dirt from work surface before welding 12 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddl...

Page 49: ...allel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 12 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move Base metal moves in the direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in ...

Page 50: ...13 PARTS LIST 803 795 B Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 10 11 13 14 15 23 24 29 30 31 32 33 2 34 35 36 37 39 38 9 12 28 27 26 25 22 21 20 19 17 18 16 Figure 13 1 Main Assembly Standard Model ...

Page 51: ...tg Engine 1 15 211459 Mount Engine Vibration 2 16 222658 Adapter Engine 1 17 210572 Rotor Generator 1 18 209899 Stator Generator 1 19 222660 Endbell Gen 1 20 495349 Screw 250 20 X 12 50 Hwd Gr5 Pld 4 21 495348 Screw 312 24 X 9 25 Hwd Gr5 Pld 1 22 222656 Cover Endbell 1 23 216195 Frame Base 1 24 214727 Mount Generator Flange Mtg 1 25 493509 Brushholder Assy Generator 1 26 210325 Tubing Corrugated P...

Page 52: ...Idle 5 Pin 1 3 CB1 218782 Supplementary Protector Man Reset 2p 20a 250vac Fr 1 4 RC1 218772 Rcpt Str 2p3w 50a 250v 6 50r Flush Mt 1 5 1T 172661 Block Stud Connection 6 Position 1 6 173734 Link Jumper 1 7 RC2 RC3 141432 Rcpt Str Dx Grd 2p3w 20a 125v 5 20r 2 7 GFCI2 GFCI3 151981 Rcpt Str Dx Grd 2p3w 15 20a 125v 5 20r Gfi 2 8 CT1 219510 Xfmr Current Sensing 1 9 154408 Bushing Snap in Nyl 562 Id X 875...

Page 53: ... 34 495124 Battery 12v Light Utility Dry 0 35 493057 Clamp Battery 1 36 494604 Bolt J Stl 250 20 X 8 000 Pld W Nuts washers 2 37 218181 Tray Battery 1 38 211180 Cable Bat Neg 19 000 6ga W 312 Rng 312 Rng 1 39 216195 Frame Base 1 40 214727 Mount Generator Flange Mtg 1 41 493509 Brushholder Assy Generator 1 42 210325 Tubing Corrugated Plastic 1 500 Dia X 3 000 1 43 209339 Duct Air 1 44 209340 Seal A...

Page 54: ...OM 4417 Page 50 ...

Page 55: ...and Blankets APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trail...

Page 56: ... retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering ...

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