Miller Blue Star 6000 Ownes Manual
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Miller Blue Star 6000 Ownes Manual

Engine driven welding generator
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OM-488
495 371B
January 2000
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Blue Star 6000
R
(Honda-Powered)
Visit our website at
www.MillerWelds.com

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  • Page 1 OM-488 495 371B January 2000 Processes Stick (SMAW) Welding Description Engine Driven Welding Generator Blue Star 6000 (Honda-Powered) Visit our website at www.MillerWelds.com...
  • Page 2 – every power source from This Owner’s Manual is designed to help you get the most out of your Miller is backed by the most Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING ......1-1. Symbol Usage .

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 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 Y Marks a special safety message.

  • Page 6: Engine Hazards

    WELDING can cause fire or explo- HOT PARTS can cause severe burns. sion. D Allow cooling period before maintaining. Welding on closed containers, such as tanks, D Wear protective gloves and clothing when drums, or pipes, can cause them to blow up. Sparks working on a hot engine.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    READ INSTRUCTIONS. stopping engine. D Do not let low voltage and frequency caused by D Use only genuine MILLER replacement parts. low engine speed damage electric motors. D Perform engine maintenance and service D Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle according to this manual and the engine where applicable.

  • Page 8: Principal Safety Standards

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment D Have only qualified persons familiar with such as robots.

  • Page 9: Section 1 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. 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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. D Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer D Porter des gants et des vêtements de protection pour leur éclatement.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Ne pas renverser la batterie. D Maintenir fermés et fixement en place les portes, D Remplacer une batterie endommagée.

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique D Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé...

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Read Operator’s Engine Choke Amperes Volts Manual Engine Oil Fuel Battery (Engine) Engine Alternating Current Positive Negative Output (AC) Protective Earth Hours Seconds Time (Ground) Circuit Breaker Temperature SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, and Engine Specifications Rated Maximum Welding...

  • Page 14: Fuel Consumption

    3-3. Fuel Consumption ST-802 122 3-4. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit void warranty. Continuous Welding 100% Duty Cycle at 100 Amperes CC/DC ST-802 093 OM-488 Page 10...

  • Page 15: Auxiliary Power Curves

    3-5. Auxiliary Power Curves The ac auxiliary power curves show the auxiliary power available in amperes at the receptacles. A. 60 Hz Model B. 50 Hz Model ST-802 125 / ST-802 126 OM-488 Page 11...

  • Page 16: Volt-Ampere Curves

    3-6. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all A. 60 Hz Model other settings fall between the curves shown. B. 50 Hz Model ST-802 127 / ST-802 128 OM-488 Page 12...

  • Page 17: Section 4 - Installation

    SECTION 4 – INSTALLATION 4-1. 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) Location install1 1/97 – ST-802 095 / Ref. ST-151 556 / ST-158 936-A / S-0854 4-2.

  • Page 18: Grounding Generator When Supplying Building Systems

    4-3. Grounding Generator When Supplying Building Systems Equipment Grounding Terminal GND/PE Grounding Cable Use #10 AWG or larger insulated copper wire. Ground Device Y 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.

  • Page 19: Connecting The Battery (Electric-Start Models Only)

    4-5. Connecting the Battery (Electric-Start Models Only) Y Turn Engine Switch to Off (electric-start models only). Y Connect negative (–) cable last. – Tools Needed: 3/8, 1/2 in ST-802 095 / Ref. S-0756-D 4-6. Connecting to Weld Output Terminals Positive (+) Weld Output Terminal Negative (–) Weld Output Terminal...

  • Page 20: Section 5 - Operating The Welding Generator

    SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Controls (See Section 5-2) Recoil-Start Electric-Start 60 Hz 50 Hz ST-802 094 / ST-802 095 / 495 187 OM-488 Page 16...

  • Page 21: Description Of Controls (See Section 5-1)

    5-2. Description Of Controls (See Section 5-1) To Start (Recoil): open fuel valve, turn engine Use label to determine correct weld amper- Weld and auxiliary power output stops if switch to On, move throttle lever to Idle, set age based on electrode size, type, and mate- generator overheats or engine speed is choke, and pull starter handle.

  • Page 22: Section 6 - Operating Auxiliary Equipment

    SECTION 6 – OPERATING AUXILIARY EQUIPMENT NOTE The welding generator provides power while welding and with the Current control in any position. However, under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations. It is recommended that only lamps be powered under these conditions.

  • Page 23: Optional Receptacle Panel Ratings

    6-2. Optional Receptacle Panel Ratings Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles. NOTE Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles. Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz) Protected Canada South...

  • Page 24: Section 7 - Maintenance

    SECTION 7 – MAINTENANCE 7-1. Routine Maintenance Y Stop engine before maintaining. See Engine Manual and Maintenance Label. Ser- Recycle vice more often if used in severe conditions. engine fluids. To be done by Factory Authorized Service Agent. 20 h Check clean Check fluid levels.

  • Page 25: Maintenance Label

    NOTE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. 7-2. Maintenance Label °C °F ENGINE MAINTENANCE 100 h +104 SG-SF/CC-CD 1.1 l (1.2 US qt, 1.94 lmp qt) Unleaded 86 + Octane 6.5 l (1.7 US Gal,...

  • Page 26: Adjusting Engine Speed

    7-4. Adjusting Engine Speed After tuning engine, check engine speeds. See table for proper no load speeds. If necessary, adjust speeds as follows: ± 1400 150 rpm Start engine and run until warm. ± Weld/Power Speed 3720 50 rpm (60 Hz) Adjustment ±...

  • Page 27: Section 8 - Troubleshooting

    SECTION 8 – TROUBLESHOOTING 8-1. Troubleshooting A. Welding Trouble Remedy No weld output. Check Amperage control setting. Check weld connections. Reduce load and allow generator Over-Temp switch TP1 to reset. TP1 opens if generator overheats. Check engine speed, and adjust if necessary (see Section 7-4). Output stops if engine speed is too low. Be sure all equipment is disconnected from receptacles when starting unit.
  • Page 28 Trouble Remedy Low power output. Check Amperage control setting. Check engine speed, and adjust if necessary (see Section 7-4). Output stops if engine speed is too low. Move throttle lever to 60 Hz position for 60 Hz equipment (see Section 5-1). Erratic power output.

  • Page 29: Section 9 - Electrical Diagrams

    SECTION 9 – ELECTRICAL DIAGRAMS SC-495 296-A Figure 9-1. Circuit Diagram For Welding Generator OM-488 Page 25...
  • Page 30 Figure 9-2. Wiring Diagram For Welding Generator (1 Of 3) OM-488 Page 26...
  • Page 31 SC-495 296-A Figure 9-3. Wiring Diagram For Welding Generator (2 Of 3) OM-488 Page 27...
  • Page 32 SC-495 296-A Figure 9-4. Wiring Diagram For Welding Generator (3 Of 3) OM-488 Page 28...

  • Page 33: Section 10 - Auxiliary Power Guidelines

    SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment Auxiliary Power Receptacles – Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Be sure equipment has this symbol and/or wording. aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577 10-2.

  • Page 34: Grounding When Supplying Building Systems

    10-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes.
  • Page 35 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 36 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 37 10-8. Power Required To Start Motor Motor Start Code AC MOTOR Running Amperage VOLTS AMPS Motor HP CODE Motor Voltage PHASE 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.
  • Page 38 10-10. Typical Connections To Supply Standby Power Power Company Service Meter Main and Branch Overcurrent Protection Double-Pole, Double-Throw Transfer Switch Obtain and install correct switch. Switch rating must be same as or Customer-supplied equipment is required if greater than the branch overcurrent generator is to supply standby power during protection.
  • Page 39 10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68)

  • Page 40: Section 11 - Stick Welding (Smaw) Guidelines

    SECTION 11 – STICK WELDING (SMAW) GUIDELINES 11-1. Stick Welding Procedure Y Weld current starts when electrode touches work- piece. Y 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.

  • Page 41: Electrode And Amperage Selection Chart

    11-2. Electrode and Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 6010 DEEP MIN. PREP, ROUGH 1/16 HIGH SPATTER 6011 DEEP 5/64 6013 EP,EN GENERAL 3/32 SMOOTH, EASY, 6013 7014 EP,EN FAST 5/32 3/16 LOW HYDROGEN, 7018 STRONG 7/32 FLAT SMOOTH, EASY,...

  • Page 42: Positioning Electrode Holder

    11-5. Positioning Electrode Holder ° ° ° ° End View of Work Angle Side View of Electrode Angle GROOVE WELDS ° ° ° ° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 11-6. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding...

  • Page 43: Conditions That Affect Weld Bead Shape

    11-8. Conditions That Affect Weld Bead Shape NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Correct Angle ° - ° Angle Too Large Angle Too Small Drag ELECTRODE ANGLE Spatter Normal Too Long Too Short...

  • Page 44: Butt Joints

    11-10. Butt Joints Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. Single V-Groove Weld °...

  • Page 45: Weld Test

    11-13. Weld Test Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) S-0057-B 11-14. Troubleshooting – Porosity Porosity –...

  • Page 46: Troubleshooting – Incomplete Fusion

    11-16. 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.

  • Page 47: Troubleshooting – Burn-Through

    11-19. Troubleshooting – Burn-Through Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 11-20. Troubleshooting – Waviness Of Bead Waviness Of Bead –...

  • Page 48: Section 12 - Parts List

    SECTION 12 – PARTS LIST Hardware is common and not available unless listed. 18 19 ST-802 118-A Figure 12-1. Main Assembly OM-488 Page 44...
  • Page 49 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ....+495 247 TOP, control box (specify color) ........
  • Page 50 Hardware is common and not available unless listed. USA-1 EUROPE AUSTRALIA S. AMERICA S. AFRICA S.E. ASIA USA-2 USA-3 CANADA (CSA) Ref. ST-802 124 / H-495 290 / H-495 283 Figure 12-2. Auxiliary Power Panel OM-488 Page 46...
  • Page 51 Item Dia. Part Mkgs. Description Quantity Figure 12-2. Auxiliary Power Panel ......PANEL, aux power assembly (USA-1) .
  • Page 52 Notes OM-488 Page 48...
  • Page 53 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions Induction Heating Coils and Blankets below, Miller Electric Mfg.

  • Page 54: Options And Accessories

    Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories To locate a distributor or service agency near you, call 1-800-4-A-Miller or visit our Personal Safety Equipment website at www.MillerWelds.com Service and Repair Miller Electric Mfg. Co.

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