Miller Blue Star 6000 Bedienungshandbuch

Blue Star 6000ProcessesDescriptionStick (SMAW) WeldingEngine Driven Welding GeneratorOM-499 197 850FApril 2002Visit our website atwww.MillerWelds.com

OM-499 Page 6Le soudage effectué sur des conteneurs fermés tels quedes réservoirs, tambours ou des conduites peut provoquerleur éclatement. Des étince

OM-499 Page 7DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas approcher les mains des ventilateurs, cour-roies et autres pièces en mouvemen

OM-499 Page 8LE RAYONNEMENT HAUTE FRÉ-QUENCE (H.F.) risque de provoquerdes interférences. Le rayonnement haute fréquence (H.F.) peutprovoquer des int

OM-499 Page 9SECTION 2 – DEFINITIONS2-1. Symbol DefinitionsEngine ChokeRead Operator’sManual AAmperesVVoltsEngine Oil Fuel Battery (Engine) EnginePosi

OM-499 Page 103-2. Dimensions, Weights, And Operating AnglesDimensionsHeight 20-3/4 in (527 mm)DWidth 22-3/4 in (577 mm)Depth 31-1/4 in (793 mm)  Do

OM-499 Page 113-4. Fuel Consumption (Honda-Powered Units)802 122Continuous Welding3-5. Duty Cycle802 093Duty cycle is the percentage of 10minutes that

OM-499 Page 123-6. Generator Power Curves198 570The generator power curves showthe ac power available in amperesat the receptacles.A. 60 Hz ModelB. 50

OM-499 Page 133-7. Volt-Ampere Curves198 570The volt-ampere curve shows theminimum and maximum voltageand amperage output capabilities ofthe welding g

OM-499 Page 14SECTION 4 – INSTALLATION4-1. Installing Welding Generatorinstall1 10/00*– 802 524-A / Ref. 151 556 / 158 936-A / S-085418 in(460 mm)18 i

OM-499 Page 154-3. Grounding Generator When Supplying Building SystemsGND/PE1 2Use ground device asstated in electrical codes.23800 576-B1 Equipment G

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-499 Page 164-5. Engine Prestart Checks (Honda-Powered Units)802 094-AFullFullGasoline1/2 in(13 mm)1Check all fluids daily. Engine mustbe cold and o

OM-499 Page 174-7. Connecting To Weld Output Terminals196 914 / 495 1781 Positive (+) Weld OutputTerminal2 Negative (–) Weld OutputTerminalFor Direct

OM-499 Page 18SECTION 5 – OPERATING THE WELDING GENERATOR5-1. Controls (Kohler-Powered Units)802 511-A / 802 0511 / 495 1786760 Hz Weld and generator

OM-499 Page 195-2. Controls (Honda-Powered Units) (See Section 5-3)802 094-A / 802 095 / 495 187Recoil-StartElectric-Start60 Hz50 Hz13621457

OM-499 Page 205-3. Description Of Controls (Honda-Powered Units) (See Section 5-2) Weld and generator power output stops ifgenerator overheats or eng

OM-499 Page 21SECTION 6 – OPERATING AUXILIARY EQUIPMENTThe welding generator provides power while welding and with the Current controlin any position.

OM-499 Page 226-2. Optional Generator Power PanelsRef. ST-802 124 / H-495 290 / H-495 283 / 495 277Generator Power Panel 495 315(USA)Generator Power P

OM-499 Page 236-3. Generator Power Panel RatingsUnless otherwise stated, the rating of duplex outlets is the combined load of allreceptacles.NOTETotal

OM-499 Page 246-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)plug3-11/99 – 802 5271 Plug Wired For 120/240 V,3-Wire L

OM-499 Page 257-2. Routine MaintenanceRecycleenginefluids. Stop engine before maintaining. See Engine Manual and Maintenance Label. Ser-vice more of

The following terms areused interchangeablythroughout this manual:TIG = GTAWStick = SMAWMIG = GMAWThe engine exhaust fromthis product containschemical

OM-499 Page 267-3. Overload Protection (Honda-Powered Units)1 Ignition Circuit Breaker(Electric-Start Models Only)The circuit breaker protects the en-

OM-499 Page 277-5. Adjusting Engine Speed (Honda-Powered Units)802 097-AAfter tuning engine, check enginespeeds. See table for proper noload speeds. I

OM-499 Page 28SECTION 8 – TROUBLESHOOTING8-1. TroubleshootingA. WeldingTrouble RemedyNo weld output. Check Amperage control setting.Check weld connect

OM-499 Page 29Trouble RemedyLow power output at generator power acreceptacles.Check Amperage control setting.Check engine speed, and adjust if necessa

OM-499 Page 30SECTION 9 – ELECTRICAL DIAGRAMS197 857-EFigure 9-1. Circuit Diagram For Welding Generator (1 Of 2)

OM-499 Page 31197 857-DFigure 9-2. Circuit Diagram For Welding Generator (2 Of 2)

OM-499 Page 32197 858-CFigure 9-3. Wiring Diagram For Welding Generator

OM-499 Page 33201 026-AFigure 9-4. Wiring Diagram For Auxiliary Power Panels (1 Of 2)

OM-499 Page 34201 026-AFigure 9-5. Wiring Diagram For Auxiliary Power Panels (2 Of 2)

OM-499 Page 35SECTION 10 – GENERATOR POWER GUIDELINES10-1. Selecting Equipmentgen_pwr 4/02 – Ref. ST-159 730 / ST-800 5771 Generator Power Receptacles

OM-499 Page 3610-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulated

OM-499 Page 3710-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 30

OM-499 Page 3810-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-499 Page 3910-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-499 Page 4010-10. Typical Connections To Supply Standby PowerS-0405-A Have only qualified personsperform these connectionsaccording to all applica

OM-499 Page 4110-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, us

OM-499 Page 42SECTION 11 – STICK WELDING (SMAW) GUIDELINES11-1. Stick Welding Procedurestick 12/96 – ST-151 593 Weld current starts whenelectrode tou

OM-499 Page 4311-2. Electrode and Amperage Selection ChartRef. S-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/321/43/321/85/323/167/321/43/

OM-499 Page 4411-5. Positioning Electrode HolderS-006090° 90°10°-30°45°45°GROOVE WELDSFILLET WELDSEnd View of Work Angle Side View of Electrode AngleE

OM-499 Page 4511-8. Conditions That Affect Weld Bead ShapeWeld bead shape is affected by electrode angle, arc length, travel speed, andthickness of

OM-499 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGrom _nd_4/021-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-499 Page 4611-10. Butt JointsS-06621 Tack WeldsPrevent edges of joint from drawingtogether ahead of electrode by tackwelding the materials in posit

OM-499 Page 4711-13. Weld TestS-0057-B1 Vise2 Weld Joint3 HammerStrike weld joint in direction shown.A good weld bends over but doesnot break.2 To 3 i

OM-499 Page 4811-16. Troubleshooting – Incomplete FusionIncomplete Fusion – failure of weld metal to fuse completely withbase metal or a preceeding we

OM-499 Page 4911-19. Troubleshooting – Burn-ThroughBurn-Through – weld metal melting completely through base metal resultingin holes where no metal re

OM-499 Page 50SECTION 12 – PARTS LIST802 509-A Hardware is common andnot available unless listed.7323334312829302423464041444243363839373547488654910

OM-499 Page 51DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 +495 247 TOP, control box (specify color) 1. . . . . . . . . . .

OM-499 Page 52DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main Assembly (Continued)Quantity41 1T 172 661 BLOCK, terminal 1. . . . . . . . . . . .

OM-499 Page 53 Hardware is common and not available unless listed.Generator Power Panel 495 315 (USA)Generator Power Panel 495 219 (USA)Generator Pow

OM-499 Page 54DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-2. Generator Power Panels (Figure 12-1, Item 39)QuantityGenerator Power Panel 495 218 (USA)1

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/02Your distributor also givesyou ...ServiceYou always get the fa

OM-499 Page 2Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flyin

PRINTED IN USA  2002 Miller Electric Mfg. Co. 5/02Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-499 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely in

OM-499 Page 4H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunic

OM-499 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom _nd_fre 11/981-1. Signification des symbolesSignifie Mise en garde ! Soyez