Miller Electric Welding System Engine Driven Welder AC Generator Air Compressor User Manual

Issued October 2008 • Index No. ED/10.5  
Engine-Driven Welder/  
®
AC Generator/Air Compressor  
Big Blue Air Pak  
Stud Welding — 1/2 in (12.7 mm)  
Air Plasma Cutting  
with Optional Spectrum Models  
Air Carbon Arc (CAC-A)  
1/2 in (12.7 mm) Carbons  
Battery Charging/Jump-Starting*  
Air Compressor  
Heavy Industrial Applications  
Railroad Maintenance  
Weld Output Rated at 104°F (40°C)  
Stick 600 A, 44 V, 26.4 kW, 40% Duty Cycle  
Stick 550 A, 42 V, 23.1 kW, 60% Duty Cycle  
MIG/FCAW 500 A, 40 V, 20 kW, 100% Duty Cycle  
AC TIG 400 A, 26 V, 10.4 kW, 100% Duty Cycle*  
Mining Maintenance  
Maintenance and Repair Rigs  
Processes  
Air Compressor 100 PSI, 60 CFM, 100% Duty Cycle  
Quick  
Specs  
Stick (SMAW)  
MIG (GMAW)  
Generator Output Rated at 104°F (40°C)  
5,500 Watts Peak — 4,000 Watts Continuous  
20,000 Watts 3-Phase/12,000 Watts 1-Phase  
Continuous*  
Output Range  
Flux Cored (FCAW)  
Submerged Arc (SAW)  
AC TIG (GTAW)*  
DC TIG (GTAW)  
DC Stick 45750 A MIG/FCAW 1440 V  
DC TIG 20450 A AC 20575 A*  
Battery Charge 12/24 V, 50750 A*  
Accu-RatedNot Inflated  
Generator Power  
*Deluxe Model Only.  
®
turbocharged four-cylinder diesel  
engine provides ample power at high altitudes.  
The Power of Blue.  
Welder/generator/air compressor.  
One machine that will do it all. Designed  
and built to be the most reliable high-  
output system in the world.  
NEW! Meter maintenance display  
• Hour meter function  
• Oil Change interval  
Improved!  
• Diesel: High coolant temperature  
and low oil pressure shutdowns  
• Diesel: Low fuel shutdown —  
engine shuts down before  
system runs out of fuel making  
restarts easy  
Maintenance Displays!  
ultra-reliable  
industrial rotary screw air compressor.  
Belt-driven with automatic belt tensioner  
with a life expectancy of 30,000 hrs.  
Independent compressor controls.  
On/off switch for applications not  
requiring compressed air. At idle  
speed will produce 100 PSI at 40 CFM.  
Hot Startprovides positive stick  
electrode starts to make it easy to  
start all types of electrodes.  
Weatherproof Lexan® nameplate  
resists cracking and fading, and is  
color-coded for ease of operation.  
Arc-Drive makes welding easy.  
Automatically enhances Stick  
welding, especially on pipe, by  
focusing the arc and preventing  
the electrode from going out.  
Enclosed robust case design protects  
internal components from impact and  
allows air flow to cool and prolong the life  
of the engine. Also reduces sound levels.  
Optional AC/DC/battery charge/  
jump-start for AC TIG welding  
and 12 or 24 volt batteries. Simply  
select the battery voltage and  
connect cables to the separate  
battery output studs.  
GFCI receptacle as required on most job sites  
to protect operators from electrical hazards.  
Low maintenance with easy single-side  
access to engine and 500 hour oil changes for  
both engine and compressor.  
(High-frequency unit required for  
AC TIG.)  
Quiet at only 70 dB (95 Lwa) when idle,  
79 dB (104 Lwa) at maximum output.  
Improves work site communications.  
Welder/Generator/Air Compressor is warranted  
by Miller for 3 years, parts and labor.  
Engine is warranted by Deutz for 3 years.  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
International Headquarters Web Site  
Phone: 920-735-4505  
1635 West Spencer Street  
Appleton, WI 54914 USA  
USA FAX: 920-735-4134  
Canadian FAX: 920-735-4169  
International FAX: 920-735-4125  
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Performance Data  
FUEL CONSUMPTION CURVE  
GENERATOR POWER CURVE OPTION  
280  
260  
240  
220  
200  
180  
3.00  
2.75  
2.50  
12 kW  
1-PHASE  
WELD AND AIR  
2.25  
2.00  
1.75  
1.50  
1.25  
1.00  
0.75  
0.50  
0.25  
0.00  
20 kW  
3-PHASE  
WELD ONLY  
IDLE  
IDLE WITH AIR  
0
50 100 150 200 250 300 350 400 450 500 550 600  
DC WELD AMPERES AT 100% DUTY CYCLE  
0
10  
20  
30  
40  
50  
60  
70  
AC AMPERES  
Ingersoll-Rand Rotary Screw Air  
Compressor  
VOLT/AMP CURVE – STICK MODE  
AIR SUPPLY CURVE  
This industrial grade compressor, has a life  
expectancy of 30,000 hours, is belt driven and  
utilizes an electric clutch control to allow the  
compressor to be turned off if not needed.  
This design increases efficiency, reduces fuel  
consumption and saves you money at the  
pump. An automatic belt tensioner provides  
proper belt tension even after years of service.  
The compressor is protected by a high  
temperature shutdown switch.  
100  
80  
60  
40  
20  
0
140  
120  
100  
80  
300–Max  
185–525  
125–400  
55–125  
IDLE  
60  
40  
20  
0
0
10  
20  
30  
40  
50  
60  
70  
0
100 200 300 400 500 600 700 800 900 1000  
DC AMPERES  
CFM  
VOLT/AMP CURVE – MIG MODE  
VOLT/AMP CURVE – DC TIG MODE  
Toolless  
Generator  
Brushes  
100% copper-  
wound  
generator  
features quick  
100  
90  
80  
70  
60  
50  
40  
30  
20  
10  
0
100  
80  
60  
40  
20  
0
60–450  
40–330  
30–220  
20–110  
MAX  
MIN  
and easy brush and slip ring inspection.  
Brushes can be removed and/or replaced  
in a matter of seconds.  
0
100 200 300 400 500 600 700 800 900 1000  
DC AMPERES  
0
100  
200  
300  
400  
500  
600  
DC AMPERES  
BATTERY CHARGE OUTPUT  
VOLT/AMP CURVE – AC TIG MODE  
50  
45  
40  
35  
30  
25  
20  
15  
10  
5
100  
80  
60  
40  
20  
0
0
0
100  
200  
300  
400  
500  
600  
700  
0
100 200 300 400 500 600 700 800 900 1000  
DC AMPS  
AC AMPERES  
The Vault  
Superior Circuit Board Design  
offer a superior arc and multiple welding  
processes. Miller’s circuit board reliability isn’t  
a concern since all PRO 300 and Big Blue  
multiprocess industrial engine drives feature  
the Vault.  
Miller’s critical circuit boards are engineered  
to carry low power and low heat to reduce  
thermal stress and minimize expansion and  
contraction. In contrast, our competitor’s  
boards carry high power and high heat, making  
them more vulnerable to failure.  
Created out of two aluminum halves sealed  
with silicone, as well as watertight harness  
connections, the Vault provides a clean circuit  
board environment, protecting the electronics  
— and controlling output — in heavy industrial  
applications. No other competitor protects their  
electronics with a sealed vault, leaving critical  
“The Vault” Makes Upgrading to Miller CC/CV  
Units Worry-Free  
Concerns with circuit board reliability have  
resulted in some operators steering clear of  
CC/CV welder/generators — even though they  
circuit boards exposed to harsh elements that  
can disrupt the machine’s electronics, and  
therefore, its operation.  
3
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Genuine Miller Accessories  
Field Kit Accessories  
Cable Holder  
#043 946  
MIG/Flux Cored Welding  
Saddle-bag-style  
cable holder.  
Convenient wrap-  
around storage of  
coiled cable for  
transportation.  
Stores 100 ft of  
2/0 cable  
Desiccant Air Dryer System #195 117  
A regenerating inline air dryer system  
that eliminates moisture in the air stream  
to prevent air tool freeze-ups in cold  
climates. Internal thermostat and heating  
elements insure good air quality in all  
climates. The system can be mounted on  
the side of the machine or remotely for  
truck mount installations.  
on each side.  
Note: For best results do not weld when cable is  
coiled! Canvas cover cannot be used with cable  
holder.  
Battery Lockout/Tagout  
Disconnect Switch  
#195 120 Field  
Millermatic® Passport® Plus  
#907 401  
Portable, all-in-one MIG package features  
ultimate arc performance, self-contained  
gas bottle, and flexibility to plug into 115 or  
230 V power with Miller exclusive Multi-  
Voltage Plug. See Lit. Index No. DC/12.53.  
Lockable battery  
disconnect switch for safe  
routine maintenance.  
AC/DC/Battery Charge/Jump-Start Switch  
#195 148 Field  
AC TIG welding and 12/24 V battery charge/  
jump-starting system.  
Stick (SMAW) Welding  
FA-1D Lockable Flame  
Arrestor Fuel Cap #043 947  
Fuel cap can be padlocked to  
prevent vandalism. A built-in  
flame arrestor prevents  
flames or sparks from  
Weld Leads  
#173 851 2/0, 350 A, 100% duty cycle,  
50 ft stinger, 50 ft work cable  
#043 952 2/0, 300 A, 100% duty cycle,  
100 ft stinger, 50 ft work cable  
entering the fuel tank.  
Plasma Cutting  
Cold Weather Starting Aids*  
#043 959 Field 12 V intake manifold heater.  
#195 086 Field 120 V oil pan heater element.  
*Note: for extreme cold weather both starting aids  
can be used in conjunction.  
SuitCase X-TREME 8VS  
Wire Feeder #300 093  
Weld Ammeter and Voltmeter  
#195 131 Field  
Panel-mounted AC/DC analog meters to  
monitor weld output.  
SuitCase X-TREME 12VS  
Wire Feeder #195 500  
Lightweight, portable, voltage-sensing  
wire feeders include secondary contactor  
and gas valve. Require drive roll kit.  
See Lit. Index No. M/6.41.  
Spectrum® 375 X-TREME#907 303  
Spectrum® 375 X-TREMEwith X-CASE™  
#907 339 (not shown)  
See Lit. Index No. PC/9.2.  
Spectrum® 625 #907 058  
See Lit. Index No. PC/9.5.  
Vandalism  
Lockout Kit  
#195 118 Field  
Lockable hinged  
steel panels cover  
and protect name  
plate gauges and  
ignition switch  
(padlock included).  
Also includes engine  
compartment door  
lock and key.  
Spectrum 2050 #903 777-01-2  
See Lit. Index No. PC/7.0.  
4
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Genuine Miller Accessories  
MIG/Flux Cored Welding (continued)  
(continued)  
WC-24 Control #137 549  
Use with Spoolmatic 30A.  
Remote Controls  
RHC-14 Hand Control  
#129 340  
Miniature hand control for  
XRWire Feeders and Guns  
Push-pull system designed to handle  
difficult-to-feed soft alloy wires such as  
aluminum. See Lit. Index No. M/1.7,  
M/1.71, and M/1.73.  
remote current and contactor  
control. Dimensions: 4 x 4 x  
3-1/4 in (102 x 102 x 82 mm). Includes  
20 ft (6 m) cord and 14-pin plug.  
TIG (GTAW) Welding  
RFCS-14 HD Foot  
Control #194 744  
Heavy-duty foot current  
and contactor control.  
Includes 20 ft (6 m)  
cord and 14-pin plug.  
SuitCase 8RC Wire Feeder #194 938  
SuitCase 12RC Wire Feeder #194 940  
Lightweight, modular design and flexible  
enough to run a variety of wires up to 5/64 in  
diameter. Comes standard with remote  
voltage control. See Lit. Index No. M/6.5.  
RMLS-14 #129 337  
®
14-pin plug Momentary- and maintained-  
contact rocker switch for contactor control.  
Push forward for maintained contact and  
back for momentary contact. Includes 20 ft  
(6 m) cord.  
Dynasty 200 Series  
For premium portable AC/DC TIG arc  
quality. See Lit. Index No. AD/4.8.  
S-32SL Wire Feeder #109 294  
Simple to use, but with all the features  
needed for heavy-duty applications up to  
7/64 in wire diameter. See Lit. Index  
No. M/6.21.  
RCC-14 Remote Contactor and Current  
Control #151 086 14-pin plug  
Rotary-motion fingertip control fastens to  
®
TIG torch using two Velcro straps.  
Includes 28 ft (8.5 m) control cord.  
HF-251 Series #042 388  
HF-251D-1, 115 VAC  
High-frequency arc starter and stabilizer.  
See Accessory Lit. Index No. AY/5.0.  
Extension Cords for 14-Pin  
Remote Controls  
#122 973 25 ft (7.6 m)  
#122 974 50 ft (15.2 m)  
#122 975 75 ft (23 m)  
Spoolmatic® 30A Spool Gun  
#130 831  
Air-cooled, 200-amp, 1-lb spool gun for  
aluminum MIG. See Lit. Index No. M/1.73.  
5
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Trailers and Hitches  
(Note: Trailers are shipped unassembled.)  
HWY-430 Tandem Axle Trailer #043 806  
HWY-224 Trailer #043 805 For highway use.  
4 West Four-Wheel Steerable  
Off-Road Trailer #042 801  
Smooth riding with 3750 lb (1701 kg) capacity.  
Includes hand-operated parking brake, hydraulic  
brake system, and a break-away device to lock  
brakes if the trailer comes loose. Includes jack  
stand, fenders and lights. (Hitch must be  
ordered separately.)  
OFR-224 Trailer #043 802 For off-road use.  
A 2650 lb (1202 kg) capacity trailer. Welded  
steel tubing frame, heavy-duty axle with roller  
bearing hubs and leaf-spring suspension.  
Includes jack stand, 2 in (50 mm) ball hitch.  
HWY-224 also includes fenders and lights.  
Note: Trailer is shipped unassembled.  
A heavy-duty 2570 lb (1166 kg) capacity trailer  
designed for use in mines, quarries, and other  
rough terrain. Has narrow 22 ft (6.7 m) turning  
radius. Includes 3 in lunette eye, universal hitch  
and safety chains.  
Note: Some assembly required.  
Note: Trailer is shipped unassembled.  
Cable Tree #043 826  
Cable Tree #043 826  
Provides an area to conveniently wrap weld  
cables and extension cords.  
Provides an area to conveniently wrap weld  
cables and extension cords.  
Ball Hitch 2 in (50 mm) #043 864  
Lunette Eye 3 in (76 mm) #043 863  
Lunette Eye 2-1/2 in (64 mm) #043 824  
Trailer Specifications (Subject to change without notice.)  
Track (Center Standard Tires  
Gross Axle  
Weight Rating Weight Rating Payload  
Gross Vehicle Net  
Height  
of Bed  
Road  
Clearance tires)  
8 in 55-1/4 in  
to center of  
(Standard rating  
or P-size rating) Dimensions  
Net  
Weight  
Model  
4 West  
2000 lb/axle  
(907 kg/axle)  
3000 lb  
(1361 kg)  
2570 lb  
21-1/4 in  
B78-13  
Length: 91 in (2311 mm)**  
Width: 61-1/4 in (1556 mm)  
430 lb  
(195 kg)  
(1166 kg) (540 mm) (203 mm) (1403 mm)  
2650 lb 7-1/2 in 52 in  
18-1/2 in  
(1202 kg) (470 mm) (191 mm) (1321 mm)  
HWY-224 3500 lb  
OFR-224 (1588 kg)  
2960 lb  
(1343 kg)  
B78-13B  
Length: 122-1/2 in (3112 mm) 355 lb  
Width: HWY 61 in (1549 mm)* (161 kg)  
OFR58-1/2 in (1486 mm)  
HWY-430 2200 lb/axle  
4280 lb  
(1941 kg)  
3750 lb  
19-1/4 in  
8-1/2 in  
52 in  
B78-13B  
Length: 156-1/2 in (3975 mm) 530 lb  
(998 kg/axle)  
(1701 kg) (489 mm) (216 mm) (1321 mm)  
Width: 61 in (1549 mm)*  
(240 kg)  
*Width at outside of fenders.  
**Does not include tongue.  
Mounting Specifications  
A. 20 in (508 mm)  
Height: (to top of exhaust)  
B. 16-1/2 in (419 mm)  
C. 1-3/4 in (44 mm)  
D. 6-1/16 in (154 mm)  
E. 32-3/4 in (832 mm)  
F. 45-3/8 in (1153 mm) (Gas)  
52 in (1321 mm) (Diesel)  
33 in (838 mm) (Gas)  
34-1/4 in (870 mm) (Diesel)  
Width: 20 in (508 mm)  
G
4 Holes  
B
A
Depth: 45-7/8 in (1164 mm) (Gas)  
52-1/2 in (1334 mm) (Diesel)  
C
G. 13/32 in (10 mm) diameter  
D
E
F
6
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Typical Installations  
Stick Electrode  
Stick (SMAW) Basic Equipment  
Work  
Flux Cored Gun  
Flux-Cored (FCAW) Basic Equipment  
X-TREME 8VS/  
X-TREME 12VS  
Feeder  
SuitCase X-TREME 8VS  
#300 093  
SuitCase X-TREME 12VS #195 500  
Work  
14-Pin  
MIG Gun  
MIG (GMAW) Basic Equipment  
SuitCase  
8RC/12RC  
SuitCase 8RC  
#194 938  
#194 940  
SuitCase 12RC  
Work  
Aluminum MIG with  
Spoolmatic 30A Gun  
14-Pin  
14-Pin  
Aluminum MIG (GMAW) Basic Equipment  
WC-24  
Spoolmatic® 30A #130 831  
WC-24  
#137 549  
Work  
TIG (GTAW) Basic Equipment  
TIG  
Dynasty® 200 Series  
Torch  
HF-251D-1  
HF-251D-1  
#042 388*  
*TIG power cable adapter required  
Work  
Cutting Torch  
Plasma Basic Equipment  
®
Spectrum 375 X-TREME #907 303  
Spectrum  
®
Spectrum 375 X-TREME with X-CASE  
#907 339  
#907 058  
#903 777-01-2  
®
Spectrum 625  
Work  
®
Spectrum 2050  
7
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Ordering Information  
Equipment and Factory Options  
Stock No.  
#907 062  
Description  
Qty.  
Price  
Big Blue® Air PakCC/CV Base Model  
Automatic Idle, Engine Gauges, 5.5 kW AC Generator  
International Model #907 062-01-1 50/60 Hz, Dry Battery, Automatic Idle, Engine Gauges, 5.5 kW AC Generator  
Cold Weather Model #907 062-04-1 Automatic Idle, Engine Gauges, 5.5 kW AC Generator, Weld Meters,  
Battery Lockout/Tagout Disconnect Switch, 12 V Intake Manifold Heater,  
120 V Oil Pan Heater  
Deluxe Model  
#907 062-07-1 Automatic Idle, Engine Gauges, 5.5 kW AC Generator, Weld Meters,  
Battery Lockout/Tagout Disconnect Switch, 12 V Intake Manifold Heater,  
120 V Oil Pan Heater, Vandalism Lockout Kit, 20 kW Generator,  
AC/DC/Battery Charge/Jump-Start Switch  
Field Kit Accessories  
Weld Ammeter and Voltmeter Kit  
Lockable Fuel Cap Flame Arrestor  
Cold Weather Starting Aids  
#195 131  
#043 947  
#043 959  
#195 086  
AC/DC analog weld output meters  
Padlock not included  
12 volt intake manifold heater  
120 volt oil pan heater  
Desiccant Air Dryer System  
Vandalism Lockout Kit  
Battery Lockout/Tagout Disconnect Switch  
AC/DC/Battery Charge/Jump-Start Switch  
Cable Holder  
#195 117  
#195 118  
#195 120  
#195 148  
#043 946  
#195 159  
Removes moisture from air supply  
Lockable front control panel and engine compartment  
Allows machine battery to be disconnected and locked  
Field  
Stores up to 200 ft of 2/0 weld cable  
Will not fit over machine with cable holder attached  
Protective Cover  
Stick Accessories  
Welding Leads  
#173 851  
#043 952  
2/0, 350 A, 100% Duty Cycle, 50 ft stinger, 50 ft work clamp  
2/0, 300 A, 100% Duty Cycle, 100 ft stinger, 50 ft work clamp  
Plasma Cutters  
Spectrum® Plasma Cutter  
See page 4  
Wire Feeders  
SuitCaseX-TREME8VS  
SuitCaseX-TREME12VS  
SuitCase8RC  
#300 093  
#195 500  
#194 938  
#194 940  
#109 294  
#130 831  
Includes contactor and gas valve. See Lit. Index No. M/6.41  
Includes contactor and gas valve. See Lit Index No. M/6.41  
See Lit Index No. M/6.5  
See Lit Index No. M/6.5  
See Lit. Index No. M/6.21  
SuitCase12RC  
S-32SL Wire Feeder  
Spoolmatic® 30A Spool Gun  
Guns and Consumables  
Requires WC-24 Control. See Lit. Index No. M/1.73  
See Lit. Index No. M/10.0 and M/13.4  
TIG Accessories  
HF-251D-1  
Water Coolant System  
TIG Torch, Consumables  
#042 388  
High frequency unit for AC TIG welding  
See Lit. Index No. AY/7.2  
Remote Controls  
RHC-14  
RFCS-14 HD  
RMLS-14  
#129 340  
#194 744  
#129 337  
#151 086  
Hand control  
Foot control  
Momentary and maintained contact switch  
Fingertip control  
RCC-14  
Extension Cords  
#122 973  
#122 974  
#122 975  
25 ft (7.6 m)  
50 ft (15.2 m)  
75 ft (22.9 m)  
Trailers and Hitches  
HWY-224 Trailer  
OFR-224 Trailer  
HWY-430 Tandem Axle Trailer  
4-West Trailer  
#043 805  
#043 802  
#043 806  
#042 801  
Highway trailer with 2650 lb (1202 kg) capacity  
Off-road trailer with 2650 lb (1202 kg) capacity  
Highway trailer with 3750 lb (1701 kg) capacity.  
Off-road steerable trailer with 2570 (1166 kg) capacity  
Lunette Eye  
#043 824  
#043 863  
2-1/2 in (64 mm). For 224 trailers only  
3 in (76 mm). For 430 trailer only  
Ball Hitch  
Clevis  
Cable Tree  
#043 864  
#043 823  
#043 826  
2 in (51 mm). For 430 trailer only  
For 430 trailer only  
Works on 224 and 430 trailers  
Date:  
Total Quoted Price:  
Distributed by:  
Litho in USA  
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