Miller Electric AC Generator/Air Compressor User manual
Quick
Specs
Quiet at only 70 dB (95 Lwa) when idle,
79 dB (104 Lwa) at maximum output.
Improves work site communications.
NEW!
Meter maintenance display
• Hour meter function
• Oil Change interval
• 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
Low maintenance with easy single-side
access to engine and 500 hour oil changes for
both engine and compressor.
Arc-Drive makes welding easy.
Automatically enhances Stick
welding, especially on pipe, by
focusing the arc and preventing
the electrode from going out.
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.
(High-frequency unit required for
AC TIG.)
Big Blue®Air Pak™Engine-Driven Welder/
AC Generator/Air Compressor
Issued April 2008 • Index No. ED/10.5
Hot Start™provides positive stick
electrode starts to make it easy to
start all types of electrodes.
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.
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.
Weatherproof Lexan®nameplate
resists cracking and fading, and is
color-coded for ease of operation.
GFCI receptacle as required on most job sites
to protect operators from electrical hazards.
turbocharged four-cylinder diesel
engine provides ample power at high altitudes.
Independent compressor controls.
On/off switch for applications not
requiring compressed air. At idle
speed will produce 100 PSI at 40 CFM.
ultra-reliable
industrial rotary screw air compressor.
Belt-driven with automatic belt tensioner
with a life expectancy of 30,000 hrs.
The Power of Blue®
.
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
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
International Headquarters
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
Heavy Industrial Applications
Railroad Maintenance
Mining Maintenance
Maintenance and Repair Rigs
Processes
Stick (SMAW)
MIG (GMAW)
Flux Cored (FCAW)
Submerged Arc (SAW)
AC TIG (GTAW)*
DC TIG (GTAW)
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
Output Range
DC Stick 45–750 A MIG/FCAW 14–40 V
DC TIG 20–450 A AC 20–575 A*
Battery Charge 12/24 V, 50–750 A*
*Deluxe Model Only.
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*
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*
Air Compressor 100 PSI, 60 CFM, 100% Duty Cycle
Weight Net: 1931 lb (876 kg)
Ship: 1982 lb (899 kg)
Improved!
Maintenance Displays!
Welding
Mode
CC/DC
CV/DC
CC/AC*
Battery*
Charge
Jump-Start
Weld Output Rated at 104˚ F (40˚ C) NEMA
Amperage and Voltage
600 A, 44 V, 26.4 kW, 40% Duty Cycle
550 A, 42 V, 23.1 kW, 60% Duty Cycle
500 A, 40 V, 20 kW, 100% Duty Cycle
500 A, 40 V, 20 kW, 100% Duty Cycle
400 A, 36 V, 14.4 kW 100% Duty Cycle
750 A, 12 V, Jump-Start
750 A, 24 V, Jump-Start
Weld
Output
Range
20 – 750 A
14 – 40 V
20 – 575 A
12/24 V
Max. Open-
Circuit
Voltage
95
56
64
14/28
Meets NEMA and IEC output ratings. *Only available on deluxe model. **Additional 7 in (178 mm) to top of exhaust. ***Additional 190 lb (86 kg) when fuel tank is full.
CSA approved.
Compressor
Brand
Ingersoll-Rand
CE55 G1
Free Air
Delivery at
1850 RPM
60 cfm
(1.70 m3/min)
Free Air
Delivery at
1235 RPM
40 cfm
(1.13 m3/min)
Idle
Features
Rotary screw with electric clutch for on/off.
Oil change intervals 500 hrs (same as engine).
Life expectancy 30,000 hrs.
Working
Pressure
Constant
100 psig
7 bar
Duty
Cycle
100%
Oil
Capacity
5 qt (4.7 L)
Automatic
Compressor
Shutdowns
Oil temperature
Engine Brand
Deutz, BF4M
2011 Diesel
Features
EPA certified, turbocharged direct-injected,
liquid-cooled (oil) engine. Right side service
access with 500 hr intervals for oil and filters.
MSHA approved with purchase of certificate
from Deutz dealer.
Type
Four-cylinder,
industrial, liquid-
cooled engine
Engine
Speeds
1850 Run
1235 Idle
HP
63.4
Fuel Capacity
25 gal (95 L)
Automatic Engine
Shutdowns
Oil pressure
Oil temperature
Oil
Capacity
11 qt
(10.4 L)
Engine
7
8
9
18
19
20
21
22
723
International Model
1
2
10
11
12
13
4
3
5
6
15
16
17
14
2
Control Panel
Weight
Without Fuel***
Net: 1931 lb
(876 kg)
Ship: 1982 lb
(899 kg)
Deluxe Model
Net: 1956 lb
(887 kg)
Ship: 2007 lb
(910 kg)
Dimensions**
H: 43 in
(1092 mm)
W: 28-1/2 in
(724 mm)
D: 67-1/2 in
(1715 mm)
Generator Output Rated
at 104˚ F (40˚ C)
Peak: 5500 watts
Continuous: 4000 watts,
120/240 VAC, 34/17 A, 60 Hz
while welding
Optional kW
3-phase, 20 kW, 36 A, 240 VAC
1-phase, 12 kW, 50 A,
120/240 VAC while not welding
Specifications (Subject to change without notice.)
1. AC/DC Voltmeter*
2. AC/DC Ammeter*
3. Amperage Range Switch
4. Amperage/Voltage Adjust Control
5. Amperage/Voltage Adjust Switch
and Remote Amperage/Voltage
Adjust 14-Pin Receptacle
6. Process/Contactor
Selector Switch
7. 120 VAC, 20 A GFCI
Duplex Receptacle
8. 240 VAC, 30 A TwistLock
Receptacle (NEMA L6-30)
9. Air Outlet Valve 3/4 in NPT
10. Engine Oil Pressure Gauge
11. Fuel Gauge—displays engine
hours and oil change intervals
12. Engine Coolant Temperature Gauge
13. Battery Voltmeter
14. Air Compressor Pressure Gauge
15. Air Compressor On/Off Switch
16. Engine Control Switch
17. Starting Aid Switch*
18. 20 kW, 3-Phase Generator*
19. Strain Relief*
20. 50 A, 3-Phase Circuit Breaker*
21. 50 A, 1-Phase 120/240 V
Receptacle (NEMA 14-50)*
22. AC/DC/Battery Charge/
Jump-Start Switch*
23. International Model—240 VAC,
16 A Pin and Sleeve Receptacle
*On Select Models
Air Compressor
3
Performance Data
FUEL CONSUMPTION CURVE
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
2.75
3.00
0 50 100 150 200 250 300 350 400 450 500 550 600
DC WELD AMPERES AT 100% DUTY CYCLE
US Gal./Hr.
VOLT/AMP CURVE – STICK MODE
0
20
40
60
80
100
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
DC VOLTS
VOLT/AMP CURVE – AC TIG MODE
0
20
40
60
80
100
0 100 200 300 400 500 600 700
AC AMPERES
AC VOLTS
WELD AND AIR
WELD ONLY
IDLE WITH AIR
IDLE
AIR SUPPLY CURVE
0
20
40
60
80
100
120
140
0 10203040506070
CFM
PSI
IDLE
300–Max
185–525
125–400
55–125
VOLT/AMP CURVE – MIG MODE
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500 600 700 800 900 1000
DC AMPERES
DC VOLTS
MAX
MIN
VOLT/AMP CURVE – DC TIG MODE
0
20
40
60
80
100
0 100 200 300 400 500 600
DC AMPERES
DC VOLTS
60–450
40–330
30–220
20–110
GENERATOR POWER CURVE OPTION
180
200
220
240
260
280
0 10203040506070
AC AMPERES
AC VOLTS
12 kW
1-PHASE
BATTERY CHARGE OUTPUT
0
5
10
15
20
25
30
35
40
45
50
0 100 200 300 400 500 600 700 800 900 1000
DC AMPS
DC VOLTS
20 kW
3-PHASE
Ingersoll-Rand Rotary Screw Air
Compressor
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.
Toolless
Generator
Brushes
100% copper-
wound
generator
features quick
and easy brush and slip ring inspection.
Brushes can be removed and/or replaced
in a matter of seconds.
The Vault
Superior Circuit Board Design
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.
“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
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.
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
circuit boards exposed to harsh elements that
can disrupt the machine’s electronics, and
therefore, its operation.
4
Genuine Miller Accessories
Field Kit Accessories
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.
AC/DC/Battery Charge/Jump-Start Switch
#195 148 Field
AC TIG welding and 12/24 V battery charge/
jump-starting system.
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
entering the fuel tank.
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.
Weld Ammeter and Voltmeter
#195 131 Field
Panel-mounted AC/DC analog meters to
monitor weld output.
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.
Cable Holder
#043 946
Saddle-bag-style
cable holder.
Convenient wrap-
around storage of
coiled cable for
transportation.
Stores 100 ft of
2/0 cable
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
Lockable battery
disconnect switch for safe
routine maintenance.
Stick (SMAW) Welding
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
Plasma Cutting
Spectrum®375 X-TREME™#907 303
Spectrum®375 X-TREME™with X-CASE™
#907 339 (not shown)
See Lit. Index No. PC/9.2.
Spectrum®625 #907 058
See Lit. Index No. PC/9.5.
Spectrum 2050 #903 777-01-2
See Lit. Index No. PC/7.0.
MIG/Flux Cored Welding
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.
SuitCase™X-TREME™8VS
Wire Feeder #300 093
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.
5
Genuine Miller Accessories (continued)
MIG/Flux Cored Welding (continued)
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.
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.
Spoolmatic®30A Spool Gun
#130 831
Air-cooled, 200-amp, 1-lb spool gun for
aluminum MIG. See Lit. Index No. M/1.73.
WC-24 Control #137 549
Use with Spoolmatic 30A.
XR™Wire 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.
TIG (GTAW) Welding
Dynasty®200 Series
For premium portable AC/DC TIG arc
quality. See Lit. Index No. AD/4.8.
HF-251 Series #042 388
HF-251D-1, 115 VAC
High-frequency arc starter and stabilizer.
See Accessory Lit. Index No. AY/5.0.
Remote Controls
RHC-14 Hand Control
#129 340
Miniature hand control for
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.
RFCS-14 HD Foot
Control #194 744
Heavy-duty foot current
and contactor control.
Includes 20 ft (6 m)
cord and 14-pin plug.
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.
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.
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)
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