Miller Electric Big Blue Air Pak User manual

Quick
Specs
Quiet at only 70 dB (95 Lwa) when idle,
79 dB (104 Lwa) at maximum output.
Improves work site communications.
Meter maintenance displays
• Fuel gauge
• Hour meter function
• Oil change interval
• High coolant temperature and
low oil pressure shutdowns
• 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 September 2010 • 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.
Heavy-duty low-speed
industrial turbocharged
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.
Heavy Industrial
Applications
Railroad Maintenance
Mining Maintenance
Maintenance and Repair Rigs
Processes
DC Stick (SMAW)
AC Stick (SMAW)*
MIG (GMAW)
Flux Cored (FCAW)
DC TIG (GTAW)
AC TIG (GTAW)*
Submerged Arc (SAW)
Stud Welding — 1/2 in (12.7 mm)
Air Carbon Arc (CAC-A)
1/2 in (12.7 mm) Carbons
Air Plasma Cutting
with Optional Spectrum Models
Battery Charging/Jump-Starting*
Air Compressor
Output Range
DC Stick 45–750 A AC Stick 35–575 A*
MIG/FCAW 14–40 V
DC TIG 20–450 A AC TIG 20–375 A*
Battery Charge 12/24 V, 50–750 A*
*Deluxe Model Only.
Weld Output Rated at 104°F (40°C)
Stick 600 A at 44 V (26.4 kW), 40% Duty Cycle
Stick 550 A at 42 V (23.1 kW), 60% Duty Cycle
MIG/FCAW 500 A at 40 V (20 kW), 100% Duty Cycle
AC TIG 400 A at 26 V (10.4 kW), 100% Duty Cycle*
Air Compressor 100 PSI, 60 CFM, 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*
Accu-Rated
™
–Not Inflated
Generator Power
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
Equipment Sales US and Canada
Phone: [phone]
FAX: [phone]
International Phone: [phone]
International FAX: [phone]
EPA Tier 4i
Compliant
EPA Tier 4i
Compliant
EPA Tier 4i
Compliant
EPA Tier 4i
Compliant
Big Blue Air Pak Deluxe Model shown.

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 at 44 V (26.4 kW), 40% Duty Cycle
550 A at 42 V (23.1 kW), 60% Duty Cycle
500 A at 40 V (20 kW), 100% Duty Cycle
500 A at 40 V (20 kW), 100% Duty Cycle
400 A at 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
*Deluxe model only. **Additional 7 in (178 mm) to top of exhaust. ***Additional 190 lb (86 kg) when fuel tank is full.
Compressor
Brand
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
TD2011L04w
Features
EPA Tier 4i compliant, turbocharged,
direct-injected, liquid-cooled (oil) engine.
Right-side service access with 500 hr intervals
for oil and filters.
Type
Four-cylinder,
industrial, liquid-
cooled engine
Engine
Speeds
1850 Run
1250 Idle
HP
63.4
Fuel
Capacity
25 gal
(95 L)
Automatic Engine
Shutdowns
Low Oil Pressure,
High Coolant
Temperature,
Low Fuel Level
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: 69-1/2 in
(1765 mm)
Generator Output
Rated at 104˚F (40˚C)
Peak: 5500 watts
Continuous: 4000 watts, 34/17 A,
120/240 VAC, 60 Hz while welding
Additional Generator Power for
Deluxe Models (while NOT welding)
3-phase: 20 kW, 48 A, 240 VAC or
1-phase: 12 kW, 50 A, 120/240 VAC
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
Meets NEMA and IEC output ratings.
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.

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 – DC STICK MODE
0
22.5
45
67.5
90
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
AC AMPERES
AC VOLTS
WELD AND AIR
WELD ONLY
IDLE WITH AIR
IDLE
AIR SUPPLY CURVE
0
20
40
60
80
100
120
140
0102030
40 50 60 70
CFM
PSI
IDLE
300–Max
185–525
125–400
85–250
55–125
VOLT/AMP CURVE – AC STICK MODE
0
20
40
60
80
100
0 100 200 300 400 500 600 700
AC AMPERES
AC VOLTS
VOLT/AMP CURVE – MIG MODE
0
25
50
75
100
0 250 500 750 1000
DC AMPERES
DC VOLTS
MAX
MIN
VOLT/AMP CURVE – DC TIG MODE
0
25
50
75
100
0 100 200 300 400 500 600
DC AMPERES
DC VOLTS
GENERATOR POWER CURVE OPTION
180
200
220
240
260
280
0 10203040506070
AC AMPERES
AC VOLTS
12 kW
1-PHASE
BATTERY CHARGE OUTPUT
0
12.5
25
37.5
50
0 100 200 300 400 500 600 700 800 900 1000
DC AMPS
DC VOLTS
20 kW
3-PHASE
60–450
40–330
30–220
20–110
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 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.
Weld Ammeter and Voltmeter
#195 131 Field
Panel-mounted AC/DC analog meters to
monitor weld output.
Cold Weather Starting Aids*
#043 959 Field
12 V intake manifold heater.
#195 086 Field
120 V oil pan heater element.
*For extreme cold weather both starting aids
can be used in conjunction.
Engine Filter Kit #246 988 Field
Includes all filters required for proper
engine maintenance. Oil filter, primary and
secondary fuel filter, and primary air filter.
Compressor Filter Kit #246 991 Field
Includes all filters required for proper
compressor maintenance. Oil filter, air filter
and coalescing filter.
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.
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!
Protective cover cannot be used with cable holder.
Protective Cover
#194 683 Field
Blue water-resistant
canvas cover resists
stains and mildew,
and protects the
finish of your welder.
Note: Protective 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
2/0 Stick Cable Set, 50 ft (15 m)
#173 851
Consists of 50 ft (15 m) 2/0 electrode cable
with holder, and 50 ft (15 m) work cable
with clamp. 350 A, 100% duty cycle.
2/0 Stick Cable Set, 100/50 ft (30.5/15 m)
#043 952
Consists of 100 ft (30.5 m) 2/0 electrode
cable with holder, and 50 ft (15 m) work
cable with clamp. 300 A, 100% duty cycle.
Plasma Cutting
Spectrum®375 X-TREME™#907 339
Comes complete with protective X-CASE™
(not shown). See Lit. Index No. PC/9.2.
Spectrum®625 X-TREME™#907 404
Comes complete with protective X-CASE™
(not shown). See Lit. Index No. PC/9.6.
Spectrum®875 #907 390-01-1
See Lit. Index No. PC/9.8.

5
Genuine Miller Accessories (continued)
MIG/Flux Cored Welding
SuitCase®X-TREME™8VS Wire Feeder
#951 182
SuitCase®X-TREME™12VS Wire Feeder
#951 184
Lightweight, portable, voltage-sensing
wire feeders include secondary contactor
and gas valve and drive roll kit. See Lit.
Index No. M/6.41.
SuitCase®8RC Wire Feeder #951 186
SuitCase®12RC Wire Feeder #951 188
Lightweight and flexible enough to run a
variety of wires up to .062 in diameter.
Includes remote voltage control and drive
roll kit. See Lit. Index No. M/6.5.
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 #242 211 020
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 control for 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 or 24 VAC Wire Feeders
#242 208 025 25 ft (7.6 m)
#242 208 050 50 ft (15.2 m)
#242 208 080 80 ft (24.4 m)

6
4 West Four-Wheel Steerable
Off-Road Trailer #042 801
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: Trailer is shipped unassembled.
HWY-224 Trailer
#043 805 For highway use.
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.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords.
Dual Hitch #300 831
2 in (50 mm) ball hitch and 3 in (76 mm)
lunette eye in one reversible assembly.
Trailers and Hitches
Trailer Specifications (Subject to change without notice.)
Gross Vehicle
Weight Rating
3000 lb
(1361 kg)
2960 lb
(1343 kg)
Gross Axle
Weight Rating
2000 lb/axle
(907 kg/axle)
3500 lb
(1588 kg)
Height
of Bed
21-1/4 in
(540 mm)
18-1/2 in
(470 mm)
Road
Clearance
8 in
(203 mm)
7-1/2 in
(191 mm)
Net
Weight
430 lb
(195 kg)
320 lb
(145 kg)
Track (Center
to center of
tires)
55-1/4 in
(1403 mm)
52 in
(1321 mm)
Standard Tires
(Standard rating
or P-size rating)
B78-13
B78-13
Dimensions
Length: 91 in (2311 mm)*
Width: 61-1/4 in (1556 mm)
Length: 105 in (2667 mm)
Width: HWY– 59-1/2 in (1511 mm)**
OFR–58-7/16 in (1484 mm)
*Does not include tongue. **Width at outside of fenders.
Model
4-West
HWY-224
OFR-224
Net
Payload
2570 lb
(1166 kg)
2650 lb
(1202 kg)
Mounting Specifications
4 holes
H
Front Panel
E
F
G
D
AB
C
Height: 50 in (1270 mm) (to top of exhaust)
Width: 28-1/2 in (724 mm)
(mounting brackets turned in)
30-3/4 in (781 mm)
(mounting brackets turned out)
Depth: 69-1/2 in (1765 mm)
*With mounting brackets in center position.
Dimensions vary with location of mounting brackets.
A. 29-13/16 in (757 mm)
B. 27-1/2 in (699 mm)
C. 1 in (25 mm)
D. 11-5/8 in (295 mm)*
E. 46-3/8 in (1178 mm)*
F. 58 in (1473 mm)*
G. 69-1/2 in (1765 mm)
H. 9/16 in (14 mm) dia.

7
MIG Gun
Work
SuitCase
8RC/12RC
Work
Stick Electrode
Work
Flux Cored Gun
Aluminum MIG with
Spoolmatic 30A Gun
Work
Cutting Torch
W
o
rk
Spectrum
14-Pin
14-Pin WC-24
TIG
Torch
Work
14-Pin
HF-251D-1
X-TREME 8VS/
X-TREME 12VS
Feeder
Plasma Basic Equipment
Spectrum®375 X-TREME™#907 339
Spectrum®625 X-TREME™#907 404
Spectrum®875 #907 390-01-1
Stick (SMAW) Basic Equipment
Flux-Cored (FCAW) Basic Equipment
SuitCase®X-TREME™ 8VS #951 182
SuitCase®X-TREME™12VS #951 184
MIG (GMAW) Basic Equipment
SuitCase®8RC #951 186
SuitCase®12RC #951 188
Aluminum MIG (GMAW) Basic Equipment
Spoolmatic®30A #130 831
WC-24 #137 549
TIG (GTAW) Basic Equipment
Dynasty®200 Series
HF-251D-1 #042 388*
*TIG power cable adapter required
Typical Installations

Litho in USA
Distributed by:
Equipment and Factory Options Stock No. Description Qty. Price
Big Blue®Air Pak™CC/CV #907 062 Base Model—Automatic Idle, Engine Gauges, 5.5 kW AC Generator,
12 V Intake Manifold Heater
#907 062-01-1 International Model— 50/60 Hz, Dry Battery, Automatic Idle,
Engine Gauges, 5.5 kW AC Generator
#907 062-04-1 Cold Weather Model — 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
#907 062-07-1 Deluxe Model — 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,
AC/DC/Battery Charge/Jump-Start Switch, 20 kW Generator,
Field Accessories
Desiccant Air Dryer System #195 117 Removes moisture from air supply
AC/DC/Battery Charge/Jump-Start Switch #195 148
Weld Ammeter and Voltmeter Kit #195 131 AC/DC analog weld output meters
Cold Weather Starting Aids #043 959 12 V intake manifold heater
#195 086 120 V oil pan heater
Engine Filter Kit #246 988 Includes air, oil and fuel filters
Compressor Filter Kit #246 991 Includes air, oil and coalescing filters
Lockable Flame Arrestor Fuel Cap #043 947 Padlock not included
Vandalism Lockout Kit #195 118 Lockable front control panel and engine compartment
Cable Holder #043 946 Stores up to 200 ft of 2/0 weld cable
Battery Lockout/Tagout Disconnect Switch #195 120 Allows machine battery to be disconnected and locked
Protective Cover #195 159 Will not fit over machine with cable holder attached
Stick Welding Leads See page 4
Plasma Cutting
Spectrum®375 X-TREME™#907 339 Includes X-CASE™. See Lit Index No. PC/9.2
Spectrum®625 X-TREME™#907 404 Includes X-CASE™. See Lit Index No. PC/9.6
Spectrum®875 #907 390-01-1 See Lit Index No. PC/9.8
MIG/Flux Cored Welding
SuitCase®X-TREME™8VS and 12VS #951 182/#951 184 See Lit Index No. M/6.41
SuitCase®8RC and 12RC #951 186/#951 188 See Lit Index No. M/6.5
Spoolmatic®30A Spool Gun #130 831 Requires WC-24 Control. See Lit. Index No. M/1.73
WC-24 Control #137 549 See Lit. Index No. M/1.5
XR™Wire Feeder Control and Guns See Lit. Index No. M/1.7, M/1.71, and M/1.73
MIG (GMAW)/Flux Cored (FCAW) Guns See Lit Index Nos. AY/15.0, AY/16.0 and AY/17.0
TIG Welding
Dynasty®200 Series See Lit. Index No. AD/4.8
HF-251D-1 #042 388 High frequency unit for AC TIG welding. See Lit. Index No. AY/5.0
Coolant System See Lit. Index No. AY/7.2
Remote Controls and Switches See page 5
Trailers and Hitches
4-West Trailer #042 801 Off-road steerable trailer with 2570 (1166 kg) capacity
HWY-224 Trailer #043 805 Highway trailer with 2650 lb (1202 kg) capacity
OFR-224 Trailer #043 802 Off-road trailer with 2650 lb (1202 kg) capacity
Cable Tree #043 826 Trailer mounted cable holder for HWY-224 or OFR-224
Dual Hitch #300 831 Combination 2 in (50 mm) ball hitch and 3 in (76 mm) lunette eye in one
reversible assembly. For HWY-224 or OFR-224
Date: Total Quoted Price:
Ordering Information