Welding Resource and Product Guide for the Rental Industry

Transcription

1 with you Welding Resource and Product Guide for the Rental Industry Rental Hotline MillerWelds.com 208

2 Understanding Welding Processes Experience the freedom of Auto-Line Now you can set yourself free from the handcuffs of primary power limitations. With Miller s patented Auto-Line technology, primary power management begins at the plug. And ends in your wallet. You get: Better weld quality, uninterrupted production Universal location flexibility: plug in anywhere Lower primary amperage draw More welding output on 5 V primary Lower utility bills and potential for rebates NOT a linking technology Only Miller inverters feature Auto-Line. And make no mistake: Auto-Line significantly raises the performance bar over the older technology of automatic linking. With automatic linking, the power source senses the incoming voltage and automatically configures or links the power switching transistors for 230 or 460 V primary. While a step up from removing the machine cover and manually linking jumpers, it still involves mechanical components that are subject to failure. And it can t compensate for voltage spikes or dips beyond ±0 % of nominal. Primary power management Auto-Line lets you manage primary power for the first time ever. No longer do you have to accept what comes out of the receptacle. Auto-Line provides so many benefits because it essentially enables the welder or plasma cutter to create its own source of primary power. Here s how it works: Auto-Line technology uses what s known as a boost converter. This circuit boosts primary input power from 5 to 575 V or anywhere in between to a higher voltage. This voltage then charges a capacitor, which is a device used to store and quickly discharge energy. Power for the actual inverter section of the welder comes from this capacitor. In short, it s like drawing water from a well that s always full. Auto-Line Steady Welding Arc Primary Power Flexibility The Auto-Line circuit boosts primary power to a higher, constant voltage. Even if incoming voltage varies widely, the Auto-Line circuit ensures a rock-steady welding or cutting arc. RENTING Multioperator Welders Multioperator welding systems from Miller are the key to industrial and multi-arc welding rental opportunities. Portable, compact, single primary, versatile, simplified inventory, easy maintenance, and low cost-per-arc are all reasons that make multioperator welders the most efficient welding systems for multi-arc industrial welding rentals. Shutdown repair work at mills, utilities and processing plants, or new construction on highrises and stadiums, all need the same thing: a large number of arcs in a concentrated area. If your customers want to setup fab shops or welding stations on the job site, then let them know that you ve got an unbeatable solution: multioperator welders from Miller. Portability up to eight arcs transported in one lightweight unit cuts down on transportation costs. Lift eyes, fork pockets and even running gear enable units to be moved easily from location to location. An XMT 4-pack rack only weighs 560 lb and fits in a freight elevator. This means there s no delay when moving an inverter. When you see someone who needs welding power on the fifth floor immediately, you ve just spotted an XMT rental opportunity. Compact up to eight arcs in one combined unit can fit in the same footprint as a single diesel welder. These space-efficient systems are ideal for tight situations where multiple arcs are needed. Ideal for confined job sites and cramped construction elevators. Both can fit through a 36-inch door. Single primary from just a single primary power connection, users get four, six or eight independently controlled welding arcs. No wasting half a day waiting for an electrician to wire six separate units. Or tripping over a multitude of high-voltage primary power cables. Versatile systems come in four-, six- or eight-arc configurations. With the CST and XMT Racks, individual welders can be removed and used separately. System welding processes can range from quality Stick electrode welding up to full multiprocess capabilities on the XMT Rack. Simplify inventory maintain the same number of arcs, but in fewer machines by using multi-arc welders instead of separate units. This reduces inventory costs and storage. Easy maintenance Miller s outstanding welder reliability reduces maintenance costs and the rugged steel enclosures withstand the roughest environmental conditions. Individual inverter modules can be removed for maintenance. Low cost-per-arc the subject always comes back to cost. With multiple arcs in one unit, the cost-per-arc for multi-arc welders is far less expensive. Compared to one 500-amp trailered diesel engine drive, a conventional eight-pack multiple operator costs about five times less per arc (an inverter eight-pack welder is 5.5 times less). Multi-arc welders provide it all. If you are targeting industrial rentals, multioperator welding systems from Miller Electric are the answer. 2

3 Renting the Right Welding Equipment Asking the right questions What is the best welder for the job and location?. What is your customer doing with the welder? Welding See question 7. Cutting or gouging See question 8. Generating AC power See Understanding AC Power Generation on page 8. Other Call the toll-free Rental Hotline at ! 2. Where will the welder be used? Inside Requires plug-in welder or LP-powered gas drive or possible scrubber equipped diesel. Outside Usually gasoline- or diesel-driven welding generators are rented for most construction sites. Multioperator-type welders are commonly rented for large construction sites having many arcs. 3. Is (commercial) power available? Yes Usually if sufficient power is available electrical welders are a more suitable rental. No If no onsite power, rent gas- or diesel-powered welders or rent large power generators and plug-in electrical welders or multioperator welders. 4. What voltage and phase is available power? The machine has to match the available power. Is power 20, 240, 460 V, etc. and is it single- or three-phase? Machine requires single-phase input power, typically found in homes and garages. Machine requires three-phase input power which is common in industrial settings, but shops can be specially wired to supply threephase, industrial power. 5. What is the duty cycle needed? Duty cycle relates to how long a machine can continuously operate without damaging the system. NEMA guidelines base the duty cycle rating on the number of minutes out of a ten-minute period an arc welding machine can be operated at maximum rated output. For example, a XMT 304 has 60% duty cycle at 300 amps of DC output. It can weld for six minutes out of 0, and then needs to cool for the remaining four minutes. Extensive arc-on time and/or high-amperage welding requires a welder with a higher duty cycle. If a welder is operated below its rated output, the duty cycle typically increases. Also see Welding Terminology on page 9 and 0 for duty cycle definition. 6. Is portable equipment required? Hand-portable power sources If welders are to be moved by hand portable welding/cutting machines under 80 lb are usually required. Gasoline-driven power sources Usually mounted on running gear for onsite movement by hand. Diesel-driven power sources Usually trailer-mounted and moved onsite by truck. Multioperator power sources Usually moved onsite by crane or lift truck. For high-rise structures check if they are to be moved and fit into temporary construction elevators. 7. If welding, what process is used? Stick electrode welding The most common process used by rental customers and contractors involved in construction welding. See page 2 for more information. MIG wire welding Integrated wire welders commonly sold by rental companies. Usually requires shielding gas. See page 4 for more information. Flux Cored wire welding Gasless type wire welding commonly used in construction type welding. Usually requires 250 A or larger welder. See page 4 for more information. TIG heliarc welding Most commonly used in installation welding during later stages of construction project. Contractors usually supply accessories. See page 4 for more information. 8. Is the customer cutting or gouging? Plasma arc cutting A cutting process requiring special machines and compressed air. See page 3 for process information. Air Carbon Arc gouging A cutting process usually requiring high amperage, compressed air and special torch. See page 3 for more information. Have you tried the Miller Extranet? You can access these sites: 24/7, 365 days of the year! Here is some of what you will find on the Extranet: Pricing and availability Account balances Electronic warranty claims/inquire Order status and tracking Invoice detail Technical manuals/documents Warranty information Parts catalog Training courses Sales/Freight policies ecommerce (Miller U.S. only) Personalized price files (Hobart only) Surcharges/Test charges (Hobart only) Product certificate of conformance forms (to prepare your own certificates) (Hobart only) Miller : Visit ; click "Partner Login" on the top left of the screen under the Miller logo. You can login with your address and password or register for access. Use the Extranet to quickly and easily submit a warranty claim. If you have questions or need assistance please contact us at 800-4A-Miller. 3

4 Welding Terminology Miller technology exclusive Accu-Rated Power The standard for measuring engine-driven generator power. Guarantees delivery of all power promised. Miller technology exclusive Active Arc Stabilizer Enhances arc starts and provides a softer arc throughout all ranges, with less puddle turbulence and less spatter. Miller technology exclusive Adaptive Hot Start Automatically increases the output amperage at the start of a Stick weld, should the start require it. Helps eliminate sticking of the electrode at arc start. Miller technology exclusive Advance Active Field Control Technology A simple and reliable patented way of accurately controlling an engine drive s generator weld output. Air Carbon Arc Cutting (CAC-A) A cutting process by which metals are melted by the heat of an arc using a carbon electrode. Molten metal is forced away from the cut by a blast of forced air. Consumables: carbon electrodes, compressed air supply Alternating Current (AC) An electrical current that reverses its direction at regular intervals, such as 60 cycles alternating current (AC), or 60 hertz. Amperage The measurement of the amount of electricity flowing past a given point in a conductor per second. Current is another name for amperage. Arc The physical gap between the end of the electrode and the base metal. The physical gap causes heat due to resistance of current flow and arc rays. Miller technology exclusive Arc-Drive Automatically enhances Stick welding, especially on pipe, by focusing the arc and preventing the electrode from going out. Miller technology exclusive Auto-Line Allows for any primary input voltage within a range, single- or three-phase, 50 or 60 Hz. Also adjusts for voltage spikes within the entire range. Miller technology exclusive Auto-Link Internal inverter power source circuit that automatically links the power source to the primary voltage being applied (230 V or 460 V), without the need for manually linking primary voltage terminals. Miller technology exclusive Automatic Start at Idle Idles engine immediately when started, extending engine life and reducing fuel consumption and noise. Miller technology exclusive Auto Remote Sense Automatically switches machine from panel to remote control with remote connected. Eliminates confusion and need for panel/remote switch. Constant Current (CC) Welding Machine Most commonly used for STICK and TIG welding. Constant-Speed Wire Feeder Feeder operates from 24 or 5 VAC supplied by the welding power source. Constant Voltage (CV) Welding Machine This type of welding machine output maintains a relatively stable, consistent voltage regardless of the amperage output. Most commonly used for MIG welding. Current Another name for amperage. The amount of electricity flowing past a point in a conductor every second. Defect One or more discontinuities that cause a testing failure in a weld. Dig Also called Arc Control. Gives a power source variable additional amperage during low voltage (short arc length) conditions while welding. Helps avoid sticking stick electrodes when a short arc length is used. Direct Current (DC) Flows in one direction and does not reverse its direc tion of flow as does alternating current. Direct Current Electrode Negative (DCEN) The specific direction of current flow through a welding circuit when the electrode lead is connected to the negative terminal and the work lead is connected to the positive terminal of a DC welding machine. Also called direct current, straight polarity (DCSP). Direct Current Electrode Positive (DCEP) The specific direction of current flow through a welding circuit when the electrode lead is connected to a positive terminal and the work lead is connected to a negative terminal to a DC welding machine. Also called direct current, reverse polarity (DCRP). Duty Cycle The number of minutes out of a 0- minute time period a welding machine can be operated at maximum rated output. An example would be 60% duty cycle at 300 amps. At 300 amps the welding machine can be used for 6 minutes and then must be allowed to cool with the fan motor running for 4 minutes. Miller technology exclusive Fan-On-Demand Internal power source cooling system that only works when needed, keeping internal components cleaner. Flux Cored Arc Welding (FCAW) An arc welding process which melts and joins metals by heating them with an arc between a continuous, consum able electrode wire and the work. Shielding is obtained from a flux contained within the electrode core. Added shielding may or may not be provided from externally supplied gas or gas mixture. Consumables: contact tips, flux cored wire, shielding gas (if required, depends on wire type) Ground Connection A safety connec tion from a welding machine frame to the earth. See Workpiece Connection for the difference between work connection and ground connection. Ground Lead When referring to the connection from the welding machine to the work, see preferred term Workpiece Lead. Miller technology exclusive Gun-On-Demand Allows you to use either a standard gun or a Spoolmatic gun on the Millermatic 20, 25, and 350 without flipping a switch. The machine senses which gun you are using when you pull the trigger. Hertz Hertz is often referred to as cycles per second. In the United States, the frequency or directional change of alternating current is usually 60 hertz. High Frequency Covers the entire fre quency spectrum above 50,000 Hz. Used in TIG welding for arc ignition and stabilization. Miller technology exclusive Hot Start Used on some Stick (SMAW) machines to make it easier to start difficult-to-start electrodes. Used for arc starting only. Inverter Power source which increases the frequency of the incoming primary power, thus providing for a smaller size machine and improved electrical character istics for welding, such as faster response time and more control for pulse welding. KVA (Kilovolt-amperes) The total volts times amps divided by,000, demanded by a welding power source from the primary power furnished by the utility company. KW (Kilowatts) Primary KW is the actual power used by the power source when it is producing its rated output. Secondary KW is the actual power output of the welding power source. Kilowatts are found by taking volts times amps divided by,000 and taking into account any power factor. Miller technology exclusive Lift-Arc This feature allows TIG arc starting without high frequency. Starts the arc at any amperage without contaminating the weld with tungsten. Miller technology exclusive Low OCV Stick Reduces OCV when power source is not in use, eliminating need for add-on voltage reducers. Miller technology exclusive LVC (Line Voltage Compensation) Keeps the output of a power source constant, regard less of minor fluctuations in input power. MIG (GMAW or Gas Metal Arc Welding) An arc welding process which joins metals by heating them with an arc. The arc is between a continuously fed filler metal (consumable) electrode and the workpiece. Externally supplied gas or gas mixtures provide shielding. Consumables: contact tips, shielding gas, welding wire Miller technology exclusive MVP (Multi-Voltage Plug) Allows connection of Millermatic Passport to 5- or 230-volt receptacles without tools just choose the plug that fits the receptacle. 4

5 Welding Terminology Open-Circuit Voltage (OCV) As the name implies, no current is flowing in the circuit because the circuit is open. The voltage is impressed upon the circuit, however, so that when the circuit is completed, the current will flow immediately. For example, a welding machine that is turned on but not being used for welding at the moment will have an open-circuit voltage applied to the cables attached to the output terminals of the welding machine. Plasma Arc Cutting An arc cutting process which severs metal by using a constricted arc to melt a small area of the work. This process can cut all metals that conduct electricity. Miller Spectrum cutters are complete packages that contain all required equipment and torch consumables. Consumables: torch consumables, gas or compressed air supply Plasma Arc Cutting Terms Quality Cut Refers to the maximum good quality cut achieved at a speed slower than 0 inches per minute. Rated Cut Based on traveling 0 inches per minute to achieve a steady, precise cut. This is the key rating that should meet or exceed your typical cutting thickness requirements. Sever Refers to the maximum cut achieved in ideal conditions. Pounds Per Square Inch (psi) A measurement equal to a mass or weight applied to one square inch of surface area. Power Efficiency How well an electrical machine uses the incoming electrical power. Power Factor Correction Normally used on single-phase, constant current power sources, to reduce the amount of primary amperage demanded from the power company while welding. Primary Power Often referred to as the input line voltage and amperage available to the welding machine from the shop s main power line. Often expressed in watts or kilo watts (KW), primary input power is AC and may be single-phase or three-phase. Welding machines with the capability of accepting more than one primary input voltage and amperage must be properly connected for the incoming primary power being used. Pulsed MIG (MIG-P) A modified spray transfer process that produces no spatter because the wire does not touch the weld puddle. Applications best suited for pulsed MIG are those currently using the short circuit transfer method for welding steel, 4 gauge (.8 mm) and up. Consumables: contact tips, shielding gas, welding wire Pulsed TIG (TIG-P) A modified TIG process appropriate for welding thinner materials. Consumables: tungsten electrode, filler metal, shielding gas Pulsing Sequencing and controlling the amount of current, the frequency, and the duration of the welding arc. Rated Load The amperage and voltage the power source is designed to produce for a given specific duty cycle period. For example, 300 amps, 32 load volts, at 60% duty cycle. RMS Root Mean Square. The effective values of measured AC voltage or amperage. RMS equals times the maximum, or peak value. Shielding Gas Protective gas used to prevent atmospheric contamination of the weld pool. Single-Phase Circuit An electrical circuit producing only one alternating cycle within a 360 degree time span. Miller technology exclusive Smart Fuel Tank Tank s design minimizes chance of fuel backflow. Smooth Start patent-pending technology provides a smooth, spatter-free start. Spatter The metal particles blown away from the welding arc. These particles do not become part of the completed weld. Spot Welding Usually made on materials having some type of overlapping joint design. Can refer to resistance, MIG or TIG spot welding. Resistance spot welds are made from electrodes on both sides of the joint, while TIG and MIG spots are made from one side only. Squarewave The AC output of a power source that has the ability to rap idly switch between the positive and negative half cycles of alternating current. Stick Welding (SMAW or Shielded Metal Arc) An arc welding process which melts and joins metals by heating them with an arc, between a covered metal electrode and the work. Shielding gas is obtained from the electrode outer coating, often called flux. Filler metal is primarily obtained from the electrode core. An AC/DC welder is recom mended for Stick. For most applications, DC reverse polarity welding offers advan tages over AC, including easier starts and out-of-position welding, smoother arc and fewer arc outages and sticking. Consumables: stick electrodes Three-Phase Circuit An electrical circuit delivering three cycles within a 360 degree time span, and the cycles are 20 electrical degrees apart. TIG Welding (GTAW or Gas Tungsten Arc) Often called TIG welding (Tungsten Inert Gas), this welding process joins metals by heating them with a tungsten electrode which should not become part of the completed weld. Filler metal is sometimes used and argon inert gas or inert gas mixtures are used for shielding. Consumables: tungsten electrode, filler metal, shielding gas Miller technology exclusive Tip Saver Short Circuit Protection Shuts down output when the MIG contact tip is shorted to the work, on the Millermatic 40 and 80. Extends contact tip life and protects machine. Trigger Reset permits quick reset at gun rather than at machine. Torch A device used in the TIG (GTAW) process to control the position of the electrode, to transfer current to the arc, and to direct the flow of shielding gas. Touch Start A low-volt, low-amp arc starting procedure for TIG (GTAW). The tungsten is touched to the workpiece; when the tungsten is lifted from the workpiece an arc is established. Miller technology exclusive Tri-Cor Technology Stabilizer design on the Bobcat 250 that delivers smoother welds and decreased spatter with E708 electrodes, without sacrificing performance with E600 electrodes. Tungsten Rare metallic element with extremely high melting point (340 C). Used in manufacturing TIG electrodes. Voltage The pressure/force that pushes the electrons through a conductor. Voltage doesn t flow, but causes amperage/current to flow. It is sometimes termed electro motive force (EMF) or difference in potential. Voltage-Sensing Wire Feeder Feeder operates from arc voltage generated by welding power source. Volt/Amp Curve Graph that shows the output characteristics of a welding power source. Shows volt and amp capabilities of a specific machine. Weld Metal The electrode and base metal that was melted while welding. This forms the welding bead. Weld Transfer Method by which metal is transferred from the wire to the molten puddle. There are several transfer methods used in MIG; they include: short circuit, spray arc, globular, buried arc, and pulsed arc. Miller technology exclusive Wind Tunnel Technology Internal air flow on many Miller inverters, that protects electrical components and PC boards from contamination, significantly improving reliability. Wire Feed Speed Expressed in in/min or mm/s, and refers to the speed and amount of filler metal fed into a weld. Generally speaking the higher the wire feed speed, the higher the amperage. Workpiece Connection A means to fasten the work lead (work cable) to the work (metal to be welded on). Also, the point at which this connection is made. One type of work connection is made with an adjustable clamp. Workpiece Lead The conductor cable or electrical conductor between the arc welding machine and the work. 5

6 Understanding Welding Processes Stick Electrode Welding (SMAW) Stick electrode welding is the most common process used in the rental construction industry. Constant-current (CC) DC power source is recom mended. Better for windy, outdoor conditions. More forgiving when welding on dirty or rusty metal. Use a drag technique for most applications. Take precautions with flying materials when chipping slag. Keep electrodes clean and dry follow manufacturer s recommendations. DCEP (also known as DC reverse polarity) welding offers advan tages over AC, including easier starts and out-of-position welding, smoother arc and fewer arc outages and sticking. Definition And General Description Shielded Metal Arc Welding (SMAW) is defined by the American Welding society (AWS) as an arc welding process with an arc between a covered electrode and the weld pool. The process uses a disposable electrode with a flux coating. As the weld is made the flux burns off to provide shielding for the weld while the electrode provides the filler metal. Shielded Metal Arc Welding, also called Stick Welding, is one of the most widely used processes, particularly for short welds in production, maintenance and repair work, and for field construction. The process has many advantages: The equipment is relatively simple, inexpensive, and portable. The filler metal, and the means of protecting it and the weld metal from harmful oxidation during welding, are provided by the covered electrode. Auxiliary gas shielding or granular flux is not required. The process is less sensitive to wind and draft than gas shielded arc welding processes. It can be used in areas of limited access. The process is suitable for most of the commonly used metals and alloys. The SMAW arc is generated between the base metal and the cored wire that makes up the electrode. This electric arc produces enough heat, about 9000 F (5000 C), to melt both the base metal and electrode forming a weld pool. Small droplets of the core wire melt and transfer to the weld pool. Small droplets of the core wire melt and transfer to the weld pool providing additional metal to the weld pool. As the electrode covering is heated and melted, it produces gasses that protect the molten puddle from atmospheric contamination. the electrode covering also contains elements that help to stabilize the welding arc, clean the base metal, and provide a protective slag coating that helps form the weld bead as well as protect it from the atmosphere. Shielding Atmosphere Solidified Slag Base Metal Setting Current Electrode Covering Core Wire Arc Solidified Weld Metal SMAW Arc Metal and Slag Droplets Weld Pool Penetration Depth The amount of current needed to weld a part depends on several factors, including type and position of joint, metal type and thickness, and electrode type and diameter. with experience, the operator is able to determine how much current is needed for the job at hand. For inexperienced operators there are several ways to establish a starting point for setting current. Principles of Operation Shielded Metal Arc Welding occurs when a constant current, high amperage, low voltage welding power supply generates an electric arc between an electrode and the workpiece. Using a welding power supply that generates a constant current high amperage low voltage welding arc. Here are the basic components needed for the welding process: Constant current welding power source Welding and work cables (electrode and work leads) Work clamp Electrode holder Covered welding electrodes ELECTRODE 708 DIAMETER 3/32 /8 5/32 3/6 7/32 / Unit requires single-phase input power Unit requires three-phase input power Unit supplies alternating current weld output Unit supplies direct current weld output SMAW Electrode Core Diameter AMPERAGE RANGE Power Icons Unit supplies alternating current and direct current weld output Unit supplies constant current weld output Unit supplies constant voltage weld output Unit supplies constant current and constant voltage weld output

7 Understanding Welding Processes Stick Electrode Welding (SMAW) Power Source There are two types of welding power sources used for the electric arc welding processes: constant current and constant voltage. The Shielded Metal Arc Welding process requires a constant current welding power source. This type of welding power source requires the operator to set welding amperage. The source may be any of the types: transformer, transformer-rectifier, inverter, or engine-driven. Electrode Holder Part of the basic welding circuit is the electrode holder. It is basically a clamping device for holding the electrode with an insulated handle for the operator to grasp. Electrode holders are rated according to their current capacities. Ratings of 50 amps through 600 amps are commonly available. Each electrode holder will accommodate cable sizes appropriate for its rated capacity. The holder should be as light-weight as possible and be well balanced to provide the operator good manipulative control. The jaws of clamp type electrode holders normally have several grooves which allow the electrode to be positioned at a comfortable angle for welding. The Bernard Shortstub or twist type holders require the operator to bend the electrode to the desired angle. Clamp Style Electrode Holder Welding Power Source Work Cable Work Clamp Electrode Cable Electrode Electrode Holder SMAW System Work Clamps The work clamp is a fundamental part of the welding circuit. A connection must be made from the work cable to the work. Different types of work clamps are shown to the right. Like the electrode holder, the work clamps are rated in amperage capacity. Another method of work connection is to secure the cable lug to the workpiece or workbench. The lug can be bolted or securely clamped to the workpiece or table. Regardless of the method used to Various Work Clamp Styles make the work connection, it is very important that there is a good firm contact. Many welding problems are related to a poor welding circuit caused by poor contact surfaces or a weakened clamp spring. Welding Cables The welding cables and connectors connect the welding power source to the electrode holder and the work. These cables are normally made of copper. The cable consists of hundreds of fine wires enclosed in an insulated casing of SMAW Cables natural or synthetic rubber. The cable connecting the work to the power source is called the work cable and is usually connected to the work by a clamping device or bolts. The cable connecting the electrode holder to the power source is called the electrode cable. 7

8 Understanding Welding Processes MIG Welding (GMAW) Welding Power Source Wire Feeder Volt Sense Lead Electrode Cable Torch Work Cable Volt Sense Clamp Work Work Clamp Feeder 2 VS Short Circuit Transfer Short Circuit Gas Metal Arc Welding (GMAW-S) is defined by the American Welding Society (AWS) as a gas metal arc welding process variation in which the consumable electrode is deposited during repeated short circuits. During Short Circuit Transfer, a metal droplet forms at the tip of the electrode wire. As the droplet grows, the arc length decreases until the droplet comes in contact with the weld puddle. Short Circuit Transfer This causes a short circuit which extinguishes the arc. The droplet then pinches off to form part of the puddle, allowing a new arc to form. Depending on the amperage/voltage relationship this cycle repeats about 20 times per second. Short Circuit transfer is commonly used to weld carbon steels and some stainless steels in thin to medium thicknesses of plate and pipe. Carbon dioxide shielding gas is used for most short circuit welding. However, a mixture of argon and carbon dioxide produces a more stable arc. GMAW Electrode Wires The electrode wire for Gas Metal Arc Welding is typically solid. Steel wires normally have a thin copper coating to improve electrical pickup and protect the wire from oxidation. The wire size is determined by its diameter. Various diameters are available based on the metal transfer, welding position, and application. The wire is contained on spools, coils and reels and packed in special containers for protection against moisture and contamination. Self-Shielded Flux Cored Arc Welding (FCAW-S) System Flux Cored Arc Welding (FCAW) Flux Cored Arc Welding (FCAW) is defined by the American Welding Society (AWS) as an arc welding process that uses an arc between a continuous filler metal electrode and the weld pool. The process is used with shielding gas from a flux contained within the tubular electrode, with (FCAW-G) or without (FCAW- S) additional shielding from an externally supplied gas, and without the application of pressure. The flux cored arc welding process is capable of welding carbon and alloy steels, cast iron and some stainless steels. The process is also capable of producing hard surfacing deposits. The process is most commonly used to weld medium to thick steels because of the high deposition rates obtained with larger electrode diameters. Welding is typically limited to the flat and horizontal positions with large diameter wires (3/32 in. and greater [2.4 mm]). Smaller diameter wires (less than 3/32 in. [2.4 mm]) can be used in all positions. A layer of slag is produced on the weld bead which must be removed after welding arc. Uses the same equipment as MIG welding and works as well as Stick on dirty, rusty material. Gasless Flux Cored wire welding is the most common process in construction. Requires CV (constant-voltage) power source, portable wire feeder and gasless gun. Self-shielded Flux Cored doesn t require an external cylinder of shielding gas (shielding is in the wire). This is useful for outside work, where external shielding gas could be blown away. The weld is similar to Stick welding, where slag must be removed from the weld after welding. Use a chipping hammer and a wire brush. Self-shielded Flux Cored is generally harder to accomplish on thin metals than MIG welding. Provides deep penetration for welding thick sections and increased metal deposition rate. Use a drag (pull) gun technique. Keep the wire clean and dry for best weld results. 8

9 Understanding Welding Processes Gas Tungsten Arc Welding (GTAW) Gas Tungsten Arc Welding (GTAW) is defined by the American Welding Society (AWS) as an arc welding process that uses an arc between a tungsten electrode (nonconsumable) and the weld pool. The process is used with shielding gas and without the application of pressure. Common names used to refer to Gas Tungsten Arc Welding are TIG and Heliarc welding. The gas tungsten arc welding process can be used to weld any weldable metal including steel, aluminum, magnesium, copper, nickel, titanium and others. The process can be used on a wide range of metal thicknesses and in all welding positions. However, due to the relatively low deposition rates associated with the process, thinner materials are most often welded. It is also popular for depositing the root and hot passes on pipe and tubing. Since a shielding gas is used, the weld is clearly visible to the welder, no spatter is produced, post weld cleaning is reduced, and slag is not present. Filler Metal Etched Oxides (AC) Tungsten Electrode Arc Base Metal GTAW Welding Arc Gas Nozzle Shielding Gas Molten Puddle Solidified Weld Metal Plasma Arc Cutting (PAC) Note: See process equipment diagram below. Quality cutting process produces clean, fast and warp-free cuts on all electrically conductive metals. Requires special power source and torch plus compressed air (6 7 cfm at 70 psi). Used primarily for difficult-to-cut alloy materials such as aluminum and stainless. Fast cuts virtually eliminate warping and help prevent paint damage. Clean and dry, oil-free air is important. Stay at recommended air pressure (more air is not necessarily better!) Welding Torch The Gas Tungsten Arc Welding torch holds the tungsten electrode and directs the shielding gas and welding power to the arc. Air-cooled torches are designed for light duty welding up to 50 amperes. Water cooled torches are used for heavy duty welding up to 600 amperes. The torches come GTAW Torch equipped with a cable assembly which directs the gas, welding current, and coolant (when used) from the power source to the torch. The Gas Tungsten Arc Welding torch can deliver the shielding gas in two basic ways. The standard collet body delivers adequate shielding gas to perform the welding process, and a gas lens provides a smooth and more stable means to shield the weld pool. Air Carbon Arc Gouging (CAC-A) Note: See process equipment diagram below. In the rental construction industry, gouging usually involves a 400 amp diesel welder powering a 3/8 in carbon to rapidly rough cut structural steel. Requires power source and special electrode holder plus compressed air (to 35 cfm at 90 PSI). Creates a high-pressure air jet that blows molten metal away. Often used for weld joint preparation, rough cutting and removal of unwanted metal. Keep as short of a stickout as possible with the electrode in order to obtain the best air flow at the arc. Carbon sizes used are determined by the output of the machine. Constant-current (CC) or constant-voltage (CV) machines can be used for CAC-A. Air Compressor (to 35 cfm at 90 psi) Torch Work Work Clamp Power Source Typical CAC-A Up to 3/6 in carbon (Bobcat 250) gouging Up to 5/6 in carbon (Big Blue 300) machines Up to 3/8 in carbon (Big Blue 400 or 500) Suggested 3/6 in carbon ( Amps), /4 in carbon ( Amps) carbon electrode 5/6 in carbon ( Amps), 3/8 in carbon ( Amps) current ranges Note: Ranges are for DC Electrode with DCEP. Air Carbon-Arc Amperage Guide Suggested Current Ranges For Commonly Used Electrode Types and Sizes Electrode DC Electrode With AC Electrode With AC Electrode With Diameter DCEP AC DCEN Minimum Maximum Minimum Maximum Minimum Maximum in. mm. Amps Amps Amps Amps Amps Amps / / / / / / / / /

10 Understanding AC Power Generation Engine-Driven welder/generators When you fleet a Miller engine-driven product you get an AC power generator too! All Miller engine-driven products are designed to produce AC power, so now you have a dualpurpose machine; a welder which can be cross-rented as an AC power generator. This dual function becomes more important in times of major power outages when demand for generators, especially in the ,000 watt range, exceeds the supply. The following charts show the AC power output of select engine-driven products and typical power usage of various tools, motors and appliances. Engine-Drive Blue Star 85 Bobcat 225 Bobcat 3 Phase Bobcat 250 Trailblazer 275 Trailblazer 325 Trailblazer 302 Air Pak Bobcat 250 LP Trailblazer 275 LP Bobcat 250 Diesel Trailblazer 325 Diesel Big Blue 350 PipePro Big Blue 450 Duo CST Big Blue 400 Pro Big Blue 500 Pro Big Blue 800 Duo Pro and Big Blue 800 Duo Pro SF Big Blue 800 Duo Air Pak Class Key: Light Industrial Industrial Heavy Industrial Class Stick MIG Flux-Cored* AC TIG DC TIG PAC** CAC-A Standard Welding Weldable Generator Amperage Portability Metals Power Range Optional lift eye, running gear Steel -Phase, 6,500 Watts DC -Phase, AC/CC,000 Watts DC/CC 3/6 -Phase, AC/CC,000 Watts DC/CC 3-Phase,,000 Watts 3/6 3/6 3/6 3/6 3/6 3/6 3/6 3/6 /4" 3/6 3/8 /2 /2 Lift eye, pickup mount, optional running gear, trailer Lift eye, pickup mount, optional running gear, trailer Lift eye, optional running gear, trailer Lift eye, pickup mount, optional trailer Lift eye, generally mounted on optional trailer Quality Key: Designed for this process Capable of this process (Indicates performance within rated output range of unit) Steel, aluminum, stainless Steel, aluminum, stainless Steel, stainless, aluminum Steel, stainless, aluminum Steel, stainless -Phase, CC,000 Watts CV -Phase, DC 2,000 Watts -Phase, DC 2,000 Watts -Phase, AC 3,000 Watts DC -Phase, CC,000 Watts CV -Phase, DC 2,000 Watts -Phase CC,000 Watts CV -Phase, 0-325DC 2,000 Watts -Phase DC 2,000 Watts Peak /3-Phase, DC 2,000 Watts -Phase, DC 0,000 Watts -Phase, DC 2,000 Watts 3-Phase, 5,000 Watts Continuous -Phase, DC 5,000 Watts 3-Phase, 27,000 Watts -Phase, DC 5,000 Watts 3-Phase, 27,000 Watts Contractor Tools Watt Usage Tool Hand Drill Circular Saw Table Saw Band Saw Air Compressor Electric Chain Saw Flood Lights Submersible Pump Centrifugal Pump High Pressure Washer Wet and Dry Vac Industrial Motor Split Phase Capacitor Start Induction Run Capacitor Start Capacitor Run Fan Rating Starting Watts /4 in 350 /2 in /2 in /4 in in in 2500 /2 HP /2 HP HP 0,500 /2 HP, 2 in 00 2 HP, 4 in 00 HID 25 Metal Halide 33 Mercury 000 Vapor gph gph 900 /2 HP 350 HP HP 900 Industrial Motors Watt Usage Lights Central Air Conditioner Rating /8 HP /2 HP /3 HP -/2 HP 5 HP -/2 HP 0 HP /8 HP /2 HP Appliances Watt Usage Appliance Rating Dishwasher Cool Dry Hot Dry Electric Range 6-in Element 8-in Element Microwave Oven 625 Watts Refrigerator or Freezer Automatic Washer Clothes Dryer Gas Electric Garage Door Opener /4 HP /3 HP Furnace Fan /8 HP /6 HP /4 HP /3 HP /2 HP 0,000 BTU 20,000 BTU 24,000 BTU 32,000 BTU 40,000 BTU Starting Watts , , Starting Watts Running Watts Running Watts , Running Watts on Bulb

11 Input Conductor/Weld Cable Sizing Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installation, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 20.2, 630., and Installation must meet all National and Local Codes have only qualified persons make this installation. Electrical Service Guide For XMT Pack Racks Input Voltage (V) Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil 2 3/0 2/0 4 4 Max Recommended Input Conductor Length In Feet (Meters) 67 (5) 67 (5) 237 (72) 37 (3) Min Grounding Conductor Size In AWG/Kcmil Reference: 204 National Electrical Code (NEC) (including article 630) If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 30.5(B)(6). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Electrical Service Guide For PipeWorx 350 FieldPro 4-Pack Racks Input Voltage (V) Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) 34 (4) 228 (70) 228 (70) Min Grounding Conductor Size In AWG/Kcmil Reference: 204 National Electrical Code (NEC) (including article 630) If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 30.5(B)(6). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Electrical Service Guide For PipeWorx 350 FieldPro 6-Pack Racks Input Voltage (V) Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil 2 2/0 4 4 Max Recommended Input Conductor Length In Feet (Meters) 67 (5) 237 (72) 37 (3) Min Grounding Conductor Size In AWG/Kcmil Reference: 204 National Electrical Code (NEC) (including article 630) If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 30.5(B)(6). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Electrical Service Guide For XMT Pack Racks Input Voltage (V)* Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) 365 () 439 (34) Min Grounding Conductor Size In AWG/Kcmil *Due to current demands, a rack containing XMT requiring 230/460 volt input power must be connected to 460 volt input power only. Reference: 204 National Electrical Code (NEC) (including article 630) If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 30.5(B)(6). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

12 Input Conductor/Weld Cable Sizing Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installation, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 20.2, 630., and Installation must meet all National and Local Codes have only qualified persons make this installation. Electrical Service Guide For XMT Pack Racks Input Voltage (V) Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) 34 (4) 34 (4) 228 (70) 228 (70) Min Grounding Conductor Size In AWG/Kcmil Reference: 204 National Electrical Code (NEC) (including article 630) If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 30.5(B)(6). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Selecting Cable Sizes* Turn Off power before connecting to weld output terminals. Do not use worn, damaged, underœ sized, or poorly spliced cables. Electrode Work NOTICE The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 00 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2cables x 00 ft). Use the 200 ft (60 m) column to determine cable size. 00 ft (30 m) or Less Welding 0-60% Duty Cycle 60-00% Duty Cycle Amperes AWG (mm 2 ) AWG (mm 2 ) Weld Cable Size** And Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 50 ft 200 ft 250 ft 300 ft 350 ft 400 ft (45 m) (60 m) (70 m) (90 m) (05 m) (20 m) 0-00% Duty Cycle AWG (mm 2 ) 00 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) (50) /0 (60) /0 (60) 50 3 (30) 3 (30) 2 (35) (50) /0 (60) 2/0 (70) 3/0 (95) 3/0 (95) (30) 2 (35) (50) /0 (60) 2/0 (70) 3/0 (95) 4/0 (20) 4/0 (20) (35) (50) /0 (60) 2/0 (70) 3/0 (95) 4/0 (20) 2x2/0 (2x70) 2x2/0 (2x70) 300 (50) /0 (60) 2/0 (70) 3/0 (95) 4/0 (20) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 350 /0 (60) 2/0 (70) 3/0 (95) 4/0 (20) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x20) 400 /0 (60) 2/0 (70) 3/0 (95) 4/0 (20) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x20) 2x4/0 (2x20) 500 2/0 (70) 3/0 (95) 4/0 (20) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x20) 3x3/0 (3x95) 3x3/0 (3x95) 600 3/0 (95) 4/0 (20) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x20) 3x3/0 (3x95) 3x4/0 (3x20) 3x4/0 (3x20) 700 4/0 (20 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x20) 3x3/0 (3x95) 3x4/0 (3x20) 3x4/0 (3x20) 4x4/0 (4x20) 800 4/0 (20) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x20) 3x4/0 (3x20) 3x4/0 (3x20) 4x4/0 (4x20) 4x4/0 (4x20) 900 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x20) 3x3/0 (3x95) *This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable. **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm 2 for metric use *** For distances longer than those shown in this guide, call a factory applications rep. at (Miller) or (Hobart). 2

13 Multiprocess XMT 350 FieldPro System with ArcReach (907739) XMT 350 FieldPro Narrow 4-Pack Rack Includes Casters (907740) XMT 350 FieldPro 6-Pack Rack Includes Casters Remote control of the power source without a control cord. For portability and reliability, Auto-Line allows for any input voltage hookup ( V, single- or three-phase) with no manual linking, providing convenience in any job setting. Ideal solution for dirty or unreliable input power. Cable Length Compensation (CLC ) makes proper setup of weld parameters faster; automatically adjusting voltage based on weld cable length. This ensures that the voltage a welder operator sets is the voltage they get. Adjust While Welding (AWW ) allows operators to make precise adjustments even while a weld bead is being laid, which allows parameters to be changed while the arc is on. RMD and pulsed welding without control cords up to 200 feet away from the power source with the ArcReach Smart Feeder. Auto-Bind automatically establishes an exclusive communication between the power source and the wire feeder, using the existing weld cables upon system power up. Wind Tunnel Technology. Internal air flow that protects electrical components and PC boards from dirt, dust and debris... greatly improving reliability Fan-On-Demand cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled through machine. Lightweight aerospace-grade aluminum case offers protection with the benefit of reduced weight. New durability standard for field construction. Designed and built to withstand the harshest field environments. Tweco -style weld disconnects provide high-quality weld cable connections. Note: Tweco cable connectors are not supplied with the unit and must be ordered separately. Jobsite mobility is made easy with a small, compact design and Auto-Line technology. Process selector switch reduces the number of control setup combinations without reducing any features. Adaptaive Hot Start makes starting stick electrodes easy without creating an inclusion. Infinite arc control available in the stick and wire modes for easier fine tuning of tough-to-weld materials and out-of-position applications. Lift-Arc provides arc starting that minimizes contamination of the electrode and with the use of high-frequency. True multiprocess system provides conventional stick, TIG, FCAW, and MIG welding as well as the advanced technologies of RMD and pulse. Fleet compatibility. ArcReach-equipped power sources and wire feeders work with non-arcreach equipment; however, the complete ArcReach benefit is only realized with the ArcReach system. Air Carbon Arc Electrode Size Power Source XMT 350 XMT 450 Single Power Source Up to 5/6 in. Up to 3/8 in. 3

14 Multiprocess XMT 350 FieldPro and XMT 350 FieldPro Polarity Reversing Packages Point of Use Control with ArcReach Stick/TIG system Remotely change process Set actual amperage Additional features of XMT 350 FieldPro Polarity Reversing power source system Remotely change polarity No need to swap weld cables Detects improper connection ArcReach Stick/TIG Remote ArcReach Stick/TIG Remote Polarity Reversing ArcReach SuitCase Wire Feeder MIG/flux-cored system MIG/flux-cored system includes power source, ArcReach SuitCase 2 feeder with drive rolls and Bernard BTB Gun 300 A. No feeder control cords Eliminates trips back to power source Total remote control Automatically changes to CV output when feeder is connected Pipe welding with RMD /pulse system RMD/pulse system includes power source, ArcReach Smart Feeder with drive rolls and Bernard PipeWorx MIG gun. Offers traditional MIG and flux-cored processes, as well as advanced RMD and pulse programs. Weld up to 200 feet away from the power source with no special cables Save welding parameters for later use on SD memory card Complete remote control at the weld joint XMT 350 MPa Built-in pulse programs for weld overlay, cladding applications that have benefits for standard steels, and high-strength steels. 4

15 XMT 350 FieldPro Specifications (Subject to change without notice.) Multiprocess Input Power Three-phase Single-phase Voltage Range in CV Mode 0 38 V 0 38 V Amperage Range in CC Mode A A Rated Out put 350 A at 34 VDC, 60% duty cycle 300 A at 32 VDC, 60% duty cycle Amps Input at Rated Load Output, 60 Hz 208 V 230 V 400 V 460 V 575 V KVA KW Max. Open- Circuit Voltage 75 VDC H: 7 in. (432 mm) W: 2.5 in. (38 mm) D: 24 in. (60 mm) Net Weight 93 lb. (42.2 kg) Certified by Canadian Standards Association to both the Canadian and U.S. Standards. Installation Diagrams OR ArcReach Stick/TIG Remote installation diagram MIG installation diagram 5

16 Multiprocess ArcReach SuitCase Specifications (Subject to change without notice.) (Use with CC or CV, DC power sources.) Model 8 2 Input Power Operates on open-circuit voltage and arc voltage: 4 48 VDC/ 0 max. OCV Input Welding Circuit Rating 330 A at 60% duty cycle 425 A at 60% duty cycle Wire Feed Speed ipm ( m/min.) dependent on arc voltage Wire Type and Diameter Capacity Solid wire: in. (0.6.4 mm) Flux-cored:.030 5/64 in. ( mm) Solid wire: in. (0.6.4 mm) Flux-cored:.030 5/64 in. ( mm) Max. Spool Size Capacity 8 in. (203 mm) 4 lb. (6.4 kg) 2 in. (305 mm) 45 lb. (20 kg) H: 2.75 in. (324 mm) W: 7.25 in. (84 mm) D: 8 in. (457 mm) H: 5.5 in. (394 mm) W: 9 in. (229 mm) D: 2 in. (533 mm) Net Weight 28 lb. (3 kg) 35 lb. (5.9 kg) XMT 450 Rack Model XMT 450 CC/CV Arc Reach ( ) 230/460 V ( ) 230/460 V with Auxiliary power ( ) 575 V XMT 450 CC/CV ArcReach Rack ( ) 4-pack rack, fused 460 V Input Power Threephase Voltage Range in CV Mode Rated Output 450 A at 38VDC, 0 38 V 00% duty cycle Amperage Range in CC Mode A Max. Open- Circuit Voltage 90 VDC Amps Input at Rated Load Output, 60 Hz 230 V 460 V KVA KW H: 7.25 in. (438 mm) W: 4.5 in. (368 mm) D: in. (689 mm) Net Weight 22 lb.(55.3 kg) 6

17 Multiprocess Ordering Information XMT 350 FieldPro Racks Stock No. Description XMT 350 FieldPro 4-Pack Rack Fused 460/575 V, 50/60 Hz, Tweco-style connectors XMT 350 FieldPro 6-Pack Rack Fused 460/575 V, 50/60 Hz, Tweco-style connectors XMT 350 FieldPro Fused 460/575 V, 50/60 Hz, Tweco-style connectors Polarity Reversing 4-Pack Rack XMT 350 FieldPro Fused 460/575 V, 50/60 Hz, Tweco-style connectors Polarity Reversing 6-Pack Rack 4-Pack Rack only XMT 350 narrow, fused included V 6-Pack Rack only XMT 350/450, NO fuses included System Components XMT 350 FieldPro Power Source V, 50/60 Hz, Tweco-style connectors XMT 350 FieldPro V, 50/60 Hz, Tweco-style connectors Polarity Reversing Power Source XMT 350 MPa V, Auto-Line with ArcReach ArcReach SuitCase Tweco-style connectors, with drive rolls and Bernard BTB Gun 300 A MIG/FCAW Feeder Tweco-style connectors, with drive rolls and Bernard S-Gun 9573 Tweco-style connectors, with drive rolls and Bernard Dura-Flux gun Tweco-style connectors, with drive rolls and Bernard PipeWorx MIG gun ArcReach SuitCase Tweco-style connectors, with drive rolls and Bernard BTB Gun 300 A MIG/FCAW Feeder Tweco-style connectors, with drive rolls and Bernard S-Gun Tweco-style connectors, with drive rolls and Bernard Dura-Flux gun ArcReach Smart Feeder Tweco-style connectors, with drive rolls and Bernard PipeWorx MIG gun MIG/FCAW/RMD /Pulse Feeder Tweco-style connectors Dinse-style connectors ArcReach Stick/TIG Remote Tweco-style connectors ArcReach Stick/TIG Remote Tweco-style connectors Polarity Reversing 4-Pack Rack 6-Pak Rack Accessories Bernard PipeWorx MIG Gun ft. (4.6 m), 250 A air-cooled MIG gun designed for use with all ArcReach smart systems Bernard PipeWorx MIG Gun ft. (4.6 m), 300 A air-cooled MIG gun designed for use with all ArcReach smart systems ArcReach Feeder Gas Flow Meter Kit For ArcReach SuitCase 8/2 feeders and ArcReach Smart Feeder 7

18 Multioperator Dimension 650 Rack See literature no. DC/9.3 Developed for harsh environmental conditions and output requirements that range from power-intensive to precise. An unbeatable combination of durability, output, efficiency and capability all in a smaller, easier-to-handle package. Inside its tough, corrosion-resistant, all-aluminum case is big power for heavy welding jobs and carbon arc gouging. In addition to excellent stick and Lift-Arc TIG,the dimension 650 also has excellent short-arc MIG characteristics for precise thin-metal welding performance. Heavy industrial Processes MIG (GMAW) Flux-cored (FCAW) Stick (SMAW) TIG (GTAW) Submerged arc (SAW) Air carbon arc cutting and gouging (CAC-A) (rated 3/8 in. carbons) BUILT TO LAST Rugged and durable inside and out POWER FOR THICK METALS PRECISION FOR THIN METALS Power and precision BETTER WELDS WITH LESS REWORK Improved weld quality More portable and takes up less floor space PRODUCTIVITY QUALITY SAFETY Arcreach remote control without a cord Stock Number ( ) Dimension 650 ArcReach Power Source Only (907702) Dimension 650 ArcReach 2-pack rack (90770) Dimension 650 ArcReach 4-pack rack Amperage/Voltage Ranges CC mode: 0 85 A CV mode: 0 44 V SAW mode: 0 65 V Rated Output 650 A at 44 VDC, 00% duty cycle Amps Input at Rated Output, 50/60 Hz 380 V 460 V KVA KW Max. Open- Circuit Voltage 87 H: in. (76 mm) (including lift eye) W: in. (424 mm) D: in. (803 mm) Net Weight 58 lb. (7.7 kg) 8

19 Drive Rolls (Two Required. Order from Miller Service Parts.) Base selection of drive rolls upon the following recommended usages:. V-Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wire. 3. U-Cogged rolls for extremely soft shelled wire. Select drive rolls from chart below according to type and wire size being used. Wire inlet guide comes installed on this wire feeder. V groove for hard wire Wire Size.023/.025 in. (0.6 mm) in. (0.8 mm) in. (0.9 mm) in. (.0 mm) in. (./.2 mm) and /6 in (.22 and.6 mm) in. (.3/.4 mm) /6 in. (.6 mm) /.072 in. (.8 mm) /64 in. (2.0 mm) Dual-size reversible drive roll. VK-Grooved. U groove for soft wire or softshelled cored wires 4. V-Knurled rolls for hard shelled cored wire. 5. Drive roll types may be mixed to suit particular requirement (example: V-Knurled roll in combination with U-Grooved). V knurled for hard-shelled cored wires U cogged for extremely soft wire or soft-shelled cored wires (i.e., hard facing types) Weld Cables In Stock and Ready to Ship We use the highest quality cable and most reliable manufacturing techniques that will maximize the life of the weld cables in tough rental applications. 2/0 Weld Cable Extensions ft. (5 m) ft. (30 m) Extends weld cables 95457, and Cable with Work Clamp Consists of a stud/tweco adapter and 0-foot (3 m) 2/0 weld cable with a Tweco male connector and work clamp. Rated up to 500A Cable with Electrode Holder Consists of a stud/tweco adapter and 0-foot (3 m) /0 weld cable with a Tweco male connector and electrode holder. Rated up to 250A (Recommended) Consists of a stud/tweco adapter and 0-foot (3 m) 2/0 weld cable with a Tweco male connector and electrode holder. Rated up to 500A

20 Multioperator CST 280 Racks See literature no. DC/8.82 Rugged enclosure provides simple means for protecting and transporting multiple welding power sources for construction, maintenance/repair and shipbuilding applications. CST Pack Rack shown. Light weight and small footprint for easy transportation. The low weight enables the use of elevators to move the rack. All controls including power switch are located on front of machine for easy access. Top cover protects machines from falling debris. Lift eye simplifies crane or overhead lifting device transport. Lift truck fork pockets. One main disconnect box with branched fusing for each machine. Common output ground connection (for same polarity use only). Optional rack running gear available for moving the rack. Heavy industrial Processes Stick (SMAW) TIG (GTAW) Air Carbon Arc Cutting and Gouging (CAC-A) (5/6-in. carbons with paralleled CST 280s) Most popular accessories 4-Pack Rack Running Gear 954 Model CST Pack Rack CST Pack Rack Input Power to Rack / VAC, 50/60 Hz, 3-Phase / VAC, 50/60 Hz, 3-Phase Amps Input at Rated Output, 50/60 Hz 220 V 230 V 400 V 440 V 460 V 575 V KVA KW H: in. (289 mm) 4-pack W: 25.5 in. (648 mm) 8-pack W: 46 in. (68 mm) D: 26.5 in. (673 mm) Net Weight 355 lb. (6 kg) 640 lb. (290 kg) Power Source Racks and Options CST 280 Rack w/tweco-style connectors CST 280 Rack w/tweco-style connectors Running Gear for Rack Stock No Description Rack with 4 CST 280, / VAC (Includes 25 A fuses for 460 V) Rack with 8 CST 280, / VAC (Includes 25 A fuses for 460 V) For 4-pack rack For 8-pack rack LINE FUSE SIZE REQUIREMENTS Product XMT 350 XMT 304 FieldPro 350 XMT 450 CST 280 Input Voltage (3-phase) 208 VAC 230 VAC 460 VAC 575 VAC 460 VAC 575 VAC 208 VAC 230 VAC 460 VAC 575 VAC Recommended Line Fuse Size (Amps) 45 A 20 A 30 A 30 A 25 A 20 A 4 Pack Rack * Buy Individualy By Individualy Miller Replacement Parts Fuse Kit # 6 Pack Rack 8 Pack Rack * Buy Individualy Buy Individualy Individual Fuse Part # Bussman Individual Fuse Part # TCF-45 TCF-20 TCF-30 KTK-R-30 KTK-R-25 KTK-R-20 20

21 Multimatic 200 See literature no. DC/2.57 Multi-voltage plug (MVP ) allows connection to common 20- and 240-volt power receptacles without the use of any tools simply choose the plug that fits the receptacle and connect to the power cord. Stock Number (90758) 20/230 V (95649) 20/230 V with TIG contractor kit Welding Mode/Process CV: MIG/ Flux-Cored CC: TIG CC: Stick Input Power 20 VAC 230 VAC 20 VAC 230 VAC 20 VAC 230 VAC Amperage Range Multimatic 25 See literature no. DC/2.59 Multi-voltage plug (MVP ) allows connection to common 20- and 240-volt power receptacles without the use of any tools simply choose the plug that fits the receptacle and connect to the power cord. Max. 3/8 in. (9.5 mm) MIG Mild Steel Min. 24 ga. (0.8 mm) Rated Output 90 A at 8.5 V, 60% duty cycle 0 A at 9.5 V, 20% duty cycle 50 A at 2.5 V, 20% duty cycle 50 A at 6 V, 30% duty cycle 50 A at 6 V, 30% duty cycle 00 A at 24 V, 35% duty cycle 50 A at 26 V, 30% duty cycle Welding Capability Max. /4 in. (6.4 mm) MIG Aluminum Min. 8 ga. (.2 mm) Max. 3/6 in. (4.8 mm) TIG Mild Steel Min in. (0.5 mm) Aluminum welding uses optional Spoolmate 00 and 4000 series aluminum wire or Spoolmate 50 (effective with Multimatic serial number MF364047N) and either 4000 or 5000 series aluminum wire. TIG welding uses optional TIG contractor kit. The only all-in-one, portable, multiprocess power source from Miller is our most versatile machine to date. Weighing only 29 pounds (3.2 kg) and running on either 20 or 230 volts, the Multimatic 200 can go anywhere you need to MIG, TIG or stick weld. Auto-Set Elite can be used on multiple materials and multiple processes with the ability to fine-tune your settings. Simple to set up and use! Excellent arc characteristics! Unit offers positive arc starts and an extremely stable arc with minimal spatter on both mixed gases and straight CO 2. Max. 3/8 in. (9.5 mm) MIG Mild Steel Min. 24 ga. (0.8 mm) Amps Input at Rated Output, 50/60 Hz 20 V 230 V KVA KW Welding Capability Max. 3/8 in. (9.5 mm) MIG Aluminum Min. 8 ga. (.2 mm) Wire Feed Speed IPM ( m/min.) Max. /4 in. (6.4 mm) TIG Mild Steel Min. 24 ga. (0.8 mm) Aluminum welding uses optional Spoolmate 00 and 4000 series aluminum wire or Spoolmate 50 (effective with Multimatic serial number MF364047N) and either 4000 or 5000 series aluminum wire. TIG welding uses optional TIG contractor kit. Multiprocess All-in-one, multiprocess capabilities Take on a variety of projects with one machine that has MIG, stick and TIG capabilities Easy-to-use color LCD interface. Easily set up the machine for all three processes with the LC interface, featuring Auto-Set Elite. Up to 230 amps of power. Capable of welding up to 3/8-inch mild steel in a single pass Excellent arc characteristics! Unit offers positive arc starts and an extremely stable arc with minimal spatter on both mixed gases and straight CO 2. Light industrial Processes MIG (GMAW) Flux-Cored (FCAW) DC Stick (SMAW) DC TIG (DC GTAW) Comes complete with 0-ft. (3 m) Bernard Q50 MIG gun 3-ft. (4 m) cable with electrode holder and 25-mm Dinse connector 0-ft. (3 m) work cable with clamp and 25-mm Dinse connector Power cord with MVP plugs for 5 V and 230 V Quick Select drive roll for.024-in. (0.6 mm) or.030/.035-in. (0.8/0.9 mm) solid wire, and.030/.035-in. (0.8/0.9 mm) flux-cored wire Flow gauge regulator and gas hose for argon or AR/CO 2 mix, extra contact tips, information/settings chart and material thickness gauge (229895) Max. Open- Circuit Voltage 90 VDC 90 VDC (22 25 VDC, sense voltage for Stick and Lift-Arc TIG) Light industrial MIG (GMAW) DC stick (SMAW) cable assembly solid wire mm) wire H: 4.5 in. (368 mm) W: 9.75 in. (248 mm) D: 7 in. (432 mm) Processes Flux-Cored (FCAW) DC TIG (GTAW) Comes complete with 6.5 ft. (2 m) power cord with MVP plugs for 20 V and 240 V 0 ft. (3 m) M-00 MIG gun and Net Weight 29 lb. (3.2 kg) 3 ft. (4 m) cable electrode holder and 25 mm Dinse-style connector 0 ft. (3 m) work cable with clamp and 25 mm Dinse-style connector Flow gauge regulator and gas hose for argon and AR/CO2 mix Hobart spool of.030 in. (0.8 mm) Two contact tips for.030 in. (0.8 Quick Select drive roll for.024 in. (0.6 mm) or.030/.035 in. (0.8/0.9 mm) solid wire, and.030/.035 in. (0.8/0.9 mm) flux-cored wire Stock Number (907693) 20/240 V (95674) 20/240 V with TIG contractor kit Welding Mode/Process CV: MIG/ Flux-Cored CC: TIG CC: Stick Input Power 20 VAC 240 VAC 20 VAC 240 VAC 20 VAC 240 VAC Amperage Range Rated Output 0 A at 9.5 V, 60% duty cycle 200 A at 24 V, 20% duty cycle 50 A at 2.5 V, 40% duty cycle 40 A at 5.6 V, 40% duty cycle 90 A at 7.6 V, 20% duty cycle 90 A at 23.6 V, 40% duty cycle 90 A at 27.6 V, 20% duty cycle Amps Input at Rated Output, 50/60 Hz 20 V 240 V KVA KW Wire Feed Speed IPM ( m/min.) Max. Open- Circuit Voltage 58 VDC 58 VDC H: 2.5 in. (38 mm) W:.25 in. (286 mm) D: 20.5 in. (52 mm) Net Weight 38 lb. (7.2 kg) 2

22 Engine-Driven Blue Star 85 See literature no. ED/2.5 Reliable outdoor portable power! Great for farm, ranch, maintenance, construction and hobbyist. Compact and portable, its small footprint uses little truck space. Optional running gear also makes the Blue Star one-man portable. Stick and TIG capable. Accu-Rated peak generator power is usable for maximum generator loads such as plasma cutting, Millermatic MIG welders and motor starting. Includes electric start, 20 VAC GFCI and 240 VAC receptacles, 6.25-gallon fuel capacity, auto-idle and engine hour meter. Light industrial Processes Stick (SMAW) TIG (GTAW) Gasoline engine Kohler CH440: 3.4 hp at 3,600 rpm One-cylinder, four-cycle, OHV, air-cooled Note: Engine is warranted separately by engine manufacturer. Most popular accessories Lifting Eye Running Gear Protective Cover Gasoline Stock Number (907664) Kohler Welding Mode CC/DC Welding Process DC Stick/TIG Amperage Range Rated Output at 04 F (40 C) 85 A at 25 V, 20% duty cycle 50 A at 25 V, 00% duty cycle Single-Phase Generator Power at 04 F (40 C) Peak: 6500 watts Continuous: 6200 watts Fusion 60 See literature no. ED/2.8 The Fusion 60 delivers a smooth, stable arc from either engine power or 20/240-volt utility power, providing a unique combination of versatility and productivity in a lightweight package. H: in. (629 mm) W: in. (524 mm) D: 3.25 in. (794 mm) Net Weight 296 lb. (34 kg) Gasoline Stock Number (907720) Kohler with recoil start ( ) Kohler with electric start Input Power Engine power Power Shift 20 V Power Shift 240 V Work anywhere convenience. PowerShift technology provides weld capabilities using either the Fusion 60 gasoline engine or 20/240-volt utility power. You ll have the confidence of knowing that you can weld virtually anywhere outdoors and indoors with just one machine. The multi-voltage plug (MVP ) makes it easy to connect the welder to either 20- or 240-volt power. Easier to transport. The Fusion 60 welder/generator weighs 222 pounds. That s up to 70 pounds less than similar machines, so moving the Fusion 60 is easier and faster. Less time is spent waiting, and more work can get done. Welding Mode CC/DC Welding Process DC stick Amperage Range Rated Output at 04 F (40 C) 60 A at 26.4 V, 20% duty cycle 0 A at 24.4 V, 00% duty cycle 90 A at 23.6 V, 40% duty cycle 60 A at 26.4 V, 20% duty cycle 0 A at 24.4 V, 00% duty cycle Amps Input at Rated Output, 50/60 Hz, -Phase Light industrial Process Stick (SMAW) Gasoline engine Kohler CH440: 3.4 hp at 3,600 rpm One-cylinder, four-cycle, OHV, air-cooled Note: Engine is warranted separately by engine manufacturer. Most popular accessories Lifting Eye Running Gear Twist Lock Adapter Cord Protective Cover Single-Phase Generator Power at 04 F (40 C) Peak: 6,500 watts Continuous: 6,200 watts H: in. (629 mm) W: in. (50 mm) D: 3.25 in. (794 mm) Net Weight Recoil: 222 lb. (0 kg) Electric: 242 lb. (0 kg) Bobcat 200 Air Pak See literature ED/4.35 The industry-leading power solution for increasing your capabilities, reducing expenses, and boosting profitability and efficiency. Maximize available payload. Reduce weight by up to 550 pounds and increase available payload by up to 24 cubic feet by reducing the equipment on the truck. Reduce fuel consumption. Minimize fuel costs by reducing truck engine idle time by as much as 75 percent or if you have a separate engine driven compressor by only operating one engine. Minimize operating costs. Save up to $50,000 over ten years from increased fuel efficiency, decreased maintenance costs and increased asset life. Light industrial Process Stick (SMAW) Gasoline engine Kohler CH730 with echoke : 23.5 hp at 3,600 rpm Twin-cylinder, four-cycle, overhead valve, industrial, air-cooled Note: Engine is warranted separately by engine manufacturer. Most popular accessories Spectrum 375 X-TREME Multi-Terrain Running Gear Full KVA Adapter Cord Protective Cover Without running gear With running gear Visit MillerWelds.com or your distributor for other Miller options and accessories. Gasoline Stock Number (907706) Kohler Air Compressor Process DC stick Output Ranges A Rated Weld Output at 04 F (40 C) 50 A at 26 V, 00% duty cycle 80 A at 27 V, 60% duty cycle 20 A at 25 V, 20% duty cycle Features Rotary screw with auto idle, oil change intervals of 500 hours Single-Phase Generator Power at 04 F (40 C) Continuous/peak: 5,500 watts Free Air Delivery 28 cfm (0.79 m 3 /min.) at 3,600 rpm H: in. (604 mm) H: in. (756 mm) to top of exhaust W: 20 in. (508 mm) D: in. (,85 mm) Working Pressure psig Duty Cycle 00% Net Weight 558 lb. (253 kg) Oil Capacity 2 qt. (.89 L) 22

23 Bobcat Series Gas, LP and Diesel Engine-Driven Bobcat 250 EFI shown. Bobcat engine-driven welder/generators are the top selling in their class because they are engineered to be reliable, powerful and durable. Their multiprocess capabilities make them ideal for maintenance trucks where reduced size and weight are essential. Cleaner and stronger generator power,000 watts (2,000 on Bobcat 250 with EFI) of clean, truly usable generator power that is Accu-Rated, not inflated tested to deliver uninterrupted peak output for a minimum of 30 seconds for big loads, so you can get more jobs done. Advanced generator technology virtually eliminates power spikes and other electrical imperfections so welds are cleaner and jobsite tools can run without interruption, maximizing quality, productivity and profit. Bobcat Competitor Waveform Comparison Fewer refueling trips Large 2-gallon fuel capacity means extended runtimes and less refueling. Versatile AC and DC welding Provides AC and DC welding output for greater versatility and quality welds on all types of metals. DC is smooth and easy to run while AC stick is used when arc blow occurs. More portable, uses less truck space Smaller and lighter 7 percent less cubic space and weighing up to 00 pounds less than the competition means moving Bobcat welder/generators is faster and easier, for maximum productivity. And because they take up less space, they let work trucks carry more equipment and gear so your work crews can meet weight limits and be ready for anything. Easier maintenance Easy-to-read front panel maintenance displays show engine hours and hours left before an oil change is due. This intuitive design makes maintenance fast and easy. Oil checks from the top by the front panel Toolless panels that allow for quick access Single-side fuel fill and oil drain/filter 23

24 Engine-Driven Bobcat 3 Phase (Gas) See literature ED/4.33 Designed for farm and ranch owners in need of single- and three-phase power to run 480-volt three-phase pivot irrigation systems or to provide backup power for home, farm and/or ranch. Bobcat 250 (Gas, LP or Diesel) See literature ED/4.4 (Gas/LP) and ED/4.34 (Diesel) MOST Multiprocess engine-driven welder/generator capable of carbon arc gouging POPULAR! features a larger stabilizer for less spatter and smoother arc. Ideal welder/ generator for maintenance/repair, construction, farm/ranch or as a stand-alone generator. Convenient front panel fuel gauge. More precise amperage settings with wider range for optimal stick/flux-cored welding. Features four AC/DC stick/tig controls and two wire ranges for output control. Stick ranges designed for 3/32, /8, 5/32 and 3/6 inch. Very easy to set. Add optional electronic fuel injection (EFI) improved fuel efficiency for maximum productivity and profitability Adding EFI to your Bobcat 250 welder/generator provides multiple benefits. With EFI you ll get faster, more reliable starts in any weather no choke adjustments needed. EFI-equipped Bobcat 250 machines are also up to 42 percent more fuel efficient than standard carbureted models, improving profitability. Plus, refueling less frequently means you ll spend more of your time welding, improving productivity. *Recommended for operation at altitudes above 5,000 feet. LP Package Includes running gear, multi-terrain w/never flat tires, multi-terrain LP tank rack and hose assembly. Industrial Processes AC/DC stick (SMAW) MIG (GMAW) Flux-cored (FCAW) AC2 /DC TIG (GTAW) Air carbon arc cutting and gouging (CAC-A) 3 (rated 3/6 in. carbons) With voltage-sensing feeder. 2 With Dynasty 20 Series. 3 Bobcat 250 models only. Engines Gas: Kohler CH hp at 3,600 rpm EFI gas: Kohler ECH hp at 3,600 rpm LP: Kohler CH730 Liquid withdrawal LP system 2.5 hp at 3,600 rpm V-twin-cylinder, four-cycle, overhead valve, industrial, air-cooled EPA Tier 4 Final Diesel: Kubota D722 9 hp at 3,600 rpm Three-cylinder, industrial, liquid-cooled Note: Engines are warranted separately by engine manufacturer. Most popular accessories SuitCase X-TREME Feeders Dynasty 20 Series Spectrum 625 X-TREME Multi-Terrain Running Gear Off-Road Running Gear Protective Cage with Cable Holders Hose and LP Tank Mounting Assembly Remote Oil Drain/Filter Kit All-Purpose Running Gear Full KVA Adapter Cord Protective Cover HWY-Mid Frame Trailer GFCI Panel Mount 20 VAC Duplex Kit Electric Fuel Pump Kit* (for gas models only) Spark Arrestor Kit (for gas models only) Visit MillerWelds.com or your distributor for other Miller options and accessories. Gasoline Diesel Gas or LP Model Bobcat 3 Phase Bobcat 250 Bobcat 250 Diesel Stock Number (907505) Kohler with GFCI ( ) Kohler (907500) Kohler with GFCI ( ) Kohler with electric fuel pump* (907502) EFI Kohler (907504) LP Kohler with GFCI Order hose and LP tank mounting assembly (30097) separately (907565) Kubota with GFCI Welding Mode CC/AC CC/DC CV/DC CC/AC CC/DC CV/DC CC/AC CC/DC CV/DC Process Stick/TIG Stick/TIG MIG/FCAW Stick/TIG Stick/TIG MIG/FCAW Stick/TIG MIG/FCAW Amp/Volt Ranges A A 9 28 V A A w/efi A A w/efi 7 28 V A 7 28 V Rated Output at 04 F (40 C) 200 A at 25 V, 00% duty cycle 20 A at 25 V, 00% duty cycle 200 A at 20 V, 00% duty cycle 250 A at 25 V, 60% duty cycle 225 A at 25 V, 00% duty cycle 250 A at 25 V, 00% duty cycle 275 A at 25 V, 60% duty cycle 250 A at 25 V, 00% duty cycle 250 A at 25 V, 00% duty cycle 275 A at 25 V, 60% duty cycle 250 A at 28 V, 00% duty cycle Generator Power at 04 F (40 C) Single-phase/three-phase Peak:,000 watts Continuous: 9,500 watts/0,000 watts Single-phase Peak:,000 watts Continuous: 9,500 watts EFI model Peak: 2,000 watts Continuous: 0,500 watts Single-phase Peak:,000 watts Continuous: 9,500 watts H: 28 in. (7 mm) H: in. (832 mm) to top of exhaust W: 20 in. (508 mm) D: 40.5 in. (,029 mm) H: 28 in. (7 mm) H: in. (832 mm) to top of exhaust W: 20 in. (508 mm) D: 40.5 in. (,029 mm) H: 28 in. (7 mm) H: 34.5 in. (876 mm) to top of exhaust W: 20 in. (508 mm) D: 45.5 in. (,56 mm) Net Weight 495 lb. (225 kg) 50 lb. (227 kg) 638 lb. (289 kg) 24

25 Trailblazer Series Gas, LP and Diesel See lit. ED/4.75 (Gas/LP) and ED/4.8 (Diesel) Engine-Driven IMPROVED! Now available with ArcReach. Trailblazer welder/generators deliver unbeatable arc performance providing the smoothest, most stable arc in the industry. The Trailblazer exclusive Auto-Speed technology delivers superior runtimes, increased fuel efficiency, and improved welder/generator performance. Trailblazer 325 EFI with optional ArcReach and Excel power shown. Unbeatable arc performance Wide amperage output with better welding deposition rates means you can get jobs done faster, saving time and money. The Trailblazer also has precise arc control, which allows you to fine-tune the arc to match your personal preferences and quickly dial in the perfect parameters to optimize weld quality and maximize productivity across a variety of applications and welding processes. Cleaner and stronger generator power Combines a 25 hp engine and 2,000 watts of clean, truly usable generator power that is Accu-Rated, not inflated tested to deliver uninterrupted peak output for a minimum of 30 seconds for big loads, so you can get more jobs done. Maximum cost savings Less money spent on fuel means more profit for you. Every Trailblazer welder/generator has fuel-saving Auto-Speed technology add optional Excel power and EFI to save even more on fuel costs and enjoy a combination of advanced, profit-enhancing features that are only available on a Trailblazer welder/generator. Safer, more productive jobsites Quieter jobsites are safer and more productive because work crews can communicate easier, and work can start earlier and end later even in noise-sensitive areas. Auto-Speed technology Get the welding power you need plus reduced fuel consumption and lower noise levels for a more-profitable, safer jobsite. Unlike competitive machines that operate at 3,600 rpm (max) under any load, Miller-exclusive Auto-Speed technology responds to weld requirements by automatically adjusting engine speed to one of four rpm levels so the engine never works harder than necessary. Refueling time and operating costs are reduced, which means more productivity and profitability. Auto-Speed technology available only from Miller. Welding at idle speed Welding below 50 A 2,400 RPM Welding between 5 20 A 2,800 RPM Fewer refueling trips Spend more time working and less time refueling. Only Trailblazer welder/ generators provide Auto-Speed technology, plus Excel power and electronic fuel injection (EFI) options, to deliver maximum runtime. More portable, uses less truck space Smaller and lighter 7 percent less cubic space and 0 percent less machine weight than the competition means moving Trailblazer welder/generators is faster and easier, for maximum productivity. Welding between A 3,200 RPM Welding above 250 A 3,600 RPM Auto-Speed in XX8 mode 25

26 Engine-Driven Options to Maximize Your Trailblazer 325 Performance Electronic fuel injection EFI (gas models) Adding EFI to your Trailblazer welder/generator adds multiple benefits. With EFI, you ll get faster, more-reliable starts in any weather no choke adjustments needed. EFI-equipped Trailblazer machines are also up to 42 percent more fuel efficient than standard carbureted models, improving profitability. Plus, refueling less frequently means you ll spend more of your time welding, improving productivity. Add Excel power to your Trailblazer with EFI, and you ll have the most fuel-efficient compact welder/generator available. Excel power Unlike competitive machines that provide auxiliary power only at 3,600 rpm (max), Excel power delivers a full 2,400 watts (20 A) of 20-volt inverter-based, pure sine wave power at all speeds, including idle. With Excel power you can operate jobsite tools like grinders at quiet, fuel-saving speeds. Refueling time and operating costs are reduced with Excel power, which means more productivity and profitability. Plus everyone on the jobsite gets a better working environment because noise levels and exhaust emissions are lowered. Excel power available only from Miller. Battery charge/crank assist (gas models) Reduce downtime with battery charge/crank assist capability. Designed and recommended for mechanics or anyone else responsible for a fleet of trucks or equipment. By using your Trailblazer to charge dead batteries or jump a stubborn engine, you ll keep your crew working and the fleet up and running. Provides up to 75 amps of DC current to quickly charge 2- and 24-volt batteries. Jobsite equipment with weak batteries can get up to 350 amps of crank assist. Note: Battery charge/jump cables (300422) must be ordered separately. Carbureted models 5 HOURS OF RUNTIME Auto-Speed technology Electronic Fuel Injection (EFI) Excel power +6 HOURS Trailblazer 325 with EFI & Excel power 2 HOURS OF RUNTIME Auto-Speed technology Electronic Fuel Injection (EFI) Excel power Based on typical usage 50 amps welding 40% of the time; 20 amps generator power 30% of the time; and idling without load 30% of the time. Based on generator-only use for total runtime. ArcReach remote control technology Remote control of the power source without a control cord. An ArcReach system allows you to change weld settings from your ArcReach feeder or remote, saving a trip to the power supply. ArcReach technology uses the existing weld cable to communicate welding control information between the feeder or remote and the power source. This technology eliminates the need for control cords, and their associated problems and costs. Learn more at MillerWelds.com/arcreach Heavy industrial Processes Stick (SMAW) MIG (GMAW) Flux-cored (FCAW) DC TIG (GTAW)2 RMD 3 Pulsed MIG (GMAW-P)3 Air carbon arc cutting and gouging (CAC-A) (rated 3/6 in. carbons) With wire feeder. 2 Two-piece TIG torch recommended. 3 ArcReach model only with ArcReach Smart Feeder. Engines Gas: Kohler CH hp at 3,600 rpm EFI gas: Kohler ECH hp at 3,600 rpm LP: Kohler PCH740 Vapor withdrawal LP system 25 hp at 3,600 rpm Twin-cylinder, four-cycle, overhead valve, industrial, air-cooled EPA Tier 4 Final Diesel: Kubota D hp at 3,600 rpm Three-cylinder, industrial, liquid-cooled Note: Engines are warranted separately by engine manufacturer. Most popular accessories SuitCase X-TREME 2VS (pg 22) ArcReach SuitCase 8/2 (pg 22) ArcReach Smart Feeder (for ArcReach model only) (pg 22) ArcReach Stick/TIG Remote (for ArcReach model only) (pg 47) Spoolmatic 30A / WC-24 Control 3083 / (pg 3) Multi-Terrain Running Gear (pg 20) Off-Road Running Gear (pg 20) Protective Cage with Cable Holders (pg 20) Hose and LP Tank Mounting Assembly (pg 20) All-Purpose Running Gear (pg 20) Full KVA Adapter Cord (pg 20) Protective Cover (pg 20) HWY-Mid Frame Trailer (pg 2) Electric Fuel Pump Kit (for gas models only) Recommended for operation at altitudes above 5,000 feet. 25 ft. Battery Charge/Jump Cables with plug (for Trailblazer 325 EFI only) Visit MillerWelds.com or your distributor for other Miller options and accessories. *Recommended for operation at altitudes above 5,000 feet. **For LP models order Hose and LP Tank Mounting Assembly (30458) separately. Gas or LP Diesel Model Trailblazer 325 Trailblazer 325 Diesel Stock Number (907753) Kohler ( ) Kohler with GFCI ( ) Kohler with electric fuel pump* (907754) EFI Kohler ( ) EFI Kohler with Excel power ( ) EFI Kohler with GFCI, Excel power and ArcReach ( ) EFI Kohler w/excel power and battery charge/crank assist (907727**) EFI LP Kohler with GFCI ( **) EFI LP Kohler with GFCI and Excel power (907755) Kubota ( ) Kubota with GFCI ( ) Kubota with GFCI and Excel power ( ) Kubota with GFCI, Excel power and ArcReach Welding Mode CC/DC CV/DC CC/DC CV/DC Process Stick/TIG MIG/FCAW Stick/TIG MIG/FCAW Amp/Volt Ranges A 0 35 V A 0 35 V Rated Output at 04 F (40 C) 325 A at 28 V, 00% duty cycle 325 A at 28 V, 00% duty cycle 325 A at 33 V, 00% duty cycle 325 A at 33 V, 00% duty cycle Single-Phase Generator Power at 04 F (40 C) Peak: 2,000 watts,800 watts (LP) Continuous: 0,500 watts Excel power (optional) 2,400 watts 20 A at 20 V, 60 Hz pure generator power at idle speed and while welding. H: 28 in. (7 mm) H: in. (832 mm) to top of exhaust W: 20 in. (508 mm) D: 40.5 in. (,029 mm) H: 28 in. (7 mm) H: 34.5 in. (876 mm) to top of exhaust W: 20 in. (508 mm) D: 45.5 in. (,56 mm) Net Weight Gas 460 lb. (209 kg) LP 475 lb. (25 kg) 620 lb. (28 kg) 26

27 Trailblazer 302 Air Pak See literature ED/4.78 Powerful all-in-one tool designed for repair and construction with multiprocess weld quality, generator power, air compressor and battery charge/jump start. *Recommended for operation at altitudes above 5,000 feet. Superior arc performance. Preset dig settings optimized for the majority of stick welding applications, best-in-class wire arc performance, and two Lift-Arc TIG modes for most DC TIG applications. Strongest combined generator/compressor power. Delivers an industry-leading 3,000 watts of peak generator power independent of weld settings can power a Spectrum 875 plasma cutter, and provide air for plasma cutting at the same time (rated /2-inch mild steel). Rotary screw air compressor. Delivers up to 3 cfm and 60 psi of air with no storage tank. Gives 00 percent deliverable air and runs many tools at idle speed. Air outputs are rated at an industry-high 04 degrees Fahrenheit (40 C). Front panel air pressure adjustment and automatic overpressure shutdown with indication. Designed for more than 30,000 hours of operation and warranted for three years by Miller. Battery charge/crank assist. Provides selectable 2- or 24-volt battery charging with up to 450 amps of battery crank assist capability. Convenient front panel access. Note: Battery charge/jump cables (300422) must be ordered separately. Engine-Driven Heavy industrial Processes AC/DC stick (SMAW) MIG (GMAW) Flux-cored (FCAW) AC2 /DC 3 TIG (GTAW) Air carbon arc cutting and gouging (CAC-A) (rated 3/6 in. carbons, capable /4 in. carbons) With wire feeder. 2 With Dynasty 20 Series. 3 Two-piece TIG torch recommended. Gasoline engine Kohler CH750: 27 hp at 3,600 rpm V-twin-cylinder, four-cycle, overhead valve, industrial, air-cooled Note: Engine is warranted separately by engine manufacturer. Most popular accessories SuitCase X-TREME 2VS Spoolmatic 30A Aluminum Spool Gun / WC-24 Control 3083 / HWY-Mid Frame Trailer ft. Battery Charge/Jump Cables with Plug Visit MillerWelds.com or your distributor for other Miller options and accessories. Gasoline Stock Number ( ) Kohler (907549) Kohler with GFCI and electric fuel pump* ( ) Kohler with GFCI, cooler/separator and electric fuel pump* Air Compressor Welding Mode CC/DC CV/DC CC/AC Features Rotary screw with electric clutch for on/off, oil change intervals of 500 hours Process Stick/TIG MIG/FCAW Stick/TIG Amp/Volt Ranges A 3 35 V, 350 A A Rated Weld Output at 04 F (40 C) 280 A at 32 V, 00% duty cycle 300 A at 32 V, 00% duty cycle 350 A at 32 V, 60% duty cycle 200 A at 25 V, 60% duty cycle Free Air Delivery 3 cfm (0.88 m 3 /min.) at 3,600 rpm 28 cfm (0.79 m 3 /min.) at 3,000 rpm 22 cfm (0.62 m 3 /min.) at 2,400 rpm (idle) Single-Phase Generator Power at 04 F (40 C) Peak: 3,000 watts Continuous:,000 watts Working Pressure Constant psig H: 28 in. (7 mm) H: 34.5 in. (876 mm) to top of exhaust W: 20 in. (508 mm) D: in. (,54 mm) Duty Cycle 00% Net Weight 77 lb. (350 kg) Oil Capacity.75 qt. (.7 L) Big Blue 400 Pro See literature ED/5.7 The professional welder s choice designed with the professional in mind, the Big Blue 400 Pro is the best for ease of use, reliability and fuel economy. IMPROVED! Now available with ArcReach. Wireless antenna kit (300749) recommended. Available on select models. Remote control of the power source without a control cord. Tailored arc control (DIG) allows arc characteristics to be changed for specific applications and electrodes. Smooth running 708 or stiffer, more penetrating 600. Industrial USB port. Quickly upload the latest software and download machine log files to retrieve in-depth information such as diagnostics and machine statistics. 0,000 watts of pure generator power. Plug in an extra Miller inverter-based power source for an additional welding arc! Quiet operation. Only 7.6 decibels (96 Lwa) under full load. Improves jobsite communication and safety. Standard features include digital meters with SunVision, automatic idle, adjustable Hot Start, output contactor control and 20-volt block heater. Heavy industrial Processes Stick (SMAW) MIG (GMAW) Flux-cored (FCAW) RMD * Pulsed MIG (GMAW-P)* DC TIG (GTAW) Air carbon arc cutting and gouging (CAC-A) (rated 3/6 in. carbons) *ArcReach models only with ArcReach Smart Feeder. Diesel engines EPA Tier 4 Final choices Kubota V505: 20.2 hp at,800 rpm Four-cylinder, industrial, liquid-cooled Mitsubishi S4L2: 24.7 hp at,800 rpm Four-cylinder, industrial, liquid-cooled Note: Engines are warranted separately by engine manufacturer. Most popular accessories SuitCase Feeders ArcReach Smart Feeder** ArcReach Stick/TIG Remote** Dynasty 20 Series Protective Cover 9530 **For ArcReach models only. Visit MillerWelds.com or your distributor for other Miller options and accessories. Diesel Stock Number ( ) Kubota w/arcreach ( ) Mitsubishi w/arcreach Welding Mode CC/DC CV/DC Process Stick/TIG MIG/FCAW Amp/Volt Ranges A 4 40 V Rated Output at 04 F (40 C) 300 A at 32 V, 00% duty cycle 350 A at 27 V, 00% duty cycle 400 A at 24 V, 00% duty cycle Single-Phase Generator Power at 04 F (40 C) Peak: 2,000 watts Continuous: 0,000 watts H: 32 in. (83 mm) W: in. (667 mm) D: 56 in. (,422 mm) Net Weight Kubota 950 lb. (43 kg) Mitsubishi 993 lb. (450 kg) 27

28 Engine-Driven Big Blue 400 PipePro See literature ED/5.8 Designed for the transmission pipeline welder the Big Blue 400 PipePro offers superior downhill stick arc characteristics, as well as MIG/flux-cored capabilities, to meet high-strength steel requirements for the most demanding pipeline jobs. Wireless antenna kit (300749) recommended. Remote control of the power source without a control cord. Tailored arc control (DIG) allows arc characteristics to be changed for specific applications and electrodes. Smooth running 708 or stiffer, more penetrating 600. Industrial USB port. Quickly upload the latest software and download machine log files to retrieve in-depth information such as diagnostics and machine statistics. 0,000 watts of pure generator power. Plug in an extra Miller inverter-based power source for an additional welding arc! Compact size and weight optimizes truck space. LINE-X cover provides superior impact, corrosion and abrasion protection. Quiet operation. Only 72. decibels (97 Lwa) under full load. Improves jobsite communication and safety. Standard features include digital meters with SunVision, automatic idle, adjustable Hot Start, output contactor control and 20-volt block heater. Also available with optional stainless steel enclosure. Heavy industrial Processes Stick (SMAW) MIG (GMAW) Flux-cored (FCAW) RMD * Pulsed MIG (GMAW-P)* DC TIG (GTAW) Air carbon arc cutting and gouging (CAC-A) (rated /4 in. carbons) *With ArcReach Smart Feeder. Diesel engine EPA Tier 4 Final Mitsubishi S4L2: 24.7 hp at,800 rpm Four-cylinder, industrial, liquid-cooled Note: Engines are warranted separately by engine manufacturer. Most popular accessories SuitCase Feeders ArcReach Smart Feeder ArcReach Stick/TIG Remote Dynasty 20 Series Full KVA Adapter Cord Single-Phase Full KVA Plug Kit 972 Protective Cover 9530 HWY-Mid Frame Trailer Wireless Remote Hand Control/ Wireless Antenna Kit / Visit MillerWelds.com or your distributor for other Miller options and accessories. Diesel Stock Number ( ) Mitsubishi w/arcreach (907703) Mitsubishi w/stainless steel and ArcReach Welding Mode CC/DC CV/DC Process Stick/TIG MIG/FCAW Amp/Volt Ranges A 4 40 V Rated Output at 04 F (40 C) 300 A at 32 V, 00% duty cycle 350 A at 27 V, 00% duty cycle 400 A at 24 V, 00% duty cycle Single-Phase Generator Power at 04 F (40 C) Peak: 2,000 watts Continuous: 0,000 watts H: 32 in. (83 mm) W: in. (667 mm) D: 56 in. (,422 mm) Net Weight 993 lb. (450 kg) Big Blue 450 Duo CST See literature ED/5.5 Durable dual-operator welder/generator delivers proven CST 280 stick/tig performance for maximum productivity and efficiency. Two separate outputs powered by one low-speed diesel engine delivers up to 280 amps of output per operator. Wireless antenna kit (300749) recommended. Two superior arcs in one compact package. See CST 280 for additional details. Save fuel, reduce maintenance costs and increase productivity. Quiet operation. At 72. decibels (97 Lwa) under full load, it s quieter than most single-operator models. Improves jobsite communication and safety. Vandalism lockout kit (not shown). Lockable hinged steel panel protects front control and ignition switch. Simple-to-operate process selector knob automatically sets proper DIG setting on E600 and E708 electrodes providing superior stick performance. Lift-Arc start for TIG starts without the use of high frequency. Remote amperage control permits the use of standard and wireless amperage control devices. Increased efficiency. More arcs and better fuel economy equal increased profits for your business. Estimated savings are 34 percent with a dualoperator unit versus two single-operator units. Heavy industrial Processes Stick (SMAW) DC TIG (GTAW) Air carbon arc cutting and gouging (CAC-A) (rated 3/6 in. carbons) Diesel engine EPA Tier 4 Final Mitsubishi S4L2: 24.7 hp at,800 rpm Four-cylinder, industrial, liquid-cooled Note: Engine is warranted separately by engine manufacturer. Most popular accessories Full KVA Adapter Cord Single-Phase Full KVA Plug Kit 972 Protective Cover 9530 HWY-Mid Frame Trailer Wireless Remote Hand Control/ Wireless Antenna Kit / Spark Arrestor Kit 9502 Visit MillerWelds.com or your distributor for other Miller options and accessories. Diesel Stock Number (907477) Mitsubishi Process DC stick/tig Output Mode Separate (dual outputs) Paralleled (combined) Amperage Range A (each side) A (one side only) A Rated Output at 22 F (50 C) 75 A at 27 V, 00% duty cycle 350 A at 27 V, 00% duty cycle Single-Phase Generator Power at 22 F (50 C) Continuous: 0,000 watts H: 32 in. (83 mm) W: in. (667 mm) D: 56 in. (,422 mm) Net Weight,064 lb. (483 kg) 28

29 Big Blue 500 Pro and 600 Series See literature ED/.0 (500) and ED/.5 (600) Clean, quiet, multiprocess machines designed to give welders the output they need for heavy-duty applications on construction and fabrication sites. Big Blue 500 and 600 Pro IMPROVED! Now available with Electronic engine display simultaneously displays fuel level, engine hours, coolant temperature, oil pressure, battery volts, and engine rpm. Also tracks oil change intervals and displays engine diagnostics for quick and easy servicing. Arc control is beneficial when welding with stick and solid wires for easier fine-tuning of tough-to-weld materials and out-of-position applications. Industrial USB port. Quickly upload the latest software and download machine log files to retrieve in-depth information such as diagnostics and machine statistics. Big Blue 600 Air Pak Engine-Driven Available on Deluxe and Air Pak models. Remote control of the power source without a control cord. Wireless antenna kit (300749) recommended. 20,000 watts of pure generator power. Plug in an extra Miller inverter-based power source for an additional welding arc! Standard features include digital meters with SunVision, adjustable Hot Start, output contactor control, automatic idle, thermal overload protection and 20-volt block heater. Deluxe models add ArcReach, a polarity reversing switch and a vandalism lockout (protects control panel and receptacles, see photo at right). Ingersoll Rand ultra-reliable industrial rotary screw compressor (Air Pak model only). 30,000-hour life expectancy. Independent on/off control for applications not requiring compressed air allows greater fuel savings and longer compressor service intervals. Heavy industrial Processes Stick (SMAW) MIG (GMAW) Flux-cored (FCAW) RMD * Pulsed MIG (GMAW-P)* DC TIG (GTAW) Air carbon arc cutting and gouging (CAC-A) (500: rated 5/6 in. carbons; 600: rated 3/8 in. carbons) *ArcReach models only with ArcReach Smart Feeder. Diesel engines EPA Tier 4 Final choices 500 and 600 Pro Kubota V hp at,800 rpm Turbo-charged, four-cylinder, industrial, liquid-cooled 600 Air Pak Deutz TD2.9 L hp at,800 rpm Turbo-charged, four-cylinder, industrial, liquid-cooled Note: Engines are warranted separately by engine manufacturer. Most popular accessories SuitCase X-TREME 8VS/2VS ArcReach SuitCase 8/2 ArcReach Smart Feeder** ArcReach Stick/TIG Remote** Dynasty 20 Series Full KVA Adapter Cord Full KVA Plug Kit Protective Cover Kubota 303 Deutz HWY-225 Trailer Wireless Remote Hand Control/ Wireless Antenna Kit / Desiccant Air Dry System (for Air Pak model only) 957 Side mount Rear mount Eliminates moisture in the air stream and prevents air line freeze-ups in cold climates. Spark Arrestor Kit 9502 **For ArcReach models only. Visit MillerWelds.com or your distributor for other Miller options and accessories. *Big Blue 600 Series has welder truck specific models available visit MillerWelds.com or your distributor. Model/Stock Number Big Blue 500 Pro ( ) Kubota Deluxe model with ArcReach Welding Mode/Process CC/DC (Stick/TIG) CV/DC (MIG/FCAW) Amp/Volt Ranges A 4 50 V Rated Output at 04 F (40 C) 400 A at 36 V, 00% duty cycle 450 A at 38 V, 00% duty cycle 500 A at 40 V, 00% duty cycle Generator Power at 04 F (40 C) Three-phase Peak: 27,000 watts Continuous: 20,000 watts Single-phase Peak: 5,000 watts Continuous: 2,000 watts H: 46 in. (,68 mm) W: 28.5 in. (724 mm) D: 69.5 in. (,765 mm) Net Weight,750 lb. (794 kg) Diesel Big Blue 600 Pro ( ) Kubota Deluxe model w/arcreach Big Blue 600 Air Pak (907750) Deutz with ArcReach CC/DC (Stick/TIG) CV/DC (MIG/FCAW) A 4 50 V 600 Pro 500 A at 40 V, 00% duty cycle 550 A at 42 V, 60% duty cycle 600 A at 42 V, 40% duty cycle 600 Air Pak 500 A at 40 V, 00% duty cycle 575 A at 43 V, 00% duty cycle 600 A at 44 V, 60% duty cycle Three-phase Peak: 27,000 watts Continuous: 20,000 watts Single-phase Peak: 5,000 watts Continuous: 2,000 watts H: 46 in. (,68 mm) W: 28.5 in. (724 mm) D: 69.5 in. (,765 mm) 600 Pro,750 lb. (794 kg) 600 Air Pak 2,040 lb. (925 kg) Ingersoll Rand CE55 G Air Compressor (Air Pak model only) Features Rotary screw with electric clutch for on/off, oil change intervals of 500 hours, life expectancy of 30,000 hours Free Air Delivery Idle: 40 cfm (.3 m 3 /min.) Weld: 60 cfm (.70 m 3 /min.) Working Pressure Constant 00 psig (7 bar) Duty Cycle 00% Oil Capacity 4 qt. (3.79 L) 29

30 Engine-Driven Big Blue 800 Series See literature ED/4.0 The most powerful lineup of diesel welder/generators in the industry. All offer robust output for welding and power generation, and are ideal for dual-operator applications on labor intensive jobsites, or jobsites with limited space. IMPROVED! Now with ArcReach. Big Blue 800 Duo Pro Multi-arc welding. One dependable engine two independent arcs with up to 400 amps each. Or plug in additional inverters for a true multioperator work platform! Example: Two additional XMT machines equals four operators, up to 200 amps each. Premium quality arcs allow operators to work independently with no arc interaction. Multioperator welding has never been easier or more versatile. Increased efficiency. More arcs and better fuel economy equal increased profits for your business. Estimated savings are 34 percent with a dual-operator unit versus two single-operator units. Simple paralleling switch makes switching from a single operator to dual operators a breeze. Weld up to 400 amps per side when set up in dual-operator mode, or up to 800 amps in single-operator mode. Electronic engine display simultaneously displays fuel level, engine hours, coolant temperature, oil pressure, battery volts and engine rpm. Also tracks oil change intervals and displays engine diagnostics for easier servicing. Air Pak model adds air pressure and compressor hours displays. Big Blue 800 Duo Air Pak Remote control of the power source without a control cord. Wireless antenna kit (300749) recommended. Arc control is beneficial when welding with stick and solid wires for easier fine-tuning of tough-to-weld materials and out-of-position applications. Industrial USB port. Quickly upload the latest software and download machine log files to retrieve in-depth information such as diagnostics and machine statistics. 20,000 watts of pure generator power. Plug in an extra Miller inverter-based power source for an additional welding arc! Standard features include digital meters with SunVision, automatic idle, 20-volt block heater and vandalism lockout (protects control panel and receptacles, see photo at right). Ingersoll Rand ultra-reliable industrial rotary screw compressor (Air Pak model only). 30,000-hour life expectancy. Independent on/off control for applications not requiring compressed air allows greater fuel savings and longer compressor service intervals. Heavy industrial Processes Stick (SMAW) MIG (GMAW) Flux-cored (FCAW) RMD * Pulsed MIG (GMAW-P)* (CAC-A) (rated /2 in. carbons) Stud (/2 in.) DC TIG (GTAW) Air carbon arc cutting and gouging *With ArcReach Smart Feeder. Diesel engine EPA Tier 4 Final Deutz TD2.9 L4: 65.7 hp at,800 rpm Turbo-charged, four-cylinder, industrial, liquid-cooled Note: Engines are warranted separately by engine manufacturer. Most popular accessories SuitCase X-TREME 8VS/2VS ArcReach SuitCase 8/2 ArcReach Smart Feeder ArcReach Stick/TIG Remote Dynasty 20 Series Full KVA Adapter Cord Full KVA Plug Kit 972 Single-phase Three-phase Protective Cover 303 HWY-225 Trailer Wireless Remote Hand Control/ Wireless Antenna Kit / Desiccant Air Dry System (Air Pak model only) 957 Side mount Rear mount Eliminates moisture in the air stream and prevents air line freeze-ups in cold climates. Spark Arrestor Kit 9502 Visit MillerWelds.com or your distributor for other Miller options and accessories. *Big Blue 800 Duo Air Pak has welder truck specific models available visit MillerWelds.com or your distributor. Diesel Model/Stock Number* Big Blue 800 Duo Pro (90775) Deutz with ArcReach Big Blue 800 Duo Air Pak (907752) Deutz with ArcReach Welding Mode/Process CC/DC (Stick/TIG) CV/DC (MIG/FCAW) Output Mode Separate (dual outputs) Paralleled (combined) Separate (dual outputs) Paralleled (combined) Amp/Volt Ranges A A 4 50 V 4 50 V Rated Output at 00% Duty Cycle at 04 F (40 C) 400 A at 36 V (each side) 700 A at 44 V, 800 A at 38 V 400 A at 34 V (each side) 750 A at 40 V, 800 A at 38 V Generator Power at 04 F (40 C) Three-phase Peak: 27,000 watts Continuous: 20,000 watts Single-phase Peak: 5,000 watts Continuous: 2,000 watts H: 46 in. (,68 mm) W: 28.5 in. (724 mm) D: 69.5 in. (,765 mm) Net Weight Duo Pro,869 lb. (848 kg) Duo Air Pak 2,095 lb. (968 kg) Ingersoll Rand CE55 G Air Compressor (Air Pak model only) Features Rotary screw with electric clutch for on/off, oil change intervals of 500 hours, life expectancy of 30,000 hours Free Air Delivery Idle: 40 cfm (.3 m 3 /min.) Weld: 60 cfm (.70 m 3 /min.) Working Pressure Constant 00 psig (7 bar) Duty Cycle 00% Oil Capacity 4 qt. (3.79 L) 30

31 Towable Welders One stock number and one price what could be easier. Saves 4 5 man hours of trailer assembly and welder mounting time. And especially for large orders, who has that kind of manpower? Fleet managers appreciate the opportunity to create their own unique welder-trailer spec to standardize their national fleet. Take the guess work out of ordering a Ready-to-Rent Premium Miller welding system. Saves 4 5 hours of trailer assembly and welder mounting time. Equipment features will ensure maximum utilization/deployment rates. Can be rented as generator as well as a premium multiprocess welder. Power source is warranted for 3 years, parts and labor. Rental/Construction welding lead kits ordered separately Weld Cable with Electrode Holder Consists of 0 ft 2/0 cable with electrode holder and Tweco male connector, and stud/tweco adapter. Rated up to 400 A. Weld Cable with Work Clamp Consists of 0 ft 2/0 cable with work clamp and Tweco male connector, and stud/tweco adapter. Rated up to 400 A. Weld Cable Extensions ft (5.2 m) ft (30.5 m) 2/0 weld cable leads rated up to 400 A Package Big Blue 400 Pro ArcReach fully assembled, trailer mounted, includes: Big Blue 400 Pro (Kubota) ArcReach Trailer, HWY-MF Tweco in- Document & Fire Ext Holder Package Big Blue 500 Pro ArcReach fully assembled, trailer mounted, includes: Big Blue 500 Pro (Kubota) ArcReach Trailer HWY Tweco in- Document & Fire Ext Holder 3

32 Stick SMAW Maxstar 6 S See literature DC/27.3 Maxstar 6 S with X-CASE ( ) shown. *Sense voltage for stick. Best in class provides maximum portability and performance in the most compact stick package in the industry. Allows for any input voltage hook-up ( V) with no manual linking. Digital meter for more precise control when presetting or monitoring welding amperage. Adaptive Hot Start for stick arc starts. Portable with adjustable handle/shoulder strap. Easy to transport at only 3 pounds. Fan-On-Demand power source cooling system operates only when needed, reducing noise, energy use and the amount of contaminates pulled through the machine. Stick-Stuck detects if the electrode is stuck to the part and turns the welding output off to safely and easily remove the electrode. Menu selectable. Superior stick arc performance even on the difficult-to-run electrodes like E600. Light industrial Process Stick (SMAW) Comes complete with 6.5 ft. (2 m) 20 V and 240 V power cords 3 ft. (4 m) electrode cable with holder and 25 mm Dinse-style connector 0 ft. (3 m) work cable with clamp and 25 mm Dinse-style connector Quick-reference guide includes above plus Protective X-CASE Most popular accessories Protective X-CASE Visit MillerWelds.com or your distributor for other Miller options and accessories. Stock Number (907709) ( ) with X-CASE Input Power 20 V 240 V Welding Amperage Range Rated Output 90 A at 23.6 V, 30% duty cycle 60 A at 26.4 V, 20% duty cycle CST 280 See literature DC/29.55 Durable power source designed for the construction industry. Ideal for stick electrodes up to 3/6-inch and TIG welding of pipe and plate. Amps Input at Rated Output, 50/60 Hz KVA at Duty Cycle KW Max. Open- Circuit Voltage 48 VDC (2 6 VDC*) H: 0.3 in. (262 mm) W: 5.6 in. (42 mm) D: 3.5 in. (343 mm) Net Weight 3 lb. (5.9 kg) CST 280 *Output on single-phase reduced to comply with current limitation on input cable. CST 280 with meter Superior stick arc performance even on the difficult-to-run electrodes like E600. Simple voltage-changeover switch saves time when changing primary voltage. Input voltage can be changed without removal from inverter rack or removal of machine case. Optional digital meter for more precise control when presetting or monitoring welding amperage. Portable in the shop or at the jobsite at 4 pounds (8.6 kg) the CST 280 is easily moved from location to location. Lift-Arc start provides TIG arc starting without the use of high frequency. Rack mountable for protection, storage and transportation of multiple power sources while using a single primary power cable. Industrial Processes Stick (SMAW) TIG (GTAW) Comes with 6 ft. (.8 m) power cord One set of male connectors (Dinse-style model only) Most popular accessories CST 280 Rack Remote Controls For TIG torches see literature DC/29.55 Visit MillerWelds.com or your distributor for other Miller options and accessories. Stock Number ( ) Tweco (907696) Tweco with meter / V (907250) Tweco (907563) Dinse with meter / V Welding Process Stick/TIG Stick/TIG Input Power Threephase Singlephase Threephase Singlephase Welding Amperage Range Rated Output 280 A at 3.2 V, 35% duty cycle 200 A at 28 V, 00% duty cycle 200 A at 28 V, 50% duty cycle* 50 A at 26 V, 00% duty cycle* 280 A at 3.2 V, 35% duty cycle 200 A at 28 V, 00% duty cycle 200 A at 28 V, 50% duty cycle* 50 A at 26 V, 00% duty cycle* Amps Input at Rated Load Output, 50/60 Hz 208 V 220 V 230 V 400 V 440 V 460 V 575 V KVA KW Max. Open- Circuit Voltage 77 VDC 67 VDC H: 3.5 in. (343 mm) W: 7.5 in. (9 mm) D: 8 in. (457 mm) Net Weight 4 lb. (8.6 kg) 32

33 Maxstar 20 STR See literature DC/32. SMAW Maximum flexibility with automatic connection to any input power while maintaining the best DC stick/tig welding performance in its product class. Allows for any input voltage hook-up ( V) with no manual linking, providing convenience in any job setting. Ideal solution for dirty or unreliable power. Lift-Arc provides TIG arc initiation without the use of high frequency. Dual schedule allows operators to switch between welding parameters for specific electrodes without readjusting the machine. Hot Start adaptive control provides positive arc starts without sticking. Fan-On-Demand power source cooling system operates only when needed, reducing noise, energy use and the amount of contaminates pulled through the machine. Remote amperage control. Digital meters for more precise control when presetting or monitoring welding amperage. Portable with adjustable shoulder strap. Stick Industrial Processes Stick (SMAW) TIG (GTAW) Comes complete with 8 ft. (2.4 m) power cord (no plug) Two 50 mm Dinse-style connectors Most popular accessories 2.5 ft. (3.8 m) Weldcraft A-50 Valve TIG torch WP-7V-25-2 Remote Controls Air-Cooled TIG Torch Connector Visit MillerWelds.com or your distributor for other Miller options and accessories. *Sense voltage for stick and Lift-Arc TIG. Stock Number (907682) Welding Process Stick TIG Input Power V 20 V V 20 V Welding Amperage Range Rated Output 60 A at 26.4 V, 60% duty cycle 90 A at 23.6 V, 60% duty cycle 20 A at 8.4 V, 60% duty cycle 25 A at 5 V, 60% duty cycle Phase Three-phase Single-phase Single-phase Three-phase Single-phase Single-phase Amps Input at Rated Load Output, 50/60 Hz 20 V 208 V 240 V 400 V 480 V KVA KW Max. Open- Circuit Voltage 80 VDC ( VDC*) H: 3.6 in. (346 mm) W: 8.6 in. (29 mm) D: 9.5 in. (495 mm) Net Weight 36 lb. (6.3 kg) 33

34 ALL-IN-ONE MIG GMAW Millermatic 4 and 2 See literature DC/2.42 (4) and DC/2.58 (2) Millermatic 2 Multi-voltage plug (MVP ) allows connection to common 20- and 240-volt power receptacles without the use of any tools simply choose the plug that fits the receptacle and connect to the power cord. Light industrial Processes MIG (GMAW) Flux-cored (FCAW) Comes complete with 0 ft. (3 m) M-00 MIG gun and cable assembly (248282) 0 ft. (3 m) work cable with clamp 6.5 ft. (2 m) power cord with plug (Millermatic 4) OR 6.5 ft. (2 m) power cord with MVP plugs for 20 V and 240 V (Millermatic 2) Quick Select drive roll for.024 in. (0.6 mm) or.030/.035 in. (0.8/0.9 mm) solid wire, and.030/.035 in. (0.8/0.9 mm) flux-cored wire Millermatic 4 Mild Steel Welding Capability Max. Model Min. Recommended aluminum solution Spoolmate 00 (30037) with both Millermatic models OR 50 (30272) with Millermatic 2. 3/8 in. (9.5 mm) 3/6 in. (4.8 mm) ga. (0.6 mm) 24 ga. (0.6 mm) Aluminum Welding Capability Max. Model Min. 4 ga. (.9 mm) 4 8 ga. (.2 mm) 3/8 in. (9.5 mm) 2 8 ga. (.2 mm) Aluminum welding with the Millermatic 4 uses optional Spoolmate 00 spool gun and 4043 series aluminum wire. Aluminum welding with the Millermatic 2 uses optional Spoolmate 00 spool gun with 4043 aluminum series wire or optional Spoolmate 50 spool gun with 4000 or 5000 series aluminum wire. Auto-Set automatically provides the right settings to weld mild steel while infinite voltage control allows the flexibility to manually set your own parameters. Millermatic 2 model provides additional capabilities. Set the wire diameter (4:.024/.030 in.) (2:.024/.030/.035 in.), a blue light shows Auto-Set is activated Dial in the thickness of material you are welding Start welding with the exact parameters you need! Angled cast-aluminum drive system with calibrated tension knob creates consistent feeding and easy setup with included 0-foot (3 m) MIG gun or optional 5-foot (4.6 m) M-50 MIG gun (pg 27). Quick Select drive roll makes setup quicker by offering three grooves two for different size solid wire and a third for flux-cored wire. Auto Spool Gun Detect automatically detects when a MIG gun or spool gun is connected eliminating the need for a switch. Smooth-Start provides a smooth, spatter-free start. Thermal overload protection shuts down unit and activates the over temperature light if airflow is blocked or duty cycle is exceeded. Automatically resets when unit cools. Uses 4- or 8-inch (02 or 203 mm) spools. Millermatic 2 model additional features Advanced Auto-Set includes five different wire/gas combinations and.024-,.030- and.035-inch wire capabilities. Inverter technology combines best-in-class arc characteristics with the portability of a 38-pound machine. The arc is extremely forgiving to variations in arc length and travel speeds. Fan-On-Demand power source cooling system operates only when needed, reducing noise, energy use and the amount of contaminants pulled though the machine. Flow gauge regulator and gas hose for argon or AR/CO 2 mix, two.030 in. contact tips, Hobart spool of.030 in. solid wire, hook-and-loop cord wraps and material thickness gauge (229895) Most popular accessories Spoolmate Spoolmate (Millermatic 2 only) Running Gear/Cylinder Rack Protective Cover V-Knurled Drive Roll Visit MillerWelds.com or your distributor for other Miller options and accessories. Model/Stock Number Millermatic 4 (90762) (9560) with running gear/cylinder rack Millermatic 2 (90764) (95603) with running gear/cylinder rack Input Power 20 V 20 V 240 V Amperage Range Rated Output 90 A at 8.5 VDC, 20% duty cycle 5 A at 9.8 VDC, 20% duty cycle 50 A at 2.5 VDC, 40% duty cycle Amps Input at Rated Output, 50/60 Hz 20 V 240 V KVA KW Wire Feed Speed ipm ( m/min.) ipm ( m/min.) Wire Type and Diameter Capacity Solid steel in. ( mm) Stainless in. ( mm) Flux-cored in. ( mm) Solid steel in. ( mm) Stainless in. ( mm) Flux-cored in. (0.8.2 mm) Power Source H: 2.5 in. (38 mm) W:.25 in. (286 mm) D: 20.5 in. (52 mm) Power Source Net Weight 5 lb. (23. kg) 38 lb. (7.2 kg) 34

35 Millermatic 252 See literature DC/2.49 Recommended aluminum solution Spoolmatic 5A (9556) or 30A (3083). *With Spoolmatic 30A, regulator and dual cylinder rack. Max. /2 in. (3 mm) Mild Steel Min. 22 ga. (0.8 mm) Welding Capability Max. 3/8 in. (9.5 mm) Aluminum Min. 4 ga. (.9 mm) Aluminum welding uses optional Spoolmatic 5A or 30A spool gun. ALL-IN-ONE GMAW Infinite voltage control with self-calibrating digital meters that permit presetting of voltage and wire feed speed. Ensures precise parameters and accuracy. EXCLUSIVE! Auto-Gun Detect automatically adjusts voltage, wire speed and timers for faster switching between MIG, push-pull and spool guns. Integrated digital timers come complete with presettable preflow/ postflow, burnback, spot and delay (stitch) timers. Independent timers for MIG and spool gun. Heavy-duty aluminum, two-drive-roll system. Fan-On-Demand cooling system only operates when needed reducing power consumption and keeping internal components cleaner. Superior aluminum MIG welding with direct connection of optional Spoolmate 200 and Spoolmatic /Spoolmatic Pro spool guns or XR push-pull guns. No extra module to buy or install. MIG Industrial Processes MIG (GMAW) Flux-cored (FCAW) Comes complete with 5 ft. (4.5 m), 250-amp M-25 gun 0 ft. (3 m) work cable with clamp 0 ft. (3 m) industrial power cord (and plug on 200/230 V model) Factory-installed gas solenoid Flow gauge regulator and gas hose for argon or AR/CO 2 mix Factory-installed lowered running gear/cylinder rack.030/.035 in. reversible dual-groove drive rolls Extra contact tips Most popular accessories Spoolmate 200 and Spoolmatic Spool Guns (pg 30/3) XR Air-Cooled Push-Pull Guns (pg 32) Dual EZ-Change Low Cylinder Rack (pg 8) Elevated Gun and Cable Rack (pg 8) Protective Cover 9542 (pg 2) 230-Volt Extension Cord Visit MillerWelds.com or your distributor for other Miller options and accessories. Model/Stock Number (90732) 200(208)/230 V (95066*) 200(208)/230 V (907322) 230/460/575 V (95065*) 230/460/575 V Amperage Range Rated Output 200 A at 28 VDC, 60% duty cycle 250 A at 28 VDC, 40% duty cycle Amps Input at Rated Output, 60 Hz 200 V 230 V 460 V 575 V KVA KW (at 60% duty cycle) (at 60% duty cycle) Wire Feed Speed ipm ( m/min.) Wire Type and Diameter Capacity Solid steel in. (0.6.2 mm) Stainless in. (0.6.2 mm) Flux-cored in. (0.8.2 mm) H: 30 in. (762 mm) W: 9 in. (483 mm) D: 40 in. (,06 mm) Net Weight 205 lb. (94 kg) 35

36 TIG GTAW Maxstar 6 STL and STH DC TIG and Stick See literature DC/27.5 Maximum portability and performance provided in one compact TIG/stick package. Maxstar 6 STH TIG/stick package with remote fingertip control (907700) shown includes X-CASE. *Sense voltage for stick and Lift-Arc TIG. TIG Welding Capability Max. 3/6 in. (4.8 mm) Steel Min in. (0.5 mm) Two models available. See page 50 in the Stick section for Maxstar 6 S. STL: DC TIG/stick with Lift-Arc starting without high frequency. STH: DC TIG/stick with high frequency and Lift-Arc starting, plus built-in pulsing from 0 50 pulses per second. Allows for any input voltage hook-up ( V) with no manual linking. Portable with adjustable handle/shoulder strap. Easy to transport at only 3 pounds. Built-in gas solenoid eliminates need for a bulky torch with a gas valve. Digital meter for more precise control. Fan-On-Demand power source cooling system. Superior stick arc performance even on the difficult-to-run electrodes like E600. Light industrial Processes Stick (SMAW) Pulsed TIG (GTAW-P) with STH model TIG (GTAW) Comes with power cords 6.5 ft. (2 m) 20 V and 240 V 3 ft. (4 m) electrode cable with holder and 25 mm Dinse-style connector 0 ft. (3 m) work cable with clamp and 25 mm Dinse-style connector Air-cooled TIG torch connector Quick-reference guide TIG/stick packages include above plus 2.5 ft. (3.8 m) Weldcraft A-50 TIG torch (WP72RDI25) Protective X-CASE (30429) Flow gauge regulator with hose AK2C TIG torch accessory kit RCCS-6M remote fingertip control (packages and only) Visit MillerWelds.com or your distributor for Miller options and accessories. DC Model/Stock Number Model/Stock Number Maxstar 6 STL Maxstar 6 STH (90770) Power source only (9077) Power source only ( ) TIG/stick package (907700) TIG/stick package ( ) TIG/stick package with remote fingertip control with remote fingertip control Welding Process TIG Stick Input Power 20 V 240 V 20 V 240 V Welding Amp Range Rated Output 30 A at 5.2 V, 30% duty cycle 60 A at 6.4 V, 20% duty cycle 90 A at 23.6 V, 30% duty cycle 60 A at 26.4 V, 20% duty cycle Amps Input at Rated Output, 50/60 Hz KVA at Duty Cycle KW Max. Open- Circuit Voltage 48 VDC (2 6 VDC*) H: 0.3 in. (262 mm) W: 5.6 in. (42 mm) D: 3.5 in. (343 mm) Net Weight 3 lb. (5.9 kg) 36

37 GTAW TIG Maxstar 20/280 Series DC TIG and Stick See literature DC/32. (20) and DC/35.0 (280) Dynasty 20/280 Series AC/DC TIG and Stick See literature AD/4.8 (20) and AD/4.9 (280) Dynasty 280 DX Maxstar and Dynasty 20 Series (Maxstar 20 shown). 20 Series TIG Welding Capability Max. /4 in. (6.4 mm) Steel Min in. (0.05 mm) Max. /4 in. (6.4 mm) Aluminum (Dynasty only) Min in. (0.3 mm) 280 Series TIG Welding Capability Max. 3/8 in. (9.5 mm) Steel Min in. (0. mm) Max. 3/8 in. (9.5 mm) Aluminum (Dynasty only) Min in. (0.3 mm) Base and DX models available. Base model provides essential TIG and stick functions. DX model adds extended ranges to sequencer, full trigger options, and full preflow and pulser functions. Allows for any input voltage hook-up (20 models: V, 280 models: V) with no manual linking, providing convenience in any job setting. Ideal solution for dirty or unreliable power. Blue Lightning high-frequency (HF) arc starter for non-contact arc initiation. Provides more consistent arc starts and greater reliability compared to traditional HF arc starters. Lift-Arc provides AC or DC arc initiation without the use of high frequency. Hot Start adaptive control provides positive arc starts without sticking. Auto-postflow adjusts the length of postflow time based on the amperage setting, shielding your tungsten and eliminating the need to set the postflow time. Pro-Set eliminates the guesswork when setting weld parameters. Use Pro-Set when you want the speed, convenience and confidence of preset controls. Simply select the feature and adjust until Pro-Set appears on the display. Sleep timer conserves electricity. This programmable feature will power down the machine if it sits idle for a specified time. Update and expand. Front panel memory card data port provides the ability to easily update software and expand product features. Optional cooler power supply (CPS) is an integrated 20-volt dedicated-use receptacle for the Coolmate.3. Not available on Maxstar 20 Series. Cooler-On-Demand feature operates the auxiliary cooling system only when needed, reducing noise, energy use, and airborne contaminants pulled through the cooler. Only available on CPS models. *Refer to owner s manual for 208-volt output ratings and duty cycle. **Sense voltage for low OCV stick and Lift-Arc TIG. Model/ Stock Number Welding Process Input Power Welding Amp Range Rated Output at 60% Duty Cycle Amps Input at Rated Load Output, 50/60 Hz 20 V 208 V 230 V 240 V 400 V 460 V 480 V 575 V KVA KW Max. Open- Circuit Voltage Net Weight DC Maxstar Maxstar 20 (907683) Maxstar 20 DX (907684) Maxstar 280 (907552) (907538) with CPS Maxstar 280 DX (907553) (907539) with CPS TIG Stick TIG Stick 3-phase -phase -phase (20 V) 3-phase -phase -phase (20 V) 3-phase -phase 3-phase -phase A at 8.4 V 20 A at 8.4 V 25 A at 5 V 60 A at 26.4 V 60 A at 26.4 V 90 A at 23.6 V 235 A at 9.4 V 235 A at 9.4 V* 200 A at 28 V 80 A at 27.2 V* VDC ( VDC**) 60 VDC ( VDC**) H: 3.6 in. (346 mm) W: 8.6 in. (29 mm) D: 9.5 in. (495 mm) H: 3.6 in. (346 mm) W: 8.6 in. (29 mm) D: 22.5 in. (569 mm) 38 lb. (7.2 kg) 47 lb. (2.3 kg) 50 lb. (22.7 kg) with CPS 37

38 TIG GTAW Dynasty welders add AC TIG capabilities and the following AC features (limited on base model) Waveforms for advanced squarewave, soft squarewave, sine wave and triangular wave. Balance control provides adjustable oxide removal which is essential for creating the highest quality aluminum welds. DX models provide extended ranges. Frequency controls the width of the arc cone and can improve directional control of the arc. Dynasty 280 DX with Insight Designed to deliver Welding Intelligence. The Dynasty 280 DX with Insight incorporates Insight Core (standard) and Insight Centerpoint (optional) welding information management systems into its capabilities. These systems help welding operations improve quality, retain weld records, increase productivity and manage costs. See pages 69 and 70 for more information. Industrial TIG (GTAW) Comes with Maxstar is DC only Processes Stick (SMAW) Pulsed TIG (GTAW-P) Air carbon arc (CAC-A) w/280 models 8 ft. (2.4 m) power cord (no plug) Two 50 mm Dinse-style connectors Quick-reference guide (Dynasty only) Complete packages come with 8 ft. (2.4 m) power cord (no plug) Quick-reference guide Small Runner cart Coolmate.3 Coolant (4 one-gallon bottles) Remote control (foot or wireless foot) Weldcraft water-cooled torch kit Dynasty 20: W-250 (WP-20) Dynasty 280: W-280 (WP-280) Most popular accessories 2-Wheel Trolley Cart Small Runner Cart 3038 Coolmate Coolant Contractor Kits 303 w/rccs-4 finger control w/rfcs-4 HD foot control Dynasty Water-Cooled Complete Packages Additional packages are available visit MillerWelds.com or your distributor. Model Dynasty 20 Dynasty 20 DX Dynasty 280 Dynasty 280 DX Packages with Foot Control and CPS (95666) (95668) (95466) (95468) Packages with Wireless Foot Control and CPS (95667) (95669) (95469) Dynasty 280 DX Complete package (95469) shown. Weldcraft Water-Cooled Torch Kits (pg 24) W-250 (WP-20) W-280 (WP-280) W-375 Remote Controls RCCS-4 fingertip control RFCS-4 HD foot control Wireless foot control Visit MillerWelds.com or your distributor for other Miller options and accessories. *Refer to owner s manual for 208-volt output ratings and duty cycle. **Sense voltage for low OCV stick and Lift-Arc TIG. AC/DC Dynasty Model/Stock Number Dynasty 20 (907685) ( ) with CPS Dynasty 20 DX (907686) ( ) with CPS Dynasty 280 (907550) (907537) with CPS Dynasty 280 DX (90755) (90754) with CPS ( ) w/insight and CPS Welding Process TIG Stick TIG Stick Input Power 3-phase -phase -phase (20 V) 3-phase -phase -phase (20 V) 3-phase -phase 3-phase -phase Welding Amp Range (DC) (AC) Rated Output at 60% Duty Cycle 20 A at 8.4 V 20 A at 8.4 V 25 A at 5 V 60 A at 26.4 V 60 A at 26.4 V 90 A at 23.6 V 235 A at 9.4 V 235 A at 9.4 V* 200 A at 28 V 80 A at 27.2 V* Amps Input at Rated Load Output, 50/60 Hz 20 V 208 V 230 V 240 V 400 V 460 V 480 V 575 V KVA KW Max. Open- Circuit Voltage 80 VDC ( VDC**) 60 VDC ( VDC**) H: 3.6 in. (346 mm) W: 8.6 in. (29 mm) D: 22.5 in. (569 mm) H: 3.6 in. (346 mm) W: 8.6 in. (29 mm) D: 22.5 in. (569 mm) Net Weight 47 lb. (2.3 kg) 50 lb. (22.7 kg) with CPS 52 lb. (23.6 kg) 55 lb. (25 kg) with CPS 38

39 Spectrum 375 X-TREME /625 X-TREME See literature no. PC/9.2 (375 XT) and PC/9.6 (625 XT) Allows for any input voltage hook-up ( V, singlephase, 50/60 Hz for 375 XT and 60 Hz for 625 XT) with no manual linking, providing convenience in any job setting. X-CASE provides the ultimate protection during transport and storage. Additional space is ideal for MVP plugs, consumables box, gloves, etc. Multi-voltage plug (MVP ) on 375 XT or MVP adapter on 625 XT allows connection to 20- or 240-volt receptacles without tools. Automatic air regulation compensates for input pressure variation to provide constant recommended torch pressure for optimum cutting performance. Automatic gouging consumable detection (625 XT only). Detects gouging consumable and adjusts gas pressure to optimize performance, eliminating the need for a manual regulator. Spectrum 875 Auto-Line See literature no. PC/9.8 Spectrum 875 Auto-Line model allows for any input voltage hook-up ( V, single- or three-phase) with no manual linking, providing convenience in any job setting. Standard Spectrum 875 model operates on 208/230 V, single-phase input voltage only. Consumables storage compartment provides convenient access to consumables and parts. Automatic air regulation compensates for input pressure variation to provide constant recommended torch pressure for optimum cutting performance. Includes Ultra-Quick Connect XT60 hand-held torch with ergonomic design and flexible cable; or XT60M long body or short body machine torch. Spectrum 875 shown. 375 XT model includes XT30 hand-held torch with ergonomic design and flexible cable. 625 XT model includes Ultra-Quick Connect XT40 hand-held torch with ergonomic design and flexible cable; or XT40M long body or short body machine torch. Steel/ Stainless Aluminum Spectrum Plasma Cutters Spectrum 625 X-TREME shown. Steel/Stainless/Aluminum Rated Cutting Capacity 3/8 in. (9.5 mm) /4 in. (6.4 mm) 375 XT 5/8 in. (5.9 mm)* 3/8 in. (9.5 mm) 625 XT 7/8 in. (22.2 mm) 5/8 in. (5.9 mm) 875/875 AL *Stainless: /2 in. (2.7 mm) for Spectrum 625 X-TREME. Cut capacity ratings are based on traveling speed of approximately 5 inches per minute to achieve a precise cut. This is the key rating that should meet or exceed your typical cutting thickness requirements. Factors that can affect actual cut speeds, thickness capacity and duty cycles are: types of thermally conductive material being cut, available input power, output power settings and operator technique. For highly thermal conductive metals such as aluminum, cutting capacities may be reduced up to 30 percent compared to mild steel. Light industrial Industrial 375 XT/625 XT 875/875 Auto-Line Only 875 Auto-Line has 3-Phase capabilities. Processes Air Plasma Cutting Air Plasma Gouging (625/875 models) 375 X-TREME comes complete with XT30 hand-held torch with 2-ft. (3.7 m) cable Heavy-duty work clamp with 2-ft. (3.7 m) flexible cable 0-ft. (3 m) power cord with MVP 5-5P (20 VAC, 5 A) and 6-50P (240 V, 50 A) plugs X-CASE for protection and storage Shoulder strap Consumables box with two electrodes, two tips, deflector and air fitting 625 X-TREME comes complete with XT40 hand-held torch with 2-ft. (3.7 m) or 20-ft. (6. m) cable; OR XT40M long body or short body machine torch with 25-ft. (7.6 m) cable Heavy-duty work clamp and flexible cable with quick connect 2-ft. (3.7 m) power cord with 240 V, L6-30P twist lock plug MVP adapters with 5-5P (20 VAC, 5 A) and 6-50P (240 V, 50 A) plugs X-CASE for protection and storage Shoulder strap Consumables box with two electrodes, two 40 A tips and one 30 A tip, 30 A drag shield, deflector and air fitting corresponding automation kit 875 Auto-Line comes complete with XT60 hand-held torch with 20-ft. (6 m) or 50-ft. (5.2 m) cable; OR XT60M long body or short body machine torch with 25-ft. (7.6 m) or 50-ft. (5.2 m) cable Heavy-duty work clamp and flexible cable with quick connect 0-ft. (3 m) power cord Extra consumables Machine torch packages include corresponding automation kit Model Spectrum 375 X-TREME VAC, 50/60 Hz Stock Number (907529) 2 ft. (3.7 m) Input Power Singlephase Rated Output at 04 F (40 C) 20 V (5 A): 20 A at 88 VDC, 35% duty cycle 20 V (20 A): 27 A at 9 VDC, 20% duty cycle 240 V: 40 A at 40 VDC, 50% duty cycle Amps Input at Rated Output KVA KW Compressor Requirement 5.0 CFM (42 L/min.) at 90 PSI (62 kpa) H: 9 in. (229 mm) W: 5.5 in. (40 mm) D: 3.25 in. (337 mm) Net Weight with Torch 9 lb. (8.6 kg) Spectrum 625 X-TREME VAC, 60 Hz (907579) 2 ft. (3.7 m) ( ) 20 ft. (6. m) Singlephase 20 V (5 A): 20 A at 88 VDC, 35% duty cycle 20 V (20 A): 27 A at 9 VDC, 20% duty cycle 240 V: 40 A at 40 VDC, 50% duty cycle CFM (70 L/min.) at 90 PSI (62 kpa) H: 9 in. (229 mm) W: 5.5 in. (40 mm) D: 3.25 in.(337 mm) 2 ft. 2 lb. (9.5 kg) 20 ft. 23 lb. (0.5 kg) 25 ft. 24 lb. (0.7 kg) Spectrum 875 Auto-Line VAC, 50/60 Hz (907584) 20 ft. (6. m) Threephase Singlephase 208 V: 60 A at 40 VDC, 40% duty cycle V: 60 A at 40 VDC, 50% duty cycle V: 60 A at 40 VDC, 60% duty cycle V: 50 A at 40 VDC, 00% duty cycle 208 V: 60 A at 40 VDC, 40% duty cycle 230 V: 60 A at 40 VDC, 50% duty cycle 230 V: 50 A at 40 VDC, 00% duty cycle 208 V: V: V: V: V: V: V: CFM (9 L/min.) at 90 PSI (62 kpa) H: 3.5 in. (343 mm) W: 8.75 in. (222 mm) D: 8.5 in. (470 mm) 20 ft. 54 lb. (24.5 kg) 25 ft. 56 lb. (25.4 kg) 50 ft. 63 lb. (28.6 kg) 39

40 Gas Equipment Heavy-Duty Cutting, Welding & Heating Cuts up to 8 inches (203 mm) with optional tips Welds up to /2 inch (3 mm) with optional tips These premium heavy-duty outfits feature our proven in-tip gas mixing technology and include torch-mount flashback arrestors. This combination greatly improves operator safety and increases torch life. The outfits feature rugged, highly accurate brass regulators. Outfits with Series 30, 2-inch corrosion-resistant gauges and shatter-resistant polycarbonate lenses. Outfits are complete with safety and operations manual. Note: Welding may require additional equipment depending on which outfit is ordered. See chart below. What s Included: Torch Handle (WH200A) Cutting Attachment (SC209) Oxygen Regulator ( ) Acetylene Regulator ( ) Cutting Tip (SC2-) Welding Tip (SW205) Heating Tip (ST602) 25-ft. /4-in. Twin Hose (RL3) Friction Lighter (N3ANB) Safety Glasses (78000) Tip Cleaner (N250) Torch Mount Flashback Arrestors (H743) Operations Manual Stock Number HBA-3050 Fuel Gas Acetylene Torch Handle WH200A Cutting Attachment SC209 Cutting Tip SC2- Welding Tip SW205 Heating Tip ST602 Oxygen Regulator CGA 540 Fuel Gas Regulator CGA 50 Includes 25-ft. (7.6 m) /4-in. (6 mm) twin hose, lighter, safety glasses, tip cleaner, H743 torch-mount flashback arrestors, operations manual CGA 300 Propane/Propylene (LP/MP) outfits include 20-ft (6. m) /4-in. (6 mm) T grade hose and check valves, not flashback arrestors Tag-A-Long TL-550/TL-500 Tag-A-Long Outfits (Acetylene) Portable, lightweight Tag-A-Long cutting and welding outfits are ready to go where you need them. Compact design stores easily for road travel or when not in use. Series 30 regulators provide efficient and dependable control of gases. The high-density polyethylene carrier is extremely durable and includes a hose wrap and covered storage compartment for accessories. Outfit also includes reverse flow check valves for added safety plus safety and operations manual. What s Included: Torch Handle (CW5A) Cutting Attachment (CC509P) Oxygen Regulator ( ) Acetylene Regulator ( ) Cutting Tip (MC2-0) Welding Tip (MW203) Torch and Cylinder Carrier (3493) Oxygen Cylinder (OC20) Acetyline Cylinder (2329E) Cylinder Key (2328) 2.5-ft. 3/6-in. Twin Hose (RL92) Friction Lighter (N3ANB) Safety Glasses (78000) Regulator Mount Check Valves (H698) Operations Manual Stock Number TL-500 (No Tanks) TL-550 Fuel Gas Acetylene Torch Handle CW5A Cutting Attachment CC509P Cutting Tip MC2-0 Welding/ Brazing Tip MW203 Oxygen Regulator CGA 540 Fuel Gas Regulator CGA 200 Includes 2.5-ft. (3.8 m) 3/6-in. (5 mm) twin hose, carrier, lighter, safety glasses, regulator-mount safety check valves, operations manual, R 20-cu.-ft. oxygen and MC 0-cu.-ft. acetylene cylinders (cylinders not included with TL-500) 40

41 FILTAIR 30 See literature AY/3. Portable, high-vacuum weld fume extractor designed for use with accessories like nozzles and fume guns to collect weld fume particles at the source. Stock Number (300595) Accu-Rated Airflow 32 cfm (62 L/sec.) Designed to capture weld fume. The MERV 5 rating of FilTek XL filters provides superior filtering of up to 95 percent of weld fume particulate. Unrivaled filtering performance. Designed to capture weld fume particles with a cleanable filter and safely deposit them in an integrated particle bin. Less noise. Up to 70 percent quieter than some other extractors. Only 68.5 decibels at five feet. Portable and compact. At only 46 pounds (2 kg) the vertical-shaped machine is easy to move around. Sound Level 68.5 dba at 5 ft. (.5 m) FILTAIR MWX Series Welding Safety & Health Motor. kw Input Power 5 V, -phase, 60 Hz at.25 A Powerful systems mounted next to the weld area or easily positioned near the weld area. Disposable or cleanable filter models for multiple applications. MWX mobile fume extraction systems designed specifically for welding. MWX-S (self-cleaning) model with 0 ft. extraction arm shown. See literature AY/3.2 (SWX) and AY/3.0 (MWX) Features common to all models Designed to capture weld fume. The MERV 5 rating of FilTek XL filters provides superior filtering of up to 95 percent of weld fume particulate. Class-leading suction power of 875 cfm is Accu-Rated at the hood to better capture weld fumes and provide a cleaner environment. Superior filters. Our FilTek XL filters are specifically designed for welding with a MERV 5 rating to outlast, out-filter, and outperform all the rest. Durable aluminum pre-assembled extraction arm with external adjustments for better airflow and longer life. Self-cleaning models additional features Unrivaled filtering performance. Designed to capture weld fume particles with a cleanable filter and safely deposit them in an integrated particle bin. Quick and efficient cleaning cycle operates with a push of a button on the control panel. Note: Compressed air required to operate cleaning mechanism. Disposal drawer provides easy and convenient access to empty out collected particles. Handle releases drawer allowing it to slide out. Upgrade to self-cleaning models for high arc-on time, extracting from heavy fume processes, or when welding aluminum or galvanized materials. Processes Stick (SMAW) MIG (GMAW) Comes with FilTek XL filter Flux-cored (FCAW) TIG (GTAW) 8 ft. collection hose 20 ft. power cord Most popular consumables Replacement FilTek XL Filter Most popular accessories Collection Hose ft. (5.2 m) ft. (0.4 m) Magnetic Nozzles in. (300 mm) width Flexible Funnel Magnetic Nozzle H: 23 in. (584 mm) W: 2 in. (305 mm) D: 2 in. (305 mm) Processes Stick (SMAW) MIG (GMAW) Comes with FilTek XL filter Net Weight 46 lb. (2 kg) Flux-cored (FCAW) TIG (GTAW) Pre-assembled arm Most popular consumables Replacement FilTek XL Filters Self-cleaning models Disposable filter models Filters efficiently capture the smallest weld fume particles and offer superior filter life. Most popular accessories Hood Light with Arc Sensor For MWX Series Illuminates the welding zone and enables the fume extractor to start automatically when welding begins. Model/Stock Number MWX-S (Self-Cleaning Model) Pkg (9550) 7 ft. standard arm (955) 0 ft. standard arm (9552) 2 ft. standard arm MWX-D (Disposable Filter) Pkg (95507) 7 ft. standard arm (95508) 0 ft. standard arm (95509) 2 ft. standard arm Filter Media 490 sq. ft. (45.52 sq. m) Accu-Rated Airflow 875 cfm (43 L/sec.) Extraction Arm Diameter 8 in. (203 mm) Sound Level AApproximatel y 70 dba at 5 ft. (.5 m) Motor hp, 3,450 rpm Input Power 5 V, -phase, 60 Hz at approximately.9 A SH: in. (883 mm) W: 3.75 in. (806 mm) D: 48 in. (,29 mm) Net Weight without Arm MWX-S 300 lb. (36 kg) MWX-D 238 lb. (08 kg) 4

42 Accessories Engine Drive Accessories Big Blue Accessories Blue Star Accessories Cable Holder For Big Blue 500 Pro/600 Series/ 800 Series. Vandalism Lockout Kit Field For Big Blue 500 Pro/600 Series. Lockable hinged steel panels cover and protect name plate gauges and ignition switch (padlock included). Also includes engine compartment door lock and key. Lifting Eye For Fusion and Blue Star. Running Gear For Fusion and Blue Star. Compact and balanced, lightweight wheelbarrow-style running gear provides easy onsite mobility. Bobcat and Trailblazer Accessories (Gas/LP) Multi-Terrain Running Gear For Bobcat Air Pak. Includes two heavy-duty Never Flat 5-inch tires, two 8-inch rubber swivel casters and a heavy-duty handle. Recommended for all surfaces and applications and is easy to move around the jobsite. Multi-Terrain Running Gear Inner tubes Never Flat tires For gas/lp Bobcat and Trailblazer (except Air Pak models). Includes two heavy-duty 5-inch tires, two 8-inch rubber swivel casters and a heavy-duty handle. Recommended for all surfaces and applications and is easy to move around the jobsite. Off-Road Running Gear Inner tubes Never Flat tires For gas/lp Bobcat and Trailblazer (except Air Pak models). Includes four heavy-duty 5-inch tires and a rugged handle to provide maximum maneuverability. Off-Road Running Gear with Protective Cage and Never Flat Tires For gas/lp Bobcat and Trailblazer (except Air Pak models). Running gear and rugged cage with cable holders protects your investment and is easy to move around the jobsite. Protective Cage with Cable Holders For gas/lp Bobcat and Trailblazer (except Air Pak models) For Trailblazer 302 Air Pak. Rugged cage with cable holders protects your investment. Works with Running Gear, Gas Cylinder Mounting Assembly or LP Tank Mounting Assembly. Gas Cylinder Mounting Assembly For gas Bobcat and Trailblazer (except Air Pak models). Designed for use with Running Gear, Protective Cage, or by itself. Includes base tray with bottle bracket, vertical support rack and safety chain. Note: Not for use with LP Tank Mounting Assembly. Not recommended for use with Protective Cover. Hose and LP Tank Mounting Assembly For LP Bobcat For LP Trailblazer. Designed for use with Running Gear, Protective Cage, or by itself. Includes bracket and clamp to mount 33- and 43-pound tanks horizontally, and hose with fittings to converter. Note: Cannot be used with Gas Cylinder Mounting Assembly. Not recommended for use with Protective Cover. Remote Oil Drain and Filter Kit Field For gas Bobcat and Trailblazer (except Air Pak models). Front mount for Kohler engines makes servicing easy when engine drive is mounted in tight spots. Bobcat and Trailblazer Accessories (Diesel) All-Purpose Running Gear with Never Flat Tires For diesel Bobcat and Trailblazer. Includes two heavy-duty 5-inch tires, two 8-inch rubber swivel casters and a heavy-duty handle. Recommended for all surfaces and applications and is easy to move around the jobsite. Protective Cage with Cable Holders 9533 For diesel Bobcat and Trailblazer. Rugged cage with cable holders protects your investment. Works with Running Gear, or with trailer. Note: Not for use with Protective Cover. Generator Accessories Female Receptacle Twist Lock Adapter Cord For Fusion. L4-30R to NEMA 6-50R. Adapts engine drive 20/240-volt twist lock plug to common Millermatic and Spectrum 240-volt plug. Full KVA Adapter Cord For Bobcat, Trailblazer and Big Blue models. NEMA 4-50P to NEMA 6-50R. Adapts engine drive 20/240-volt plug to common Millermatic and Spectrum 240-volt plug. Full KVA Plug Kit 972 -phase, 20/240 V, 50 A plug (NEMA 4-50P). For Bobcat, Trailblazer and Big Blue models phase, 480 V, 30 A plug (NEMA L6-30P). For Bobcat 3 Phase phase, 240 V, 50 A plug (NEMA 5-50P). For Big Blue 500 Pro/ 600 Series/800 Series. Protective Covers Female Receptacle Protective covers (30099) and (9530) shown. Protective Covers Heavy-duty, water- and mildew-resistant covers protect and maintain the finish of the welder For Fusion and Blue Star For Bobcat 200 Air Pak withoutrunning Gear For Bobcat 200 Air Pak withrunning Gear For gas Bobcat and Trailblazer (except Air Paks) withoutprotective Cage or Running Gear For gas Bobcat and Trailblazer (except Air Paks) withprotective Cage or Running Gear For diesel Bobcat and Trailblazer withoutprotective Cage or Running Gear For Trailblazer 302 Air Pak For Big Blue 400 Pro/400 PipePro/450 Duo CST For Big Blue 500 Pro/600 Pro with Kubota. 303 For Big Blue 600 Air Pak/800 Series with Deutz. 42

43 Accessories International-Style Connectors For Dynastys, Syncrowaves, Maxstars, Invision 350 MPa, and XMT 304 and 350. These power sources are equipped with International-style con nectors for secondary con nec tions. (Power source is shipped with two 50 mm male International-style plugs for use with #4 to #/0 AWG size cable.) International-Style Connector Kit Kits include one International-style male plug which attaches to the work and/or weld cables and plugs into the International-style receptacles on the power source mm Accepts #4 to #/0 AWG cable size. Required if male plugs shipped with power source must be re placed, or if additional plugs are needed mm Accepts #/0 or #2/0 AWG cable size. Required if #/0 or #2/0 AWG size cable is to be used. Extension Kit For International-Style Cable Connectors Used to adapt or extend weld and/or work cables. Kit includes one male International-style plug and one in-line female International-style receptacle mm Accepts #4 to #/0 AWG size cable. International/Tweco Adapter A one-piece adapter which has an International-style male plug (to power source) on one end and a female Tweco receptacle (for weld cable connection) on other end. International/Cam-Lok Adapter A one-piece adapter which has an International-style male plug (to power source) on one end and a Cam-Lok receptacle (for weld cable connection) on other end. Tweco -Style Connector 50 mm 998 Accepts #/0 or #2/0 AWG cable size. Kit includes one Tweco-style male plug which attaches to the work and/or weld cables and plugs into the receptacle on the power source. Tweco -StyleConnector 50 mm Accepts #3/0 or #4/0 AWG cable size. Kit includes one Tweco-style male plug which attaches to the work and/or weld cables and plugs into the receptacle on the power source. Tweco -Style Connector 50 mm Accepts #/0 or #2/0 AWG cable size. Kit includes one Tweco-style female plug which attaches to weld cables. Tweco -Style Connector 50 mm Accepts #3/0 or #4/0 AWG cable size. Kit includes one Tweco-style female plug which attaches to weld cables Adapter, Threaded Stud to Tweco (stud hole dia. 5/8 in) Load Banks LBP Designed to provide an adjustable load for troubleshooting or calibrating welding power sources or generators. Standard equipment includes analog meters for both AC and DC output with jacks for external metering connections. It comes with a 3 ft (4 m) 5 V power cord and has seven 50 amp load switches, providing a maximum capacity of 350 amps. Welding Power Load Bank Design ed to load test the output of transformer-type, engine- or motor-driven generator welding power sources. This unit can be used to test AC or DC welder outputs, and to demonstrate welding equip ment to prospective customers. Air-Cooled TIG (GTAW) Torch Adapters For Maxstar mm (small) International-style flow thru for (WP7, WP9, WP50) onepiece torch For Syncrowave mm International-style flow thru for (WP7, WP9, WP50, WP23) one-piece torch. Remote Controls See also Remote Control Extension Kits and TIG Accessories Remote Controls. PRHC-4 Hand Control 955 For all solid-state power sources after serial number JK Complete current or voltage control brings 20 volts GFCI power to work area in a single cord. Housed in a durable light aluminum case and includes 25 ft (38 m) cord with plugs. Remote On/Off Control Field For Gold Stars, Deltawelds, and. Allows you to turn your power source on or off from a distance of 20 ft (6 m). This is especially useful if power source is up in a mezzanine. Accessory Kits With Ring Lugs No. 2 Stick Cable Sets ft. (4.6 m) ft. (5 m) Consists of either 5- or 50-foot electrode cable with holder and work cable with clamp. 200 A, 00% duty cycle. Rack Running Gear 954 Caster kit, includes 4 swivel casters. Mounting on ends of rack Caster kit, includes 2 swivel and 2 fixed casters. Mounting under rack. RHC ft (6 m) cord ft (30 m) cord Miniature hand current/contactor control. : 4 x 4 x 3.25 inches (02 x 02 x 82 mm). Includes cord and plug. 2/0 Stick Cable Set ft. (5 m), 350 A /50 ft. (30/5 m), 300 A Consists of either 50- or 00-foot 2/0 electrode cable with holder and 50-foot work cable with clamp. 00% duty cycle. 43

44 Accessories Weld Cables In Stock and Ready To Ship We use the highest quality cable and most reliable manufacturing techniques that will maximize the life of the weld cables in tough rental applications. 2/0 Weld Cable Extensions Stock No ft. (5 m) Stock No ft. (30 m) Extends weld cables 95457, and Cable with Work Clamp Consists of a stud/tweco adapter and 0- foot (3 m) 2/0 weld cable with a Tweco male connector and work clamp. Rated up to 500A. Stock No Cable with Electrode Holder Consists of a stud/tweco adapter and 0- foot (3 m) /0 weld cable with a Tweco male connector and electrode holder. Rated up to 250A. Stock No (Recommended) Consists of a stud/tweco adapter and 0- foot (3 m) 2/0 weld cable with a Tweco male connector and electrode holder. Rated up to 500A. Stock No Trailers See literature AY/20.0 HWY-Mid Frame Trailer For Bobcat, Trailblazer, and Big Blue 400 Pro/400 PipePro/ 450 Duo CST models. A,424-pound (646 kg) capacity highway trailer with welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Includes jack stand, fenders, lights, and dual hitch with 2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye. Trailer accessories Fender Kit For HWY-Mid Frame and HWY-225. Replacement fenders. Dual Hitch 3044 For HWY-Mid Frame and HWY-225. Combination 2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye in one reversible assembly. HWY-225 Trailer For Big Blue models. A 2,700-pound (,225 kg) capacity highway trailer with welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Includes jack stand, fenders, lights, and dual hitch with 2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye. Cable Tree For HWY-Mid Frame and HWY-225. Provides an area to conveniently wrap weld cables and extension cords. 4 West Four-Wheel Steerable Off-Road Trailer For Big Blue 500 Pro/600 Series/800 Series. A heavy-duty 2,550-pound (,57 kg) capacity trailer designed for use in mines, quarries and other rough terrain. Has narrow 22-foot (6.7 m) turning radius. Includes 3-inch (76 mm) lunette eye, universal hitch and safety chains. 2-In- Document/Fire Extinguisher Holder For HWY-Mid Frame and HWY-225. Stores documents and holds a 5-pound fire extinguisher. Note: Holder shown mounted on trailer. Fire extinguisher not included. Note: Trailers are shipped unassembled. *Width at outside of fenders. **Does not include tongue. Model HWY-Mid Frame HWY West Gross Axle Weight Rating,605 lb. (728 kg) 3,500 lb. (,588 kg) 2,000 lb./axle (907 kg/axle) Gross Vehicle Weight Rating,424 lb. (646 kg) 2,999 lb. (,360 kg) 3,000 lb. (,36 kg) Net Payload,424 lb. (646 kg) 2,700 lb. (,225 kg) 2,550 lb. (,57 kg) Height of Bed 9.5 in. (495 mm) 9 in. (483 mm) 2.25 in. (540 mm) Road Clearance 8 in. (203 mm) 7.5 in. (9 mm) 8 in. (203 mm) Track (Center to Center of tires) 46 in. (,68 mm) 50 in. (,270 mm) in. (,403 mm) Standard Tires (Standard Rating or P-size Rating) ST75/80D-3 Load Range C ST75/80R-3 Load Range D B78-3 L: 0 in. (2,565 mm) W: 55 in. (,397 mm)* L: 05.5 in. (2,680 mm) W: 56.5 in. (,435 mm)* L: 9 in. (2,3 mm)** W: 6.25 in. (,556 mm) Net Weight 8 lb. (82 kg) 280 lb. (27 kg) 420 lb. (9 kg) 44

45 Accessories for use with the XMT 350 racks (4 and 6 pack), it contains 6 weld cables (2/0) with a tweco connector on one end and /2 ring lugs on the other end, the lengths are sized to fit in the rack for use with the XMT 450 racks, it contains 4 weld cables (2/0) with /2 inch ring lugs on each end, the lengths are sized to fit in the rack. A-50 WP-7V-25-2 Air-cooled (two cable), 998 Tweco -style connector required A-200 WP-26V-25-2 Air-cooled (two cable), 998 Tweco -style connector required Cable cover: WC-3-22 recommended for use with either torch. Wireless Remote Foot and Hand Controls See literature no. AY/6.5 (Foot) and AY/6.6 (Hand) Increases productivity, saves money, improves safety and easy to use. Wireless 4-pin receiver (included with both systems) Foot control Wireless Foot Control Wireless Hand Control Foot control is designed specifically for TIG welding in manufacturing, fabrication and plant applications, allowing operator to adjust amperage at point of use without the limitations of remote cord. Auto on feature extends the battery life up to 250 hours of welding without turning the pedal on and off. Easy-Glide Wear Pads glide across concrete, making it easy to reposition the pedal for comfort and speed. *Some applications are not suitable for wireless communication. Keep in mind that the rated range is subjective, and depends on factors such as obstructions, frequency interference, transmission technology, and weather. The figures listed assume ideal conditions are present. Improves productivity and maneuverability by eliminating cord tangles. Reduces clean up time and work area cord clutter. Improves safety by eliminating control cord and reducing potential trip hazard. Improves reliability by eliminating control cord failure. Multiple frequency sharing allows up to 20 systems to operate in a 90-foot (27.4 m) radius with accuracy and precision and without delay, system interference, or crosstalk. Easy-to-install receiver plugs directly into the 4-pin receptacle of Miller machines. Easily programmable. Control can be quickly and easily paired with any other Miller 4-pin wireless receiver. (Control is preprogrammed when purchased with the receiver.) Hand control Hand control is designed for Stick, TIG, MIG and Flux-Cored welding, allowing operator to adjust parameters for different joint configurations, electrodes and wire types/sizes at the point of use instead of walking back to the machine. Allows parameter adjustments up to 300 feet away from welder without returning to machine. Improves weld quality. Operators can adjust their machines to optimize the parameters for different joint configurations, electrodes, and wire types and sizes. Smart Touch buttons allow quick and accurate machine parameter adjustments. Digital meter display allows presetting percent age of machine output before welding, and viewing amperage and voltage while welding. Industrial Processes TIG (GTAW) Pulsed TIG (GTAW-P) The following processes are with hand control only Stick (SMAW) MIG (GMAW)* Flux-Cored (FCAW) *Only with voltage-sensing feeder. Comes complete with Wireless foot control (300429) or hand control (300430) transmitter Wireless 4-pin receiver (300722) Battery box (249297) Three AA batteries Four Easy-Glide Wear Pads (foot control only) (sold individually, (248274) Belt clip (hand control only) (249233) Suggested power sources Look throughout this catalog for the icon above signifying compatibility with a wireless remote. For a complete power source compatibility list visit MillerWelds.com/wireless. Model/Stock Number Wireless Foot Control System (300429) Wireless Hand Control System (300430) Component Foot control (transmitter) Hand control (transmitter) Power Supply Three AA batteries Three AA batteries Battery Life 250 hours 250 hours Rated Range* 90 ft. (27.4 m) 300 ft. (9 m) Temperature -3 F to +58 F (-25 C to +70 C) Radio Frequency 2.4 Ghz (ISM band) RF Power <3 mw Antenna Internal H: 6 in. (52 mm) W: 5.75 in. (46 mm) D:.5 in. (292 mm) H: 5 in. (27 mm) W: 2.75 in. (70 mm) D:.375 in. (35 mm) Weight 3 lb. (.4 kg) w/batteries 0.6 lb. (0.27 kg) w/batteries 45

46 Accessories Bernard 300 Amp Best of the Best MIG Gun Service Parts/Consumables Item # Part # Q305AE8XMC Part # Q305AE8VMC Part # Q305AE8HMC Description N-5800C NS-588C Centerfire Nozzle 2 T-045 T-035 T-052 Centerfire Contact Tip 3 D- DS- Centerfire Gas Diffuser R 4323R Insulator Cap 5 QT3-45 Neck 6 QJL-3545 QJL-6 Jump Liner 7 423B Stay-Tite End Fitting Stay-Tite Cone Nut NS 499 (N/A) Conduit Clamp (2 Req d) NS 4939 (N/A) Jacket Clamp (2 Req d) Handle Kit, Standard Trigger, Standard 4207 Post Fastener ( Req d) (N/A) Post Fastener, Short (4 Req d) Handle Screw (5 Req d) Terminal, Quick Disconnect (2 Req d) (N/A) Handle Spring 6 40 (N/A) Straight Rear Strain Relief (N/A) Adaptor Block (N/A) Miller Power Pin Assembly 9 L3A-5 L3A-5 L4A-5 Liner (N/A) Power Pin Tip (N/A) Power Pin Insulator (N/A) Rear Terminal Housing M (N/A) Screw, Trigger Housing (2 Req d) (N/A) Cover, Rear Screw (2 Req d) Trigger Control Plug Assembly Part is only available through Bernard -855-MIGWELD ( ). 300 Amp Best of the Best MIG Gun, Miller Connection Part # Intergrated Miller Product Standard Configuration Cable Length Duty Cycle Q305AE8XMC 22A and 24A Feeders, Millermatic 350/350P.045 (.2 mm), Flush Tip 5 (4.57 m) 00% Q305AE8HMC Suitcase 8RC, 8VS, X-TREME 8VS, 2RC, X-TREME 2VS MIG Packages.052 (.4 mm) 5 (4.57 m) 00% Q305AE8XMC can be converted to run.035 (0.9 mm) wire by simiply changing the contact tip. Q305AE8HMC can be converted to run.045 (.2 mm) or /6 (.6 mm) wire. 46

47 AMP Accessories Dura-Flux Service Parts/Consumables Item # Part # Description Quantity FLX355AM Gun Assembly Tip Holder Kit (includes) Insulator, Tip Tip Holder, Slip-On 4 T-062 Centerfire Contact Tip, /6" (.6 mm) T-072 Centerfire Contact Tip,.072" (.8 mm) (Included w/gun) T-078 Centerfire Contact Tip, 5/64" (2.0 mm) (Included w/gun) T-094 Centerfire Contact Tip, 3/32" (2.4 mm) (Included w/gun) Neck Replacement Kit (includes) Sleeved, 6" (5.2 cm) x 30 Sleeved, 6" (5.2 cm) x 60 (Pictured) Sleeved, 8" (20.3 cm) x 90 Sleeved, 2" (30.5 cm) x 30 Sleeved, 2" (30.5 cm) x 60 Aluminum Armored, 6" (5.2 cm) x 30 Aluminum Armored, 6" (5.2 cm) x 60 Aluminum Armored, 8" (20.3 cm) x 90 Aluminum Armored, 2" (30.5 cm) x 30 Aluminum Armored, 2" (30.5 cm) x 60 Neck Liner, 6" (5.2 cm) Neck Liner, 2" (30.5 cm) Trigger Guard Kit (includes) Trigger Guard Screw, #8-32 x -/2 (2 Req d) Nut, #8-32 (2 Req d) Heat Shield (Optional) Snap Ring Clamp Screw, /4-20, Hex Socket Handle Kit (includes) Handle Halves Handle Screw Post Fastener Switch Assy, Trigger Terminal, Quick Disconnect Cord Assembly, 0 (3.05 m) Cord Assembly, 5 (4.57 m) Screw, Cap Spring, Strain Relief Rigid Strain Relief SCLN Lincoln Power Pin Kit (includes) Power Pin Trigger Cord Adapter (Lincoln Only) Liner, Power Pin, Lincoln O-Ring Miller Power Pin Kit (includes) Power Pin Liner, Power Pin, Miller O-Ring Each kit contains neck and neck liner. 2 Part is only available through Bernard Replacement Dura-Flux, Miller Connection Part # Intergrated Miller Product Standard Configuration Cable Length Duty Cycle FLX355AM X-TREME 2VS MIG Packages /6-3/32 5' (4.57 m) 350 amps 00% duty cycle 47

48 Click On A Whole New World MillerWelds.com Ready- To-Rent Order and receive a trailer-mounted diesel welder in a Ready-to-Rent condition no assembly required!...and to your company specification! One stock number and one price what could be easier. Saves 4 5 man hours of trailer assembly and welder mounting time. And especially for large orders, who has that kind of manpower? Fleet managers appreciate the opportunity to create their own unique welder-trailer spec to standardize their national fleet. Step-by-Step Welding Project Plans, along with hundreds of project photos displayed in the Project Idea Gallery. Three active Forums Welding Discussions, Welding Projects and Motorsports as well as an Industrial Welding Blog. Two clicks get you details for any product, and one more click gets you product spec sheets, parts and accessories recommendations, selection and comparison guides even connect with a local distributor to check price and availability. Articles, Videos and additional Training Tools for Improving Your Skills. Welding information organized by Industry & Interest to meet your professional and recreational welding needs. Easy-to-find Miller Sales, Service and Rental locations, downloadable product information, Owner s Manuals and much more! Miller Gear, Special Offers and Gift Certificates at the Company Store (MillerWeldsStore.com). T F Literature / Manuals T F Service / Application Support T F Rental Customer Service T Rental Orders by Fax: Rental Orders by rentalsales@millerwelds.com Stk # Miller Electric Mfg. Co.