Engine Drive Buyer`s Guide Engine Drive Buyer`s Guide

For detailed specification sheets or to locate your
nearest Miller distributor, call:
1-800-4-A-Miller
(1-800-426-4553)
M i l l e r We l d s . c o m
For Welding and
Power Generation
Engine Buyers Guide Cover 12x18:doc
4/15/2009
12:59 PM
Page 1
An Illinois Tool Works Company
©2008 Miller Electric Mfg Co.
Engine
Drive
Buyer’s
Guide
For detailed specification sheets or to locate your
nearest Miller distributor, call:
1-800-4-A-Miller
(1-800-426-4553)
M i l l e r We l d s . c o m
An Illinois Tool Works Company
©2008 Miller Electric Mfg Co.
Engine
Drive
Buyer’s
Guide
For Welding and
Power Generation
April 2009
Table of Contents
Engine Drive Products
Understanding Features and Benefits
Reliability
Welding Processes
Welding Amperage Requirements
Duty Cycle
Generator Power
Generator Power while Welding
Power Requirements to
Run Tools and Motors
Plasma Cutters and Generator Power
Engine Options
Engine Drive Chart
Engines and Fuel Economy
Product Highlights
1
Page
2
3
4
5
6
7
8
8
9
10
12
14
Understanding Features
and Benefits
Picking the best engine drive isn’t easy! Each model
delivers a variety of features and benefits. Some offer a
lower purchase price, while others reduce operating
expenses and cost less over the long haul. For special
applications, certain machines deliver superior results.
To help you choose an engine-driven welding
generator, Miller produced this Engine Drive Buyer’s
Guide. We hope this review of products, processes,
selection criteria, application notes and common Q&A
leads you to select an engine drive that satisfies you for
years.
Reliability
We know you value reliability more than any other
attribute. If a machine doesn’t work, it affects your whole
operation. That’s why Miller designs its engine drives so
you can count on flawless operation day after day, year
after year.
If you earn a living with your welding machine,
check out these facts, taken from an independent, blind
survey of welding service technicians:
Miller Rated Most Reliable by High Margins
Su y
y
p ny I
don’t have warranty problems with,” “Miller does an
excellent job with their service and procedure booklets
their 1-800 number is a great resource,” “I have worked with
Miller for 35 years and they are the best by far.”
2
Welding Processes
Stick Welding (SMAW): All Miller engine
drives produce a DC constant current (CC) output
for Stick welding. Every Miller machine offers a great
Stick arc to satisfy the most demanding
professionals.
DC TIG Welding (GTAW): TIG welding
done in the field on steel, stainless and other ferrous
metals requires a DC, CC arc. You can DC TIG weld
with every Miller engine drive.
AC TIG Welding (GTAW): For TIG
welding on aluminum and other non-ferrous
metals, you need an AC output. Miller offers
engine drives for making critical welds that
meet code requirements, as well as for noncritical AC welding.
MIG and FCAW (Wire Welding/GMAW):
If you want to weld with solid or cored wires,
consider an engine drive with DC constant voltage
(CV) capabilities. While you can run cored wires by
adding a voltage-sensing wire feeder to a CC engine
drive, machines with CV capabilities deliver
superior results. To start, they are much easier to
fine tune, especially when welding with certain selfshielded wires in structural applications. In
addition, you’ll need CV capabilities if you want to
run aluminum or small diameter hard wires for thin
gauge material.
Miller offers engine drives with CV capabilities, as well as CC
engine drives with factory and/or field installed CV options.
Gouging: Air Carbon Arc gouging puts a lot of
stress on a machine. While you can do it with a
smaller unit, engine drives offering at least 300 amps
of power at a high duty cycle work best for gouging. If you need
to remove a lot of metal, look for an engine drive with a peak
output of at least 500 amps. This will let you run 3/8 in. diameter
carbons, so you’ll get the job done faster.
3
Amperage Requirements
Welding amperage requirements largely depend on
the diameter and type of electrode you want to
use. The following charts provide suggested operating
ranges for common Stick, wire and carbon arc gouging
electrodes. This helps you determine which electrode
sizes you can run with a particular machine.
Stick dia.
1/8 in.
5/32 in.
6010, 6011 40 – 85
3/32 in.
75 –125
110 – 165 140 – 210 210 – 315
3/16 in.
6013
40 – 90
80 – 130
105 –180 150 – 230 250 – 350
7018
60 – 100
110 – 165 150 – 220 200 – 275 320 – 400
Wire
.030 in.
.035 in.
.045 in.
Tubular
––
––
15 – 36V
15 – 36V 15 – 40V
105 – 340A 110 – 430A 140 – 480A
Self––
shielded
flux cored
MIG
14 –20V 15 –18V
50 –120A 70 –160A
17 – 23V 18 – 25V 18 – 34V
50 – 200A 50 – 225A 85 – 355A
5/64 in.
3/32 in.
.052 in.
1/4 in.
––
1/16 in.
14– 22V
146–322A
21– 39V
26 – 40V
150 – 500A 250 – 610A
Wire
.072 in.
Tubular
22 – 36V 23 – 33V 24 – 36V
––
200–495A 250–510A 355–615A
7/64 in.
1/8 in.
26 – 32V
375–640A
Self16 – 25V 16 – 35V 16 – 35V 22 – 33V 28 – 38V
shielded 130–350A 145–545A 200–525A 310–625A 400–600A
flux cored
Air Carbon Arc Gouging
Carbon
Diameter
1/8 in.
3 mm
5/32 in.
4 mm
3/16 in.
5 mm
1/4 in.
6 mm
5/16 in.
8 mm
Min. Amps 60
90
200
300
350
Max. Amps 90
150
250
400
450
Carbon
Diameter
1/2 in.
13 mm
5/8 in.
16 mm
Flat
3/8 in.
10 mm
Flat
5/8 in.
16 mm
Min. Amps 450
800
1000
250
300
Max. Amps 600
1000
1250
450
500
3/8 in.
10 mm
4
Duty Cycle
Duty cycle is the amount of time during a 10-minute
period that an engine drive can continuously operate at
its rated welding output without causing overheating
damage to the system.
Taking the Heat. Miller runs duty cycle tests at
104° F (40° C) ambient temperature, which simulates hot
summer conditions. 104° F is rated higher than any
competitive machine. In side-by-side, real-world
encounters at Gulf Coast refineries, Miller engine drives
gouged all day long. Competitive units overheated and
shutdown, causing work delays.
For applications requiring extensive arc-on time
with large electrodes, choose a welder with a high duty
cycle and high amperages.
40% Duty Cycle
4 Minutes Welding
6 Minutes Resting
Many Miller engine drives provide outputs higher
than their 100% rating, but at a lower duty cycle. For
instance, the Big Blue 500 produces a maximum of 600
amps, but has a 40% duty cycle with this output.
Note: Most Stick electrodes are consumed in less than two minutes, which
means they require a 20% duty cycle. All Miller engine drive product
specification sheets include duty cycle times.
No Cut Outs. Most Miller machines are rated at 60%
duty cycle or higher. Most of these are rated at 100%,
giving you full weld and generator power in the toughest
environments.
5
Generator Power
Miller packs its engine drives with 120/240VAC
generator power to run tools, lights, start motors and
power equipment. In fact, tools perform better when run
off Miller engine drives.
Full Speed Ahead. Never put up with slow tool
speed, such as limited RPM on drills or saws. Miller
engine drives provide full voltage for optimum
performance and maximum tool life.
Full Voltage. Miller’s minimum standard for rating
generator power holds the voltage within 10% of 120/240V
(within the ratings of most jobsite equipment).
Smooth Power—Not Spike Power.
Revolutionary ten-degree skewed-rotor design found in
the Bobcats optimizes generator performance for
smoother power not spiked power found with other
brands. Better power better performance.
Continuous Power. To ensure continuous power in
hot summer conditions, we place engine drives in
a 104° F (40° C) test cell, and run them under load until
internal temperatures stabilize. For example, the
Trailblazer 302 runs at 9.5 kW for a minimum of 4 hours.
Toughest Test. Miller obtains its continuous
generator power ratings (100% duty cycle) using the
industry’s most stringent guidelines: our own.
Peak Power. At Miller peak power refers to
generator power beyond the “continuous” rating. You can
use this temporary burst of power to start motors or
plasma cut. To test peak power, we place engine drives in
an 86° F (30° C) test cell and run them under heavy load
for 30 minutes. We then put them under a peak load for a
minimum of 30 seconds. If the voltage stays within 10%
of nominal and the machine remains cool, we approve
the peak rating.
6
Generator Power While
Welding
All Miller engine drives provide simultaneous
welding and generator power. This means that while one
operator welds, others can run tools and lights. Miller is
the clear choice when productivity counts.
Bobcat® Generation
Weld
Current
(Amps)
Total Power
(Watts)
120V Receptacle
(Amps available)
240V Receptacle
(Amps available)
0
90
125
180
250
11,000
8000
5200
3500
2200
88*
66*
43*
29*
18
44*
33
21
14
9
*50A, 120/240 VAC receptacle. See owner's manual for additional information.
Several Miller engine drives deliver superior
performance in multiple-task applications providing
continuous generator power independent of weld settings.
This means the operator who is welding with a product
like the Trailblazer® Series can set the amperage control
less than maximum while other operators can still draw
on full auxiliary voltage (120/240 V).
Trailblazer® Power
Weld
Current
(Amps)
Total Power
(Watts)
120V Receptacle
(Amps available)
240V Receptacle
(Amps available)
300
250
200
150
100
1000
3500
5200
6700
8000
10
31
46
60
70
5
15
23
30
35
When welding at an average of 150 amps, the Trailblazer ® Series still delivers
6,700 watts of power to run lights and tools. Some competitive engine drives
cannot provide any generator power under this welding load.
7
Power Requirements To Run
Tools and Motors (Approximate)
FARM EQUIPMENT
Starting Watts Running Watts
Barn cleaner (5 HP)
11,600
3,000
Silo unloader (5 HP)
12,200
4,300
Portable conveyer (1/2 HP)
3,400
1,000
Milker (5 HP)
10,500
2,800
CONTRACTOR TOOLS
Hand drill (1/2 in)
600
600
Circular Saw (8-1/4 in)
1,400
1,400
Air compressor (1-1/2 HP)
8,200
2,200
Flood lights (vapor)
1,250
1,000
Refrigerator/freezer
2,200
700
Sump pump
1,300
800
Millermatic® 212 Auto-Set™
MIG welder, 230 V
6,500
6,500
Spectrum® 625 X-TREME™
230 V 1/2 in. cut
6,900
6,900
HOUSEHOLD
WELDING/CUTTING EQUIPMENT
Plasma Cutters and
Generator Power
Tired of dragging around a bulky oxy-fuel rig and fed
up with the slow cutting speeds of saws, cut-off wheels
and shears? That’s why many contractors have switched
to plasma machines for cutting stainless steel, aluminum,
mild steel or any conductive metal. Miller Spectrum
series of plasma machines cut substantially faster than
any other option and they can run off your engine
drive’s generator power.
Miller designed the Spectrum plasma cutters listed
below to operate smoothly using generator power.
Spectrum® 875. Can be powered by any Miller
welding generator with power output of 10.5 kW or more.
Rated at 5/8 inch on twin cylinder engine drives and up to
7/8 inch on large frame diesel engine drives..
Spectrum® 625 X-TREME™. Can be powered by
any Miller welding generator with power output of 8 kW
or more. Can produce a 5/8 in. quality cut and has loads
of features that make your cutting needs a breeze.
8
Spectrum® 375 X-TREME™. For steel less than 3/8
in. thick, consider using the Spectrum 375 X-TREME. It
only needs 4 kW of generator power to produce its
maximum cutting output.
Following are a few engine drive products
and their plasma cutting capabilities when
linked to a Spectrum® 875.
Engine-Driven
Welders
Steel Cut
Output
Amp Setting
Generator
Power
Wildcat® 200
Not
Recommended
Not
Recommended
6.5 kW
Bobcat™,
Trailblazer®
1/2 in.
45 A
11 kW
PipePro® 304,
PRO 300
5/8 in.
50 A
12 kW
Big 40® CC/CV
7/8 in.
60 A
15 kW (optional)
Big Blue® 500 CC/CV 7/8 in.
60 A
20 kW (optional)
Smooth Cutting. Tired of plasma cutters that are
highly susceptible to erratic arcs, shut downs or failures
when operating off engine drives? Then turn to the
Spectrum series from Miller. Their Auto-Line, Auto-Link
and extra-wide line voltage compensation features
ensure consistent power for smooth cutting.
Engine Options
Which engine works best for you? The answer may
depend on brand preference, fuel costs and consumption,
the need to match other equipment, convenience of local
service and meeting safety* regulations (such as those
mandating diesel or LP fuel in hazardous environments).
Choice: Miller gives you the choice of powering your
welding generator with the industry’s best-known
engines: Kohler, Subaru, Kubota, Deutz, Perkins and
Caterpillar.
Engineers from Miller and engine manufacturers
work together to optimize the engine for use in a welding
generator. This improves the performance of both the
engine and the welding generator.
True Blue® Confidence. Miller covers all weldingrelated components under its True Blue 3-Year Warranty.
Engine manufacturers separately warrant the engine.
9
50–200 DC
Bobcat ™ 225
GAS
■
Special Features
H: 31" W: 32" D: 41"
H: 22.75" W: 22.75"
D: 31.6"
H: 22.75" W: 22.75"
D: 31.6"
H: 24.75" W: 20"
D: 35.5"
275 lb
295 lb
5 kW
4.5 kW
Kohler 10 HP gas
Kohler 10 HP gas
315 lb
6 kW
Kohler 13 HP gas
■
▼
■
Portable, capable of DC TIG
345 lb
6.5 kW
Subaru 14 HP gas
■
▼
▼
Compact lightweight
50–225 AC/CC
50–210 DC/CC
50-225 AC/CC
50-210 DC/CC
40–250 CC
90–275 CV
H: 33" W: 20"
D: 45.5"
H: 33" W: 20"
D: 45.5"
H: 33" W: 20"
D: 45.5"
530 lb
10.5 kW
Kohler 23 HP gas
Subaru 23 HP gas
10 kW-1Ø Kohler 23 HP gas
11 kW-3Ø
11 kW
Kohler 23 HP gas/LP
Subaru 23 HP gas
■ ▼ ▼
■ ▼ ■
■ ▼ ▼
■ ▼ ■
■ ▼ ▼
■ ■ ■
Trailblazer ® 275 DC
20–275 DC
H: 33" W: 20"
D: 45.5"
580 lb
11 kW
Kohler 23 HP gas/LP
Subaru 23 HP gas
■ ■
■ ■ ■
Trailblazer ® 302
30–225 AC
20–325 DC
H: 33" W: 20"
D: 45.5"
580 lb
11 kW
Kohler 23 HP gas/LP
Subaru 23 HP gas
■ ■ ■
■ ■ ■
Trailblazer ® 302
Air Pak™
30–225 AC
10–350 DC
H: 34.25" W: 20"
D: 59.5"
771 lb
12 kW
Kohler 30 HP gas
■ ■ ■
■ ■ ■
Trailblazer ®
302 Diesel
35–225 AC
20–325 DC
H: 33" W: 20"
D: 52"
720 lb
11 kW
Kubota 19 HP
diesel
■ ■ ■
■ ■ ■
Bobcat™ 250
Diesel
40–250 CC
90–275 CV
H: 33" W: 20"
D: 52"
700 lb
11 kW
Kubota 19 HP
diesel
■ ▼ ▼
■ ■ ■
PipePro™ 304
5–400 DC
H: 30" W: 24"
D: 59.5"
910 lb
12 kW
Kubota 26 HP diesel
■ ■
■ ■ ■
PRO 300 /
PRO 300D
20–410 DC
H: 32" W: 26"
D: 56"
1,100 lb 12 kW
CAT 22 HP diesel
Deutz 24 HP diesel
■ ■
■ ■ ■
BIG 40®*
20–500 DC
■ ■ ▼
■ ■ ▼
Big Blue® 400
20–500 DC
H: 43" W: 28.5"
D: 64-7/16"
H: 43" W: 28.5"
D: 64-7/16"
■ ■
■ ■ ▼
Big Blue® 500
20–650 DC
■ ■
■ ■ ▼
Big Blue® Turbo
20-750 DC
■ ■
■ ■ ▼
1/2”
Miller Du-Op™
15–600 DC
■ ■
■ ■ ▼
3/8”
Big Blue Air Pak™
20–750 DC
■ ■ ■
■ ■ ■
1/2”
Bobcat™ 3 Phase
DIESEL
CAC-A
Wildcat™ 200
PAC**
55–185 DC
■
Flux Core*
Blue Star ® 185 DX
Dimensions
DC TIG
30–180 DC
40–145 DC
AC TIG
Renegade™ 180
Blue Star ® 145/145 DX
Standard
Generator
Engine Brand
Weight Power
MIG
Product
Welding
Amperage
Range
Stick
Engine Drive Chart
Bobcat™
250
®
PRODUCT KEY
QUALITY: ■ Excellent
540 lb
560 lb
CAT 33 HP diesel
1,545 lb 5.5 kW
15kW**
Perkins 33 HP
1,545 lb 5.5 kW
15 kW** diesel, Deutz 35 HP
diesel
5.5 kW
Turbo Perkins
1,785
H: 43" W: 28.5"
20 kW** 47 HP Deutz
1,785
D: 64-7/16"
42 HP Deutz
1,695 lb
47 HP diesel
Turbo Deutz
1,772 lb 5.5 kW
H: 43” W: 28.5”
64 HP diesel
D: 67.5
Deutz 42 HP diesel
H: 47-5/8" W: 31.25" 2,005 lb 5.5 kW
D: 60.5"
Turbo Deutz
1,931 lb 5.5 kW
H: 43" W: 28.5"
20 kW** 64 HP diesel
D: 67.5"
■
▼
Portable wire welder
Portable, capable of DC TIG
Durable, multi-purpose, 10,000 watts (peak)
generator power; capable of MIG applications
Back up power for pivot irrigation.
3/16” For rugged use especially in Stick,
FCAW and DC TIG application;
11,000 watts (peak) generator power;
capable of MIG applications
3/16” Professional’s choice for multi-process
welding; flawless arc performance;
separate power and weld generators
3/16” Professional’s choice for multi-process
welding; flawless arc performance;
separate power and weld generators
3/16” AC/DC, CC/CV, 26 CFM air,
battery charge/jump start
3/16” Professional’s choice for multi-process
welding; flawless arc performance;
separate power and weld generators
3/16” For rugged use especially in Stick,
FCAW and DC TIG application;
11,000 watts (peak) generator power;
capable of MIG applications
1/4” XMT arc quality and reliability within an
engine drive unit; can also run as
electric unit
1/4” Ideal for the independent rig owner or
fleet manager who values reliable
multiprocess, excellent arc quality,
light weight and economy.
5/16” Arc Drive technology for active DIG
control in Stick
5/16” Multiple engine and process selections
make this ideal choice for construction,
offshore and rental
3/8” Multiple engine and process selections
make this ideal choice for construction,
offshore and rental
High amp output for heavy-duty
Mining and Tank manufactures
Two operators, one engine - lower
costs and maintenance
All-in-one welder/generator/air
compressor. Mining, railroad
▼ Good/Fair (Indicates performance within rated output range of unit)
*If using self-shielded wire, use CV weld output.
** With appropriate Spectrum plasma cutter.
10
11
Engines and Fuel Economy
When selecting an engine drive, remember that fuel
efficiency provides big savings and a fast payback. Miller’s
fleet of engine drives are the most fuel-efficient models available.
Most engine options that Miller uses are designed for
1800 or 3600 RPMs, both of which have outstanding fuel
efficiency compared to competitive products. In fact,
Miller’s PipePro™ 304, when welding at idle, is the most fuel
efficient diesel engine drive welding power source available.
HP and Fuel Efficiency. Compared to some other
machines, Miller diesels produce an equivalent weld output
using an engine 25 to 30% smaller. This saves you money. In
fact, one contractor building a large petrochemical plant
with a large fleet of Big Blue engine drives conservatively
estimated fuel savings of $3,000 per day.
Most Miller engine drives also feature an automatic idle
mode. This lowers RPM levels when no demand is being
placed on the machine, saving fuel and reducing noise. So
that you can compare cost of operation, Miller now
includes a fuel consumption chart on its engine drive spec
sheets (for a spec sheet, visit MillerWelds.com, call
1-800-4-A-MILLER or see your distributor).
Why buy a GAS or DIESEL Engine?
Gas Advantages
• Lower product cost 50 to 70% lower
• Smaller size and less weight uses less space and a
smaller truck can be used
• Less expensive engine repairs and better warranties
longer and unlimited hours
• Gas is most common fuel supply and costs less than
diesel fuel
• Easier cold weather starting
Diesel Advantages
• Uses 20 to 40% less fuel
• 1-1/2 to 2-1/2 times the engine life
• Required on some job sites for safety
• Typically longer maintenance intervals
• Convenient if other equipment is primarily diesel
Need help choosing the right gas or diesel engine drive for
your needs? Learn more at MillerWelds.com/enginedriven.
12
Examples:
Bobcat 250: On a typical job using 1/8 in. 7018
electrodes (125 amps, 40% duty cycle), you can expect to
use an average of 0.8 gallons of fuel per hour.
PipePro 304: With its patented weld-at-idle feature
while welding at 150 A at 40% duty cycle using 5/32 in. 7018
electrode, the PipePro averaged 0.4 gallons per hour.
Big Blue 400: On a typical job using 5/32 in. 7018
electrodes (150 amps, 40% duty cycle), you can expect to
use an average of 0.522 gallons of fuel per hour.
13
Product Highlights
Renegade™ 180
The industry’s first all-in-one wire
welder/generator combines the simplicity
of the most popular all-in-one wire
welders with the portability and power of
a Miller engine-driven welder/generator
for solid or flux cored wire welding.
• Comes standard with running gear, making this
welder/generator truly one man portable.
• Dual Input Power Convenience - runs off 230 V wall
power in the shop or engine driven power for
welding in the field.
• 5,000 watts of generator power to run your tools,
lights, appliances, or for emergency power backup.
• Welds 24 gauge up to 5/16 inch mild steel in a single
pass.
Blue Star ® Series
Power and reliability in a compact
package. Blue Star's provide classleading welding and generator power
and offers features to increase your
productivity and decrease your fuel costs
• Compact and portable
• Class leading welding output
-145 amps at 25 volts (Blue Star 145/145 DX)
-185 amps at 25 volts (Blue Star 185 DX)
• Receptacle covers improve reliability by protecting
receptacles from debris.
• Strong Accu-Rated™, not inflated generator power
-4500 watts of peak power (Blue Star 145/145 DX)
-6000 watts of peak power (Blue Star 185 DX)
DX models have:
• 5 gallons fuel capacity
• Auto Idle
• Electric start
14
Wildcat™ 200
Compact, lightweight, durable and
cost-effective machine designed for
the contractor and is great for
maintenance/repair, farm and ranch
applications.
• 30% smaller and 150 lbs less than competitive
welder/generators freeing up needed space and weight.
• Fully enclosed case protects the engine and internal
welding components from dust and debris.
• Provides excellent DC Stick and TIG capabilities up
to 200 amps (5/16 inch electrode)
• 6,500 watts of Accu-Rated™ generator power cranks
out enough power for most applications: jobsite,
farm and ranch, or home.
• 7-gallon fuel capacity providing up to 12 hours of run
time when using a typical 1/8 inch Stick electrode.
Bobcat™ Series
Reliable Bobcat engine-driven welding
generators are the industry standard
for quality and value. Multiprocess
weld output, strong generator power
and most important - #1 in reliability,
make the Bobcat the welding industry’s
most popular choice.
• Fully enclosed case protects the engine, eliminates hot
air recirculation and decreases sound levels 1/3 over
previous models.
• Exclusive! Super-tough protective armor with covers receptacle and output stud covers meet/exceed OSHA
and CE requirements for job site safety.
• 12-gallon tank can keep the generator running for 14
hours with a 4000-watt load.
• Class leading welding output
225 amps at 25 volts (Bobcat 225)
250 amps at 25 volts (Bobcat 250)
• Strong Accu-Rated™, usable peak power:
Bobcat 225: 10,500 watts (Kohler) 11,000 watts (Subaru)
Bobcat 250 11,000 watts (Kohler and Subaru)
• Ten-degree skewed-rotor design for smoother
generator power.
• Tri-Cor™ Technology provides improved Stick arc
performance with 7018 electrodes (Bobcat 250 only)
15
Bobcat™ 3 Phase
• Same features as
Bobcat 225 Plus
• 11,000 watts (peak) of
Accu-Rated™, 480 V, 3-phase
power for running pivot
irrigation systems, or
emergency backup power for
milking pumps and other
motors.
Trailblazer® 302 & 275 DC
The Professional Welder's
Choice - designed with the
professional in mind, the
Trailblazer Series has the best
welding arc in its class!
• Exclusive! Trailblazers are
the only machines in the
industry that utilize a
4-pole, 3-phase generator
to produce the best
welding arc and have a
separate 11,000 watt power generator - no interaction.
• Fully enclosed case protects the engine, eliminates
hot air recirculation and decreases sound levels 1/3
over previous models
• Accu-Rated™ 11,000 watts of usable peak power
• 12-gallon tank can keep the generator running for
14 hours with a 4000-watt load.
• Exclusive! Super-tough Protective Armor with
receptacle and output stud covers receptacle and
output stud covers meet/exceed OSHA and CE
requirements for job site safety.
• Digital meters with SunVision™.
• Four preset DIG settings
• Lift-Arc™/Scratch Start TIG
16
Trailblazer® 302 Air Pak™
Three tools air compressor,
welder and generator packed
in one powerful package for
maximum performance,
convenience and space
efficiency.
• Requires only half the bed
space of a separate enginedriven air compressor and
welder freeing up 50% more room on your truck for
equipment and supplies.
• Two Generators One machine eliminates
interaction between power tools and the welding arc.
• 13,000 watts of Accu-Rated™ generator power cranks
out enough power for most applications: jobsite,
farm and ranch, or home.
• Rotary-screw air compressor delivers 26 CFM of air at
100% duty cycle.
• Easy to service side and top access to engine and
air compressor service points. Digital maintenance
meters automatically track hours and service
schedules.
• Deliverable Air, On Demand
waiting for tanks to fill.
no more down time
PipePro™ 304
Quiet, compact, yet extremely
powerful multiprocess diesel
engine drive for the crosscountry pipeliner and
mechancial contractor.
• Unbeatable arc in all DC
weld processes
• The new standard for downhill pipe welding
• Most compact engine drive in its class
• 12,000 watts generator power
• Dual Power option allows you to operate on engine
OR electric input power
• Welds to 200 amps at idle and automatically switches
to high speed for more power without any arc change
17
Miller Du-Op™
Dual operator welding machine
• Two independently
controlled arcs
• Reduces number of
machines on jobsite
• Decreases transportation,
maintenance costs
• Multi-process capabilities
• Includes adjustable DIG
and digital weld meters
Big 40® Diesel
Powered by CAT diesel engine with
added power and more features;
improved noise reduction at both
idle and weld speed.
Excellent Stick/TIG/MIG machine
• Arc-Drive for E6010 pipe welding
• Uncompromised
7018 performance
• Factory option AC/DC polarity switch provides
350 amps of AC weld power for TIG welding aluminum
• Best reliability and simple-to-use
PRO 300/PRO 300 D
Low-speed, compact diesel
welder ideal for professional
welders.
• Caterpillar or Deutz diesel
engine
• Digital weld meters
• Quiet 71dBA@23 ft-Catepillar;
73 dBa @ 23 ft-Deutz
• 1800 RPM engine for longevity
• Compact 32 x 26 x 56, 1100 lbs
• Ideal for pipe welding
• Economically priced
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Big Blue® 400 and 500
Heavy industrial machine
designed for fleet owners;
easy to maintain and
always ready to weld.
Excellent Stick/TIG
machines.
• Arc-Drive for E6010
pipe welding
• Uncompromised 7018
performance
• CV option for superior flux
cored welding performance
• Generator power options up to 20 kW
• Best reliability, simple-to-use
• 1000 hours between oil changes on Deutz 2011
engines
• 10,000 hours before first basic overhaul
• 25 gallon fuel tank
• Environmental stainless steel model available on the
Big Blue 500 for corrosion resistance in the most
caustic environments.
Big Blue® Turbo
High altitude, high output
multiprocess welder
provides a superior arc.
• Deutz turbocharged
four-cylinder diesel
engine provides ample
power at high
altitudes.
• 600 amp/44 volts 100% duty
cycle
• Quiet at only 70 dB (95 Lwa)
when idle, 79 dB (104 Lwa) at maximum output.
Improves work site communications.
• Hot Start™ provides positive stick electrode starts to
make it easy to start all types of electrodes.
• Arc-Drive makes welding easy. Automatically
enhances Stick welding, especially on pipe, by
focusing the arc and preventing the electrode from
going out.
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Big Blue® Air Pak™
The complete package a
multiprocess welder/generator/air
compressor/optional battery
charger.
• A go anywhere solution to
field jobs requiring welding,
gouging or cutting, and AC
power generation
• 600 amps/44 volts at 40% Duty Cycle
• Excellent arc performance in all
processes
Built-in Ingersoll-Rand air compressor
• Produces 100 PSI at 60 CFM, 100%
Duty Cycle
• Independent compressor controls, on/off switch
for applications not requiring air
For detailed literature, a full-line catalog or
to locate your nearest distributor,
call 1-800-4-A-MILLER (1-800-426-4553)
20
For detailed specification sheets or to locate your
nearest Miller distributor, call:
1-800-4-A-Miller
(1-800-426-4553)
M i l l e r We l d s . c o m
For Welding and
Power Generation
Engine Buyers Guide Cover 12x18:doc
4/15/2009
12:59 PM
Page 1
An Illinois Tool Works Company
©2008 Miller Electric Mfg Co.
Engine
Drive
Buyer’s
Guide
For detailed specification sheets or to locate your
nearest Miller distributor, call:
1-800-4-A-Miller
(1-800-426-4553)
M i l l e r We l d s . c o m
An Illinois Tool Works Company
©2008 Miller Electric Mfg Co.
Engine
Drive
Buyer’s
Guide
For Welding and
Power Generation