Trailblazer® 302 Air Pak™

Trailblazer® 302 Air Pak™
Trailblazer 302 Air Pak
®
Quick
Specs
Issued July 2011 • Index No. ED/4.78
™
Gas Engine-Driven Welder/
AC Generator/Air Compressor/
12/24 V Battery Charger/Jump Starter
Industrial Applications
Processes (X-Ray Quality)
Output Range
Fabrication
Maintenance
Repair
Structural Steel Work
Sheet Metal
Stick (SMAW)
MIG (GMAW)
Flux Cored (FCAW)
AC/DC TIG (GTAW)
Battery Charger/Jump Starter
Air Carbon Arc (CAC-A) Cutting and Gouging
Rated: 3/16 in carbons,
Capable: 1/4 in carbons
Air Plasma Cutting and Gouging with
optional Spectrum® models
Rated: 5/8 in mild steel
DC Stick
25– 300 A
AC TIG/Stick 10 – 225 A
DC TIG
10 – 300 A
MIG/FCAW 13 – 35 V, 350 A
Generator Power Output Rated at 104˚F (40˚C)
Peak: 13,000 W — Continuous: 11,000 W
Air Compressor
26 CFM, 100% Duty Cycle, 70 – 160 PSI
Battery Charger/Jump Starter
Battery Charger: 12/24 V, 10–75 A
Battery Jump Starter: 12/24 V, 450 A /350 A
The Power of Blue .
®
Improved!
The all-in-one tool that delivers
multiprocess output for welding,
plasma cutting, gouging, air tools, and
12/24 volt battery charger/jump starter.
Trailblazer 302 Air Pak with Battery
Charger/Jump Starter (Welder, Generator,
Air Compressor, Battery Charger)
Welder/generator/air compressor/battery charger is
warranted for 3 years, parts and labor. Engine is
warranted separately by the engine manufacturer.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
www.MillerWelds.com
®
Trailblazer 302 Air Pak Features
™
Size and Weight
Battery Charger/Jump Starter
Takes only half the bed space of a separate
engine-driven air compressor and welder,
freeing up to 50% more room on your truck
for equipment and supplies. Plus decrease
axle weight up to 25%.
• Provides selectable 12 or 24 volt battery
charging capability
• Provides up to 450 amps of battery jumpstarting capability
• Convenient front panel battery charger/jump
starter access
• 25 ft battery jumper cables available (#300 422)
Independent Weld and Generator Advantages
Industrial Rotary Screw Air Compressor
• 13,000 watts of voltage-regulated power
• No interaction between grinders, power tools, etc. and the
welding arc
• Generator power is independent of weld
• 4-pole weld generator produces the best arc quality
• Runs most air impact wrenches at idle
• Produces 26 CFM of air at 100% duty cycle
• Delivers 70 –160 PSI of air with no storage tank
• Gives 100% deliverable air
• Compressor is warranted by Miller for 3 years
Weld Power
Generator Power
2
Trailblazer 302 Air Pak Features
®
™
Easy to Service
Toolless Top Access to:
• Engine air cleaner
• Engine oil check/fill dipstick
• Battery
• Compressor oil check/fill dipstick
• Compressor oil separator
• Air compressor air filter
Toolless Side Access to:
• Engine oil filter
• Engine oil drain
• Engine fuel filter
Rear Access to:
• Compressor oil filter
• Compressor oil drain
Front Panel Air
Pressure Adjustment
• Simple to adjust the correct
air pressure for specific
applications (70 –160 PSI)
• Lower pressure will increase
engine power for more
gouging and plasma cutting
output capabilities
Easy Operation
• Reduce fuel consumption and noise by
using the front panel air flow control
which matches engine speeds to air
flow requirements for tools, plasma
cutting and gouging.
3
®
™
Answers to Frequently Asked Trailblazer 302 Air Pak Questions
Air facts
What does Average vs Continuous CFM mean?
• Moisture going into a compressor also comes out.
• Air compressors heat air, turning moisture droplets into vapor.
• Air tools are often rated as “Average CFM.” “Average CFM” is
typically based on 15 second usage intervals.
Impact wrenches, button punch/deck tools, and decking crimp
tools are typically used intermittently (short time durations).
• Continuous CFM: This rating is based on continuous usage.
Air grinders and sand blasters are examples of air tools that are
used continuously.
How can I reduce moisture in the air?
Air Cooler with Separator #300 420
• Most popular.
• The cooler cools air which turns vapor
moisture into droplets and the separator
removes the droplets.
• Removes 70% of the moisture from the air.
• Use for most applications including tools,
blasters, plasma cutters and gouging.
• Effective when temperatures are above freezing (this is also
when the most moisture is in the air).
Below 32 degrees the separator can freeze. If this happens,
bypass the cooler/separator system and continue air operations
without drying it.
• Fully integrated inside of the Air Pak.
RTI Filter #300 491
• Recommended for plasma cutting. Separators
remove droplets of water, not vapor, but this is
good enough for most plasma cutting applications.
• Because compressors heat air, this filter option is
less effective at removing moisture (heat turns
droplets into vapor and vapor is not filtered).
WATER IN AIR (g/ft3)
10
5
0
100
Air Cooler with Separator (#300 420)
Desiccant Air Dryer (#300 690)
No Air Cooler or Dryer
4
Continuous
CFM*
3/4 in Impact Wrench (IR 2141)
10
40
3/4 in Impact Wrench (Speedaire)
7
26
1/2 in Impact Wrench (IR 231C)
4
22
Needle Scaler (IR 182LNA1)
3
13
4-1/2 in Grinder (Dayton)
7
26
1/4 in Die Grinder (IR G1H350RG4)
6
25
1/2 in Drill (IR 7AQSTB)
4
17
Air Shears (IR 7802SA)
4
21
Sand Blaster
—
6
Soda Blaster
—
18
Button Punch/Deck Tool
—
4
Decking Crimp Tool
4
15
The Trailblazer Air Pak provides 4 convenient air compressor
access points. The air outlet connection requires a 1/2 in
NPT swivel fitting (50 ft air hose assembly #300 571
includes the 1/2 in NPT swivel fitting).
MAX FLOW ABSOLUTE HUMIDITY
50
Average
CFM*
How do I access the air?
Note: Reduces air flow up to 4 CFM at all speeds.
DRYER AIR PRESSURE (PSI)
Air Tools
*1/2 in air hose is recommended for better tool efficiency.
Note: Impact wrenches use Continuous CFM when “free” spinning.
In actual use, CFM requirements are less. Thus, the Trailblazer Air Pak
is rated to run a 40 CFM impact wrench.
Desiccant Air Dryer #300 690
• Cools air and removes 99% of the
moisture from the air.
• Primary use is when temperature ranges
below freezing and moisture still must be
removed from the air.
• Has a built in heater.
• Mounted externally from the machine with some wiring that
needs to take place inside of the machine.
0
The Air Pak will easily run the following:
150
Specifications
(Subject to change without notice.)
Single-Phase
Weld Output Rated at 104°F/40°C* Generator Power
Sound Levels at
Rated Output
7 m (23 ft)
13–35 V
300 A, 32 V at 100% Duty Cycle
350 A, 32 V at 60% Duty Cycle
2400 RPM (Idle)
73.4 dB (98.4 Lwa)
Stick/TIG
10–300 A
280 A, 32 V at 100% Duty Cycle
Stick/TIG
10–225 A
200 A, 25 V at 60% Duty Cycle
Air
Compressor
26 CFM @ 3600 RPM
21 CFM @ 3000 RPM
17 CFM @ 2400 RPM
26 CFM at 100% Duty Cycle
Battery Charger/
Jump Starter
12 V
24 V
450 A, 12 V, Jump Start
350 A, 24 V, Jump Start
10 – 75 A, Charge
Welding
Mode
Process
Amp/Volt Ranges
CV/DC
MIG/FCAW
CC/DC
CC/AC
*Rated at sea level.
Peak:
13,000 watts
Continuous:
11,000 watts
120/240 VAC,
100/50 A, 60 Hz
Dimensions
Weight
H: 28 in (838 mm)
34-1/4 in (870 mm)
(to top of exhaust)
3000 RPM
76.5 dB (101.5 Lwa) W: 20 in (508 mm)
D: 59-5/8 in (1514 mm)
3600 RPM
81.2 dB (106.6 Lwa)
Without
Fuel:
771 lb
(350 kg)
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
Engine Specifications
(Engines warranted separately by the engine manufacturer.)
Engine Brand/
Warranty
Horsepower (HP)
Type
Weld Speed
Idle
Speed
Fuel
Capacity
Oil Capacity
Standard
Shutdowns
Kohler: 3-year mfg
30 HP (Gas)
Twin-cylinder, 4-cycle overhead valve
3600/3000 RPM
2400 RPM
12 gal (45 L)
1.75 qt (1.7 L)
Low Oil Pressure
Air Compressor Specifications
Compressor
Warranty
Features
3-year True Blue®
Warranty by Miller
Rotary screw with electric
clutch for on/off. Oil change
intervals 500 hours.
Free Air
Delivery at
2400 RPM
Free Air
Delivery at
3000 RPM
Free Air
Delivery at
3600 RPM
Working
Pressure
Constant
Duty
Cycle
Oil
Capacity
Automatic
Compressor
Shutdowns
17 CFM
21 CFM
26 CFM
100 PSIG
100%
1.75 qt
(1.7 L)
High Pressure
(160 PSI)
Performance Data
AIR COMPRESSOR FUEL CONSUMPTION
(at 100% Duty Cycle)
2.25
1.2
2.00
1.1
1.75
US GAL/HR.
1.0
0.9
0.8
US GAL/HR.
FUEL CONSUMPTION DATA
• 12-gallon fuel capacity.
• On a typical job using 1/8 in 7018 electrodes
(125 A, 20% duty cycle) expect over 16 hours
of operation.
• Welding at 150 A, 40% duty cycle uses
approximately: 3/4 gallon per hour —
over 13 hours of operation.
• Many air tools can be used when running at
idle. Running at idle with a compressor load
will provide 14 hours of run time.
• Running the air compressor at 26 CFM will
provide 11 hours of run time.
• Reduce fuel consumption by turning the air
compressor off when the Air Pak is not in use.
For weld/generator fuel consumption chart see
chart at left.
WELD/GENERATOR FUEL CONSUMPTION
0.7
0.6
1.50
1.25
1.00
0.75
0.5
0.50
0.4
0.25
0.3
0.00
0.2
IDLE
0
50
100 150 200
250 300 350 400
DC WELD AMPS AT 100% DUTY CYCLE
0.1
0.0
2400
3000
0
3600
2
4
6
8
10
12
GENERATOR POWER IN KILOWATTS AT
100% DUTY CYCLE
ENGINE SPEED RPM
Mounting Specifications
Height: 28 in (838 mm)
34-1/4 in (870 mm)
(to top of exhaust)
Width: 20 in (508 mm)
Depth: 59-5/8 in (1514 mm)
Lifting eye rating:
1000 lb (453 kg)
A
4 Holes
Engine End
G
A. 20 in (508 mm)
B. 16-1/2 in (419 mm)
C. 1-3/4 in (44 mm)
D. 6-1/16 in (154 mm)
E. 32-3/4 in (832 mm)
F. 59-5/8 in (1514 mm)
G. 13/32 in (10 mm) diameter
B
C
D
E
F
5
Function Guide
1
8
2
9
3
4
10
5
6
11
12
7
13
14
*Category Exclusive
1. Self-calibrating digital weld meters with
meter maintenance displays capable of
displaying engine and air compressor oil
change intervals.
5. Lift-Arc™ TIG with Auto-Crater™* and
Auto-Stop™*
2. Four preset DIG settings* offer the best
arc characteristics for different electrodes
and joint designs. The amount of DIG
determines how much amperage (heat)
varies with Stick arc length. The combined
Process switch along with preset DIG
settings make the Trailblazer easy to set
without the complication of multiple switches.
7. Air pressure gauge/regulator gives the
approximate air pressure settings needed
for common air tools/plasma/carbon arc
gouging. The pressure gauge also reads the
actual air pressure being used. The regulator
allows user control of the pressure settings
up to 160 psi.
3. Adaptive Hot Start ™* (Stick) automatically
sets starting amperage for great arc starts.
4. Great MIG/FCAW performance and arc
starts make the Trailblazer’s arc best in its
class. Easy to run all wires from .023 in
solid wires to large diameter 5/64 in flux
cored wires.
6
6. Air compressor, battery charger/jump
starter, and maintenance selector.
8. Front panel fuel gauge* LEDs indicate fuel
level. The “E” LED lights when fuel is low.
9. AC/DC and battery charger/jump starter
switch allows selection between AC or
DC weld output and battery charger/
jump function.
10. Battery charger/jump starter receptacle
for connection to battery charger/jump
cable (12 or 24 volt).
11. Standard 14-pin receptacle for simple
connection of remote controls and wire
feeders. It features Auto Remote Sense™*
which automatically switches from Panel to
Remote Amperage/Voltage (A/V) control
with remote connected. Eliminates
confusion of the Panel/Remote A/V switch.
12. Speed control switch allows for control of
engine speed based on the switch position.
In the auto speed mode, the speed will be auto
selected depending on total power needed.
The speed will auto select between 3000 and
3600 RPM depending on weld demand or
weld + air demand. Anytime auxiliary load is
needed the engine will go to 3600 RPM.
13. Engine choke control
14. 120 VAC and 240 VAC receptacles with
circuit breakers (optional 120 VAC GFCI
receptacles available).
Note: For matching plug, order #119 172.
Genuine Miller Options
*Available as factory option. See ordering information on back page.
Protective Cover
#300 379
Heavy-duty, waterresistant and mildewresistant covers protect
and maintain the
finish of the welder.
For models without Protective Cage.
Protective Cage with
Cable Holders
#300 473
Rugged cage with
cable holders protects
your investment. Can
be used with trailer.
25 ft Battery Charger/
Jump Cable
#300 422
50 ft Air Hose
#300 571
Includes 1/2 in NPT
swivel fitting.
Air Cooler with
Separator #300 420
Cools and removes
moisture from the air
supply. Designed for
use above 32˚ F.
Bypass in colder
temperatures. See air
dryer choices on
page 4 for details.
Micron Filter Element #203 877
Replacement micron filter for the Air Cooler
with Separator.
RTI Filter and Bracket
#300 491
Dryer will remove water,
dirt and oil as small as
one micron with 99.9%
efficiency. Can be mounted
on plasma cutter or on wall.
Install as close as possible
to point of air consumption.
Designed for use above 32˚ F.
Bypass in colder temperatures. See air dryer
choices on page 4 for details.
Desiccant Air Dryer System
#300 690
A regenerating inline air
dryer system that eliminates
moisture in the air stream to
prevent air tool freeze-ups in cold climates.
See air dryer choices on page 4 for details.
Remote Oil Drain and Filter Kit Front/Chassis Truck Mounted #300 236
Field. For Kohler.
Engine Tune-Up Kit #238 743 Field
Kohler CH750 Tune-up kit includes spark
plugs and engine filters.
Spoolmatic® 30A
Spool Gun #130 831
Air-cooled, 200 amp,
1 lb spool gun for
aluminum MIG. See Lit. Index No. M/1.73.
WC-24 Control #137 549
Use with Spoolmatic 30A.
Millermatic® 180 Auto-Set™ #907 312
See Lit. Index No. DC/12.44
Millermatic® 212 Auto-Set™ #907 405
See Lit. Index No. DC/12.46
Plasma Cutting
Air Compressor Tune-Up Kit #235 202
Field. Air Compressor
Tune-up kit includes oil filter, air filter
and oil separator.
GFCI Protection* #195 496 Field
Ground Fault Circuit Interruptors are required
on some construction sites. Kit contains
two GFCI 120 VAC duplex receptacles.
(240 VAC GFCI receptacle not required).
Adapter Cord, Full KVA #300 517 Field
NEMA 14-50P to NEMA 6-50R. Adapts
engine drive 120/240 V plug to common
Millermatic® and Spectrum® 240 V plug.
Spectrum® 375 X-TREME™ #907 339
See Lit. Index No. PC/9.2.
Spectrum® 625 X-TREME™ #907 404
See Lit. Index No. PC/9.6.
Spectrum® 875 #907 390-01-1
See Lit. Index No. PC/9.8.
The Spectrum 375 X-TREME and 625
X-TREME come complete with protective
X-CASE™ (not shown).
MIG/Flux Cored Welding
TIG (GTAW) Welding
Female
Receptacle
SuitCase® X-TREME™
8VS Wire Feeder
#951 182
SuitCase® X-TREME™
12VS Wire Feeder
#951 184
Lightweight, voltage-sensing wire feeders
include secondary contactor, gas valve and
drive roll kit. See Lit. Index No. M/6.41.
SuitCase® 8RC
Wire Feeder
#951 186
SuitCase® 12RC
Wire Feeder
#951 188
Lightweight and flexible enough to run a
variety of wires up to .062 in diameter.
Includes remote voltage control and drive
roll kit. See Lit. Index No. M/6.5.
Dynasty® 200 Series
For premium portable AC/DC
TIG arc quality.
See Lit. Index No. AD/4.8.
HF-251 Series #042 388
HF-251D-1, 115 VAC
High-frequency arc starter
and stabilizer. See Accessory
Lit. Index No. AY/5.0.
Remote Controls
RHC-14 Hand Control
#242 211 020
20 ft (6 m) cord
#242 211 100
100 ft (30.5 m) cord
Miniature hand control for remote current
and contactor control. Dimensions: 4 x 4 x
3-1/4 in (102 x 102 x 82 mm). Includes
cord and 14-pin plug.
7
Trailers and Hitches
(Note: Trailers are shipped unassembled.)
HWY-224 Trailer #043 805 For highway use.
A 2650 lb (1202 kg) capacity trailer. Welded
steel tubing frame, heavy-duty axle with roller
bearing hubs and leaf-spring suspension.
Includes jack stand, 2 in (50 mm) ball hitch,
fenders and lights.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords.
Dual Hitch #300 831
2 in (50 mm) ball hitch and
3 in (76 mm) lunette eye in
one reversible assembly.
Note: Trailer is shipped unassembled.
Trailer Specifications
Model
HWY-224
(Subject to change without notice.)
Gross Axle
Weight Rating
Gross Vehicle
Weight Rating
Net
Payload
Height
of Bed
Road
Clearance
Track (Center
to center of
tires)
Standard Tires
(Standard rating
or P-size rating)
3500 lb
(1588 kg)
2960 lb
(1343 kg)
2650 lb
(1202 kg)
18-1/2 in
(470 mm)
7-1/2 in
(191 mm)
52 in
(1321 mm)
B78-13
Dimensions
Net
Weight
Length: 105 in (2667 mm)
Width: 59-1/2 in (1511 mm)*
320 lb
(145 kg)
*Width at outside of fenders.
Ordering Information
Equipment and Options
Stock No.
Description
Trailblazer® 302 Air Pak™
with Battery Charger/Jump Starter
(30 HP Kohler)
#907 447
#907 447-001
#907 447-002
#907 447-003
#907 447-004
#907 447-005
#907 447-006
Base machine, CC/CV, AC/DC 13,000 watts, battery charger/jump starter
With No Battery (International)
With GFCI Receptacles
With Electric Fuel Pump and GFCI Receptacles
With Air Cooler/Separator
With Air Cooler/Separator and GFCI Receptacles
With Air Cooler/Separator, Electric Fuel Pump and GFCI Receptacles
GFCI Protection
Remote Oil Drain & Filter Kit
Adapter Cord, Full KVA
Full KVA Plug
Engine Tune-Up Kit
Air Compressor Tune-Up Kit
#195 496
#300 236
#300 517
#119 172
#238 743
#235 202
Field
Field
Field
Field
Field. For Kohler CH750 (Gas). Order from Miller Service Parts
Field. For screw compressor. Order from Miller Service Parts
#300 379
#300 473
#300 422
#300 571
#300 420
#203 877
#300 690
#300 491
Blue with logo
Accessories
Protective Covers
Protective Cage
25 ft Battery Charger/Jump Cable
Air Hose
Air Cooler with Separator
Micron Filter Element
Desiccant Air Dryer System
RTI Filter and Bracket
SuitCase® Portable Wire Feeders
Spoolmatic® 30A Spool Gun
WC-24 Control
MIG Welders and Plasma Cutters
Dynasty® 200 Series
HF-251D-1
RHC-14 Hand Control
HWY-224 Trailer
Cable Tree
Dual Hitch
#130 831
#137 549
#042 388
#242 211 020
#242 211 100
#043 805
#043 826
#300 831
Date:
50 ft
See page 4 for more information
For use with Air Cooler with Separator
Reduces air flow up to 4 CFM at all speeds. See page 4 for more information
See page 4 for more information
See page 7
Requires WC-24 Control. See Lit. Index No. M/1.73
See Lit. Index No. M/1.5
See page 7
See Lit. Index No. AD/4.8
115 VAC. See Lit. Index No. AY/5.0
20 ft (6 m cord)
100 ft (30.5 m cord)
Combination 2 in (50 mm) ball hitch and 3 in (76 mm) lunette eye
Total Quoted Price:
Distributed by:
Litho in USA
Qty.
Price
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