Miller and the businesses

Miller and the businesses
11/9/09
11:17 AM
Page 1
“
When the hood is down,
It’s just you and the metal.
“
A FLE10 Cover.qxd:Cover
F U L L - L I N E C ATA L O G
1-800-4-A-Miller
MillerWelds.com
THE POWER OF BLUE
®
A FLE10 Cat P 02 Intro.qxd:Intro
11/5/09
10:38 AM
Page 1
The Power of Blue.
®
It’s not just about the machine. It’s about you and the metal,
your imagination and ideas — for your company that’s three
times larger five years from now. For a career that carries
you and your family far into the future. For results that put
your customers ahead of schedule. And for shop projects
that become a labor of love.
We share your passion. It starts with a relentless drive to
develop world-class products, ends with an obsession for
customer service and doesn’t include any compromises.
Because every time you put the hood down, the family of
Miller employees feels the weight of your trust. The trust that
we’ve done our job, so you can concentrate on yours — that’s
The Power of Blue.
®
Enjoy the catalog!
To see list prices or find
your local distributor,
go to our Web site
MillerWelds.com
or give us a call at
1-800-4-A-MILLER
(1-800-426-4553)
Contents
What’s
New
3
Help Me
Choose
4
MIG (GMAW)
Power
Sources 6
Automated
Wire
Manufacturing Feeders
Systems 22
24
Stick (SMAW)
Power
Sources 33
TIG (GTAW)
Power
Sources 37
Multiprocess
Power
Sources 46
Multioperator
Power
Sources 52
Engine-Driven
Welder/
Generators 55
A FLE10 Cat P 03 Intro.qxd:Intro
11/5/09
WHAT’S
Page 1
FROM BLUE?
Millermatic® Reach
Wire Feeder 10
AlumaFeed™
Welding System 13
Invision™ MPa
Plus System 18
Spoolmate™ 200
Series Spool Gun 27
Diversion™ 180
TIG Welder 45
FILTAIR™ Fume
Extraction 76
Respiratory and Heat
Stress Systems 78
Spot
Welders
68
10:39 AM
Submerged
Arc
69
Plasma
Cutters
70
ArcStation™ Welding
Workstation 75
Titanium™ Series
Industrial Helmets 79
Welding
Workstations
74
Fume
Extraction
76
Welding
Protection
78
Accessories
81
Miller
Recommended
Brands 92
Glossary
98
Literature
Sheets/
Index 99
A FLE10 Cat P 04 Help.qxd:Layout 1
11/5/09
10:40 AM
Page 1
Help Me Choose
MillerWelds.com
If you’re not familiar with welding basics, the following information can make choosing a machine easier.
For interactive, highly informative assistance, go to MillerWelds.com.
1. Pick Your Welding or Cutting Process
Select the process that matches the metals you want to weld or cut.
Metal Type
Stick
MIG
FCAW
SAW
AC-TIG
DC-TIG
Resistance
Spot
CAC-A AC
CAC-A DC
Plasma
Steel
Stainless Steel
Nickel Alloys
Aluminum
Cast Iron
Copper, Brass
Titanium
Magnesium Alloys
All Electrically Conductive
Skill Level
Moderate
Low
Low
Moderate
High
High
Low
Moderate
Low
Key:
Recommended
Welding Process
Moderate
Cutting Process
2. Understand Process Advantages
Unfortunately, there is no single welding or cutting process suitable for all applications. For this reason, it is
necessary to consider the advantages of one process over another.
Welding Process
Stick (SMAW)
Better suited for windy, outdoor conditions
More forgiving when welding on dirty or rusty metal
Resistance Spot
Portable, easy-to-operate welder for light industrial
applications
MIG (GMAW)
Easiest process to learn
High welding speeds possible
Provides better control on thinner metals
Cleaner welds possible with no slag to clean
Same equipment can be used for Flux Cored welding
Submerged Arc (SAW)
High deposition rates can enhance weld speed and
production
Excellent mechanical properties for high-quality code
and X-ray requirements
Improves welding operator comfort and appeal —
arc is below a bed of flux
Pulsed MIG (GMAW-P)
Flexibility and productivity — nearly all metals can
be welded in all positions
Larger diameter electrode wires
Virtually no spatter
Welds thin to thick metals
Flux Cored (FCAW)
Works as well as Stick on dirty or rusty material
Out-of-position welding
Deep penetration for welding thick sections
Increased metal deposition rate
TIG (GTAW)
Provides highest quality and most precise welds
Highly aesthetic weld beads
Allows adjustment of heat input while welding by
use of a remote control
Pulsed TIG (GTAW-P)
More control on thin metals
Less heat distortion on thin metals
Cutting Process
Air Carbon Arc Cutting and Gouging (CAC-A)
Wide variety of metals
Removes discontinuities or inferior welds
4
Plasma Arc Cutting and Gouging (PAC)
Use with any electrically conductive metals
Small and precise cut
Small heat-affected zone which helps prevent
warping or paint damage
A FLE10 Cat P 05 Help.qxd:Layout 1
Call
11/5/09
10:41 AM
Page 1
Help Me Choose
1-800-4-A-MILLER for more information.
3. Pick Your Power and Portability Needs
What should I know about duty cycle?
What kind of input power do I have available?
Duty cycle is the amount of time during a 10-minute period that the
welder can continuously operate at its rated output without causing
heat damage to the system. For example, a Millermatic 252 has
60% duty cycle at 200 amps of DC output. It can weld for six minutes
out of 10 and then needs to cool for the remaining four minutes.
To select the right product, you need to know the type of primary
power available.
For applications requiring extensive arc-on time and/or welding at
high amperages, choose a welder with a higher duty cycle, such as a
Deltaweld 452 with 450 amps of DC output at 100% duty cycle. If a
welder is operated below its rated output, the duty cycle typically increases.
How much welding or cutting output power do I need?
● Light Industrial products are suitable for the home hobbyist or
occasional user. Designed to be easy to operate, affordably priced and
typically have a 20% duty cycle and rated output of 230 amps or lower.
● Industrial products are suitable for applications that do not require
high-volume production and typically have a 40 – 60% duty cycle
and/or rated output of 300 amps or lower. Appropriate choice for
professional welders.
● Heavy Industrial products typically have a duty cycle of 60 – 100%
and a rated output of at least 300 amps, making them suited to
high-volume production and/or welding of thicker materials. Designed
with the arc characteristics and product features professional welders
demand for code-quality work.
Note: Units listed in more than one classification share attributes of both.
Generator power
Out in the field, you may need an engine-driven welder/generator to
supply 120 or 240 VAC power to run tools, lights and to start motors.
Miller’s engine drives are packed with power and the larger units even
offer option packages that add 10 to 20 kW of generator power.
Single-phase products require single-phase input power, typically
found in homes and garages.
Three-phase products require three-phase input power which is
common in industrial settings, but shops can be specially wired
to supply three-phase, industrial power.
For locations where an electrical hook-up is not practical, consider
a gas or diesel-powered, engine-driven welder/generator to supply
welding and generator power.
Is portability needed?
Can you bring the work to the machine, or does the machine need to go
to the work? Check the Product Guide pages for types of portability:
Shoulder strap, handles, running gear, carts, etc.
Many engine-driven welding generators fit in the back of a pick-up
truck, enabling them to drive to wherever the welding is needed.
Heavy-duty trailers are also available for engine drives.
Power Icons
Unit requires
single-phase input power
Unit requires
three-phase input power
Unit supplies alternating current
weld output
Unit supplies direct current
weld output
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
4. Check Out the Product Guides
The Product Guides (start of each major section) contain a complete list of Miller’s power sources for that process
section. Note: Visit MillerWelds.com for the most current information.
5. Go to Product Descriptions
Each color-coded section is
identified by a primary
process icon and title.
For more product
specifications, give the
product name and literature
number to your distributor,
visit us on the Web at
MillerWelds.com or
call 1-800-4-A-MILLER.
Note: Product specifications
subject to change without notice.
Listing of recommended
processes. Colored bullets
indicate power classification.
Power icons indicate power
supplied or required. See
descriptions above.
Brief listing of most popular
accessories. Refer to pages
listed for more details.
5
A FLE10 Cat P 06 MIG Intro.qxd:MIG Intro
MIG
11/3/09
10:42 AM
Page 1
GMAW
“
The only way to maintain prices and not
pass every price increase to our customers
is to make production as efficient as I can.
Winter Douglas, Manufacturing Engineer
Iron Grip Barbell Company
”
1 & 3-Phase
1-Phase
Product
Guide
Millermatic®
140 Auto-Set™
8
Millermatic®
180 Auto-Set™
8
Millermatic®
Passport® Plus
9
Millermatic® 211
Auto-Set™ w/MVP™
9
Millermatic®
212 Auto-Set™
10
Millermatic® 252
11
Millermatic® 350
12
Millermatic® 350P
12
AlumaFeed™
Synergic Aluminum
Welding System
13
Invision™ MPa
Plus System
18
XMT® Series
48
CP-302
16
Delta-Fab™ System
Deltaweld®
302
Deltaweld® 452
3-Phase
Page
Class
MIG
MIG-P
Flux Cored*
CAC-A
MillerWelds.com/MIG
Deltaweld®
652
Invision™ 456MP
Invision™ 456P
Axcess® 300
Axcess® 450
Axcess® 675
Dimension™ Series
PipeWorx™ System
PRODUCT KEY
Portability
Welding
Weldable Output
Metals
Range
Special Features
Typical Applications
30 –140 A 115 VAC input, Auto-Set,™ Smooth-Start™
Up to 3/16 in** maintenance/repair, auto body, hobby
30 –180 A 230 VAC input, Auto-Set,™ Smooth-Start™
Up to 5/16 in*** maintenance/repair, auto body, hobby
Handle
30 –180 A Welds on 115 or 230 V input, includes
12 oz gas cylinder inside power source
Up to 3/8 in*** maintenance/repair, fabrication, auto body,
farm/home, construction
Handle, optional
running gear
30 –210 A Welds on 115 or 230 V input,
Auto-Set,™ Smooth-Start™
Up to 3/8 in*** maintenance/repair, auto body, hobby
Installed running gear
30 –210 A Gun-On-Demand™
Up to 3/8 in*** fabrication, farm, garage/body shops
30 – 300 A Standard timers menu, Fan-On-Demand,™
can connect standard MIG or push-pull gun
Up to 1/2 in*** industrial production/fabrication, farm
Handle, optional
running gear
Installed running gear
Steel,
stainless,
aluminum
Steel,
stainless,
aluminum
25 – 400 A Can connect a standard MIG gun
or push-pull gun
Up to 1/2 in*** industrial production/fabrication
Handles, optional cart,
MIGRunner
Aluminum
5 – 425 A
10 – 38 V
Profile Pulse, lightweight feeder can be
carried up to 100 ft from power source
Heavy industrial aluminum production/fabrication,
truck trailer, shipbuilding
Handles, optional cart,
MIGRunner
Most
metals
5 – 425 A
10 – 38 V
Alumination allows push/pull gun.
Optimized with 74 MPa Plus wire feeder
Manufacturing and production
See the Multiprocess section on page 46.
Lift eye,
optional
running gear,
Most
metals
14 – 44 V
Hi/Lo stabilizer, power efficient
Equip/auto mfg, metal fab, construction, agri equipment
Up to 1/2 in*** industrial production/fabrication,
Pulsed MIG ideal for thin gauge aluminum
10 – 45 V Material-specific output terminals
Light to medium fabrication, manufacturing
MIGRunner
15 – 32 V Power efficient, material-specific output terminals Equip/auto mfg, metal fab, construction, agri equipment
17 15 – 38 V Power efficient, material-specific output terminals Equip/auto mfg, metal fab, construction, agri equipment
17 ⁄
15 – 44 V Power efficient, material-specific output terminals Equip/auto mfg, metal fab, construction, agri equipment
17 ⁄
10 – 38 V Pulsing made easy
Metal fabrication, manufacturing
19 ⁄ Handles, optional cart
10 – 38 V 600 A max output, power efficient
Industrial production, manufacturing
19 ⁄ MIGRunner
Manufacturing and production
Optional cart,
10 – 44 V Auto-Line, Accu-Pulse
20 10 – 44 V Auto-Line, Accu-Pulse
Manufacturing and production
20 ⁄ MIGRunner
10 – 44 V Auto-Line, Accu-Pulse
Manufacturing and production
20 ⁄
47 See the Multiprocess section on page 46.
51 See the PipeWorx Welding System on page 51.
CLASS: Light Industrial Industrial Heavy Industrial
CAPABILITY: Designed for this process Capable of this process
New! or Improved! products appear in blue type. *If using self-shielded wire on a CC/CV machine, use CV weld output. **In a single pass using self-shielded wire. ***In a single pass.
16
1 4"
3 8"
1 4"
1 4"
™
™
1 4"
™
™
3 8"
™
™
For more detailed information, see individual specification sheets.
6
See Millermatic Product Selector (pg 7), Aluminum Solutions chart (pg 14) and MIG Packages chart (pg 15) for additional information.
A FLE10 Cat P 07 MIG.qxd:MIG
11/3/09
10:42 AM
Page 1
All-In-One
Call
1-800-4-A-MILLER for more information.
GMAW
MIG
Millermatic Series
®
Whether it’s thick steel or thin aluminum, conventional MIG or Pulsed MIG, the Millermatic line combines
easy-to-use features with ultimate arc performance to give you the best all-in-one MIG welders in the industry.
Auto-Set
Material thickness gauge — To help select
parameters every Millermatic that features
Auto-Set now comes with a material
thickness gauge.
™
Available on Millermatic 140, 180, 211 and 212.
The right setting automatically —
• Set the wire diameter, a blue light
shows that Auto-Set is activated
• Dial in the thickness of what
you’re welding
• Start welding with the exact
parameters you need!
No more burnthrough and rework — Correct Auto-Set parameters
make it easy to get quality welds, every time.
Weld flexibility with infinite voltage control — You also have the
flexibility to manually adjust weld parameters to the exact settings
you want. This comes in handy for broader welding applications
such as aluminum or stainless steel.
(#229 895)
Aluminum drive systems — Every Millermatic
features a heavy-duty aluminum drive system designed to provide
superior feeding and durability. The toolless, quick-change reversible
drive rolls and easy-to-set scaled tension knob make them the
easiest to use in the industry.
Thermal overload protection — Designed to protect your investment,
every Millermatic is now equipped with built-in thermal overload
protection… not that you’ll need it.
Set-up and operation CD — Miller makes it easy to get started. Every
Millermatic comes standard with a CD that goes through the basics
of how to set up and operate your machine to get optimal results.
Aluminum solutions — Whether you purchase a Millermatic 140
Auto-Set and a Spoolmate 100 Series spool gun or a Millermatic
350P with an Aluma-Pro push-pull gun, the entire Millermatic
product line now offers an aluminum solution for your application.
True Blue® 3-year warranty — You should never have an issue
with your Millermatic… but just in case. Welder is warranted for
three years, parts and labor. Original main power rectified parts are
warranted for five years. Gun is warranted for 90 days parts and labor.
Product Selection Made Easy!
An online product selection tool designed specifically for the personal user or light fabricator. With this new tool,
customers can simply select their process, answer a few questions, and find the right welder or plasma cutter
for their needs. It’s easy, it’s fast, it’s smart — it’s the Smart Selector. Check it out at MillerWelds.com/select
Millermatic Product Selector
®
Thickness of Steel Welded in a Single Pass
Machine
Thin Gauge
3/16 in
1/4 in
5/16 in
3/8 in
Millermatic®
350/350P
200/230/460 or 460/575 VAC
300 A at 60% Duty Cycle, 1-Phase or 3-Phase
Millermatic®
252
208/230 VAC or 230/460/575 VAC
200 A at 60% Duty Cycle
Millermatic® 212
Auto-Set™
Millermatic® 211
Auto-Set™ w/MVP™
Millermatic®
Passport® Plus
Millermatic® 180
Auto-Set™
Millermatic® 140
Auto-Set™
208/230 VAC
160 A at 60% Duty Cycle
115 VAC: 90 A at 20% Duty Cycle
230 VAC
150 A at 30% Duty Cycle
115 VAC: 110 A at 20% Duty Cycle
230 VAC
130 A at 30% Duty Cycle
115 VAC
90 A at 20% Duty Cycle
230 VAC
150 A at 20% Duty Cycle
1/2 in
Features
• Pulsed MIG (P Model)
• Push-Pull Gun/Spool Gun Ready
• Millermatic Reach Wire Feeder Compatible
• Standard Timers Menu
• Push-Pull Gun/Spool Gun Ready for Alum Apps
• Millermatic Reach Wire Feeder Compatible
• Gun-On-Demand™
• Auto-Set™
• Spool Gun Ready for Aluminum Applications
• Millermatic Reach Wire Feeder Compatible
• MVP™ Plug
• Auto-Set™
• Dual Voltage Input
• Spool Gun Compatible
• MVP™ Plug
• Auto-Line™
• Spool Gun Ready • 45 lb
• Auto-Set™
• Spool Gun Compatible
• Auto-Set™
• Spool Gun Compatible
7
A FLE10 Cat P 08 MIG.qxd:MIG
11/3/09
10:43 AM
Page 1
MIG G M A W
All-In-One
MillerWelds.com
Millermatic 140 Auto-Set
®
™
See Literature
No. DC/12.42
Not to scale.
Min. — 24 ga (0.8 mm)
Max. — 3/16 in (4.8 mm)
Min. — 18 ga (1.2 mm)
Max. — 14 ga (1.9 mm)
Aluminum
w/Spoolmate 100
Series Spool Gun
EXCLUSIVE! Auto-Set™ feature makes set up quick and easy.
On the Millermatic 140, Auto-Set works with .024 and .030 in
diameter solid steel wire (for more info see pg 7).
Infinite voltage adjustment provides broader operating range
with finer control than a tap machine.
Smooth-Start ™ patent-pending technology provides smooth,
spatter-free starts — no pop gun starts and no spatter to clean up.
“Tip Saver” shuts down output when tip is shorted to the
work. Extends contact tip life and protects internal components
from damage.
Heavy duty aluminum drive system (for more info see pg 7).
Uses 4 or 8 in (102 or 203 mm) spools.
Recommended
aluminum solution:
Spoolmate 100 Series (#300 371).
• MIG (GMAW) • Flux Cored (FCAW)
Comes Complete With
Mild Steel
Welding Capability
Light Industrial
Processes
• 10 ft (3 m) M-10 MIG gun and
cable assembly (#195 605)
• 10 ft (3 m) work cable with clamp
• Factory-installed gas solenoid valve
• Smith® regulator and gas hose
• 6 ft (1.8 m) power cord with plug
• Dual groove quick-change drive
rolls for .024 in (0.6 mm) or
.030/.035 in (0.8/0.9 mm) wire
• Extra contact tips, Hobart® spool
of solid wire, information/settings
chart, set-up/operation CD and
material thickness gauge (#229 895)
Most Popular Accessories
• Spoolmate™ 100 Series #300 371
(pg 27)
• Running Gear/Cylinder Rack (pg 82)
Small
#300 425
Regular #770 187
• Protective Cover #195 149 (pg 86)
See your Miller distributor or
MillerWelds.com for other popular
Miller options and accessories.
*Dimensions and net weight are for machine only.
Stock Number
(#907 335) 115 V
(#907 335-01-1) 115 V with
Small Running Gear/Cyl. Rack
Amperage
Range
Rated Output at
20% Duty Cycle
Amps Input at Rated Output, 60 Hz
115 V
KVA
KW
30 –140
90 A at 18 VDC
20
2.8
2.4
63 A at 21 VDC
15
2.1
1.8
Wire Feed Speed
Wire Type and Diameter
Dimensions*
15 – 390 IPM
(0.4 – 9.9 m/min)
Solid Steel .024 –.030 in (0.6 – 0.8 mm)
Stainless .024 –.030 in (0.6 – 0.8 mm)
Flux Cored .030 –.035 in (0.8 –0.9 mm)
H: 153⁄4 in (400 mm)
W: 105⁄8 in (270 mm)
D: 171⁄2 in (445 mm)
Millermatic 180 Auto-Set
®
™
See Literature
No. DC/12.44
Net
Weight*
60 lb
(27 kg)
Light Industrial
Processes
• MIG (GMAW) • Flux Cored (FCAW)
Comes Complete With
Mild Steel
Welding Capability
Not to scale.
Min. — 24 ga (0.8 mm)
Max. — 5/16 in (7.9 mm)
Min. — 18 ga (1.2 mm)
Max. — 1/4 in (6.4 mm)
Aluminum
w/Spoolmate 100
Series Spool Gun
Welds thickest material in its class — up to 5/16 in (7.9 mm)
in a single pass!
EXCLUSIVE! Auto-Set™ feature makes set up quick and easy.
On the Millermatic 180, Auto-Set works with .024 and .030 in
diameter solid steel wire (for more info see pg 7).
Infinite voltage adjustment provides broader operating range
with finer control than a tap machine.
Smooth-Start ™ patent-pending technology provides smooth,
spatter-free starts — no pop gun starts and no spatter to clean up.
“Tip Saver” shuts down output when tip is shorted to the
work. Extends contact tip life and protects internal components
from damage.
Heavy duty aluminum drive system (for more info see pg 7).
Uses 4 or 8 in (102 or 203 mm) spools.
Recommended
aluminum solution:
Spoolmate 100 Series (#300 371).
• 10 ft (3 m) M-10 MIG gun and
cable assembly (#195 605)
• 10 ft (3 m) work cable with clamp
• Factory-installed gas solenoid valve
• Smith® regulator and gas hose
• 6 ft (1.8 m) power cord with plug
• Dual groove quick-change drive
rolls for .024 in (0.6 mm) or
.030/.035 in (0.8/0.9 mm) wire
• Extra contact tips, Hobart® spool
of solid wire, information/settings
chart, set-up/operation CD and
material thickness gauge (#229 895)
Most Popular Accessories
• Spoolmate™ 100 Series #300 371
(pg 27)
• Running Gear/Cylinder Rack (pg 82)
Small
#300 425
Regular #770 187
• Protective Cover #195 149 (pg 86)
See your Miller distributor or
MillerWelds.com for other popular
Miller options and accessories.
*Dimensions and net weight are for machine only.
Stock Number
(#907 312) 230 V
(#907 312-01-1) 230 V with
Small Running Gear/Cyl. Rack
8
Amperage
Range
30 –180
Rated Output
135 A at 22.5 VDC,
30% Duty Cycle
Amps Input at Rated Output, 60 Hz
230 V
KVA
KW
21.7
5.0
4.1
Wire Feed Speed
Wire Type and Diameter
Dimensions*
40 – 460 IPM
(1.0 – 11.7 m/min)
Solid Steel .024 –.035 in (0.6 – 0.9 mm)
Stainless .024 –.035 in (0.6 – 0.9 mm)
Flux Cored .030 –.045 in (0.8 –1.2 mm)
H: 153⁄4 in (400 mm)
W: 105⁄8 in (270 mm)
D: 171⁄2 in (445 mm)
Net
Weight*
72 lb
(33 kg)
A FLE10 Cat P 09 MIG.qxd:MIG
11/3/09
10:44 AM
Page 1
All-In-One
Call
1-800-4-A-MILLER for more information.
GMAW
Millermatic Passport Plus
Light Industrial
Processes
®
®
MIG
See Literature
No. DC/12.53
• MIG (GMAW) • Flux Cored (FCAW)
Comes Complete With
Mild Steel
Welding Capability
Not to scale.
Min. — 24 ga (0.8 mm)
Max. — 3/8 in (9.5 mm)
Min. — 18 ga (1.2 mm)
Max. — 1/4 in (6.4 mm)
Aluminum
w/Spoolmate 100
Series Spool Gun
Portability is #1 because not all jobs can come to you — weighing in at
45 lb and running either 115 or 230 V, the Passport Plus is great for
steel, aluminum and stainless steel jobs you need to go to.
Multi-Voltage Plug (MVP™)—Miller’s exclusive MVP allows
connection to 115 or 230 V receptacles without tools.
Excellent arc characteristics! Unit offers positive arc
starts and an extremely stable arc with minimal spatter on
both mixed gases and straight CO2.
Flexibility to use either external or internal gas cylinder. Self-contained
gas cylinder provides 25 minutes of arc time or about 25 ft of weld on
3/16 in thick material with .030 in mild steel wire.
Recommended
aluminum solution:
• Spoolmate™ 100 Series #300 371
(pg 27)
• MVP™ Plugs (pg 88)
• CO2 Gas Cylinder (empty) #195 272
See your Miller distributor or
MillerWelds.com for other popular
Miller options and accessories.
Impact-resistant polymer case provides strength and durability while
protecting the internal components and welding wire.
Input
Power
Amperage
Range
Rated Output at
20% Duty Cycle
Amps Input at Rated Output, 50/60 Hz
115 V
230 V
KVA
KW
115 VAC
30 –140
110 A at 19.5 V
20
—
2.9
2.7
230 VAC
30 –180
150 A at 21.5 V
—
18
4.0
3.8
Wire Feed Speed
Wire Type and Diameter
Dimensions
40– 400 IPM
(1.0 –10 m/min)
Solid Steel .023 –.030 in (0.6 – 0.8 mm)
Stainless .023 –.030 in (0.6 – 0.8 mm)
Flux Cored .030 –.035 in (0.8 –0.9 mm)
H: 151⁄2 in (394 mm)
W: 12 in (305 mm)
D: 201⁄2 in (520 mm)
Millermatic 211 Auto-Set with MVP
™
®
™
See Literature No. DC/12.54
Net
Weight
45 lb
(20.4 kg)
Light Industrial
Processes
• MIG (GMAW) • Flux Cored (FCAW)
Comes Complete With
Mild Steel
Welding Capability
Not to scale.
Min. — 24 ga (0.8 mm)
Max. — 3/8 in (9.5 mm)
Min. — 18 ga (1.2 mm)
Max. — 3/8 in (9.5 mm)
Aluminum
w/Spoolmate 100
Series Spool Gun
Welds thickest material in its class — up to 3/8 in (9.5 mm) in
a single pass!
EXCLUSIVE! Auto-Set™ feature makes set up quick and easy.
On the Millermatic 211, Auto-Set works with .030 and .035 in
diameter solid steel wire (for more info see pg 7).
Infinite voltage adjustment provides broader operating range with
finer control than a tap machine.
Multi-Voltage Plug (MVP™) — Miller’s exclusive
MVP allows connection to 115 or 230 V receptacles
without tools.
Smooth-Start ™ patent-pending technology provides
smooth, spatter-free starts.
“Tip Saver” shuts down output if tip is shorted to work. Extends
contact tip life and protects internal components from damage.
Recommended
aluminum solution:
Spoolmate 100 Series (#300 371).
*Dimensions and net weight are for machine only.
Stock Number
(#907 422) 115/230 V
(#907 422-01-1)
115/230 V with Small
Running Gear/Cyl. Rack
Most Popular Accessories
Auto-Line™ provides state-of-the-art flexibility, automatically connecting
to 115/230 VAC, single-phase power.
Spoolmate 100 Series (#300 371).
Stock Number
(#907 401)
115/230 VAC
• 10 ft (3 m) power cord and MVP™
adapter plugs for 115 and 230 V
• 10 ft (3 m) M-10 MIG gun and
cable assembly #195 605
• 10 ft (3 m) work cable with clamp
• One CO2 gas cylinder (empty)
• Dual-groove, quick-change drive
rolls for .024 in (0.6 mm) and
.030/.035 in (0.8/0.9 mm) wire
• Two contact tips for .024 in
(0.6 mm) wire and two for
.030 in (0.8 mm) wire
Input
Power
Amperage
Range
115 VAC
30 –140
90 A at 20 V at
20% Duty Cycle
20
—
2.9
2.5
230 VAC
30 – 210
150 A at 23.5 V at
30% Duty Cycle
—
24.3
5.5
4.8
Rated Output
Amps Input at Rated Output, 60 Hz
115 V
230 V
KVA
KW
• 6 ft (1.8 m) power cord and MVP™
adapter plugs for 115 and 230 V
• 10 ft (3 m) M-10 MIG gun and
cable assembly #195 605
• 10 ft (3 m) work cable with clamp
• Factory-installed gas solenoid valve
• Smith® regulator and gas hose
• Dual groove quick-change drive
rolls for .024 in (0.6 mm) or
.030/.035 in (0.8/0.9 mm) wire
• Extra contact tips, Hobart® spool
of solid wire, information/settings
chart, set-up/operation CD and
material thickness gauge (#229 895)
Most Popular Accessories
• Spoolmate™ 100 Series #300 371
(pg 27)
• Running Gear/Cylinder Rack (pg 82)
Small
#300 425
Regular #770 187
• Protective Cover #195 149 (pg 86)
See your Miller distributor or
MillerWelds.com for other popular
Miller options and accessories.
Wire Feed Speed
Wire Type and Diameter
Dimensions*
60– 460 IPM
(1.5 –11.7 m/min)
Solid Steel .023 –.035 in (0.6 – 0.9 mm)
Stainless .023 –.035 in (0.6 – 0.9 mm)
Flux Cored .030 –.045 in (0.8 –1.1 mm)
H: 15 3⁄4 in (400 mm)
W: 10 5⁄8 in (270 mm)
D: 17 1⁄2 in (445 mm)
Net
Weight*
74 lb
(33.6 kg)
9
A FLE10 Cat P 10 MIG.qxd:MIG
11/3/09
10:44 AM
Page 1
MIG G M A W
All-In-One
MillerWelds.com
Millermatic 212 Auto-Set
®
™
See Literature
No. DC/12.46
Industrial
Processes
• MIG (GMAW) • Flux Cored (FCAW)
Comes Complete With
Mild Steel
Welding Capability
Not to scale.
Min. — 22 ga (0.9 mm)
Max. — 3/8 in (9.5 mm)
Min. — 14 ga (1.9 mm)
Max. — 3/8 in (9.5 mm)
Aluminum
w/Spoolmate 200
Series Spool Gun
EXCLUSIVE! Auto-Set™ feature makes set up quick and easy. On the
Millermatic 212, Auto-Set works with .030 and .035 in diameter solid
steel wire (for more info see pg 7).
Infinite voltage adjustment — when used in manual mode provides
broader operating range with finer control than a tap machine.
Compatible with Spoolmate™ 200 Series spool gun with wire feed
speed control on the gun. Saves time by reducing trips back to
the machine. Also compatible with more industrial Spoolmatic® 15A or
30A spool gun.
Gun-On-Demand™ — simply pull the trigger for either gun and you’re
ready to weld. No wasted time installing modules and using gas valve kits.
Heavy duty aluminum drive system (for more info see pg 7).
Recommended
aluminum solution:
Spoolmate 200 Series
(#300 497).
Stock Number
(#907 405) 200(208)/230 V
(#951 177) 200(208)/230 V
with Spoolmate 200 Series,
Dual Cylinder Rack, Regulator
and Gas Hose
Amperage
Range
30 – 210
Rated Output
160 A at 24.5 VDC,
60% Duty Cycle
Amps Input at Rated Output, 60 Hz
200 V
230 V
KVA
KW
31
27
6.5
5.5
Millermatic Reach
®
Solid Steel .023 –.035 in (0.6 – 0.9 mm)
Stainless .023 –.035 in (0.6 – 0.9 mm)
Flux Cored .030 –.045 in (0.8 –1.2 mm)
H: 30 in (762 mm)
W: 19 in (483 mm)
D: 40 in (1016 mm)
Use only with Millermatic Power Sources.
See Literature No. M/6.8
Synergic Pulse Capability when connected to Millermatic 350P.
Remotely change weld output by simply adjusting wire feed speed setting.
Patent-pending Hybrid Technology. Connects to Millermatic 10-pin and
welding output circuit. Eliminates the need for a heavy mechanical
contactor — more portable!
Works with any Miller-compatible MIG gun (sold separately).
Two models available: 6 ft (1.8 m) and 25 ft (7.6 m) cable assemblies.
10
Wire Feed Speed
Wire Type and Diameter
50 –700 IPM
(1.3 –17.8 m/min)
Actual range is
dependent on arc
voltage applied
Solid Steel
Stainless
Aluminum
Metal-Core
Flux Cored
.023 –.045 in (0.6 –1.2 mm)
.030 –.045 in (0.8 –1.2 mm)
.047 in (1.2 mm)
.035 –.052 in (0.9 –1.3 mm)
.030 –.052 in (0.8 –1.3 mm)
178 lb
(81 kg)
Light Industrial
Wire Feeder
Auto-Gun Detect™ — when connected to a Millermatic 252 or 350P,
simply pull the trigger on either gun and the Millermatic machine will
recall both voltage and wire feed speed of the active gun.
300 A at
60% Duty Cycle
Net
Weight
50 –700 IPM
(1.3 –17.8 m/min)
Polypropylene case with built-in slide rails gives you the ability to
easily change wire when in vertical position. Holds a 12 in spool of wire.
Operates on
open-circuit
voltage and
arc voltage:
14 – 100 VDC
See your Miller distributor or
MillerWelds.com for other popular
Miller options and accessories.
Dimensions
Use as a dual feeder option! Keep one wire in the machine and a different
wire in the feeder. No more downtime changing spools and drive rolls.
Input Welding
Circuit Rating
• Millermatic® Reach Wire Feeder
6 ft #907 437 (see below)
25 ft #907 438 (see below)
• Spoolmate™ 200 Series Spool Gun
for aluminum welding
#300 497 (pg 27)
• Dual EZ Cyl. Rack #300 337 (pg 82)
• Elevated Gun and Cable Rack
#300 335 (pg 82)
• Protective Cover #195 142 (pg 86)
Wire Type and Diameter
Extend your Millermatic work area up to 40 feet! No more moving the
machine and pulling primary power cables around the shop.
Input Power
Most Popular Accessories
Wire Feed Speed
Use the Reach with your Millermatic 212 Auto-Set, 252, or 350/350P to extend your work
area or to create a dual feeder, avoiding downtime from changing wire spools.
Stock Number
(#907 437) 6 ft (1.8 m)
(#907 438) 25 ft (7.6 m)
• 15 ft (4.5 m), 250 amp M-25 gun
• 10 ft (3 m) work cable with clamp
• Smith® argon mix regulator/flow
gauge w/hose
• 7 ft (2.1 m) power cord and plug
• Factory-installed running gear/
cylinder rack
• .030/.035 in reversible dual groove
drive rolls
• Extra contact tips, set-up/operation
CD and material thickness gauge
(#229 895)
Maximum Spool
Size Capacity
12 in (305 mm),
45 lb (20 kg)
Processes
• MIG (GMAW)
• Flux Cored (FCAW)
• Pulsed MIG (GMAW-P) with
Millermatic 350P
Suggested Power Sources
• Millermatic® 212 Auto-Set™
(see above)
• Millermatic® 251
(discontinued product)
• Millermatic® 252 (pg 11)
• Millermatic® 350/350P (pg 12)
Suggested Guns
• MIGmatic™ M-25 (GMAW) (pg 87)
• Bernard® Q300 (GMAW)
• Bernard® Q400 Aluminum Gun
with Kit (GMAW) #300 542 (pg 87)
Most Popular Accessories
• Running Gear/Cylinder Rack (pg 82)
Small
#300 425
Regular #770 187
See your Miller distributor or
MillerWelds.com for other popular
Miller options and accessories.
Dimensions
H: 151 ⁄2 in (394 mm)
W: 9 in (229 mm)
D: 21 in (533 mm)
Net Weight with
Cable Assembly
6 ft Cables
29 lb (13.2 kg)
25 ft Cables
48 lb (21.8 kg)
A FLE10 Cat P 11 MIG.qxd:MIG
11/5/09
9:53 AM
Page 1
All-In-One
Call
1-800-4-A-MILLER for more information.
GMAW
Millermatic 252
MIG
Industrial
Processes
®
See Literature No. DC/12.49
• MIG (GMAW) • Flux Cored (FCAW)
Comes Complete With
Welding Capability
Mild Steel
Not to scale.
Min. — 22 ga (0.9 mm)
Max. — 1/2 in (13 mm)
Min. — 14 ga (1.9 mm)
Max. — 1/2 in (13 mm)
Aluminum
w/Spoolmatic 15A
or 30A Spool Gun
Infinite voltage control with digital meters
have self-calibrating meters that permit
presetting of voltage and wire feed speed.
Ensures precise parameters and accuracy.
Integrated digital timers come complete with
presettable preflow/postflow, burnback, spot
and delay (Stitch) timers. Independent timers
for MIG and spool gun.
Superior aluminum MIG welding with direct
connection of optional XR push-pull guns,
Spoolmatic 15A/30A and Spoolmate 200 Series
spool guns. No extra module to buy or install.
Auto-Gun Detect™ automatically adjusts
voltage, wire speed and timers for faster,
easier switching between MIG, push-pull and
spool guns.
Heavy duty aluminum drive system
(for more info see pg 7).
Fan-On-Demand™ cooling system only operates
when needed reducing power consumption.
15 ft (4.5 m) M-25 MIG gun features durable
one-piece handle, unicable outer jacket, trigger
rated for one million cycles, and steel spring
coils protecting cable ends.
Recommended
aluminum solution:
Spoolmatic 15A (#195 156)
or 30A (#130 831).
Stock Number
(#907 321) 200(208)/230 V
(#907 322) 230/460/575 V
(#951 066*) 200(208)/230 V w/Spoolmatic 30A
(#951 065*) 230/460/575 V w/Spoolmatic 30A
Amperage
Range
30 – 300
Rated Output
200 A at 28 VDC,
60% Duty Cycle
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V 575 V KVA KW
48
42
21
17
10
7.7
(at 60% Duty Cycle)
• 15 ft (4.5 m), 250 amp M-25
MIG gun
• 10 ft (3 m) work cable with clamp
• Factory-installed gas solenoid
• Smith® argon mix regulator/flow
gauge with hose
• 10 ft (3 m) industrial power cord
and plug (plug on 200/230 V
model only)
• Factory-installed running gear/
cylinder rack
• .030/.035 in reversible dual groove
drive rolls
• Extra contact tips
• Set-up and operation CD
Most Popular Accessories
• Millermatic® Reach Wire Feeder
6 ft #907 437 (pg 10)
25 ft #907 438 (pg 10)
• XR™-A Push-Pull Guns
(see below/pg 28/29)
• Spoolmate™ 200 Series Spool Gun
for aluminum welding #300 497
(pg 27)
• Spoolmatic® 15A Spool Gun for
aluminum welding #195 156
(pg 28)
• Spoolmatic® 30A Spool Gun for
aluminum welding #130 831
(pg 28)
• Dual EZ-Change™ Low Cylinder
Rack #300 337 (pg 82)
• Elevated Gun and Cable Rack
#300 335 (pg 82)
• Protective Cover #195 142 (pg 86)
• MIG Consumable Kit (pg 87)
See your Miller distributor or
MillerWelds.com for other popular
Miller options and accessories.
Wire Feed Speed
Wire Type and Diameter
Dimensions
50 –700 IPM
(1.3 –17.8 m/min)
Solid Steel
.023 –.045 in (0.6 –1.2 mm)
Stainless
.023 –.045 in (0.6 – 1.2 mm)
Flux Cored
.030 –.045 in (0.8 –1.2 mm)
H: 30 in
(762 mm)
W: 19 in
(483 mm)
D: 40 in
(1016 mm)
250 A at 28 VDC,
40% Duty Cycle
*Comes complete with Dual Cylinder Rack,
Regulator and Gas Hose.
Net
Weight
207 lb
(94 kg)
Featured Accessories
NEW! Wire Feeder Designed for Millermatics
Millermatic Reach (see page 10)
#907 437 6 ft (1.8 m)
#907 438 25 ft (7.6 m)
Extend your Millermatic work area up to
40 feet! No more moving the machine and
pulling primary power cables around the
shop. Or use as a dual feeder option! No
more downtime changing spools and drive
rolls. For use with Millermatic 212 Auto-Set,
251, 252 and 350/350P.
Note: For use with MIG guns only (sold separately).
Optional XR™-A Push-Pull Guns
Direct connect to Millermatic 252 and 350/350P.
Allows usage of 12 in rolls of aluminum
reducing downtime from changing 1 lb spools.
XR-Pistol
XR-Aluma-Pro
Gun
15 ft (4.6 m) Cable
25 ft (7.6 m) Cable
30 ft (9 m) Cable
35 ft (10.7 m) Cable
XR-Aluma-Pro™ A
#300 000
#300 001
—
#300 264
XR™-A Pistol
#198 127
—
#198 128
—
Aluminum U-Groove Drive
Roll and Accessory Kit
.035 in (0.9 mm)
.047 in (1.2 mm)
XR-Aluma-Pro™ A
#195 311
#195 313
XR™-A Pistol
#195 201
#195 202
11
A FLE10 Cat P 12 MIG.qxd:MIG
11/3/09
10:46 AM
Page 1
MIG G M A W
All-In-One
MillerWelds.com
Millermatic 350 and 350P
®
Welding Capability
Industrial
Processes
See Literature
No. DC/12.51
• MIG (GMAW)
• Flux Cored (FCAW)
• Pulsed MIG (GMAW-P) w/350P
Comes Complete With
Mild Steel
Not to scale.
Min. — 24 ga (0.8 mm)
Max. — 1/2 in (13 mm)
Min. — 18 ga (1.2 mm)
Max. — 1/2 in (13 mm)
Aluminum
w/Aluma-Pro
Push-Pull Gun
Aluminum Pulse Hot Start™ (350P model) automatically
provides more arc power to eliminate a “cold start” that is
inherent with aluminum starts.
Built-in Pulsed MIG programs (350P model). All programmed
information is restored after each power up — aluminum/steel/
stainless steel/metal core.
Infinite voltage control with digital meters have selfcalibrating meters that permit presetting of voltage and wire
feed speed. Ensures precise parameters and accuracy.
Most Popular Accessories
Integrated digital timers come complete with presettable
preflow/postflow and spot timers. Independent timers for MIG
and push-pull guns.
Superior aluminum MIG welding with direct connection
of optional XR push-pull guns and Spoolmatic 15A/30A
spool guns. No extra module to buy or install.
Recommended
aluminum solution:
XR-Aluma-Pro push-pull
gun (see pages 11 and 29).
See Aluminum Solutions
comparison chart on page 14.
Model/Stock Number
Millermatic 350
(#907 299) 200/230/460 V
(#907 167) 460/575 V
Millermatic 350P
(#907 300) 200/230/460 V
(#907 168) 460/575
Millermatic 350P/Aluma-Pro System
(see below for contents)
(#907 379) 200/230/460 V
(#907 380) 460/575
Amperage
Range
25 – 400
Rated Output
Auto-Gun Detect™ automatically adjusts voltage, wire speed
and timers for faster, easier switching between MIG, push-pull
and spool guns.
Heavy duty aluminum drive system (for more info see pg 7).
Fan-On-Demand™ cooling system only operates when
needed reducing power consumption and keeping internal
components cleaner.
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V 575 V KVA KW
Three-Phase
300 A at 32 VDC,
60% Duty Cycle
34
30
15
12
11.6 11.5
Single-Phase
300 A at 32 VDC,
60% Duty Cycle
69
61
30
24
13.1 11.2
• 15 ft (4.5 m) Bernard® Q300 MIG
gun with Centerfire™ consumables
• 10 ft (3 m) work cable with clamp
• Factory-installed gas solenoid
• Smith® argon mix regulator/flow
gauge with hose
• 10 ft (3 m) industrial power cord
(without plug) for single- or
three-phase
• Factory-installed, low-mounted
running gear/cylinder rack
• .035/.045 in reversible V-groove
drive rolls (order U-groove drive
rolls for aluminum welding)
• Extra contact tips
• Set-up and operation CD
• Millermatic® Reach Wire Feeder
6 ft #907 437 (pg 10)
25 ft #907 438 (pg 10)
• XR™-A Push-Pull Guns
(pg 11/28/29)
• Spoolmatic® 15A Spool Gun for
aluminum welding #195 156
(pg 28)
• Spoolmatic® 30A Spool Gun for
aluminum welding #130 831
(pg 28)
• Dual Cylinder Rack #195 299
(pg 82)
• Protective Cover #195 142 (pg 86)
See your Miller distributor or
MillerWelds.com for other popular
Miller options and accessories.
Wire Feed Speed
Wire Type and Diameter
Dimensions
MIG Gun
50 – 700 IPM
(1.3 –17.8 m/min)
Optional Spool Gun/
Push-Pull Gun
50 – 800 IPM
(1.3 –20 m/min)
Solid Steel
Stainless
Aluminum
Metal-Core
Flux Cored
H: 34 in
(863 mm)
W: 19 in
(483 mm)
D: 41 in
(1041 mm)
.023 –.045 in (0.6 –1.2 mm)
.030 –.045 in (0.8 –1.2 mm)
.035 –.047 in (0.9 –1.2 mm)
.035 –.052 in (0.9 –1.3 mm)
.030 –.052 in (0.8 –1.3 mm)
Net
Weight
181 lb
(82 kg)
(Regardless of
input power)
Featured Accessories
NEW! Wire Feeder Designed for Millermatics
Optional Aluminum System
Millermatic 350P/XR-Aluma-Pro -A
Push-Pull Gun Aluminum System
#907 379 200/230/460 V
#907 380 460/575 V
The ideal aluminum welding package. Allows
usage of 12 inch rolls of aluminum. Includes
Millermatic 350P, 25 ft XR-Aluma-Pro™ push-pull
gun, .035 and 3/64 in FasTip™ contact tips, and
.035 & 3/64 in reversible U-groove drive rolls.
™
Note: MIG gun not included (sold separately).
Millermatic Reach (see page 10)
#907 437 6 ft (1.8 m)
#907 438 25 ft (7.6 m)
Extend your Millermatic work area up to
40 feet! No more moving the machine and
pulling primary power cables around the
shop. Or use as a dual feeder option! No
more downtime changing spools and drive
rolls. For use with Millermatic 212 Auto-Set,
251, 252 and 350/350P.
Note: For use with MIG guns only (sold separately).
12
A FLE10 Cat P 13 MIG.qxd:MIG
11/13/09
9:41 AM
Page 1
Aluminum
Call
1-800-4-A-MILLER for more information.
AlumaFeed
GMAW
MIG
Heavy Industrial
™
Synergic Aluminum Welding System
Processes
See Literature No. DC/34
• MIG (GMAW)
• Pulsed MIG (GMAW-P)
The XR-AlumaFeed™ and AlumaPower™ 350 MPa combine for a synergic system that
simplifies and improves MIG and Pulsed MIG welding applications for aluminum welding.
Comes Complete With
• XR-AlumaFeed push-pull feeder
• AlumaPower 350 MPa power
source
• XR-Aluma-Pro™ or XR™-Pistol Grip
push-pull welding guns (air- or
water-cooled)
• .035 and 3/64 in (0.9 and 1.2 mm)
contact tips, drive roll and liners
for guns
• .035 and 3/64 in (0.9 and 1.2 mm)
drive rolls for wire feeder,
3/64 (1.2 mm) installed
Weld Cross Section
Hot Start On
Hot Start Off
Hot Start ™ allows operator to begin and end welds
with ease and confidence. Eliminates incomplete
fusion at the beginning of a weld, a common
issue with aluminum welding. Crater gradually
decreases weld current at the end of a weld to
eliminate crater defects. Adjustable pre- and
post-flow rates ensure that the puddle always has
adequate gas coverage.
Note: All AlumaFeed systems come
setup out of the box to run 3/64 in wire.
MIGRunner™ Package Includes
Above Plus
• MIGRunner™ Cart
• Industrial MIG 4/0 Kit with Dinse
Connector (see contents below)
Synchronized, true push-pull wire feed system
for precise wire feeding and arc performance.
AlumaFeed Synergic Aluminum Welding System with 25 ft
XR-Aluma-Pro gun shown. Also available with XR-Pistol Grip gun.
Parameter and system locks enhance quality
assurance and protect weld consistency.
NEW! Profile Pulse™ provides TIG
appearance with MIG simplicity
and productivity. Achieve “stacked
dimes” without gun manipulation.
Profile Pulse frequency can be changed to increase or
decrease the spacing between the ripple pattern to achieve
the desired weld appearance.
Trigger schedule select allows operator to
change between two sets of weld parameters.
Synergic “one-knob” control
makes adjustments easy. Set the
wire feed speed control on the gun
and the system handles the rest.
Synergic Pulsed MIG provides communication between the
power source, feeder and gun. As wire speed increases/
decreases, the pulse parameters also increase/decrease to
match the right amount of power needed.
Most Popular Accessories
• MIGRunner™ Cart #195 445 (pg 81)
Easily maneuverable with small
footprint and a cylinder rack low
enough that you do not have to
lift bottles.
• Remote Control Extension Kits
(pg 89)
25 ft (7.6 m) #043 725
50 ft (15 m) #043 726
75 ft (23 m) #043 727
Allows for any input voltage
hookup (208 – 575 V) with
no manual linking.
Optional MIGRunner
packages available —
AlumaFeed MIGRunner
(#951 151) shown.
• Industrial MIG 4/0 Kit with Dinse
Connector #300 405 (pg 86)
Includes Smith® regulator/flowmeter
with 10 ft (3 m) gas hose, 10 ft
(3 m) 4/0 feeder weld cable with
Dinse connector on one end and a
lug on the other, and 15 ft (4.6 m)
work cable with Dinse connector
on one end and 600-amp C-clamp.
• 1/16 Inch (1.6 mm) Liner and
Wire Kit #230 708
Built-in aluminum Pulsed MIG programs for simplicity and
improved puddle control. Pulsed welding virtually eliminates
burnthrough and warping issues on thinner materials.
Note: See Aluminum Solutions comparison chart on page 14.
*More system packages are available — see our Website or your local distributor.
Packages include gun and feeder drive rolls and consumables to run .035 – 3/64 in
(0.9 – 1.2 mm) wire. 1/16 inch consumables not included — order separately at right.
See your Miller distributor for other
popular Miller options and accessories.
Input Welding
Circuit Rating
Maximum Spool
Size Capacity
Wire Feeder
Dimensions
Wire Feeder
Net Weight
.035 –.062 in
(0.9 – 1.6 mm)
Wire kit #230 708
required to run 1/16 in
(1.6 mm) wire.
12 in (305 mm)
H: 16 in
(406 mm)
W: 9 1 ⁄2 in
(241 mm)
D: 211 ⁄4 in
(540 mm)
42.5 lb
(19.2 kg)
Stock Number
Input Power
AlumaFeed
Synergic
Aluminum
Welding System*
(#951 147) w/25-ft, air-cooled XR-Aluma-Pro gun
(#951 148) w/25-ft, water-cooled XR-Aluma-Pro gun
(#951 149) w/30-ft, air-cooled XR-Pistol Grip gun
(#951 150) w/30-ft, water-cooled XR-Pistol Grip gun
(#951 151) MIGRunner w/25-ft air-cooled Aluma-Pro
(#951 152) MIGRunner w/25-ft water-cooled Aluma-Pro
24 VAC, 5 A,
50/60 Hz
XR-AlumaFeed
Wire Feeder only
(#300 509) Note: Feeder is 14-pin compliant, but
only operates synergicly with an MPa power source.
Model
Stock Number
Input
Power
Amperage/
Voltage Ranges
Rated Output at Amps Input at Rated Load Output, 60 Hz
60% Duty Cycle 208 V 230 V 400 V 460 V 575 V KVA KW
AlumaPower
350 MPa Power
Source only
(#907 420) Note: Power source is MIG and Pulsed
MIG aluminum-only machine.
ThreePhase
CC Mode: 5 – 425 A
CV Mode: 10 – 38 V
350 A at 34 VDC 40.4
36.1
20.6
17.8
14.1
Single- CC Mode: 5 – 425 A
Phase CV Mode: 10 – 38 V
300 A at 32 VDC 60.8
54.6
29.7
24.5
19.9
400 A at 100%
Duty Cycle
System duty
cycle is limited
to gun rating.
Wire Feed Speed
Wire Diameter
Capacity
Model
70 – 780 IPM
(1.8 – 22.2 m/min)
Dimensions
Net
Weight
14.2 13.6 H: 17 in (432 mm)
80 lb
W: 121 ⁄2 in (318 mm) (36.3 kg)
11.7 11.2 D: 24 in (610 mm)
13
A FLE10 Cat P 14 MIG AL Chart.qxd:MIG
11/5/09
9:55 AM
Page 1
MIG G M A W
Aluminum
MillerWelds.com
Choose the Right Industrial Aluminum
MIG Solution
Millermatic 350P Aluminum System
shown with XR-Aluma-Pro gun (pg 12).
AlumaFeed Synergic Aluminum System
shown with XR-Aluma-Pro gun (pg 13).
Invision MPa Plus System shown with
dual feeder Stationary Package (pg 18).
Millermatic® 350P
AlumaFeed™ Synergic Aluminum System
Invision™ MPa Plus System
Cost-effective light-industrial all-in-one
MIG/Pulsed MIG solution with easy-to-use interface
for aluminum and steel wire welding on material
up to 1/2-in thick. Features built-in running gear
for mobility.
Dedicated industrial-fabrication aluminum-welding
solution with advanced welding features that can
handle larger weldments. Its lightweight push-pull
feeder can easily be carried up to 100 ft from the
power source.
Versatile industrial advanced system for large,
high-duty-cycle aluminum and steel weldments.
Features push and/or push-pull benchtop feeder
for easy switchover between solid, aluminum and
tubular wires.
Millermatic 350P (All-In-One)
All-In-One — add optional Millermatic Reach to
create dual-wire feeder (pg 10)
1- or 3-Phase
300 A at 60% Duty Cycle
Auto-Link® — Automatically links the power source to
primary voltage being applied (either 200/230/460 V
or 460/575 V). For the 200/230/460 V models,
Auto-link is used to link to 208 or 230 V and requires
manually moving a link board to link to 460 V.
.035 – 3/64 in (0.9 –1.2 mm)
AlumaPower™ 350 MPa
Single-Wire XR-AlumaFeed — portable feeder can
be carried up to 100 feet from power source
1- or 3-Phase
350 A at 60% Duty Cycle
Auto-Line™ — Allows for any primary input voltage
(208 – 575 V, single- or three-phase, 50 or 60 hertz)
with no manual linking. Also adjust for voltage spikes
within the entire range.
Invision 352 MPa
Single- or Dual-Wire 74 MPa Plus — stationary feeders
can be mounted up to 100 feet from power source
1- or 3-Phase
350 A at 60% Duty Cycle
Auto-Line™ — Allows for any primary input voltage
(208 – 575 V, single- or three-phase, 50 or 60 hertz)
with no manual linking. Also adjust for voltage spikes
within the entire range.
.035 – 1/16 in (0.9 –1.6 mm)
.035 – 1/16 in (0.9 –1.6 mm)
XR-Aluma-Pro™, XR™-Pistol or standard MIG Gun
XR-Aluma-Pro™ or XR™-Pistol
XR-Aluma-Pro™ Plus or standard MIG Gun
Profile Pulse™
—
Synergic
Pulsed MIG
MIG
Yes — “one-knob” control, only need to change wire
feed speed to weld different material thicknesses
Conventional MIG — modes for aluminum, steel and
other wires
Yes — achieve a “stacked dime” appearance quickly
and easily without gun manipulation
Yes — “one-knob” control, only need to change wire
feed speed to weld different material thicknesses
Spray Transfer MIG — for aluminum wires
Yes — achieve a “stacked dime” appearance quickly
and easily without gun manipulation
Yes — “one-knob” control, only need to change wire
feed speed to weld different material thicknesses
Conventional MIG — modes for aluminum, steel and
other wires
Aluminum, steel and stainless
Aluminum
Aluminum, steel, stainless and others
Built-in running gear with cylinder rack —
easily maneuverable from area to area
—
—
Lightweight, portable feeder with handle — can be
carried up to 100 feet from power source
Yes — reduces operator fatigue from holding trigger
Yes — allows operator to switch between two preset
weld conditions by pumping the trigger
Yes — prevents unintended changes to the welding
program weld parameters
Yes — allows flow to be set at feeder even when gas
supply is a long distance away
Stationary feeder — can be mounted up to 100 feet
from power source
Yes — reduces operator fatigue from holding trigger
Yes — allows operator to switch between two preset
weld conditions by pumping the trigger
Yes — prevents unintended changes to the welding
program weld parameters
—
Power Source
Feeder
Input Voltage
Rated Output
Primary
Connection
Aluminum Wire
Diameters
Gun Capability
MIG Modes
Features
Built-In Pulsed
Programs
Portability
Trigger Hold
Trigger Dual
Schedule
Program Locks
Flow Meter
14
—
—
A FLE10 Cat P 15 MIG Pkg Chart.qxd:MIG
11/3/09
10:49 AM
Page 1
Power Sources and Packages
Call
1-800-4-A-MILLER for more information.
GMAW
MIG
MIG Packages for Demanding
Industrial Applications
Each Product Offers Three Options That Will Help Fit Your Specific Welding Needs
GOOD
BETTER
CP-302/22A
Power Source
Welding
Performance
Material
Mild Steel
Stainless Steel
Aluminum
Material
Thickness
Gauge
(.020 –.125)
Sheet
(.125 –.375)
Plate
(.375 – 1 in)
Plate
(1+ in)
Wire Size
.030
.035
.045
.052
1/16
5/64
3/32
Process
Short Circuit
Pulsed Spray
Accu-Pulse®
RMD™
CAC-A
ICON KEY
OPTIMIZED
BEST
Delta-Fab/24A
Deltaweld/S-74D
Invision/S-74D
450 Amp
300 Amp
®
Axcess/Axcess Feeder
Delta-Fab™
(Pg 16)
Deltaweld
302
(Pg 17)
Invision
352 MPa
(Pg 18)
Axcess
300
(Pg 20)
Deltaweld
452
(Pg 17)
Invision
456P/MP
(Pg 19)
Axcess
450
(Pg 20)
Deltaweld®
652
(Pg 17)
Axcess®
675
(Pg 20)
®
®
Optional 1/4"
®
Optional 1/4"
CAPABILITY:
Designed for
Capable of
PROCESS QUALITY:
Good
Note: All machines listed are designed for MIG spray transfer and Flux Cored welding.
™
650 Amp
CP-302
(Pg 16)
™
5/16"
1/4"
Optional 3/8"
3/8"
Better Best Optimized
15
A FLE10 Cat P 16 MIG.qxd:MIG
11/3/09
10:50 AM
Page 1
MIG G M A W
Power Sources and Packages
CP-302
MillerWelds.com
Industrial
Processes
See Literature No. DC/13.0
• MIG (GMAW) • Flux Cored (FCAW)
Most Popular Accessories
Delivers dependable performance and productivity in more semiautomatic applications.
Combined with 22A wire feeder it makes this a “Good!” light to medium industrial solution.
• 22A and 24A Wire Feeders (pg 30)
• 70 Series Wire Feeders (pg 31)
• Standard Running Gear #042 886
(pg 82)
• Standard Cylinder Rack #042 887
(pg 82)
Adjustable weld stabilizer (high-low
inductance) provides the flexibility to
produce the optimal arc characteristics.
Solid-state weld contactor provides
longevity to match the ultra-durable and
reliable reputation of the CP Series.
Machine only
Stationary Package
Presettable welding voltage allows you
to easily set weld output before welding.
• Industrial MIG 4/0 Kit #300 390
(pg 86)
• Bernard® and Tregaskiss™ MIG Guns
Power efficiency gives exceptional value
and return on your investment.
MIG Power Source Solutions
OR
Build your own system by choosing machine,
feeder, gun, drive rolls, cables, etc. at
MillerWelds.com/equiptoweld
When purchasing components separately
please see your Miller distributor or visit
MillerWelds.com/equiptoweld for other
popular Miller options and accessories.
Large analog voltmeter and ammeter
for easy viewing.
MIGRunner Package
*Dimensions and weight are for power source only — includes lift eye and strain relief.
Stock Number
(#903 786) 200/230/460 V, Machine only
(#903 521) 575 V, Machine only
(#951 231) 200/230/460 V, Stationary Pkg
(#951 230) 200/230/460 V, MIGRunner Pkg
Voltage Range
Rated Output
14 – 44 V
300 A at 32 V,
100% Duty Cycle
Delta-Fab System
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V 575 KVA
38
33
16.5
13
KW
13.1 12.3
Open-Circuit Voltage
Dimensions*
14 – 44
H: 30 in (762 mm)
W: 23 in (585 mm)
D: 301 ⁄2 in (775 mm)
See Literature No. DC/15
• MIG (GMAW) • Flux Cored (FCAW)
Most Popular Accessories
375 amps, excellent arc performance, and a 24A wire feeder with remote voltage control
make this a “Better!” system solution for light and medium industrial applications.
Stationary
Package
MIG Power Source Solutions
MIGRunner Package
*Dimensions and weight are for power source only —
includes lift eye and strain relief.
Model/Stock Number
Delta-Fab System (#951 022) 230/460/575 V, Pwr Source, Feeder and Gun
Delta-Fab System (#951 233) 230/460/575 V, Stationary Pkg
Delta-Fab System (#951 232) 230/460/575 V, MIGRunner Pkg
• Standard Running Gear #042 886
(pg 82)
• Standard Cylinder Rack #042 887
(pg 82)
Material specific output studs provide the flexibility to
produce the optimal arc characteristics for aluminum,
stainless steel and all other materials.
Solid-state weld contactor provides longevity to match
the ultra-durable and reliable reputation of the Delta-Fab.
Line voltage compensation keeps welding parameters
constant even when input voltages change ±10%. Eliminates
need to change welding parameters throughout the day.
Thermal overload protection automatically shuts down
the system to prevent high repair costs.
Large analog volt and ammeters for easy viewing.
115 VAC duplex receptacle provides 15 amps of
auxiliary power.
Auto Remote Sense™ automatically selects remote control
requirements through the 14-pin receptacle. Eliminates
switches and confusion for the operator.
Remote voltage control is standard. Parameter adjustments
can be made in weld cell or at a remote location.
Voltage Range
Rated Output
10 – 45
375 A at 35 VDC,
100% Duty Cycle
332 lb
(151 kg)
Industrial
Processes
™
Power Source/
Feeder/Gun
Net
Weight*
• Industrial MIG 4/0 Kit #300 390
(pg 86)
• Remote Control Extension Cords
(pg 89)
• Bernard® and Tregaskiss™ MIG Guns
When purchasing components separately
please see your Miller distributor or visit
MillerWelds.com/equiptoweld for other
popular Miller options and accessories.
Amps Input at Rated Load Output, 60 Hz, 3-Phase
230 V
460 V
575 V
KVA
KW
69
34.5
27.5
27.5
17.5
Dimensions*
Net Weight*
H: 30 in (762 mm)
W: 23 in (585 mm)
D: 301 ⁄2 in (775 mm)
374 lb
(180 kg)
Wire Feeder
Input Power
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
24A
(Includes .035/.045 drive rolls)
24 VAC, 7 A, 50/60 Hz
75 – 750 IPM (1.9 – 19 m/min)
.023 – 3/32 in (0.6 – 2.4 mm)
60 lb (27 kg) coil
H: 11 in (279 mm)
W: 10 3⁄4 in (273 mm)
D: 231⁄ 2 in (597 mm)
40 lb
(18 kg)
16
A FLE10 Cat P 17 MIG.qxd:MIG
11/3/09
10:51 AM
Page 1
Power Sources and Packages
Call
1-800-4-A-MILLER for more information.
GMAW
Deltaweld Series
Industrial 302 model
Hvy Industrial 452/652 models
®
See Literature No. DC/16.2
Rock solid reliability, exceptional value and power efficient operation make this the “Better!”
MIG solution for the most demanding industrial manufacturing applications. Combined with
the 70 Series wire feeder this system is the workhorse of the industrial market.
Deltaweld models are available in 300, 450 and 650 amps.
Line voltage compensation keeps welding parameters constant even when
input voltages change ±10%. Eliminates need to change welding parameters
throughout the day.
Material specific output studs provide the flexibility to produce the optimal
arc characteristics for aluminum, stainless steel and all other materials.
Unique Fan-On-Demand™ cooling system operates only when needed.
Reduces excess noise and contaminants drawn into the machine.
Deltaweld (see stock numbers
below) Purchase components
separately. See list at right for
most popular accessories.
MIG
Processes
• MIG (GMAW)
• Flux Cored (FCAW)
• Air Carbon Arc
Cutting and Gouging (CAC-A)
(452: 1/4 in carbons)
(652: 3/8 in carbons)
Most Popular Accessories
• 70 Series Wire Feeders (pg 31)
• Standard Running Gear #042 886
(pg 82)
• Standard Cylinder Rack #042 887
(pg 82)
Thermal overload protection automatically shuts down the system to prevent
high repair costs.
Remote control capability allows operators fine tuning capability at an
extended distance.
15 amp, 115 VAC duplex receptacle for operating auxiliary tools.
Digital meters for presetting or monitoring welding voltage or amperage for
more precise control.
Power efficient for exceptional value
and return on your investment.
MIG Power Source Solutions
OR
Build your own system by choosing machine,
feeder, gun, drive rolls, cables, etc. at
MillerWelds.com/equiptoweld
• Industrial MIG 4/0 Kit #300 390
(pg 86)
Includes Smith® regulator/flowmeter
with 10 ft (3 m) gas hose, 10 ft
(3 m) 4/0 feeder weld cable with
lugs, and 15 ft (4.6 m) work cable
with 600-amp C-clamp.
• Remote On/Off Control #042 869
(pg 89)
• Remote Control Extension Cords
(pg 89)
• Air Filter Kit #042 939
• Bernard® and Tregaskiss™ MIG Guns
When purchasing components separately
please see your Miller distributor or visit
MillerWelds.com/equiptoweld for other
popular Miller options and accessories.
Deltaweld MIGRunner ™ Package
(see stock numbers below) MIGRunner system
with factory-installed running gear/cylinder rack.
Comes Complete With:
• Deltaweld power source
• S-74D wire feeder with drive rolls
• Bernard® Q-Gun™
• Industrial MIG 4/0 Kit
(see listing at right for kit contents)
• Factory-installed running gear/cylinder rack
Deltaweld Stationary Package
(see stock numbers below) Stationary display
without running gear/cylinder rack.
Comes Complete With:
• Deltaweld power source
• S-74D wire feeder with drive rolls
• Bernard® Q-Gun™
• Industrial MIG 4/0 Kit
(see listing at right for kit contents)
*Dimensions and weight are for power source only — includes lift eye and strain relief.
Voltage
Range
Recommended
Welding Range
(#903 376) 200-208/230/460 V, Machine only
(#903 392) 230/460/575 V, Machine only
(#951 235) 200-208/230/460 V, Stationary Pkg
(#951 127) 230/460/575 V, Stationary Pkg
(#951 234) 200-208/230/460 V, MIGRunner Pkg
(#951 129) 230/460/575 V, MIGRunner Pkg
10 – 32
15 – 32 V
Deltaweld
452
(#903 377) 200-208/230/460 V, Machine only
(#903 394) 230/460/575 V, Machine only
(#951 237) 200-208/230/460 V, Stationary Pkg
(#951 128) 230/460/575 V, Stationary Pkg
(#951 236) 200-208/230/460 V, MIGRunner Pkg
(#951 130) 230/460/575 V, MIGRunner Pkg
10 – 38
Deltaweld
652
(#903 396) 230/460/575 V, Machine only
(#951 239) 230/460/575 V, Stationary Pkg
(#951 238) 230/460/575 V, MIGRunner Pkg
10 – 44
Model
Stock Number
Deltaweld
302
Net
Weight*
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
300 A at 32 VDC,
100% Duty Cycle
48
42
21
17
16.9 12.9
42 VDC
H: 30 in (762 mm)
W: 23 in (585 mm)
D: 301 ⁄2 in (775 mm)
323 lb
(147 kg)
15 – 38 V
450 A at 38 VDC,
100% Duty Cycle
72
63
32
25
25.1 21.1
48 VDC
H: 30 in (762 mm)
W: 23 in (585 mm)
D: 38 in (966 mm)
384 lb
(174 kg)
15 – 44 V
650 A at 44 VDC,
100% Duty Cycle
—
96
48
38
38.2 34.2
54 VDC
H: 30 in (762 mm)
W: 23 in (585 mm)
D: 38 in (966 mm)
472 lb
(214 kg)
Rated Output
Dimensions*
17
A FLE10 Cat P 18 MIG.qxd:MIG
11/3/09
10:51 AM
Page 1
MIG G M A W
Power Sources and Packages
MillerWelds.com
Heavy Industrial
Invision MPa Plus System
™
Available
1st Quarter
Processes
See Literature No. DC/23.6
Features Alumination to provide the versatility of extended reach push-pull aluminum and
includes Pulsed MIG programs for many other wires, providing the “Best!” solution for all
your MIG welding needs.
™
Built-in MIG and Pulsed MIG programs automatically
set the optimal parameters for a wide variety of wires
providing immediate productivity.
Optimized arc control from start to finish is achieved
using communication between Invision 352 MPa power
source and 74 MPa Plus feeder.
Alumination™ allows use of extended reach push-pull
gun for consistent, dependable aluminum wire feeding.
Synergic Pulsed MIG provides communication between
the power source, feeder and gun. As wire speed
Allows for any input voltage hookup increases/decreases, the pulse parameters also increase/
(208–575 V) with no manual linking. decrease to match the right amount of power needed.
Profile Pulse™ gives you a
Robust and stable arc, even at short lengths, provides
improved control with reduced heat input and the ability cosmetic bead appearance for
welds you want to show off.
to weld a wider range of material thicknesses.
• MIG (GMAW) • Flux Cored (FCAW)
• Pulsed MIG (GMAW-P)
• Air Carbon Arc Cutting and
Gouging (CAC-A) (1/4 in carbons)
Most Popular Accessories
• MIGRunner ™ Cart (Single Feeders
only) #195 445 (pg 81)
• Running Gear Cylinder Rack
#300 408 (pg 82)
• Industrial MIG 4/0 Kit with Dinse
Connector #300 405 (pg 86)
• Remote Control Extension Kits
(pg 89)
25 ft (7.6 m) #043 725
50 ft (15 m) #043 726
75 ft (23 m) #043 727
74 MPa Plus Wire Feeders
Easy to set up. Select wire diameter, wire type and gas
being used, set your wire speed and strike an arc.
Invision 352 MPa
(see stock numbers
below) Purchase
components separately.
See list at right for most
popular accessories.
MIG Power Source Solutions
OR
Build your own system by
choosing machine, feeder, gun,
drive rolls, cables, etc. at
MillerWelds.com/equiptoweld
Air-cooled package
with single feeder
shown.
Water-cooled
package with
dual feeder
shown (wire
not included).
Invision MPa Plus Stationary Package
(see stock numbers below) Stationary display without
running gear/cylinder rack.
Comes Complete With:
• Invision 352 MPa power source with or without auxiliary pwr
• Single or dual 74 MPa Plus wire feeder with drive rolls
• 25 ft XR-Aluma-Pro™ Plus push-pull gun for aluminum
• 15 ft Bernard® Q400 Gun (2 included w/dual feeder pkgs)
• Industrial MIG 4/0 Kit with Dinse Connector
(see page 86 for kit contents)
• Coolmate™ 3 for single feeders or Coolmate™ V3 for dual
feeders (water-cooled packages only)
Invision MPa Plus MIGRunner ™ Package
(see stock numbers below) MIGRunner system with
factory-installed running gear/cylinder rack.
Includes everything in the Stationary Package plus:
• Factory-installed running gear/cylinder rack (MIGRunner
Cart for single feeders or Running Gear Cylinder Rack for
dual feeders)
Note: See Aluminum Solutions comparison chart on page 14. *Additional packages are available, see our Web site or lit sheets.
**Duty cycle rating below achieved with 6 gauge input power cord (8 gauge cord supplied with unit). ***Dimensions/weight for power source only.
Stock Number*
(#907 431)
Machine only
(#907 431 001)
Machine only
w/Auxiliary
Power
18
Water-Cooled Pkgs
with 25 ft Guns
Air-Cooled Pkgs
with 25 ft Guns
Input
Power
Amperage/
Voltage Ranges
Rated Output
Stationary Packages
(#951 284) w/Aux Pwr
and Single Feeder
(#951 286) w/Aux Pwr
and Dual Feeder
MIGRunner Packages
(#951 288) w/Aux Pwr
and Single Feeder
(#951 290) w/Aux Pwr
and Dual Feeder
Stationary Packages
(#951 283)
w/Single Feeder
(#951 285)
w/Dual Feeder
MIGRunner Packages
(#951 287)
w/Single Feeder
(#951 289)
w/Dual Feeder
ThreePhase
CC Mode:
5 – 425 A
S-74 MPa Plus (single) #951 291
• Synergic Pulsed MIG benefits
when used with Invision 352 MPa.
• Wire speed of 50 – 780 IPM.
• Program locks allow operator to
maintain proper weld parameters.
• Trigger hold reduces fatigue.
D-74 MPa Plus (dual) #951 292
All of the features listed above plus:
• Cover all your wire needs with one
feeder. Saves setup and changeover
time by allowing two different
wires to be ready at the same time.
Note: Feeders include Bernard Q-Guns
(one for S-74 models and two for D-74
models. Feeders are 14-pin compliant,
but only operate synergicly with an MPa
power source. For more information on
74 MPa Plus feeders, see Lit. No. DC/23.6.
XR-Aluma-Pro Plus Push-Pull Guns
15 ft air-cooled
#300 000 001
25 ft air-cooled
#300 001 001
35 ft air-cooled
#300 264 001
15 ft water-cooled #300 003 001
25 ft water-cooled #300 004 001
35 ft water-cooled #300 265 001
Dedicated gun works with MPa Plus
feeders using tachometer feedback
to coordinate wire feed speed of the
gun and the feeder.
When purchasing components separately
please see your Miller distributor or visit
MillerWelds.com/equiptoweld for other
popular Miller options and accessories.
Amps Input at Rated Load Output, 60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
350 A at 34 VDC,
60% Duty Cycle
40.4
36.1
20.6
17.8
14.1
14.2 13.6
75 VDC
300 A at 32 VDC,
60% Duty Cycle**
60.8
54.6
29.7
25.4
19.9
11.7 11.2
CV Mode:
10 – 38 V
SinglePhase
Dual
feeder
shown.
Dimensions***
H: 17 in
(432 mm)
W: 121 ⁄2 in
(318 mm)
D: 24 in
(610 mm)
Net
Weight***
80 lb
(36.3 kg)
A FLE10 Cat P 19 MIG.qxd:MIG
11/3/09
10:52 AM
Page 1
Power Sources and Packages
Call
1-800-4-A-MILLER for more information.
GMAW
Invision 456MP and 456P
™
MIG
Heavy Industrial
See Literature No. DC/23
and No. DC/20
Inverter design with variable inductance control provides the “Best!” industrial MIG welding
performance for manufacturing applications.
Variable electronic inductance helps minimize
spatter and optimize weld bead profile.
Dual digital meters for quick and easy viewing.
14-pin select remote control allows “plug and
play” convenience. Makes set-up time quicker.
Fan-On-Demand™ improves power efficiency
and noise reduction.
Invision 456P
is CV only.
Processes
• MIG (GMAW)
• Flux Cored (FCAW)
• Pulsed MIG (GMAW-P) w/456MP
(456P requires optional control)
• Stick (SMAW) with 456MP
• Air Carbon Arc Cutting and
Gouging (CAC-A) (5/16 in carbons)
Most Popular Accessories
• 70 Series Wire Feeders (pg 31)
• Running Gear Cylinder Rack
#300 408 (pg 82)
Wind Tunnel Technology™ protects electrical
components and PC boards from contamination,
significantly improving reliability.
Machine only
Stationary Package
MP Model Additional Features
Built-in Pulsed MIG capabilities eliminates
pendants and cables that could potentially get
damaged or lost.
MIG Power Source Solutions
OR
Build your own system by
choosing machine, feeder, gun,
drive rolls, cables, etc. at
MillerWelds.com/equiptoweld
MIGRunner Package
*Additional models are available, see our Web site or literature sheets.
**Dimensions and weight are for power source only.
Amperage/
Voltage Range
Model*
Stock Number
Invision
456MP
(#903 725) 230/460 V, Machine only
(#907 056) 575 V, Machine only
(#951 243) 230/460 V, Stationary Pkg
(#951 242) 230/460 V, MIGRunner Pkg
CC Mode:
5 – 600 A Stick
CV Mode: 10 – 38 V
Invision
456P
(#903 505) 230/460 V, Machine only
(#903 546) 575 V, Machine only
(#951 245) 230/460 V, Stationary Pkg
(#951 244) 230/460 V, MIGRunner Pkg
CV Mode: 10 – 38 V
Microprocessor-based technology allows
process parameter storage to be retained
between power down, power up, and also
between program changes.
Rated Output
450 A at 38 VDC,
100% Duty Cycle
• Industrial MIG 4/0 Kit with Dinse
Connector #300 405 (pg 86)
When purchasing components separately
please see your Miller distributor or visit
MillerWelds.com/equiptoweld for other
popular Miller options and accessories.
RMS Amps Input at Rated Load Output, 60 Hz,
at NEMA Load Voltages and Class I Rating
230 V
460 V
575 V
KVA
KW
Max. OpenCircuit
Voltage
50.8
95 VDC
27.8
24.4
21.2
19.2
Dimensions**
H: 17 in (432 mm)
W: 141 ⁄2 in (368 mm)
D: 26 in (660 mm)
Net
Weight**
118 lb
(53.5 kg)
Build a Complete Industrial System
Online with Equip to Weld
™
With Equip to Weld, you can build your own industrial
system online and get a detailed summary, complete
with list prices for accurate budgeting. Take or email the
summary to your distributor to place your order.
Available for most industrial welding systems, Equip to Weld provides:
• Fast, easy and accurate system
configuration. It’s a user-friendly
system building tool.
• Customization. When applicable,
Equip to Weld allows you to specify your
choice of guns, drive rolls, custom cable
lengths, and connection terminations.
• All Necessories™ included. Equip to
Weld accounts for secondary cables,
• Fast Delivery. Most custom systems
clamps, primary cable, regulators, gas leave the factory within 48 hours
hose and other necessary accessories. of receipt.
Go to MillerWelds.com/equiptoweld
19
A FLE10 Cat P 20 MIG.qxd:MIG
11/3/09
10:53 AM
Page 1
MIG G M A W
Power Sources and Packages
MillerWelds.com
Axcess Systems
Industrial 300 model
Hvy Industrial 450/675 models
®
See Literature No. DC/8.0
Optimize your industrial MIG welding system with digital control capability and exceptional
MultiMIG® performance. A dedicated, menu-driven wire feeder provides a true synergic solution.
Miller’s patented technology allows for
any input voltage hookup (208 – 575 V)
with no manual linking. Assures
rock-solid, consistent output on fluctuating primary lines.
9-pin Palm™ handheld (PDA) RS-232 serial communication port
provides Axcess to data transfer and optional program downloads
from Web at MillerWelds.com/AMS/axcess.
Axcess four-drive-roll wire drive feeder is combined with operator
interface leaving no controls back at the power source.
MIG welding programs include patented Accu-Pulse,® Accu-Curve,™
Accu-Speed,™ standard or adaptive pulse, conventional MIG and metal
core programs.
Axcess (see stock numbers below)
Purchase components separately. See list
at right for most popular accessories.
Note: Look for high-speed video clips of Accu-Pulse ®, Accu-Curve ™,
Accu-Speed ™ and Front Panel Simulator at MillerWelds.com/AMS/axcess.
Accu-Pulse® MIG process delivers precise control of the arc even over
tack welds and in tight corners.
SureStart ® technology provides consistent arc starts by precisely
controlling power levels for specific wire and gas combinations.
Processes
Multi-MIG®
• Accu-Pulse™ MIG (GMAW-P)
- Accu-Curve™
- Accu-Speed™
• Pulsed MIG (GMAW-P)
• Metal Core
• MIG (GMAW)
• RMD™ Regulated Metal Deposition
(GMAW-SCT) (optional)
• Carbon Arc Gouging (CAC-A) can
also be activated.
Most Popular Axcess-ories
• RMD™ (Regulated Metal Deposition)
#195 252 (pg 23)
• Palm™ Convenience Package
#195 517 (pg 23)
• Axcess® File Management
Software (pg 23)
for Palm #195 249
for PC #300 529
• WaveWriter ™ File Management
Software (consult factory, pg 23)
• Feeder Cart #142 382 (pg 81)
• Running Gear Cylinder Rack
(Axcess 300 and 450 only)
#300 408 (pg 82)
MIG Power Source Solutions
OR
Build your own system by choosing machine,
feeder, gun, drive rolls, cables, etc. at
MillerWelds.com/equiptoweld
Axcess Stationary Package (only available
with 300 and 450 models, see stock numbers below)
Stationary display without running gear/cylinder rack.
Comes Complete With:
• Axcess power source
• Axcess wire feeder with drive rolls
• Bernard® Q-Gun™
• Industrial MIG 4/0 Kit (see listing at right for kit contents)
*Additional models are available, see our Web site or literature sheets.
**Dimensions and weight are for power source only.
Axcess MIGRunner ™ Package (only available with
300 and 450 models, see stock numbers below)
MIGRunner system with factory-installed running gear/
cylinder rack.
Comes Complete With:
• Axcess power source
• Axcess wire feeder with drive rolls
• Bernard® Q-Gun™
• Industrial MIG 4/0 Kit (see listing at right for kit contents)
• Factory-installed running gear/cylinder rack
Amperage/
Voltage Ranges
Three-Phase
Rated Output
Amps Input at Rated Output, 50/60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
(#907 150) Machine only
(#951 227) Stationary Pkg
(#951 226) MIGRunner Pkg
5 – 400 A
10 – 44 V
300 A at 32 VDC,
60% Duty Cycle
33
29.7 16.9 14.6 11.6 11.7 11.2
80 VDC
Axcess
450
(#907 152) Machine only
(#951 229) Stationary Pkg
(#951 228) MIGRunner Pkg
5 – 600 A
10 – 44 V
450 A at 44 VDC,
100% Duty Cycle
—
60
80 VDC
Axcess
675
(#907 154) Machine only
5 – 900 A
10 – 44 V
675 A at 44 VDC,
100% Duty Cycle
—
89.7 —
Model*
Stock Number
Axcess
300
20
33.7 28.8 22.8 23.8 22.9
43.7 34.8 35.7 34.4
80 VDC
• Industrial MIG 4/0 Kit #300 390
(pg 86)
Includes Smith® regulator/flowmeter
with 10 ft (3 m) gas hose, 10 ft
(3 m) 4/0 feeder weld cable with
lugs, and 15 ft (4.6 m) work cable
with 600-amp C-clamp.
• Aluminum Gun Kits —
for pushing aluminum wire (pg 87)
.035, 10 ft (3 m) #300 541
.047, 12 ft (3.7 m) #300 542
1/16, 12 ft (3.7 m) #300 543
Kits include .035, .047 or 1/16 in
drive rolls and 10 or 12 ft Bernard®
Q-Gun.™
When purchasing components separately
please see your Miller distributor or visit
MillerWelds.com/equiptoweld for other
popular Miller options and accessories.
Dimensions**
300 H: 23 in (584 mm)
450 H: 31 in (787 mm)
675 H: 39 in (991 mm)
W: 17 in (432 mm)
D: 22-1/2 in (572 mm)
Net
Weight**
116 lb
(52.6 kg)
163 lb
(73.9 kg)
208 lb
(94.3 kg)
A FLE10 Cat P 21 MIG.qxd:MIG
11/3/09
10:53 AM
Page 1
Power Sources and Packages
Call
1-800-4-A-MILLER for more information.
GMAW
Wire Feeding Options
MIG
Go to the online Axcess
System Configurator at
MillerWelds.com/AMS
Customize your industrial MIG welding system with the
wire feeding options listed below.
Axcess Feeders
®
Single-Wire Model
Dual-Wire Model
#195 182
#195 325
DeviceNet Interconnecting
Feeder Control Cable
(One required per machine)
#195 240
#195 241
#195 242
#195 243
5 ft (1.5 m)
10 ft (3 m)
25 ft (7.6 m)
50 ft (15.2 m)
Axcess ROI Swingarc Boom-Mounted Feeders
®
™
Single-Wire Models
#300 363
#195 484
#195 346
#300 364
#195 434
#195 435
Dual-Wire Models
8 ft (2.4 m)
12 ft (3.7 m)
16 ft (4.9 m)
8 ft (2.4 m)
12 ft (3.7 m)
16 ft (4.9 m)
MIG gun (required,
order separately)
Pipe post NOT included.
Must be ordered separately.
4 ft Pipe Post with 18 in Base #149 838
6 ft Pipe Post with 18 in Base #149 839
Swingarc boom-mounted semiautomatic wire feeders bring an extra
dimension of flexibility and efficiency to high-production MIG welding
stations. You get an effective solution that maximizes output, especially
when dealing with large weldments and hard-to-reach places.
Axcess ROI (Remote Operator Interface)
®
Single ROI #195 238
Dual ROI #195 433
ROI includes the operator interface and wire
motor control packaged into a separate sheet
metal enclosure allowing the power source, wire
drive motor assembly and operator interface (ROI)
to be located in three separate places. Does NOT
include AA-40GB Wire Drive Motor Assembly,
Motor Control Cable or DeviceNet Interconnecting
Feeder Control Cable. These must be ordered
separately (see below). Ideal for retrofitting
existing booms (Miller and competitive brands).
Auto ROI #195 239
The Auto ROI is different from
other ROI models in that it
allows for control of simple
automated equipment with
two programmable contacts
when used with semiautomatic Axcess AND E-Stop
option. Used for fixed/hard
Auto ROI back
automation applications.
panel showing
connection for input Includes 30 ft cable for wiring
and output signals. to other external devices.
Cables and Wire Feed Motors
Feeder
Base with
Spool
Support
#195 369
Boom
Retrofit
Applications
Flexible Mounting Options
Axcess
Power
Source
DeviceNet Interconnecting
Feeder Control Cable
5 ft (1.5 m)
#195 240
10 ft (3 m)
#195 241
25 ft (7.6 m) #195 242
50 ft (15.2 m) #195 243
ROI (Remote
Operator
Interface)
Gun
Motor Control Cable
20 ft (6.1 m) #300 097
30 ft (9 m)
#300 096
50 ft (15.2 m) #300 098
AA-40GB Wire Drive
Motor Assembly
Left-Hand Drive #195 426
Right-Hand Drive #195 515
(Two cables required for Dual ROI.)
(Two wire drive motor assemblies
required for Dual ROI.)
21
A FLE10 Cat P 22 AMS.qxd:AMS
11/3/09
10:55 AM
Page 1
Automated Manufacturing Systems
Consult the factory for ALL Automation and Robotic applications at
MillerWelds.com/AMS
1-920-954-3813.
Products shown in this section are more complex
and may require Miller factory support at additional
expense to assure the system and components
needed are properly selected and installed.
Go to the online Axcess
System Configurator at
MillerWelds.com/AMS
Auto-Axcess Systems
Processes
®
Multi-MIG®
• Accu-Pulse® MIG (GMAW-P)
- Accu-Pulse® tandem (optional)
- Accu-Curve™
- Accu-Speed™
• Pulsed MIG (GMAW-P)
• Metal Core
• MIG (GMAW)
• RMD™ Regulated Metal Deposition
(GMAW-SCT) (optional)
See Literature No. AU/8.0
For robotic automation — seamless integration of digital control technology combines
inverter welding power source and robotic interface.
Features Auto-CAL…
A patented automatic calibration feature
that uses the Auto-Axcess internal
digital technology to allow simple,
automatic scaling and synchronization
to analog robot controllers. This
assures consistent and repeatable
results with minimal downtime when
installing Auto-Axcess power sources
into existing robot cells.
Miller’s
patented
technology
allows for any input voltage hookup
(208 – 575 V) with no manual linking.
Assures rock-solid, consistent output on
fluctuating primary lines.
AA-40GB Motors
(Motor control cables must
be ordered separately.)
MIG welding programs include patented
Accu-Pulse,® Accu-Curve,™ Accu-Speed,™
standard or adaptive pulse, conventional
MIG and metal core programs.
AA-40GB motor
connections.
AA-40GB Wire Drive Motor Assembly with OCP (Over Current
Protection) to protect against current surges. New design utilizes
an improved sheet metal enclosure including printed circuit board.
It features a threaded gas connection and a direct-panel-mounted,
quarter-turn motor control cable connection that eliminates motion
stress on the motor’s power and tachometer feedback wires.
72-pin Harting connector for quick, easy connection to common
analog robot controllers. DeviceNet Connector for quick, easy
connection to common robot controllers (ABB, Fanuc, KuKa and
Motoman) with standard device net cables.
Accu-Pulse® MIG process delivers precise
control of the arc even over tack welds and
in tight corners.
SureStart ® technology provides consistent
arc starts by precisely controlling power
levels for specific wire and gas combinations.
Optional Axcess-able software:
Accu-Pulse™ tandem (factory-installed only),
RMD™ (Regulated Metal Deposition),
Axcess® File Management for Palm or PC
and WaveWriter™ with Wave Shaping.
Required Wire Drive Motor
Assembly/Motor Control Cable
• AA-40GB Wire Drive Motor
(includes 50 ft volt-sense lead)
Left-Hand Drive #195 426
Right-Hand Drive #195 515
(Order required Motor Control
Cable separately)
• Motor Control Cable
20 ft (6.1 m) #300 097
30 ft (9 m)
#300 096
50 ft (15.2 m) #300 098
Most Popular Axcess-ories
• RMD™ (Regulated Metal Deposition)
#195 252 (pg 23)
• Palm™ Convenience Package
#195 517 (pg 23)
• Axcess® File Management
Software (pg 23)
for Palm #195 249
for PC #300 529
• WaveWriter ™ File Management
Software (consult factory, pg 23)
• Coolant Flow Switch #195 461
(pg 81)
• Receptacle/Adapter Kits
(One required per machine)
ABB
#194 793
Fanuc
#194 791
Motoman
#194 790
Universal
#195 002
Panasonic
#300 056
• Smart Adapter #300 012 —
allows automatic to be configured
to function as semi-automatic
• Fanuc/Motoman Motor Bracket
#300 013
*Order Wire Drive Motor Assembly and required length Motor Control Cable separately.
Model
Stock Number*
Amperage/
Voltage Ranges
Three-Phase
Rated Output
Amps Input at Rated Output, 50/60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
Auto-Axcess
300
(#907 151) Base Power Source
(#907 151-01-1) w/RMD Process Software
5 – 400 A
10 – 44 V
300 A at 32 VDC,
60% Duty Cycle
33
29.7 16.9 14.6 11.6 11.7 11.2
80 VDC
Auto-Axcess
450
(#907 153) Base Power Source
(#907 153-01-1) w/RMD Process Software
(#907 153-02-2) w/tandem Syncronization
5 – 600 A
10 – 44 V
450 A at 44 VDC,
100% Duty Cycle
—
60
80 VDC
Auto-Axcess
675
(#907 155) Base Power Source
(#907 155-02-1) w/tandem Syncronization
5 – 900 A
10 – 44 V
675 A at 44 VDC,
100% Duty Cycle
—
89.7 —
22
33.7 28.8 22.8 23.8 22.9
43.7 34.8 35.7 34.4
80 VDC
Dimensions
300 H: 23 in (584 mm)
450 H: 31 in (787 mm)
675 H: 39 in (991 mm)
W: 17 in (432 mm)
D: 22-1/2 in (572 mm)
Net
Weight
116 lb
(52.6 kg)
163 lb
(73.9 kg)
208 lb
(94.3 kg)
A FLE10 Cat P 23 AMS.qxd:AMS
11/3/09
10:55 AM
Page 1
Automated Manufacturing Systems
MillerWelds.com/AMS
Consult the factory for ALL Automation and Robotic applications at
®
Axcess Multi-MIG Welding
Process Capabilities
®
Process
Weld Puddle
Control
Standard
Spray
Accu-Pulse®
Accu-Speed™
Accu-Curve™
Pulsed
Spray
Flat/Horizontal
Standard
Short Circuit
All Position Performance
1-920-954-3813.
RMD ™ Regulated
Metal Deposition (Optional)
Thin Materials/Gap Filling
Look for high-speed video clips of Accu-Pulse, Accu-Curve, Accu-Speed and Front Panel Simulator at MillerWelds.com/AMS/axcess.
Accu-Pulse
®
STANDARD on all Axcess models
The patented Accu-Pulse process allows for precise control of the pulse
arc. Accu-Pulse provides optimum molten puddle control and has
power to increase wire feed speeds and deposition 20 to 25% in many
applications. Two Accu-Pulse variations, Accu-Curve and Accu-Speed,
are included FREE with every new Axcess® or Auto-Axcess® system.
Accu-Pulse – CV Peak/Background
Taught
Peak Voltage
Voltage
Taught
Background
Voltage
Fixed current beginning points
CC Ramps
Min Current Limit
Current
CV Peak CV Background CV Peak
Accu-Pulse tandem OPTIONAL on all Auto-Axcess models
®
CV Background
Patent-pending Miller technology synchronizes pulsing between two Auto-Axcess power supplies to
achieve two stable, independent arcs in one torch. Each wire has its own power source, wire drive,
and contact tip. Accu-Pulse tandem welding unites the arc characteristics of Accu-Pulse with the
high deposition rates and travel speeds achievable with the tandem process.
Accu-Curve
(Compared to conventional pulse)
• Shorter arc lengths possible
• Better puddle control
• More tolerant of contact tip to work variation
• Less audible noise
• No arc wandering in tight corners
• Narrow arc plasma column
• Allows weld to fill in at toes increasing travel
speed and deposition
• More tolerant of poor fit up and gaps
• Ideal for seam tracking robot welding applications
™
STANDARD on all Axcess models
Accu-Curve is a variation of the Accu-Pulse process. The transitions from peaks to background
voltage are “curved”. The curved transitions provide a “softer” feel without sacrificing the tight arc
lengths that allow for better puddle control that have become the hallmark of the Accu-Pulse process.
Note: Accu-Curve can be added to existing Axcess or Auto-Axcess systems for FREE by updating code
online at MillerWelds.com/AMS/axcess. Requires Palm handheld to transfer code from PC to Axcess.
Accu-Speed
Benefits of Accu-Pulse
Benefits of Accu-Curve
• “Softer” arc feel than Accu-Pulse
• Maintains tight arc lengths
• Maintains better puddle control
™
STANDARD on all Axcess models
Accu-Speed is a variation of the Accu-Pulse process and was developed for the type of arcs needed
in automated welding applications. Accu-Speed has a tighter driving arc that can be directed into
the joint, yet still remains stable at the higher travel speeds used in automated welding. In general,
Accu-Speed has lower average voltage and amperage when compared to Accu-Pulse.
Note: Accu-Speed can be added to existing Axcess or Auto-Axcess systems for FREE by updating code
online at MillerWelds.com/AMS/axcess. Requires Palm handheld to transfer code from PC to Axcess.
RMD (Regulated Metal Deposition)
™
Field #195 252 (Field installation requires Palm handheld with data card slot.)
The patented RMD (Regulated Metal Deposition) process — a software-based OPTION for all Axcess
models — is a precisely controlled short-circuit transfer. It is a method of detecting when the short
is going to clear and then rapidly reacting to this data changing the current (amperage) levels.
Features Proactive Dynamic Puddle Control.
Note: FREE demonstration is included with every new Axcess or Auto-Axcess. Requires Palm to
activate. FREE eight-hour trial can also be downloaded from MillerWelds.com/AMS/axcess for
existing Axcess or Auto-Axcess systems.
Software Options
Palm™ Convenience Package #195 517
Includes a compatible Palm™ handheld loaded
with Service Pak software and an Axcess
connection cable.
Note: Palm model may vary and File Management and
WaveWriter software are sold separately. See at right.
Axcess® File Management
#195 249 for Palm, #300 529 for PC
Simply put, the Miller Axcess File Management
software turns a standard Palm handheld (PDA)
or a PC into a remote pendant control for all
Axcess systems. By using a Palm handheld or
PC in this manner, we have built a powerful
intuitive interface on a common, affordable,
portable platform. This opens the door to
additional functions and capabilities. See Axcess
Literature Index No. AU/8.0 for more details.
Benefits of Accu-Speed
•
•
•
•
Up to 20% greater travel speed than Accu-Pulse
Lower average voltage/amperage than Accu-Pulse
Tight, driving arc
Remains stable at higher travel speeds
Benefits of RMD
•
•
•
•
•
•
•
Well suited to thin materials
Can replace TIG process in some applications
Gap filling
Spatter reduction
Provides less heat into work piece
Excellent performance on stainless steel
Can be combined with other Axcess®-related
programs
• Minimize distortion
• Use larger diameter wire on thin materials
WaveWriter™ File Management with
Wave Shaping (Consult Factory)
WaveWriter is our premium software package
for Axcess systems. It includes all of the
Axcess File Management functions plus a
simple, Pulse MIG wave-shaping program for
the most demanding Pulsed MIG applications.
See Axcess Literature Index No. AU/8.0 for
more details.
23
A FLE10 Cat P 24 Wire Intro.qxd:Wire Intro
11/3/09
10:57 AM
Page 1
Wire Feeders
“
After seeing what this machine
can do, I can honestly say that
soon we will double our footage
amounts in an 8-hour day.
Shawn Moreland, Owner
Hot Az Hell Welding
”
Voltage-Sensing
Constant-Speed
Millermatic® Reach
(MIG section)
10
SuitCase®
8RC,
SuitCase® 12RC
26
26
22A
30
24A
30
R-115
30
70 Series —
Singles and Duals
31
Flux Core Flux Core
Dual Shld Self Shld
Wire Diameters
Special Features
Typical Applications
.023 – .052 in (0.6 – 1.3 mm)
Portable, self-enclosed case,
designed exclusively for Millermatics
Metal fab, maintenance/repair,
farm/home
8RC: .023 – 5/64 in (0.6 – 2.0 mm) Portable, self-enclosed case,
12RC: .023 – 5/64 in (0.6 – 2.0 mm) remote control
Construction, field maintenance,
site fabrication
.023 – 5/64 in (0.6 – 2.0 mm)
(2) Quick-change drive rolls
Manufacturing, fabrication
.023 – 3/32 in (0.6 – 2.4 mm)
(4) Quick-change drive rolls
Manufacturing, fabrication
.023 – 5/64 in (0.6 – 2.0 mm)
115 V replacement feeder
In-shop replacement
.023 –1/8 in (0.6 – 3.2 mm)
Low speed option recommended
for 1/8 in wires
Four drive roll, adjustable
weld control
Heavy and light manufacturing,
fabrication
CV
CV
CV
CV
CV
CV
Alum
Wire Types
Hard
Portable
Power
Source
Required
Flux Cored**
MIG-P*
MIG
Product
Guide
Page
Class
MillerWelds.com/WireFeeders
70 Series Swingarc™ — 32
Singles and Duals
CV
.023 – 5/64 in (0.6 – 2.0 mm)
8, 12 and 16 ft booms, four drive
roll, adjustable weld control
Heavy and light manufacturing,
fabrication
74 MPa Plus — Singles 18
and Duals (MIG section)
CV
.035 – 3/32 in (0.9 – 2.4 mm)
Alumination allows push/pull gun.
Optimized with Invision 352 MPa
Manufacturing requiring
multiple wire types
SuitCase®
X-TREME™ 8VS
25
CC/CV
CV** .023 – 1/16 in (0.6 –1.6 mm)
Lightweight, portable,
8 in diameter spool capacity
Shipbuilding, construction,
site fabrication
SuitCase®
X-TREME™ 12VS
25
CC/CV
CV** .023 – 5/64 in (0.6 – 2.0 mm)
Lightweight, portable,
12 in diameter spool capacity
Shipbuilding, construction,
site fabrication
Handles 60 lb coils of wire
Construction, field fabrication
CV** .023 – 5/64 in (0.6 – 2.0 mm)
CC/CV
5/64
–
7/64
in
(2.0
–
2.8
mm)
Handles
60
lb
coils
of
wire
Construction, field fabrication
CC/CV
CV**
Economical, 135 A
Light-duty aluminum fabrication
Spoolmate 100 Series 27 .023 –.035 in (0.6 – 0.9 mm)
CV
.023
–.035
in
(0.6
–
0.9
mm)
Economical,
160
A
Light-duty aluminum fabrication
CV
Spoolmate 200 Series 27 .023
–1/16
in
(0.6
–1.6
mm)
Portable,
4
in
spool,
15
and
30
ft
Aluminum fabrication
CC/CV
Spoolmatic 15A/30A 28 .030
–1/16
in
(0.8
–1.6
mm)
Push-pull
system
Heavy aluminum fabrication
CC/CV
XR -Pistol 15A/30A
28 .030
–1/16
in
(0.8
–1.6
mm)
Push-pull
system
Heavy aluminum fabrication
CC/CV
XR -Pistol 15W/30W
28 High-amperage air-cooled gun
All aluminum fabrication needs
XR-Aluma-Pro A
29 .030 –1/16 in (0.8 –1.6 mm)
CC/CV High-amperage water-cooled gun
All aluminum fabrication needs
XR-Aluma-Pro W
29 .030 –1/16 in (0.8 –1.6 mm)
CC/CV Push-pull system
Heavy aluminum fabrication
XR -Controls
29 .030 –1/16 in (0.8 –1.6 mm)
CC/CV CLASS: Light Industrial Industrial Heavy Industrial
CAPABILITY: Designed for this process Capable of this process
PRODUCT KEY New!
or Improved! products appear in blue type. *Millermatic Reach requires Millermatic 350P. Other feeders require optional Optima control and a recommended inverter.
S-32S
30
S-32SL
30
™
™
Aluminum
®
™
™
™
™
™
**Certain self-shielded wires require CV output. Miller recommends a CV power source whenever possible. For more detailed information, see individual specification sheets.
24
See pages 20 – 23 for information on Axcess® and Auto-Axcess® Pulsed MIG wire feeding options.
A FLE10 Cat P 25 Wire.qxd:Wire
Call
11/3/09
10:58 AM
Page 1
Wire Feeders
1-800-4-A-MILLER for more information.
Industrial
SuitCase X-TREME 8VS and 12VS
™
®
Use with CC/CV, DC Power Sources.
Processes
See Literature No. M/6.41
• MIG (GMAW) • Flux Cored (FCAW)
Taking portable welding to the extreme — available in two sizes, these voltage-sensing feeders
have every feature you will ever need.
• Dimension™ Series (pg 47)
• XMT® Series (pg 48/49)
• Dimension™ NT 450 (pg 50)
• Mark VI™ (pg 53)
• Bobcat™ (pg 57/59/60)
• Trailblazer® (pg 61/62)
• Big Blue® 300 Pro (pg 64)
• Big Blue® 400/500 (pg 65)
Suggested Power Sources
Smaller 8VS size is ergonomically sound, lightweight, and well
balanced for ease of carrying to remote welding sites. Fits through
a 14 in (25 mm) manhole/manway.
Polypropylene case with built-in slide rails has door for changing
wire with the feeder in a vertical position.
Potted and trayed main printed circuit board for the harshest
environments adds exceptional reliability. Board has full-trigger
isolation so a shorted gun trigger will not affect feeder operation.
Improved contactor for high-amperage, high duty cycle applications.
Digital meters with SunVision™ technology can display voltage,
wire feed speed, and also amperage if desired. Meters can be
seen clearly even in direct sunlight. (8VS: meters are optional.)
SuitCase
SuitCase
Trigger hold, wire jog, and gas purge are located on
X-TREME 8VS
X-TREME 12VS
front panel. (8VS: trigger hold is optional.)
Wider voltage range for small and large wires with no
Models include Bernard® Q300 MIG
contactor chatter or arc outages.
gun (8VS/12VS) with reversible
Double-filtered gas valve helps keep dirt from clogging
dual size (.045 and 1/16 in) VK
drive rolls or Dura-Flux Flux Cored
and affecting gas flow.
Bernard®
gun (12VS) with reversible dual size
Excellent starts and superior arc performance for all
Q300 shown.
(.068/.072 and 5/64 in) VK drive rolls!
types and sizes of wires whether using CV or CC power
For other gun and drive roll options,
supply. (CV is recommended for best arc performance.)
please go to MillerWelds.com/equiptoweld
Model
Stock Number
Input Power
SuitCase
X-TREME
8VS
(#951 181) w/Bernard® Q300 Gun
(#951 182) w/Bernard® Q300 Gun and Meters
(#951 183) w/Bernard® Q300 Gun, Meters and Trigger Hold
SuitCase
X-TREME
12VS
(#951 184) w/Bernard® Q300 Gun
(#951 185) w/Bernard® Dura-Flux™ Gun
Operates on
open-circuit
voltage and
arc voltage:
14 – 48 VDC/
110 Max. OCV
Miller SuitCase
Selection Chart
®
Input Welding
Circuit Rating
330 A at 60%
Duty Cycle
425 A at 60%
Duty Cycle
Wire Feed Speed
50 –780 IPM
(1.3 –19.8 m/min)
Actual range in
CC mode is
dependent on arc
voltage applied
Suggested Guns
• Bernard® Q300 (GMAW)
• Bernard® Dura-Flux™ (FCAW)
• Roughneck® (GMAW) (pg 87)
• Ironmate™ FC-1260 (FCAW)
(pg 87)
Most Popular Accessories
• 8VS Meter Kit #300 331 (pg 86)
• 8VS Trigger Hold #300 332
• Flowmeter Kit #300 343
See your Miller distributor for other
popular Miller options and accessories.
Net
Weight
Wire Type and
Diameter Capacity
Maximum Spool
Size Capacity
Solid Wire .023 – .062 in
(0.6 – 1.6 mm)
Flux Cored .030 – .062 in
(0.8 – 1.6 mm)
8 in (203 mm),
14 lb (6.4 kg)
H: 123⁄4 in (324 mm)
W: 71⁄4 in (184 mm)
D: 18 in (457 mm)
28 lb
(13 kg)
Solid Wire .023 – 5/64 in
(0.6 – 2.0 mm)
Flux Cored .030 – 5/64 in
(0.8 – 2.0 mm)
12 in (305 mm),
45 lb (20 kg)
H: 151⁄2 in (394 mm)
W: 9 in (229 mm)
D: 21 in (533 mm)
35 lb
(15.9 kg)
Dimensions
1. Not recommended for use with AC power sources. 2. When paired with CC power source, VS feeder will vary wire feed speed (WFS) to maintain voltage.
As such, accuracy of parameters and deposition rates cannot be guaranteed. For critical welds, Miller recommends using CV power source.
Note: Use CV power source for best performance when wire welding. Also, set VS feeder to “CV mode” and welder to “CV or volt sense feeder mode” if applicable.
Application Requirements
SuitCase 8RC
SuitCase 12RC
SuitCase X-TREME 8VS
SuitCase X-TREME 12VS
Selection Guidance
Feeder Type
Remote Control
(constant speed)
Remote Control
(constant speed)
Voltage Sensing
Voltage Sensing
Use RC feeders when welding procedures or
codes specify wire feed speed and voltage.
Power Source Compatibility
CV Power Source (must
have 14-pin connection)
CV Power Source (must
have 14-pin connection)
DC1 CC/CV
DC1 CC/CV
VS feeders offer flexibility, as they work with
almost any welder2.
8 in/14 lb
8 in/14 lb or 12 in/45 lb
8 in/14 lb
8 in/14 lb or 12 in/45 lb
Use 12RC or 12VS for larger wire spools. Use
8VS or 8RC when weight or size is a factor.
Duty Cycle
500 Amps at 100%
500 Amps at 100%
330 Amps at 60%
425 Amps at 60%
Use 12RC or 12VS to maximize deposition rates
with larger wires.
Recommended Distance
Between Feeder and
Power Source
75 ft (150 ft “round trip”
cable length)
75 ft (150 ft “round trip”
cable length)
400+ ft (distance depends
on the power source,
weld cable size used,
and welding amperages)
400+ ft (distance depends
on the power source,
weld cable size used,
and welding amperages)
Use VS feeders when longer distances between
the power source and feeder are required.
Number of Feeder
Connections Back to
Power Source
2 (weld cable,
24 VAC power/14-pin
control cable)
2 (weld cable,
24 VAC power/
14-pin control cable)
1 (weld cable)
1 (weld cable)
VS feeders have less cable to carry, damage
or lose.
Remote Control Capabilities
Voltage Set at Feeder
Voltage Set at Feeder
Voltage or Current Set at
Power Source
Voltage or Current Set at
Power Source
RC feeders add convenience — no need to return
to the power source to adjust voltage parameters.
Gas Purge, Wire Jog and
Trigger Hold
- Gas Purge Standard
- Wire Jog (inside case)
- Trigger Hold Optional
- Gas Purge Standard
- Wire Jog (inside case)
- Trigger Hold Optional
- Gas Purge Standard
- Wire Jog (front panel)
- Trigger Hold Optional
All Standard (front panel)
VS and RC feeders have most often used controls
conveniently located on front panel.
Physical Specifications
Spool Size/Capacity
Weld Performance
Simplicity & Control
25
A FLE10 Cat P 26 Wire.qxd:Wire
11/3/09
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Page 1
Wire Feeders
MillerWelds.com
SuitCase 8RC and 12RC
Industrial
®
Use with CV, DC Power Sources.
See Literature No. M/6.5
Processes
• MIG (GMAW) • Flux Cored (FCAW)
The SuitCase 8RC and 12RC offer remote voltage control, light weight and small size,
with superior durability needed to stay in service and meet production schedules.
Suggested Power Sources
• CP-302 (pg 16)
• Deltaweld® 302 (pg 17)
• Invision® 352 MPa (pg 18)
• Invision® 456MP (pg 19)
• XMT® Series (except VS model)
(pg 48/49)
• Trailblazer® (pg 61/62)
• PipePro® 304 (pg 66)
The SuitCase 12RC door opens with feeder in
upright position and has built-in slide rails.
Totally enclosed, impact-resistant, flameretardant case provides strength and durability,
and protects components and welding wire from
moisture, dust and other contaminants.
Suggested Guns
Ergonomically sound, lightweight, modular
design is well balanced, and allows improved
mobility and ease of carrying to remote welding
sites and for serviceability.
• Bernard® Q300 (GMAW)
• Bernard® Dura-Flux™ (FCAW)
• Roughneck® (GMAW) (pg 87)
• Ironmate™ (FCAW) (pg 87)
Most Popular Accessories
Flexibility to run a variety of wires up to
5/64 in diameter.
SuitCase 8RC
SuitCase 12RC
Quick-change drive rolls are easy to change —
no tools required.
Drive roll accessibility makes it easy to install
wire, adjust tension and change drive rolls.
Models include Bernard® Q300
MIG gun with reversible dual size
(.045 and 1/16 in) VK drive rolls!
For other gun and drive roll options,
please go to MillerWelds.com/equiptoweld
Carrying handle folds up out of operators way,
yet large enough for a gloved hand to carry.
Remote voltage control—standard for exceptional
weld quality.
*Other models available. A remote extension cord must be ordered separately.
Gas solenoid valve — standard.
See your Miller distributor for other
popular Miller options and accessories.
Input
Power
Input Welding
Circuit Rating
Wire Feed Speed
Wire Type and Diameter Capacity
Maximum Spool
Size Capacity
(#951 186) w/Bernard® Q300 Gun and
Remote Voltage
(#951 187) w/Bernard® Q300 Gun, Meters,
Remote Voltage and Trigger Hold
24 VAC,
7 A,
50/60 Hz
500 A at
100% Duty Cycle
75 –700 IPM
(1.9 –17.8 m/min)
Solid Wire .023 –5/64 in (0.6 –2.0 mm)
Flux Cored .030 –5/64 in (0.8 –2.0 mm)
8 in (203 mm),
14 lb (6.4 kg)
H: 141⁄2 in (368 mm)
W: 61⁄2 in (165 mm)
D: 15 5⁄8 in (397 mm)
22 lb
(10 kg)
(#951 188) w/Bernard® Q300 Gun and
Remote Voltage
(#951 189) w/Bernard® Q300 Gun, Meters,
Remote Voltage and Trigger Hold
24 VAC,
10 A,
50/60 Hz
Solid Wire .023 – 5/64 in (0.6 – 2.0 mm)
Flux Cored .030 – 5/64 in (0.8 – 2.0 mm)
12 in (305 mm),
44 lb (20 kg)
H: 151⁄2 in (394 mm)
W: 9 in (229 mm)
D: 21 in (533 mm)
25.5 lb
(11.6 kg)
Model
Stock Number*
SuitCase
8RC
SuitCase
12RC
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26
• Meter Kits (pg 86)
• Remote Extension Cords
(1 required) 25, 50, or 75 ft
(7.6, 15, or 23 m) (pg 91)
• Shielding Gas Filter #195 189 Field
• Flowmeter Kit #300 343
• Volt/Current Sensor Kit
#195 194 Field (For both models—
required for digital meter operation
with power sources not having
pins F and H in 14-pin receptacle.)
MillerWelds.com/newsletters
Dimensions
Net
Weight
A FLE10 Cat P 27 Wire.qxd:Wire
11/3/09
10:59 AM
Page 1
Aluminum
Call
Wire Feeders
1-800-4-A-MILLER for more information.
Spoolmate 100 Series
Light Industrial
™
Use with CV, DC Power Sources.
See Literature No. M/1.45
Process
• MIG (GMAW) with aluminum and
other soft alloy wires
Reliable and economical spool gun with excellent feeding to weld aluminum.
For use with all Millermatic® 140 and 180 models, Millermatic® Passport® Plus,
and Millermatic® 211 Auto-Set™ with MVP™.
Suggested Power Sources
Light industrial spool gun rated at
135 amps at 30% duty cycle.
12 ft direct-connect cable with
heavy-duty strain relief provides
reach and accessibility to your work.
Dual V-knurled drive rolls with
adjustable tension control for
consistent feeding of different types
of wire.
• Millermatic® 140 Auto-Set™ (pg 8)
• Millermatic® 180 Auto-Set™ (pg 8)
• Millermatic® Passport® Plus (pg 9)
• Millermatic® 211 Auto-Set™
with MVP™ (pg 9)
• Renegade™ 180
(discontinued product)
Most Popular Accessories
• Retrofit Kit for Millermatic 140
and 180 models (prior to serial
#LH210051N) #300 409
See your Miller distributor for other
popular Miller options and accessories.
Clear spool canister protects the wire
and allows you to easily see the spool.
Convenient carrying case holds gun
and cable, extra contact tips, nozzle
and wire (wire not included).
Model includes carrying case,
extra contact tips and nozzle!
Stock Number
(#300 371)
Welding Output Rating
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Gun Weight
135 A at 30% Duty Cycle
5 – 365 IPM (MM 140)
65 – 625 IPM (MM 180)
70– 370 IPM (MM Passport Plus)
65 – 625 IPM (MM 211)
65 – 625 IPM (Renegade 180)
.030 –.035 in (0.8 – 0.9 mm)
aluminum
.023 –.035 in (0.6 – 0.9 mm)
steel and stainless steel
4 in (102 mm)
H: 111 ⁄2 in (291 mm)
W: 3 in (76 mm)
L: 13 in (330 mm)
5 lb (2.3 kg) with cable assembly
9 lb (4.1 kg) with case
Spoolmate 200 Series
Light Industrial
™
Use with CV, DC Power Sources.
See Literature No. M/1.47
Highly reliable and economical spool gun with excellent feeding to weld aluminum.
Designed for home hobbyists and light fabricators. For use with Millermatic® 212 Auto-Set™,
and Millermatic® 252.
Light industrial spool gun rated at 160 amps at
60% duty cycle. Ideal for welding with .023 –.035 in
(0.6 – 0.9 mm) wires.
20 ft direct-connect cable with strain relief and
sheath provides extended reach and accessibility to
your work.
Wire feed speed adjustment is on the gun, not the
machine — makes setup easy and saves time.
Easy access to drive assembly and drive rolls.
Two-stage trigger with built-in gas valve allowing
preflow and postflow.
Toolless barrel removal for easy replacement of gun
barrels. Three optional gun barrels!
Stock Number
(#300 497)
Process
• MIG (GMAW) with aluminum and
other soft alloy wires
Suggested Power Sources
• Millermatic® 212 Auto-Set™ (pg 10)
• Millermatic® 252 (pg 11)
• Millermatic® 251
(discontinued product)
• Millermatic® 210/212
(discontinued product) with
adapter cable #195 287
Most Popular Accessories
• 45-Degree Barrel #300 591
• 9-Inch Extension Barrel #300 592
• Heavy-Duty Barrel #300 593
• Spoolmatic Adaptor Cable #195 287
Allows connection to Millermatic
210 and 212 (non-Auto-Set).
Wire feed speed controlled at
the machine.
See your Miller distributor for other
popular Miller options and accessories.
Welding Output Rating
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Gun Weight with Cable Assembly
160 A at 60% Duty Cycle
70 – 875 IPM
.030–.035 (0.8– 0.9 mm)
aluminum
.023–.035 (0.6–0.9 mm)
mild and stainless steel
4 in (102 mm)
H: 9 in (229 mm)
W: 2 1 ⁄2 in (64 mm)
L: 14 1 ⁄2 in (368 mm)
11 lb (5 kg)
27
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Aluminum
Wire Feeders
MillerWelds.com
Pistol Grip Guns
®
Industrial Spoolmatic 15A/30A
Heavy Industrial XR-Pistol
See Literature No. M/1.73
Use with CC/CV,
DC Power Sources.
™
Spoolmatic spool guns and XR push-pull guns are the professional’s choice for
exceptional aluminum welding results in industrial or commercial applications.
Processes
Engineered for operator comfort, our well-balanced pistol grip
guns give you portability and a 15 or 30 ft cable assembly to
access those hard-to-reach welds.
Patented quick-change, single-turn contact tip
provides excellent performance and ease of replacement.
Barrels are Roughneck® and Bernard® Centerfire™
compatible.
Easy access to drive assembly and removable head
tube reduces service time by allowing a simple means
of changing drive rolls and head tube or performing
routine maintenance without disassembly of gun.
Spoolmatic
pistol grip
spool gun
Improved, more robust drive housing machined from
aluminum extrusion instead of a casting.
Wire feed speed adjustment on the gun handle and
reversible drive rolls save time and money.
XR-A
pistol grip
push-pull gun
For Spoolmatic Guns Only
• Millermatic® 212 Auto-Set™ (pg 10)
• Shopmate™ 300 DX (pg 47)
• Bobcat™ (pg 57/59/60)
For Spoolmatic and XR Guns
• Millermatic® 252 (pg 11)
• Millermatic® 350 (pg 12)
• AlumaPower™ 350 MPa (pg 13)
• CP-302 (pg 16)
• Dimension™ Series (pg 47)
• XMT® Series (except VS model)
(pg 48/49)
• Dimension™ NT 450 (pg 50)
• Trailblazer® (pg 61/62)
• PipePro® 304 (pg 66)
Most Popular Accessories
Built-in gas valve eliminates the need to purge long gas lines.
For Spoolmatic Guns Only
• WC-24 #137 549 (pg 91)
• WC-115A #137 546 (pg 91)
• WC-115A (with contactor)
#137 546-01-1 (pg 91)
• WC-115 Contactor Kit #137 548
(pg 91)
For XR Gun Only
• XR-AlumaFeed™ (pg 13) or
XR-Controls (pg 29) —
Required with most power
sources. See Hook-Up
Recommendations chart at left.
• Hardwire Liner Kit #198 377
Two-stage trigger includes gas preflow.
Spool canister rotates 180°.
Both air- or water-cooled versions are available.
Trigger hold reduces fatigue by allowing operator to weld
without holding trigger. (Feature only available when paired with
XR™-Controls or XR-AlumaFeed™.)
Replaceable feed cable liner reduces parts cost and service time
by allowing a simple means of removing and replacing liner and not
the complete feed cable.
Hook-Up Recommendations
XR 15A/30A and
15W/30W
Pistol Grip Guns
Suggested Power Sources
Spoolmatic Spool Gun Additional Features
XR Push-Pull Gun Additional Features
Spoolmatic
15A/30A
Pistol Grip Guns
• MIG (GMAW) with aluminum
and other wires (XR guns require
optional hardwire kits to run
hard wire)
• Pulsed MIG (GMAW-P) with
optional pulsing power source
See your Miller distributor for other
popular Miller options and accessories.
*Discontinued product.
CV Power Supply
Control/Module/Cable
Millermatic® Vintage*
Need Module #043 084
Millermatic® DVI™*, DVI2™*, 210*, 212*
Need Adapter Cable #195 287
(WFS controlled at machine)
Millermatic® 212 Auto-Set™, 250X*, 251*, 252, 300 w/meters*, 350/350P, Shopmate™ 300 DX
Direct Hook-Up
AlumaPower™ 350 MPa, CP Series, Deltaweld® Series, Dimension™ Series, Regency® 250*,
Shopmaster™*, XMT® Series, PipePro™ 304, Trailblazer® 275 DC, 302, 302 Air Pak™
Need WC-24 #137 549
Bobcat™ Series, Miller Legend® 302*
Need WC-115A #137 546-01-1
Millermatic 252, 350/350P
Direct Hook-Up
AlumaPower™ 350 MPa, Deltaweld® Series, Dimension™ Series, Invision™ Series,
XMT® Series (except VS model), PipePro™ 304, Trailblazer® 275 DC, 302, 302 Air Pak™
XR-AlumaFeed™ (pg 13) or
XR™-Controls (pg 29)
*Drive rolls and drive roll kits must be ordered separately. A=Air-Cooled W=Water-Cooled
Model
Stock Number*
Spoolmatic 15A
(#195 156) 15 ft (4.5 m) cable
Spoolmatic 30A
(#130 831) 30 ft (9 m) cable
XR-A Pistol Gun
(#198 127) 15 ft (4.6 m) cable
(#198 128) 30 ft (9 m) cable
XR-W Pistol Gun
(#198 129) 15 ft (4.6 m) cable
(#198 130) 30 ft (9 m) cable
28
Welding
Output Rating
Maximum Spool
Size Capacity
Wire Diameter Capacity
200 A at
100% Duty Cycle
70 – 875 IPM (1.8 – 22.2 m/min)
Wire speed dependent on
control box or Millermatic used.
.030 –1/16 in (0.8 –1.6 mm)
aluminum wire and hard
wire up to .045 in (1.1 mm)
4 in (102 mm)
H: 10 1 ⁄4 in (260 mm)
W: 2 1 ⁄2 in (64 mm)
L: 15 1 ⁄8 in (384 mm)
9 lb (4.1 kg)
Air: 200 A at
100% Duty Cycle
70 – 875 IPM (1.8 – 22.2 m/min)
Wire speed dependent on
control box or Millermatic used.
.030 – 1/16 in (0.8 –1.6 mm)
aluminum wire
—
H: 7 3⁄8 in (187 mm)
W: 17⁄8 in (48 mm)
L: 10 5⁄8 in (270 mm)
13 lb (5.9 kg)
Water: 400 A at
100% Duty Cycle
Dimensions
Gun Weight with
Cable Assembly
Wire Feed Speed
14 lb (6.4 kg)
21 lb (9.6 kg)
14 lb (6.4 kg)
21.5 lb (9.7 kg)
A FLE10 Cat P 29 Wire.qxd:Wire
11/3/09
11:00 AM
Page 1
Aluminum
Call
Wire Feeders
1-800-4-A-MILLER for more information.
Gooseneck-Style Gun
Heavy Industrial
Use with CC/CV, DC Power Sources.
See Literature No. M/1.71
Processes
• MIG (GMAW) with aluminum wire
(capable of other wires with
optional hardwire kits)
• Pulsed MIG (GMAW-P) with
optional pulsing power source
XR-Aluma-Pro™ guns work in conjunction with XR-Controls, XR-AlumaFeed or select
Millermatic machines to provide an outstanding solution for push-pull applications.
Accepts patented, single-turn, quick-change FasTip™ and Bernard®
Centerfire™ contact tips.
Suggested Power Sources
• Millermatic® 252 (pg 11)
• Millermatic® 350 (pg 12)
• AlumaPower™ 350 MPa (pg 13)
• Deltaweld® Series (pg 17)
• Invision™ 352 MPa (pg 18)
• Invision™ 456MP (pg 19)
• XMT® Series (except VS model)
(pg 48/49)
• Trailblazer® (pg 61/62)
Replaceable feed cable, easy drive assembly access and removable
head tube liner reduce service time.
Isolated, common, knurled drive rolls provide positive feeding performance.
Rotatable, self-seating head tube for various welding positions, reducing
operator fatigue.
Hook-Up Recommendations
XR-Aluma-Pro
GooseneckStyle Gun
*Discontinued product.
Most Popular Accessories
CV Power Supply
Control/Module/Cable
Millermatic 252, 350/350P
Direct Hook-Up
AlumaPower® 350 MPa, Deltaweld® Series,
Dimension™ Series, Invision™ Series,
XMT® Series (except VS model), PipePro™ 304,
Trailblazer® 275 DC, 302, 302 Air Pak™
XR-AlumaFeed™ (pg 13)
or XR™-Controls
(see below)
• XR-AlumaFeed™ (pg 13) or
XR™-Controls (see below) —
Required with most power
sources. See Hook-Up
Recommendations chart at left.
• Hardwire Liner Kit #198 377
See your Miller distributor for other
popular Miller options and accessories.
A=Air-Cooled W=Water-Cooled
Gun Style
Stock Number
Weld Current Capacity
Wire Feed Speed
Wire Diameter Capacity
Dimensions
Gun Weight
Net Weight with Cable Assembly
XR-Aluma-Pro A Gun
(#300 000) 15 ft (4.6 m)
Air: 300 A at
100% Duty Cycle
70 – 900 IPM
(1.8 – 23 m/min)
H: 5 in (127 mm)
W: 21⁄2 in (64 mm)
L: 17 in (432 mm)
2.5 lb
(1.1 kg)
20 lb (9.1 kg)
Water: 400 A at
100% Duty Cycle
Wire speed
dependent on
control box or
Millermatic used.
.030 –1/16 in
(0.8 –1.6 mm)
aluminum wire
(#300 001) 25 ft (7.6 m)
(#300 264) 35 ft (10.6 m)
XR-Aluma-Pro W Gun
(#300 003) 15 ft (4.6 m)
(#300 004) 25 ft (7.6 m)
Wire kit #230 708
required to run
1/16 in (1.6 mm) wire.
33 lb (15 kg)
2.9 lb
(1.3 kg)
(#300 265) 35 ft (10.6 m)
Use with CC/CV, DC Power Sources.
See Literature No. M/1.7
The updated XR-S and XR-D Controls offer unsurpassed performance and reliability for
feeding aluminum and other difficult-to-feed wire types. The perfect choice for use with
basic CV MIG power sources.
Digital wire feed speed readout.
Available 1st Quarter — Updated design,
same great reliability and performance.
True torque feed motor push-pull design provides
continuous push force to the wire while the gun
motor controls the speed at the gun. The motors
work together to provide accurate and positive wire
feed speed without wire shaving or deformation.
Standard jog and purge as well as trigger hold
for making long weldments without hand fatigue.
Adjustable wire run-in control allows arc starting to
be fine tuned, reducing wire stubbing or arc flaring
which can result in a burnback to the contact tip.
XR-D Model Additional Features
Digital weld voltage readout.
XR-D
Models include both .035 and factory-installed 3/64 in drive
rolls. Order 1/16 in control box drive rolls separately (#195 591).
Stock Number
(#300 601) XR-S
(#300 678) XR-D
29 lb (13.2 kg)
Heavy Industrial
™
XR-S
22 lb (10 kg)
35 lb (15.9 kg)
XR-S and XR-D Controls
™
27 lb (12.2 kg)
Remote voltage control plus basic programmable
weld sequencing for preflow, postflow, start, and
crater provide higher quality welds.
Processes
• MIG (GMAW) with aluminum and
other soft alloy wires
• Pulsed MIG (GMAW-P) with
optional pulsing power source
Suggested Power Sources
• Deltaweld® Series (pg 17)
• Invision™ 352 MPa (pg 18)
• Invision™ 456MP (pg 19)
• XMT® Series (except VS model)
(pg 48/49)
• Trailblazer® (pg 61/62)
Suggested Guns
• XR™-Pistol (GMAW) (pg 28)
• XR-Aluma-Pro™ (GMAW)
(see above)
Most Popular Accessories
• Optima™ MIG Pulse Control
#043 389 (pg 86)
• Remote Extension Cords (pg 91)
• PSA-2 Control #141 604 (pg 91)
• Gas Flowmeter Kit for XR-S Model
#246 127
See your Miller distributor for other
popular Miller options and accessories.
Input Power
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
24 VAC, 50/60
or 100 Hz
70 – 780 IPM
(1.8 –19.8 m/min)
.030 –1/16 in (0.8 –1.6 mm) aluminum wire
Wire kit #230 708 required to run 1/16 in (1.6 mm) wire.
12 in (305 mm)
H: 16 in (406 mm)
W: 91 ⁄4 in (235 mm)
D: 211 ⁄4 in (540 mm)
38 lb
(19.1 kg)
29
A FLE10 Cat P 30 Wire.qxd:Wire
11/5/09
9:57 AM
Page 1
Wire Feeders
MillerWelds.com
Industrial
22A and 24A
See Literature No. M/11.0
Use with CV, DC Power Sources.
Includes Bernard ® Q300
15-ft MIG Welding Gun!
Processes
• MIG (GMAW) • Flux Cored (FCAW)
Simple to use, but built with the strength and flexibility to handle industrial
manufacturing and fabricating, the 22A and 24A deliver proven reliability and economy.
Suggested Power Sources
• CP-302 (pg 16)
• Deltaweld® Series (pg 17)
• Invision™ 352 MPa (pg 18)
• Shopmate™ 300 DX (pg 47)
• XMT® Series (except VS) (pg 48/49)
Both wire feeders are ideal for most high-duty-cycle applications
requiring day-in/day-out trouble-free operation.
Trigger hold control for extended welds.
Suggested Guns
Two gear-driven drive rolls on 22A for smooth, positive wire feed.
Four gear-driven drive rolls on 24A for larger wire sizes.
• Bernard® and Tregaskiss™
• Roughneck® (pg 87)
On-board burnback and motor ramp control for excellent starting
and stopping performance.
Most Popular Accessories
• Digital Display #186 498
• Pre/Post Flow and Spot Control
#186 496
• Voltage Control (22A) #194 211
Heavy-duty 16-gauge metal enclosure for extra durability.
All models include Bernard® Q300 MIG gun and
.035/.045 drive rolls! For other gun and drive roll
options, please go to MillerWelds.com/equiptoweld
Remote voltage is standard on 24A.
Optional presettable voltage and wire feed speed on most power
sources for 22A.
See your Miller distributor for other
popular Miller options and accessories.
Model
Stock Number
Input Power
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
22A
(#951 190)
(#951 191) w/Run-In Control
(#951 192) w/Digital Display and Voltage Control
24 VAC, 7 A,
50/60 Hz
75 – 750 IPM
(1.9 –19 m/min)
.023 – 5/64 in
(0.6 – 2.0 mm)
60 lb (27 kg) coil with optional
Wire Reel Assembly #108 008
H: 11 in (279 mm)
W: 10 3⁄4 in (273 mm)
D: 231⁄2 in (597 mm)
36 lb (15.4 kg)
24A
(#951 193)
(#951 194) w/Digital Display
(#951 195) w/Digital Display and Pre/Post Flow
24 VAC, 7 A,
50/60 Hz
75 – 750 IPM
(1.9 –19 m/min)
.023 – 3/32 in
(0.6 – 2.4 mm)
60 lb (27 kg) coil with optional
Wire Reel Assembly #108 008
H: 11 in (279 mm)
W: 10 3⁄4 in (273 mm)
D: 231⁄2 in (597 mm)
40 lb (18 kg)
R-115
Industrial
See Literature No. M/8.0
Use with CV, DC Power Sources.
Includes Bernard ® Q400
15-ft MIG Welding Gun!
Processes
Universal, constant-speed, semi-automatic wire feeder uses an interconnecting cord
(sold separately) to adapt to Miller and competitive power sources that only supply 115 VAC.
Interconnecting cord (sold separately) adapts universal feeder to many
power sources.
Model includes
Bernard® Q400
MIG gun and
.035/.045
drive rolls!
Convenient terminal block adapts to existing feeder interconnecting cords.
Industrial four-drive-roll system offers exceptional feed performance
and reliability.
Heavy-duty 16-gauge metal enclosure for durability in harsh environments.
Trigger hold control for making extended welds without holding gun trigger.
Motor ramp and burnback control aids in starting and stopping performance
to match power source characteristics.
*Power source interconnecting cord
must be ordered separately.
Stock Number*
(#951 282)
• MIG (GMAW) • Flux Cored (FCAW)
Compatible Power Sources
(Interconnecting Cords)
• Miller w/14-pin connector (#194 842)
• Old-style Miller and Airco
w/2- and 3-prong (Hubbell style)
twistlock connectors (#193 387)
• Hobart w/115 V wall-type plug and
5-pin plug (#193 383)
• Hobart w/19-pin plugs (#193 381)
• Lincoln w/5-wire terminal strip
connection (#193 385)
• Lincoln w/14-pin connectors
(#193 384)
• … power sources supplying 115 V
See your Miller distributor for additional
power sources and suggested guns.
Gas solenoid for gas-shielded wires.
Input Power
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
115 VAC, 2 A, 50/60 Hz
75 –750 IPM
(1.9 –19 m/min)
.023 – 5/64 in (0.8 – 2.0 mm)
60 lb (27 kg) coil with optional
Wire Reel Assembly #108 008
H: 11 in (279 mm)
W: 10 3⁄4 in (273 mm)
D: 23 1⁄2 in (597 mm)
40 lb (18 kg)
S-32S and S-32SL
S-32S shown with
optional Wire
Reel Assembly.
*Drive roll kits
must be ordered
separately.
Heavy Industrial
Use with CC/CV, DC Power Sources.
See Literature No. M/6.21
Processes
Simple to use, plus the features needed for heavy-duty applications.
• Operates on open-circuit voltage and arc voltage, straight or reverse polarity.
• Solid-state speed control and brake circuit, plus voltage-sensing control circuit.
• High-torque, 24 VDC, two-drive-roll system handles high-end speed for small
diameter wires and low-end speed for large diameter wires.
• Quick-change drive rolls and quick-connect feature for Miller guns.
• MIG (GMAW) • Flux Cored (FCAW)
Suggested Guns
• Bernard® and Tregaskiss™
• Roughneck® (pg 87)
• Ironmate™ (pg 87)
See your Miller distributor for suggested
Miller power sources and accessories.
Model/Stock Number*
Input Power
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
S-32S (#088 816)
Operates on open-circuit
voltage and arc voltage
15 –100 V
50 –700 IPM (1.3 –18 m/min)
.023 – 5/64 in (0.6 – 2.0 mm)
5/64– 7/64 in (2.0 – 2.8 mm)
H: 10 in (254 mm)
W: 10 3⁄4 in (273 mm)
D: 22 1⁄2 in (572 mm)
33 lb (15 kg)
25 – 325 IPM (0.6 – 8.2 m/min)
60 lb (27 kg) coil with optional
Wire Reel Assembly #108 008
S-32SL (#109 294)
30
A FLE10 Cat P 31 Wire.qxd:Wire
Call
11/3/09
11:02 AM
Page 1
Wire Feeders
1-800-4-A-MILLER for more information.
70 Series
Heavy Industrial
Use with CC/CV, DC Power Sources.
Includes Bernard ® Q400
See Literature No. M/3.0 15-ft MIG Welding Gun!
Processes
• MIG (GMAW) • Flux Cored (FCAW)
Raising the bar for industrial-class wire feeders with all the traditional features, plus
enhanced flexibility provided by features such as trigger hold, automatic run-in, and
tool-less rotatable drive.
Suggested Power Sources
• Deltaweld® Series (pg 17)
• Invision™ (pg 18/19)
• Dimension™ Series (pg 47)
• XMT® Series (except VS model)
(pg 48/49)
• Dimension™ NT 450 (pg 50)
Suggested Guns
• Bernard® and Tregaskiss™
Most Popular Accessories
D-74D
S-74DX
S-74D
Models
74S Standard
74D Digital Meters
74DX Deluxe — Digital Full Feature
Tool-less rotatable
drive assembly
allows operator
to rotate the
drive housing,
eliminating severe
bends in the wire
feed path which reduce gun liner life. This feature also
aids in feeding difficult wires.
Automatic run-in control significantly improves arc
starts. Run-in can be independently set on the DX model.
Trigger hold allows the operator to make long welds
without having to hold the trigger continuously.
Reduces operator fatigue.
All models include performance matched Bernard® Q400
MIG gun (two with D-74 models), .035/.045 drive rolls and
Centerfire™ contact tips! For other gun and drive roll options,
please go to MillerWelds.com/equiptoweld
DX Models Additional Features
Dual schedule control allows the operator to switch
between two welding parameters without readjusting
the machine, saving time and enhancing quality.
Sequence control gives the operator complete control
of the welding parameters: preflow, run-in, weld time,
crater, burnback and postflow.
• Feeder Cart #142 382 (pg 81)
• Aluminum Gun Kits —
for pushing aluminum wire (pg 87)
.035, 10 ft (3 m) #300 541
.047, 12 ft (3.7 m) #300 542
1/16, 12 ft (3.7 m) #300 543
Kits include .035, .047 or 1/16 in
drive rolls and 10 or 12 ft Bernard®
Q-Gun.™
• Control Detachment Kits (pg 91)
• Remote Extension Cords (pg 91)
25 ft (7.6 m) #122 973
50 ft (15 m) #122 974
75 ft (23 m) #122 975
• Spool Adapter #047 141 (pg 91)
• Turntable Assembly #146 236
(pg 91)
• Wire Straightener (pg 91)
• Hanging Bail #058 435
• Wire Reel Assembly #108 008
• Conversion Kit — For old power
source to new 70 Series wire
feeder #195 043
• .023 –1/8 in drive rolls
See your Miller distributor for other
popular Miller options and accessories.
Also Available
Welding process range control locks parameters at a
set percentage of welding parameters to ensure welding
procedures and quality standards are maintained.
Four weld programs allow the operators to store four
independent welding parameters reducing weld setup time.
Includes 10 ft 14-pin interconnecting cord.
S-74 MPa (single) #300 411
Gives you the benefit of Synergic
Pulsed MIG on MPa power sources.
As you increase/decrease the wire
feed speed, the pulse parameters
increase/decrease, matching the
right amount of power output to the
wire speed.
*See page 18 for NEW! single- and dual-wire 74 MPa Plus wire feeders
that operate synergicly with Invision 352 MPa power source.
Input
Power
Stock Number*
Single-Wire Models
S-74S (#951 196)
S-74S (#951 197) w/High-Speed Motor
S-74D (#951 198)
S-74D (#951 199) w/High-Speed Motor
S-74DX (#951 200)
S-74DX (#951 201) w/High-Speed Motor
S-74DX (#951 202) w/Low-Speed Motor
Dual-Wire Models
D-74S (#951 203)
D-74D (#951 204)
D-74D (#951 205) w/High-Speed Motor
D-74DX (#951 206)
D-74DX (#951 207) w/High-Speed Motor
24 VAC,
10 A,
50/60 Hz
Net
Weight
Wire Feed Speed
Wire Diameter
Capacity
Maximum Spool
Size Capacity
Dimensions
50 –780 IPM
(1.3 –19.8 m/min)
.023 –1/8 in
(0.6 – 3.2 mm)
Optional Low Speed:
20 –400 IPM
(0.5 –10.2 m/min)
Low-speed
motor option is
recommended
when using 1/8 in
(3.2 mm) wire.
60 lb (27 kg) coil
with optional Wire
Reel Assembly
#108 008
Single
H: 14 in (356 mm)
W: 12 in (305 mm)
D: 261⁄2 in (673 mm)
Single
58 lb
(26 kg)
Dual
H: 14 in (356 mm)
W: 121⁄2 in (318 mm)
D: 35 in (889 mm)
Dual
87 lb
(39.5 kg)
Optional High Speed:
92 –1435 IPM
(2.3 –36.6 m/min)
31
A FLE10 Cat P 32 Wire.qxd:Wire
11/3/09
11:02 AM
Page 1
Wire Feeders
MillerWelds.com
70 Series Swingarc
Heavy Industrial
™
Use with CV, DC Power Sources.
Includes Bernard ® Q400
15-ft MIG Welding Gun!
Processes
See Literature No. M/13.11
• MIG (GMAW) • Flux Cored (FCAW)
Swingarc boom-mounted wire feeders bring an extra dimension of flexibility and efficiency
to weld stations dealing with large weldments, or wherever operator mobility is required.
• Deltaweld® Series (pg 17)
• Invision™ (pg 18/19)
• Dimension™ Series (pg 47)
• Dimension™ NT 450 (pg 50)
• XMT® Series (except VS model)
(pg 48/49)
Single-wire Swingarc shown with pipe post, power
source, welding gun, and optional Swingpak™ base.
Suggested Guns
Suggested Power Sources
• Bernard® and Tregaskiss™
Most Popular Accessories
• Remote Extension Cords (pg 91)
• Wire Reel Assembly #108 008
• Swingpak™ Base #183 997
• Pipe Post with 18 in Base
4 ft pipe #149 838
6 ft pipe #149 839
• Single/Dual Spool Carrier
(Pipe Post not included)
For use with 4 ft pipe #300 353
For use with 6 ft pipe #300 352
Swingarc
Pipe post (required,
order separately)
Power source
(required, order separately)
See your Miller distributor for other
popular Miller options and accessories.
Bernard Q-Gun™
is included
Swingpak™ Base optional
Models include performance matched Bernard®
Q400 MIG gun, .035/.045 drive rolls and Centerfire™
contact tips! For other gun and drive roll options,
please go to MillerWelds.com/equiptoweld
Models in 8, 12 or 16 ft lengths maximize output.
The unique counterbalance design makes it easy and
convenient to position the boom exactly where it is needed.
360-degree rotation and 60-degree lift angle maximizes
work area (16, 24 or 32 ft diameter work area).
Includes 10 ft 14-pin interconnecting cord.
In-boom cable routing organizes hoses and cables,
protecting them from damage.
Quick-change drive rolls mean no tools are required by
the operator to change drive rolls.
Stock Number
with Single-Wire Feeders
Stock Number
with Dual-Wire Feeders
Input
Power
8 ft (2.4 m)
Boom
SS-74S8 (#951 208) w/S-74S
SS-74D8 (#951 211) w/S-74D
SS-74DX8 (#951 214) w/S-74DX
DS-74S8 (#951 217) w/D-74S
DS-74D8 (#951 220) w/D-74D
DS-74DX8 (#951 223) w/D-74DX
24 VAC,
10 A,
50/60 Hz
12 ft (3.7 m)
Boom
SS-74S12 (#951 209) w/S-74S
SS-74D12 (#951 212) w/S-74D
SS-74DX12 (#951 215) w/S-74DX
DS-74S12 (#951 218) w/D-74S
DS-74D12 (#951 221) w/D-74D
DS-74DX12 (#951 224) w/D-74DX
16 ft (4.9 m)
Boom
SS-74S16 (#951 210) w/S-74S
SS-74D16 (#951 213) w/S-74D
SS-74DX16 (#951 216) w/S-74DX
DS-74S16 (#951 219) w/D-74S
DS-74D16 (#951 222) w/D-74D
DS-74DX16 (#951 225) w/D-74DX
Model
32
Wire Feed Speed
Wire Diameter
Capacity
Maximum Spool
Size Capacity
50 –780 IPM
(1.3 –19.8 m/min)
.023 –5/64 in
(0.6 – 2.0 mm)
60 lb (27 kg) coil
with optional Wire
Reel Assembly
#108 008
Consult factory for
low- and high-speed
motor options
Net Weight with Feeder
Single-Wire Feeder 110 lb (50 kg)
Dual-Wire Feeder 134 lb (61 kg)
Single-Wire Feeder 160 lb (73 kg)
Dual-Wire Feeder 207 lb (94 kg)
Single-Wire Feeder 210 lb (95 kg)
Dual-Wire Feeder 280 lb (127 kg)
A FLE10 Cat P 33 Stick Intro.qxd:Stick Intro
11/3/09
11:04 AM
Page 1
SMAW
Stick
“
I make a better weld —
we all make better welds —
with an inverter such as this
one at arm’s length.
”
Roy Saltz, Journeyman Pipe Welder
UA Local 598
34
Thunderbolt® XL
225/150 AC/DC
34
Thunderbolt® XL
300/200 AC/DC
34
Dialarc® 250 AC/DC
34
Maxstar® 150 S
35
Maxstar® 200 STR
35
Shoulder strap, handle,
optional cart
CST™ 280
36
Handle, optional cart
XMT® Series
48
SRH-444
34
Gold
Star®
452
Gold Star® 652
Dimension™ Series
PRODUCT KEY
Special Features
Typical Applications
Steel,
stainless
30–235 AC
Infinite control
Education, maintenance/repair, farm
30–235 AC
30–160 DC
Infinite control
Education, maintenance/repair, farm
40–300 AC
30–200 DC
Infinite control
Maintenance/repair, farm
Lift eye, optional
running gear
35–300 AC
35–265 DC
One control knob with
high/low range
Education, maintenance/repair, fabrication
Shoulder strap,
optional case
20–150 DC
115–230 V Auto-Line™,
MVP™ plugs
MRO, ship installation/repair, farm/ranch
1–200 DC
115– 460 V Auto-Line ™,
Stick/TIG machine
Construction, fabrication, pipe, steel erection,
shipbuilding
5–280 DC
High output, portable at 41 lb,
also available in multi-unit rack
Construction, fabrication, pipe, steel erection,
shipbuilding
30–280 DC
50 – 500 DC
Built-in Hot Start™
Steel erection, pipe, fab, shipbuilding, foundries
Optional running gear
3⁄ 16"
See the Multiprocess section on page 46.
Lift eye, optional
⁄ running
gear
5 16"
Most metals
Most metals
15–395 DC
Built-in arc control
Steel erection, pipe, fab, shipbuilding, foundries
⁄
20–590 DC
Built-in arc control
Steel erection, pipe, fab, shipbuilding, foundries
34 ⁄
50–850 DC
Built-in arc control
Steel erection, pipe, fab, shipbuilding, foundries
34 ⁄
47 See the Multiprocess section on page 46.
CLASS: Light Industrial Industrial Heavy Industrial
CAPABILITY: Designed for this process Capable of this process
*Constant-current (Stick) machines can utilize voltage-sensing wire feeders for some flux-core applications.
34
1 4"
5 16"
3 8"
3-Phase
Gold Star® 302
Welding
Amperage Range
1 & 3-Phase
Thunderbolt® XL 225 AC
Weldable
Metals
Portability
1-Phase
Product
Guide
Page
Class
Stick
DC TIG
DC TIG-P
Flux Cored*
CAC-A
MillerWelds.com/Stick
For more detailed information, see individual specification sheets.
Also see the TIG section (page 37) for machines that Stick weld.
33
A FLE10 Cat P 34 Stick.qxd:Stick
11/3/09
11:05 AM
Page 1
Stick S M A W
MillerWelds.com
Thunderbolt XL
®
Thunderbolt
XL 300/200
AC/DC
shown.
225 AC, 225/150 AC/DC and 300/200 AC/DC
See Literature No. AC/2.0 for AC model and AD/8.0 for AC/DC models
Light Industrial
225 AC model
is AC only.
Economical Stick machines with precise, dependable control.
Process • Stick (SMAW)
Comes Complete With
• Accu-Set™ amperage indicator.
• Unit allows higher duty cycle when
amperage decreases.
• Infinite current control.
• 15 ft (4.5 m) No. 4 electrode cable
with heavy-duty electrode holder
• 10 ft (3 m) work cable with clamp
• Power cord on all models with plug
included on 225 and 225/150 models
• Output selector switch on AC/DC units.
• 225 and 225/150 models certified by
Canadian Standards Association to both
the Canadian and U.S. Standards.
See distributor for Miller accessories.
Welding Amperage
Range
Rated Output at 20% Duty Cycle, 60 Hz
(15% Duty Cycle, 50 Hz)
Rated Output at
100% Duty Cycle
Amps Input at Rated Output
220 V
230 V
Max. OpenCircuit Voltage
(#903 641)
230 V, 50/60 Hz
AC 30 –235
AC 225 A at 25 VAC
AC 100 A
—
47.5
80
Thunderbolt XL
225/150 AC/DC (CSA)
(#903 642)
230 V, 50/60 Hz
AC 30 –235
DC 30 –160
AC 225 A at 25 V
DC 150 A at 25 V
AC 100 A
DC 65 A
—
47.5
80
Thunderbolt XL
300/200 AC/DC (Non-CSA)
(#903 686)
220 V, 50/60 Hz
AC 40 – 300
DC 30 – 200
AC 300 A at 30 V
DC 200 A at 25 V
AC 130 A
DC 90 A
70
—
80
Model
Stock Number
Thunderbolt XL
225 AC (CSA)
Dialarc 250 AC/DC
See Literature No. AD/2.1
Superb performance and versatility in a flexible Stick machine.
• Single-dial infinite current control.
• High and low ranges.
• Forced-draft cooling fan.
Stock
Number
Rated Output
Amps Input at Rated Output, 60 Hz
200 V 208 V 230 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
35 –300
225 A at 29 VAC, 30% Duty Cycle
84
—
73
36
29
16.8 9.8
70
DC
35 –265
225 A at 29 VAC, 30% Duty Cycle
92
—
80
40
32
18.6 11.8
79
With Power Factor Correction
(#907 015) 208/230/460/575 V
AC
35 –300
225 A at 29 VAC, 30% Duty Cycle
—
60
55
27
22
12.5 9.9
70
DC
35 –265
225 A at 29 VAC, 30% Duty Cycle
—
66
60
30
24
13.7 10.8
79
See Literature No. DC/7.0
• Electrical amperage control.
• Remote control capability.
• High and low output studs.
• Control circuit overload protection.
Welding Amperage
Ranges
Rated Output at
60% Duty Cycle
Amps Input at Rated Output, 60 Hz
208 230 V 460 V 575 V KVA
KW
Max. Open-Circuit
Voltage
30 –280
50 – 500
400 A at 36 V
89
19.6
75
80
40
32
31.9
See Literature No. DC/8.1
Rugged, reliable performance and superior arc characteristics.
• Hot Start™ and built-in arc control.
• Enclosed circuit board.
• Thermal overload protection with light.
• Fan-On-Demand™.
H: 241 ⁄4 in (616 mm)
W: 19 in (483 mm)
D: 28 in (711 mm)
• Stick (SMAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (5/16 in carbons)
See distributor for Miller accessories.
Dimensions
Net Weight
H: 301 ⁄4 in (768 mm)
W: 221 ⁄2 in (572 mm)
D: 353⁄4 in (908 mm)
784 lb
(356 kg)
• 15 A, 115 VAC duplex receptacle.
• Power efficient.
• Remote control capability.
• Optional digital volt and amp meters.
• Stick (SMAW) • TIG (GTAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (Carbons — 302: 1/4 in,
452: 5/16 in, 652: 3/8 in)
• Flux Cored (FCAW)
• MIG Spray Transfer (GMAW) with
voltage-sensing feeder
See distributor for Miller accessories.
KW
Max. Open-Circuit
Voltage
Dimensions (Includes
lift eye and strain relief.)
300 A at 32 VDC,
60% Duty Cycle
70
61
31
25
24.5
13.8
72 VDC
20 – 590
450 A at 38 VDC,
60% Duty Cycle
102
89
45
36
35.5
23.3
72 VDC
50 – 850
650 A at 44 VDC,
60% Duty Cycle
—
124
62
50
49.4
36
72 VDC
H: 30 in (762 mm)
W: 23 in (585 mm)
302 D: 301 ⁄2 in (775 mm)
450 D: 38 in (966 mm)
675 D: 38 in (966 mm)
Stock Number
Gold Star
302
(#903 373) 200(208)/230/460 V
(#903 398) 230/460/575 V
15 – 395
Gold Star
452
(#903 374) 200(208)/230/460 V
(#903 400) 230/460/575 V
Gold Star
652
(#903 402) 230/460/575 V
360 lb
(163 kg)
365 lb
(166 kg)
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V 575 V KVA
Amperage Range
in CC Mode
Model
Net
Weight
Dimensions
Heavy Industrial
Processes
®
34
Industrial
Heavy Industrial
Processes
Proven durability and the ability to handle a wide range of applications.
Gold
Star
452
shown.
134 lb
(61 kg)
See distributor for Miller accessories.
Welding Amperage
Ranges
Gold Star Series
104 lb
(47 kg)
• Stick (SMAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (3/16 in carbons)
• Superior 6010 and 7018 Stick welding.
• High output and duty cycle.
• Optional remote weld output control.
AC
Stock
Number
(#900 751) 208/230/460 V
(#900 753) 230/460/575 V
85 lb
(39 kg)
Processes
Without Power Factor Correction
(#907 017) 200(208)/230/460 V
(#907 016) 230/460/575 V
SRH-444
H: 18 3⁄4 in
(476 mm)
W: 12 3⁄4 in
(323 mm)
D: 171⁄2 in
(445 mm)
Light Industrial
®
Net
Weight
Dimensions
Rated Output
Net Weight
352 lb
(160 kg)
404 lb
(183 kg)
505 lb
(229 kg)
A FLE10 Cat P 35 Stick.qxd:Stick
Call
11/3/09
11:05 AM
Page 1
1-800-4-A-MILLER for more information.
SMAW
Maxstar 150 S
Light Industrial
Process • Stick (SMAW)
#907 134 Comes Complete With
®
See Literature No. DC/27.0
Best in class — provides maximum portability and performance in the most compact Stick
package in the industry. Packs dependability and performance all in one machine.
• Power source
• Primary cord and MVP™ plugs
• 10 ft (3 m) work clamp with
25 mm Dinse connector
• 13 ft (4 m) Stick electrode holder
with 25 mm Dinse connector
• Shoulder strap
Miller’s exclusive multi-voltage plug (MVP™) allows
connection to 115 or 230 V receptacles without tools —
choose the plug that fits the receptacle and connect it to the
power cord.
#907 134-01-2 Includes Above Plus
Portable in the shop or at the job site — at 13.2 lb the
shoulder strap allows the operator to easily move from
location to location.
Maxstar 150 S
with Case
(#907 134-01-2)
shown.
Stick
• Protective X-CASE™
Most Popular Accessories
• MVP™ Plugs (pg 88)
• Protective X-CASE™ #300 184
(pg 88)
Auto-Line™ circuitry automatically connects to 115 – 230 VAC,
single-phase power without removing the covers to relink the
power source.
See your Miller distributor for other
popular Miller options and accessories.
Low OCV Stick reduces open-circuit voltage to 12 –16 VDC
when power source is not in use.
Adaptive Hot Start™ for Stick arc starts prevents electrode
from sticking.
*See page 39 in the TIG section for Maxstar 150 STL and STH.
**Sense voltage for Stick and Lift-Arc ™ TIG.
Stock Number*
(#907 134)
115 – 230 VAC, 50/60 Hz
(#907 134-01-2)
115 – 230 VAC, 50/60 Hz w/Case
Single amperage range allows operator to accurately set
amperage on both 115 or 230 V primary power.
Input
Power
Welding
Amperage Range
Rated Output
Amps Input at Rated
Output, 50/60 Hz
KVA at
Duty Cycle
KW
115 VAC
20 –100
70 A at 22.8 VDC, 100% Duty Cycle
17.4
2.0
1.9
100 A at 24 VDC, 35% Duty Cycle
26.4
3.0
3.0
100 A at 24 VDC, 100% Duty Cycle
13.1
3.0
2.8
150 A at 26 VDC, 30% Duty Cycle
21.6
4.9
4.7
230 VAC
20 –150
Maxstar 200 STR
Max. OpenCircuit Voltage
90
(12 –16 VDC**)
90
(12 –16 VDC**)
See Literature No. DC/29.5
Comes Complete With
• Power source with primary cord
• (2) 50 mm Dinse connectors
• Adjustable shoulder strap
Excellent for thin and medium wall
pipe welding.
Most Popular Accessories
Lift-Arc™ start for TIG arc starts without
the use of high frequency.
Remote amperage control provided
through 14-pin receptacle on front of
the machine.
Adaptive Hot Start™ for Stick arc starts
automatically increases output amperage
at start of weld should the start require
it. Prevents electrode from sticking and
creating an inclusion.
• Air-Cooled TIG Torch Adapter
#195 378 (pg 86)
• Protective Cover #195 321 (pg 90)
• RCCS-14 Remote Fingertip
#043 688 (pg 90)
• RFCS-14 HD Remote Foot Pedal
#194 744 (pg 90)
• Weldcraft® WP17V12RM TIG Torch
See your Miller distributor for other
popular Miller options and accessories.
Portable at 32 lb — easily moved from
location to location.
*See page 40 in the TIG section for Maxstar 200 Series.
**Sense voltage for Stick and Lift-Arc ™ TIG.
Stock
Number*
(#907 036)
Low OCV
Welding
Process
Input Power
Welding
Amperage Range
Rated Output
Amps Input at Rated Load Output, 50/60 Hz
120 V 200 V 230 V 400 V 440 V 460 V KVA KW
Max. OpenCircuit Voltage
Stick
Three-Phase
1– 200
150 A at 26 V, 60% Duty Cycle
—
14.7
13.1
7.4
6.6
6.4
5.2
5.0
Single-Phase
1– 200
(1– 90 on 120 VAC)
150 A at 26 V, 60% Duty Cycle
—
24.9
21.7
—
—
—
5.0
5.0
70 VDC
(9 –14 VDC**)
125 A at 25 V, 50% Duty Cycle
34.1
—
—
—
—
—
4.0
3.8
90 A at 24 V, 100% Duty Cycle
25.0
—
—
—
—
—
4.0
3.8
(#907 036-00-1)
Normal OCV
TIG
13.2 lb
(6.0 kg)
• Stick (SMAW) • TIG (GTAW)
Unit provides maximum flexibility by automatically connecting to any input power while
maintaining the best DC Stick/TIG welding performance in its product class.
Low OCV Stick model reduces opencircuit voltage to 9 –14 VDC when power
source is not in use. This built-in circuit
design eliminates the need for add-on
voltage reducers. See chart below for
Low OCV model stock number.
H: 9 in (229 mm)
W: 51 ⁄2 in (140 mm)
D: 131 ⁄4 in (337 mm)
Net
Weight
Industrial
Processes
®
Allows for any
input voltage
hook-up (120 – 460 V, single- or threephase) with no manual linking, providing
convenience in any job setting. Ideal
solution for dirty or unreliable input power.
Dimensions
Three-Phase
1– 200
175 A at 17 V, 60% Duty Cycle
—
12.1
10.5
6.0
5.3
5.2
4.2
4.0
Single-Phase
1– 200
(1– 150 on 120 VAC)
175 A at 17 V, 60% Duty Cycle
—
19.9
17.4
—
—
—
4.0
4.0
150 A at 16 V, 70% Duty Cycle
29.7
17.1
14.1
—
—
—
3.4
3.4
110 A at 15 V, 100% Duty Cycle
20.0
—
—
—
—
—
2.0
2.0
70 VDC
(9 –14 VDC**)
Dimensions
H: 131 ⁄2 in
(343 mm)
W: 7 1 ⁄2 in
(191 mm)
D: 17 1 ⁄2 in
(445 mm)
Net
Weight
32 lb
(14.5 kg)
35
A FLE10 Cat P 36 Stick.qxd:Stick
11/3/09
11:06 AM
Page 1
Stick S M A W
CST 280
MillerWelds.com
Industrial
Processes
™
See Literature No. DC/29.55
• Stick (SMAW) • TIG (GTAW)
Durable yet lightweight Stick/TIG welding power source designed for construction industry.
280 amps of output is ideal for Stick electrodes up to 3/16 in and TIG welding of pipe and plate.
Easy voltage changeover between
voltage ranges through a two-position
manual switch. Conveniently located
on the rear panel, it simplifies voltage
change in racks.
Simple-to-operate process selector
knob automatically sets proper dig
setting on E6010 and E7018 electrodes
providing superior Stick performance.
Lift-Arc™ start for TIG arc starts
without the use of high frequency.
Fan-On-Demand™ cooling system
operates only when needed providing
power efficiency and noise reduction.
Stand-alone or rack-mounted.
Optional 4-pack or 8-pack rack often
used in construction/shipyards is
available for multi-operator applications. All controls including the
power switch are located on front of
machine for easy access. See page 53.
Remote amperage control provided
through 14-pin receptacle on front
of the machine. This permits use of
standard amperage control devices.
Most Popular Accessories
• CST 280 Rack (pg 53)
• RCC-14 Remote Fingertip
#151 086 (pg 90)
• RCCS-14 Remote Fingertip
#043 688 (pg 90)
• RFCS-14 Remote Foot Pedal
#043 554 (pg 90)
• RFCS-14 HD Remote Foot Pedal
#194 744 (pg 90)
• RHC-14 Remote Hand Control
#129 340 (pg 90)
• For TIG torches see Lit. Index No.
DC/29.55
See your Miller distributor for other
popular Miller options and accessories.
Tweco- or Dinse-style connectors
available. The Dinse-style includes
one set of male connectors; the
Tweco-style does not.
Note: Primary input current draw is limited to 50 A.
Stock Number
(#907 244) Dinse-style
220-230/460-575 V
(#907 244-01-1) Tweco®-style
220-230/460-575 V
(#907 251) Dinse-style
208-230/400-460 V
(#907 251-01-1) Tweco®-style
208-230/400-460 V
Welding
Process
Input
Power
Stick/TIG ThreePhase
5 – 280
Single- 5 – 200
Phase
Stick/TIG ThreePhase
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
Welding
Amperage Range Rated Output
5 – 280
Single- 5 – 200
Phase
280 A at 31.2 V, 35% Duty Cycle —
35.0 34.2 —
—
17.8 14.7 14.6 10.2 77 VDC
200 A at 28 V, 100% Duty Cycle
—
23.3 22.5 —
—
11.7 9.7
9.6 6.4
200 A at 28 V, 50% Duty Cycle
—
43.9 43.0 —
—
—
—
10.1 6.6
150 A at 26 V, 100% Duty Cycle
—
32.7 32.0 —
—
—
—
280 A at 31.2 V, 35% Duty Cycle 36.0 33.0 28.8 19.8 18.0 17.5 —
23.5 23.0 22.8 13.5 12.0 12.7 —
10.2 6.9
200 A at 28 V, 50% Duty Cycle
43.9 43.3 43.0 —
—
—
—
9.9 6.5
150 A at 26 V, 100% Duty Cycle
35.0 33.9 32.9 —
—
—
—
7.6 4.8
Do you have a Facebook or Twitter account?
Do you watch videos on You Tube? If you answered
YES to any of these questions, come visit Miller!
Our You Tube channel has a variety of videos ranging from product
set-up to welding demonstrations!
Become a Fan of our Miller page on Facebook and connect with
thousands of other welding enthusiasts that share in your passion!
If you are looking for quick updates from Miller, follow us on
Twitter and see what’s new!
36
You Tube
7.3 4.6
14.0 10.2 67 VDC
200 A at 28 V, 100% Duty Cycle
Connect with Miller
Follow us:
Max. OpenCircuit Voltage Dimensions
Facebook
Twitter
Net
Weight
41 lb
H: 131 ⁄2 in
(343 mm) (18.6 kg)
1
W: 7 ⁄2 in
(191 mm)
D: 18 in
(457 mm)
A FLE10 Cat P 37 TIG Intro.qxd:TIG Intro
11/3/09
11:09 AM
Page 1
G TAW
TIG
“
When you figure the total cost of
everything — from power savings,
to reduced warping, to a 45%
production increase — the Dynasty
paid for itself within the first week.
Joey Cannon, Welder
Barrett Firearms
”
MillerWelds.com/TIG
Power Source
Welding
Performance
Output
AC TIG
Material
Thickness
Min.– Max.
(Amps)
Min.– Max.
(Aluminum and
Magnesium)
DC
AC/DC
Maxstar®
150
(Pg 39)
Maxstar®
200
(Pg 40)
Maxstar®
350
(Pg 41)
Maxstar®
700
(Pg 41)
Dynasty®
200
(Pg 42)
Dynasty®
350
(Pg 43)
Dynasty®
700
(Pg 43)
Syncrowave® Syncrowave® Syncrowave® Diversion™
200
250 DX
350 LX
165 and 180
(Pg 44)
(Pg 44)
(Pg 44)
(Pg 45)
5 –150 A
1–200 A
3 –350 A
5 –700 A
5 –200 A (AC)
1 –200 A (DC)
3 –350 A
5 –700 A
5 – 200 A
3 – 310 A
3 – 400 A
10 –180 A
(Up to 165 A
w/165 model)
—
—
—
—
.020 –1/4"
.015 – 3/8"
.020–1"
.020 –1/4"
.015 – 3/8"
.015 –1/2"
.030 – 3/16"
.020– 3/16"
.004–1/4"
.012– 5/8"
.020–1"
.004–1/4"
.012– 5/8"
.020–1"
.020 –1/4"
.012–1/2"
.012– 5/8"
.025 – 3/16"
Material
Thickness
Min.– Max.
(Mild Steel,
Stainless Steel,
and Exotic Metals)
Stick
E6010–6011
1/8"
3/16"
5/16"
5/16"
3/16"
5/16"
5/16"
3/16"
1/4"
5/16"
—
Max.
Electrode
Diameter
E6013
1/8"
3/16"
5/16"
5/16"
3/16"
5/16"
5/16"
3/16"
1/4"
5/16"
—
E7018
1/8"
5/32"
1/4"
5/16"
5/32"
1/4"
5/16"
5/32"
7/32"
1/4"
—
E7024
3/32"
1/8"
1/4"
5/16"
1/8"
1/4"
5/16"
1/8"
3/16"
1/4"
—
—
5/32"
1/4"
3/8"
5/32"
1/4"
3/8"
5/32"
3/16"
1/4"
Optional
35 kW
12.5 kW
22 kW
30 kW
DC TIG
Stick
Process
Quality
E6010–6011
E6013
E7018
E7024
Carbon
Arc
Gouging
Max. Electrode
Diameter
6011*
DX Model
12 kW
32 kW
8.5 kW
13 kW
Balance Control
Features
AC Frequency
Pulse Capability
Generator Power
Requirement
ICON KEY
STH Model DX Model
5 kW
5.5 kW
—
—
—
—
—
5.5 kW
PROCESS QUALITY:
Good
Better
Best
New! or Improved! products appear in blue type. *For best results choose 6011.
37
A FLE10 Cat P 38 TIG.qxd:TIG
11/5/09
9:58 AM
Page 1
TIG G T A W
MillerWelds.com
TIG Technology Innovations
Improve Performance
Miller set the standard for TIG technology more
than 35 years ago with the introduction of the
Syncrowave® Series with squarewave technology.
Today, Maxstar® and Dynasty® welders continue that
tradition of innovation, featuring advanced TIG
technology. They set new standards for productivity
and weld quality improvements while lowering the
cost of product installation and operation.
Compared to conventional technology, Maxstar
and Dynasty welders give you more tools for your
specific application. Payback often occurs in
18 months or less. Here’s how:
Maxstar
Maxstar and Dynasty
Advanced DC TIG Technology for Carbon, Stainless and Other Alloys
Less to Install and Operate
■ Superior arc control
• Focused arc cone results in faster travel speeds with
advanced pulse
• Reduced heat input for less warping, better part fit-up
• Better arc control, optimizes weld bead profile to reduce
post-weld grinding
■ Lower amperage draw than conventional welding power sources
• Smaller wiring and circuit breakers required
• Add capacity with existing available power
• Eliminate costly changes to primary power
• Potential utility rebates; check with your local power company
for details
■ Blue Lightning™ arc starter
• Precise arc starting, improves weld quality and consistency
• More arc starts before re-sharpening the tungsten
■ Unmatched primary power flexibility
• Operates on single- or three-phase power
• Plug into virtually any voltage
• Extremely tolerant of voltage fluctuations to maintain weld
quality and reduce rework
Dynasty
Same as the Maxstar, Plus Advanced AC TIG Technology for Aluminum
■ Faster travel speeds
■ Increased penetration on thicker sections
■ Better arc and puddle control
• Improve weld quality
• Optimize bead profile
• Easier to train new operators to weld
38
Better for Mobile Welding
■ Compact designs allow for easy transportation
• Take your welding machine to where you need to weld
• No need for long lead extensions
• Eliminate cable clutter and increase weld performance
• Adjust settings quickly where you are welding
■ Amazing power per pound performance
• Superior TIG/Stick start and weld puddle control
• The ability to run any electrode
A FLE10 Cat P 39 TIG.qxd:TIG
Call
11/5/09
9:59 AM
Page 1
DC
G TAW
1-800-4-A-MILLER for more information.
Maxstar 150
®
STL – DC Stick/TIG Lift-Arc
STH – DC Stick/TIG HF Start
See Literature No. DC/27.1
See Literature No. DC/27.2
Welding
Capability
Not to scale.
Steel Min. — 0.020 in (0.5 mm)
Steel Max. — 3/16 in (4.8 mm)
Auto-Line™ circuitry automatically connects to 115 – 230 V,
single-phase power without removing the covers to relink
the power source.
Miller’s exclusive multi-voltage plug (MVP™) allows connection
to 115 or 230 V receptacles without tools — choose the plug that
fits the receptacle and connect it to the power cord.
Portable in the shop or at the job site at 13.7 lb.
Low OCV Stick™ reduces open-circuit voltage to 12 – 16 VDC
when power source is not in use.
Single amperage range allows operator to accurately set
amperage on both 115 or 230 V primary power.
*See page 35 in the Stick section for Maxstar 150 S.
**Sense voltage for Stick and Lift-Arc ™ TIG.
Model/Stock Number*
Maxstar 150 STL
(#907 135) Standard Package
(#907 135-01-6) TIG/Stick Package
(#907 135-01-7) TIG/Stick Package with
Remote Fingertip Control (#195 184)
Maxstar 150 STH
(#907 136) Standard Package
(#907 136-01-7) TIG/Stick Package with
Remote Fingertip Control (#195 184)
Light Industrial
Processes
• TIG (GTAW) • Stick (SMAW)
• Pulsed TIG (GTAW-P) w/STH model
Standard Pkg Comes With
Two models available —
STL: DC TIG/Stick with Lift-Arc™ starting without the use of
high frequency.
STH: DC TIG/Stick with HF and Lift-Arc™ starting, plus built-in
pulsing with a selection of four fixed-pulse frequencies.
Maxstar 150 STH TIG/Stick
Package with Remote and
Case (#907 136-01-7) shown.
TIG
Built-in gas solenoid eliminates the need for bulky torch with a
gas valve.
• Power source
• Primary cord and MVP™ plugs
• 10 ft (3 m) work clamp with
25 mm Dinse connector
• 13 ft (4 m) Stick electrode holder
with 25 mm Dinse connector
• Shoulder strap
TIG/Stick Pkg Includes Above Plus
• Weldcraft® WP1712RDI25 TIG
torch with adapter
• Protective carrying case
• Smith® flow gauge regulator
with hose
Most Popular Accessories
• MVP™ Plugs (pg 88)
• Protective X-CASE™ #300 184
(pg 88)
• RCCS-6M Remote Fingertip
(pg 90) #195 184
• RFCS-6M Remote Foot Pedal
(pg 90) #195 183
• Remote Controls (pg 90)
See your Miller distributor for other
popular Miller options and accessories.
Max. OpenCircuit Voltage
Welding
Process
Input
Power
Welding
Amperage Range
Rated Output
Amps Input at Rated
Output, 50/60 Hz
KVA at
Duty Cycle
KW
TIG
115 VAC
5 –150
100 A at 14 VDC, 100% Duty Cycle
18.4
2.1
2.1
150 A at 16 VDC, 30% Duty Cycle
28.0
3.4
3.1
100 A at 14 VDC, 100% Duty Cycle
8.3
2.0
1.9
150 A at 16 VDC, 30% Duty Cycle
14.2
3.2
3.1
70 A at 22.8 VDC, 100% Duty Cycle
17.4
2.0
1.9
90 VDC
H: 9 in
(12 –16 VDC**)
(229 mm)
W: 51 ⁄2 in
(140 mm)
D: 131 ⁄4 in
(337 mm)
90 VDC
100 A at 24 VDC, 35% Duty Cycle
26.4
3.0
3.0
(12 –16 VDC**)
100 A at 24 VDC, 100% Duty Cycle
13.1
3.0
2.8
150 A at 26 VDC, 30% Duty Cycle
21.6
4.9
4.7
230 VAC
Stick
115 VAC
230 VAC
5 –150
20 –100
20 –150
Dimensions
Net
Weight
13.7 lb
(6.2 kg)
The Professional’s Welding
and Business Resource
Whether you run a welder or a business, you’ll find a steady
stream of focused welding news for professionals in the
Industries & Interests sections of MillerWelds.com.
Pick your industry — Fabrication, Manufacturing and Construction — then look
for technical articles, case studies, products, news and online resources geared
specifically for your industry. Let us help you get the job done!
Stay Connected at MillerWelds.com/interests
Sign up for one of Miller’s eNewsletters that is tailored to
fit your needs at MillerWelds.com/newsletters
39
A FLE10 Cat P 40 TIG.qxd:TIG
11/5/09
10:00 AM
Page 1
TIG GDCT A W
MillerWelds.com
Maxstar 200 Series
®
Industrial
DC TIG and Stick
See Literature No. DC/32.0
Heavy Industrial
Processes
• TIG (GTAW) • Stick (SMAW)
• Pulsed TIG (GTAW-P) with
DX and LX models
• Air Carbon Arc (CAC-A)
Three Models Available: SD, DX, LX
Steel Min. — 0.004 in (0.1 mm)
Maxstar 200 DX
Fingertip Complete Package
Blue Lightning™ — High Frequency Arc Starter for
non-contact arc initiation. Provides more consistent
arc starts compared to traditional HF arc starters with
greater reliability and no maintenance on solid state
components. Preset parameters for tungsten sizes
from .020 – 1/8 inch provide optimized starting for
applications from thick to micro thin materials. For
unique applications, custom settings are programmable.
Easy to set and increases productivity.
NEW! Air-Cooled Package — One stock number provides
all the necessary items required for an air-cooled TIG
welding system. See at right for package contents.
Allows for any input voltage
hook-up (120 – 460 V, singleor three-phase) with no manual linking, providing
convenience in any job setting.
• Exceptionally smooth and precise arc for welding
exotic materials.
Portable in the shop or at the job site, the two-wheel
cart makes it easy to maneuver the entire package to
the work area. For more portability, detach the 37 lb
welder and take it anywhere.
DC TIG Features
DC Stick Features
• Tailored arc control (DIG) allows the arc characteristic
to be changed for specific applications and electrodes.
Smooth running for 7018 or stiffer, more penetrating
for 6010.
• Hot Start™ adaptive control provides positive arc starts
without sticking.
*See page 35 in the Stick section for Maxstar 200 STR.
**Sense voltage for Stick and Lift-Arc ™ TIG.
Water-Cooled
Complete Packages
(#951 137) DX w/Foot Pedal
(#951 138) DX w/Fingertip
Air-Cooled Packages
(#951 172) DX w/Foot Pedal
(#951 173) DX w/Fingertip
40
Welding
Process Input Power
TIG
Stick
175 A at 17 V, 60% Duty Cycle
—
12.1
10.5
6.0
5.3
5.2
4.2
4.0
175 A at 17 V, 60% Duty Cycle
—
19.9
17.4
—
—
—
4.0
4.0
1 –150
(120 V)
150 A at 16 V, 70% Duty Cycle
29.7
17.1
14.1
—
—
—
3.4
3.4
—
—
—
—
—
2.0
2.0
1 – 200
150 A at 26 V, 60% Duty Cycle
—
14.7
13.1
7.4
6.6
6.4
5.2
5.0
Single-Phase 1 – 200
150 A at 26 V, 60% Duty Cycle
—
24.9
21.7
—
—
—
5.0
5.0
1 – 90
(120 V)
125 A at 25 V, 50% Duty Cycle
34.1
—
—
—
—
—
4.0
3.8
90 A at 24 V, 100% Duty Cycle
25.0
—
—
—
—
—
4.0
3.8
110 A at 15 V, 100% Duty Cycle 20.0
• 2-Wheel Trolley Cart
• Coolmate™ 1 cooler (120 V)
• Coolant (1 gallon)
• RFCS-14 HD remote foot pedal or
RCCS-14 fingertip
• 25 ft (7.6 m) Weldcraft® WP20
water-cooled torch
• 15 ft (4.6 m) work lead with clamp
• 12 ft (3.7 m) gas hose
• Regulator/flowmeter
• Torch accessory kit with tungsten
• Cable cover
Note: Stick electrode holder not included,
must be ordered separately.
Air-Cooled Package Comes With
• Power source and Contractor Kit
which includes the following:
• RFCS-14 HD remote foot pedal or
RCCS-14 fingertip
• Protective carrying case
• 25 ft (7.6 m) Weldcraft® WP17
air-cooled torch
• 15 ft (4.6 m) electrode holder
• 15 ft (4.6 m) work lead with clamp
• 12 ft (3.7 m) gas hose
• Flow gauge regulator
• Torch accessory kit with tungsten
See your Miller distributor for popular
Miller options and accessories.
Max. OpenCircuit
Amps Input at Rated Load Output, 50/60 Hz
120 V 200 V 230 V 400 V 440 V 460 V KVA KW Voltage
1 – 200
Three-Phase
Welding
Amperage
Range
Rated Output
Single-Phase 1 – 200
Three-Phase
LX
Water-Cooled Complete Package
Includes Above Plus
Steel Max. — 1/4 in (6.4 mm)
Model/
Stock Number*
Machine Only
(#903 701) SD
(#903 701-01-1) DX
(#903 701-01-2) LX
DX
• Power source
• 10 ft (3 m) primary cord
• (2) 50 mm Dinse connectors
• Air-cooled TIG torch adapter
#195 378
• Adjustable shoulder strap
Not to scale.
Water-Cooled Complete Package — One stock
number provides all the necessary items required for
a water-cooled TIG welding system. See at right
for package contents.
SD
Digital Meters
HF
Lift-Arc™
Trigger Options
Pulser
Sequencer
Pre/Postflow
DIG
Automation
Connection
Comes With
Welding Capability
Maxstar 200 SD
machine only
Feature
Dimensions
70 VDC
Machine
(9 –14 VDC**) H: 13 1 ⁄2 in (343 mm)
W: 7 1 ⁄2 in (191 mm)
D: 17 1 ⁄2 in (445 mm)
Net
Weight
Machine
37 lb
(16.8 kg)
Complete
Complete
H: 46 1 ⁄4 in (1175 mm) 129 lb
1
W: 23 ⁄2 in (597 mm) (59 kg)
D: 22 1 ⁄4 in (565 mm)
A FLE10 Cat P 41 TIG.qxd:TIG
Call
11/3/09
11:11 AM
Page 1
DC
G TAW
1-800-4-A-MILLER for more information.
Maxstar 350 and 700
Heavy Industrial
DC TIG and Stick
®
See Literature No. DC/24.0
Processes
Maxstar 350 Welding Capability Maxstar 700 Welding Capability
Not to scale.
Not to scale.
Steel Min. — 0.012 in (0.3 mm)
Steel Min. — 0.020 in (0.5 mm)
Steel Max. — 1 in (25.4 mm)
Program memory features 9 independent program
memories that maintain/save your parameters.
Meter calibration for certification purposes.
Maxstar 350
NEW! Blue Lightning™ — High Frequency Arc Starter
for non-contact arc initiation. Provides more consistent
arc starts compared to traditional HF arc starters with
greater reliability and no maintenance on solid state
components. Preset parameters for tungsten sizes
from .020 – 1/4 inch provide optimized starting for
applications from thick to micro thin materials. For
unique applications, custom settings are programmable.
Easy to set and increases productivity.
™
Lift-Arc start provides DC arc starting without the use
of high frequency.
Allows for any input voltage
hook-up (208 – 575 V) with no
manual linking, providing convenience in any job setting.
Wind Tunnel Technology™ protects internal electrical
components from airborne contaminants, extending
product life.
Fan-On-Demand™ cooling system only operates when
needed to reduce noise, energy use and contaminants
pulled through the machine.
• TIG (GTAW)
• Pulsed TIG (GTAW-P)
• Stick (SMAW)
• Air Carbon Arc (CAC-A)
Maxstar 350 Comes With
• Power source
• 8 ft (2.4 m) primary cord
• (2) Dinse 50 mm connectors
• (1) Set-up and operation CD
Maxstar 700 Comes With
Steel Max. — 5/8 in (15.9 mm)
Maxstar 700
TIG
Auto-Postflow calculates the length of postflow time
based on the amperage setting. Eliminates need to
independently set postflow time for different
amperages, preserves tungsten and prevents porosity.
Complete Package — One stock number provides all
the necessary items required for a water-cooled TIG
welding system. See above right for package contents.
Optional Automation Interface Kit (#195 516) includes
automation PC board, 28-pin socket receptacle with
harness, and 28-pin plug connector. Provides required
and advanced automation controls.
DC TIG Features
• Exceptionally smooth and precise arc for welding
exotic materials.
• High-Speed DC TIG Pulse Controls capable of 5000
pulses per second.
DC Stick Features
• Tailored arc control (DIG) allows arc characteristics
to be changed for specific application and electrode.
Smooth running for 7018 or stiffer, more penetrating
for 6010.
• Hot Start™ adaptive control provides positive arc starts
without electrode sticking.
120 V auxiliary power receptacle for cooling system
or small tools.
• Power source
(primary cord not included)
• (1) thread lock torch adapter
• (2) thread lock weld cable connectors
• (1) Set-up and operation CD
Maxstar 350 Complete Package
Includes Above Plus
• Runner ™ cart
• Coolmate™ 3.5 cooler
• Coolant (4 gallons)
• RFCS-14 HD remote foot pedal
• 25 ft (7.6 m) Weldcraft® CS310
water-cooled torch
• Torch accessory kit with tungsten
• 15 ft (4.6 m) work lead with clamp
• 12 ft (3.8 m) gas hose
• Regulator/flowmeter
• Cable cover
Note: Stick electrode holder not included,
must be ordered separately.
Weldcraft® Water-Cooled
Torch Kits
• 250 A Torch Kit #300 185 (pg 90)
• 300 A Torch Kit #300 183 (pg 90)
• 400 A Torch Kit #300 186 (pg 90)
Most Popular Accessories
• Runner ™ Cart
#300 244
(pg 82)
• Coolmate™ 3.5
Cooler
#300 245
(pg 83)
• LowConductivity
Coolant
#043 810 (pg 83)
• Remote Controls (pg 90)
See your Miller distributor for other
popular Miller options and accessories.
*More packages are available — see our Web site or Literature No. DC/24.0. **Sense voltage for Low OCV Stick and Lift-Arc ™ TIG.
Model
Stock
Number*
Input
Power
Maxstar
350
(#907 334)
Machine only
ThreePhase
(#951 073)
Complete
Maxstar
700
(#907 103)
Machine only
Welding
Amperage
Range
Rated Output
Amps Input at Rated Load Output, 50/60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
3 –350
250 A at 30 V, 100% Duty Cycle
27
24
14
12
9
9.7
9.3
300 A at 32 V, 60% Duty Cycle
33
30
17
15
12
12
11.5
6
SinglePhase
ThreePhase
SinglePhase
5 –700
180 A at 27.2 V, 100% Duty Cycle
32
29
—
14
11
6.4
225 A at 29 V, 60% Duty Cycle
41
37
—
19
15
8.6
8.2
500 A at 40 V, 100% Duty Cycle
67
60
35
30
24
24
23
600 A at 44 V, 60% Duty Cycle
89
80
46
40
32
32
31
360 A at 34 V, 100% Duty Cycle
77
70
—
35
28
16
15
450 A at 38 V, 60% Duty Cycle
106
96
—
48
38
22
21
Dimensions
Net
Weight
75 VDC
(10 –15 VDC**)
Machine H: 24 3⁄4 in (629 mm)
W: 13 3⁄4 in (349 mm)
D: 22 in (559 mm)
Complete H: 451 ⁄8 in (1146 mm)
W: 23 1⁄8 in (587 mm)
D: 43 3⁄4 in (1111 mm)
Machine
135 lb
(61 kg)
Complete
308 lb
(140 kg)
75 VDC
(10 –15 VDC**)
Machine H: 341 ⁄2 in (876 mm)
W: 13 3⁄4 in (349 mm)
D: 22 in (559 mm)
Machine
198 lb
(90 kg)
41
A FLE10 Cat P 42 TIG.qxd:TIG
11/5/09
10:01 AM
Page 1
TIG GAC/DC
TAW
MillerWelds.com
Dynasty 200 Series
®
Industrial
AC/DC TIG and Stick
See Literature No. AD/4.8
Heavy Industrial
Processes
• TIG (GTAW) • Stick (SMAW)
• Pulsed TIG (GTAW-P) w/DX model
• Air Carbon Arc (CAC-A)
Welding Capability
Not to scale.
Two Models Available: SD and DX
Aluminum Min. — 0.020 in (0.5 mm)
Steel Min. — 0.004 in (0.1 mm)
Dynasty 200 DX
Water-Cooled
Complete Package
with Foot Pedal
Aluminum Max. — 1/4 in (6.4 mm)
Steel Max. — 1/4 in (6.4 mm)
Portable in the shop or at the job site, the two-wheel
cart makes it easy to maneuver the entire package to
the work area. For more portability, detach the 45 lb
welder and take it anywhere.
Allows for any input voltage
hook-up (120 – 460 V, singleor three-phase) with no manual linking, providing
convenience in any job setting.
• 2-Wheel Trolley Cart
• Coolmate™ 1 cooler (120 V)
• Coolant (1 gallon)
• RFCS-14 HD remote foot pedal or
RCCS-14 remote fingertip
• 25 ft (7.6 m) Weldcraft® WP20
water-cooled torch
• Torch accessory kit with tungsten
• 15 ft (4.6 m) work lead with clamp
• 12 ft (3.7 m) gas hose
• Regulator/flowmeter
• Cable cover
AC Waveforms
Advanced Squarewave, fast freezing puddle,
deep penetration and fast travel speeds.
Soft Squarewave for a soft buttery arc
with maximum puddle control and good
wetting action.
Sine wave for customers that like
a traditional arc. Quiet with good wetting.
Triangular wave reduces the heat input and is
good on thin aluminum. Fast travel speeds.
Note: Stick electrode holder not included,
must be ordered separately.
Air-Cooled Package Comes With
• Exceptionally smooth and precise arc for welding
exotic materials.
AC/DC Stick Features
NEW! Air-Cooled Package — One stock number provides
all the necessary items required for an air-cooled TIG
welding system. See at right for package contents.
Water-Cooled Complete Package
Includes Above Plus
DC TIG Features
Water-Cooled Complete Package — One stock
number provides all the necessary items required for
a water-cooled TIG welding system. See at right
for package contents.
DX
• Power source
• 10 ft (3 m) primary cord
• (2) 50 mm Dinse connectors
• Air-cooled TIG torch adapter
#195 378
• Adjustable shoulder strap
• Extended AC balance (30 – 99%) controls amount
of oxide cleaning (amperage time in EN) which is
essential for high quality welds on aluminum.
• AC frequency (20 – 250 hz) controls the width of the
arc cone and the force of the arc.
Blue Lightning™ — High Frequency Arc Starter for
non-contact arc initiation. Provides more consistent
arc starts compared to traditional HF arc starters with
greater reliability and no maintenance on solid state
components. Preset parameters for tungsten sizes
from .020 – 1/8 inch provide optimized starting for
applications from thick to micro thin materials. For
unique applications, custom settings are programmable.
Easy to set and increases productivity.
SD
Digital Meters
HF
Lift-Arc™
Trigger Options
Pulser
Sequencer
Pre/Postflow
DIG
Wave Forms
Comes With
AC TIG Features
Dynasty 200 SD
machine only
Feature
• Tailored arc control (DIG) allows the arc characteristic
to be changed for specific applications and electrodes.
Smooth running for 7018 or stiffer, more penetrating
for 6010.
• Hot Start™ adaptive control provides positive arc starts
without sticking.
• AC frequency control adds additional stability when
Stick welding in AC for smoother welds.
• Power source and Contractor Kit
which includes the following:
• RFCS-14 HD remote foot pedal or
RCCS-14 fingertip
• Protective carrying case
• 25 ft (7.6 m) Weldcraft® WP17
air-cooled torch
• 15 ft (4.6 m) electrode holder
• 15 ft (4.6 m) work lead with clamp
• 12 ft (3.7 m) gas hose
• Flow gauge regulator
• Torch accessory kit with tungsten
See your Miller distributor for popular
Miller options and accessories.
*Sense voltage for Stick and Lift-Arc ™ TIG. Note: Duty cycle is limited on 120 V power.
Model/Stock Number
Machine Only
(#907 099) SD
(#907 099-01-1) DX
Water-Cooled
Complete Packages
(#951 139) DX w/Foot Pedal
(#951 140) DX w/Fingertip
Air-Cooled Packages
(#951 174) DX w/Foot Pedal
(#951 175) DX w/Fingertip
42
Welding
Process
TIG
Input Power
Welding
Amperage
Range
Rated Output
Amps Input at Rated Load Output, 50/60 Hz
120 V 230 V 400 V 460 V KVA KW
Three-Phase
1 – 200
200 A at 18 V, 20% Duty Cycle
—
13.7
8.7
6.9
5.5
5.2
150 A at 16 V, 60% Duty Cycle
—
9.4
6.0
4.7
3.8
3.6
1 – 200
150 A at 16 V, 60% Duty Cycle
—
15.8
—
7.9
3.6
3.6
1 –150
(120 VAC)
140 A at 15.6 V, 40% Duty Cycle
31.0
—
—
—
3.6
3.5
100 A at 14 V, 100% Duty Cycle
20.7
—
—
—
2.3
2.3
1 – 200
200 A at 28 V, 20% Duty Cycle
—
20.8
13.0
10.2
8.1
7.8
130 A at 25.2 V, 60% Duty Cycle
—
12.3
7.6
6.0
4.8
4.6
1 – 200
130 A at 25.2 V, 60% Duty Cycle
—
20.0
—
10.0
4.7
4.7
1 – 105
(120 VAC)
100 A at 24 V, 60% Duty Cycle
31.3
—
—
—
3.6
3.6
90 A at 23.6 V, 100% Duty Cycle
27.6
—
—
—
3.2
3.2
Single-Phase
Stick
Three-Phase
Single-Phase
Max. OpenCircuit
Voltage
80 VDC
(5 –10 VDC*)
Dimensions
Net
Weight
Machine
H: 13 1 ⁄2 in (343 mm)
W: 7 1 ⁄2 in (191 mm)
D: 21 1 ⁄2 in (546 mm)
Machine
45 lb
(20.5 kg)
Complete
H: 46 1 ⁄4 in (1175 mm)
W: 23 1 ⁄2 in (597 mm)
D: 22 1 ⁄4 in (565 mm)
Complete
137 lb
(62 kg)
A FLE10 Cat P 43 TIG.qxd:TIG
Call
11/3/09
11:13 AM
Page 1
AC/DC
G TAW
1-800-4-A-MILLER for more information.
Dynasty 350 and 700
®
AC/DC TIG and Stick
See Literature No. AD/5.0
TIG
Heavy Industrial
Processes
Dynasty 350 Welding Capability Dynasty 700 Welding Capability
Not to scale.
Not to scale.
Aluminum Min. — 0.015 in (0.38 mm)
Steel Min. — 0.012 in (0.3 mm)
Aluminum Min. — 0.020 in (0.5 mm)
Steel Min. — 0.020 in (0.5 mm)
• TIG (GTAW) • Stick (SMAW)
• Pulsed TIG (GTAW-P)
• Air Carbon Arc (CAC-A)
Dynasty 350 Comes With
• Power source
• 8 ft (2.4 m) primary cord
• (2) Dinse 50 mm connectors
• (1) Set-up and operation CD
Dynasty 700 Comes With
Aluminum Max. — 5/8 in (15.9 mm)
Steel Max. — 5/8 in (15.9 mm)
Aluminum Max. — 1 in (25.4 mm)
Steel Max. — 1 in (25.4 mm)
Complete
Package
Complete Package — One stock number provides all
the necessary items required for a water-cooled TIG
welding system. See at right for package contents.
Machine only
NEW! Blue Lightning™ — High Frequency Arc Starter
for non-contact arc initiation. Provides more consistent
arc starts compared to traditional HF arc starters with
greater reliability and no maintenance on solid state
components. Preset parameters for tungsten sizes
from .020 – 1/4 inch provide optimized starting for
applications from thick to micro thin materials.
For unique applications, custom settings are
programmable. Easy to set and increases productivity.
Lift-Arc™ start provides DC arc starting without the use
of high frequency.
Allows for any input voltage
hook-up (208 – 575 V) with no
manual linking, providing convenience in any job setting.
Wind Tunnel Technology™ protects internal electrical
components from airborne contaminants, extending
product life.
120 V auxiliary power receptacle for cooling system
or small tools.
Program memory features 9 independent program
memories that maintain/save your parameters.
Meter calibration for certification purposes.
Auto-Postflow calculates the length of postflow time
based on the amperage setting. Eliminates need to
independently set postflow time for different
amperages, preserves tungsten and prevents porosity.
AC TIG Features
• Independent Amplitude/Amperage Control allows
the EP and EN amperages to be set independently to
precisely control heat input to the work and electrode.
• Extended Balance (30 – 99%) controls the amount
of oxide cleaning (amperage time in EN) which is
essential for high quality welds on aluminum.
• AC Frequency (20 – 400 Hz) controls the width of the
arc cone and the force of the arc (directional control).
• AC waveforms include Advanced Squarewave, Soft
Squarewave, Sine Wave and Triangular Wave for the
ultimate in control.
DC TIG Features
• Exceptionally smooth and precise arc for welding
exotic materials.
• High-Speed DC TIG Pulse Controls capable of 5000
pulses per second.
AC/DC Stick Features
• Tailored arc control (DIG) allows arc characteristics
to be changed for specific application and electrode.
Smooth running for 7018 or stiffer, more penetrating
for 6010.
• Hot Start ™ adaptive control provides positive arc starts
without electrode sticking.
• AC frequency control adds additional stability when
Stick welding in AC for smoother welds.
• Power source
(primary cord not included)
• (1) thread lock torch adapter
• (2) thread lock weld cable connectors
• (1) Set-up and operation CD
Complete Package Includes
Above Plus
• Runner ™ cart
• Coolmate™ 3.5 cooler
• Coolant (4 gallons)
• RFCS-14 HD remote foot pedal
• 25 ft (7.6 m) water-cooled torch
(350: Weldcraft® CS310)
(700: Weldcraft® WP18SC)
• Torch accessory kit with tungsten
• 15 ft (4.6 m) work lead with clamp
• 12 ft (3.8 m) gas hose
• Regulator/flowmeter
• Cable cover
Note: Stick electrode holder not included,
must be ordered separately.
Weldcraft® Water-Cooled
Torch Kits
• 250 A Torch Kit #300 185 (pg 90)
• 300 A Torch Kit #300 183 (pg 90)
• 400 A Torch Kit #300 186 (pg 90)
Most Popular Accessories
• Runner ™ Cart
#300 244
(pg 82)
• Coolmate™
3.5 Cooler
#300 245
(pg 83)
• LowConductivity
Coolant
#043 810 (pg 83)
• Remote Controls (pg 90)
See your Miller distributor for other
popular Miller options and accessories.
*More packages are available — see our Web site or Literature No. AD/5.0. **Sense voltage for Low OCV Stick and Lift-Arc ™ TIG.
Model
Stock
Number*
Input
Power
Dynasty
350
(#907 204)
Machine only
ThreePhase
(#951 074)
Complete
Dynasty
700
(#907 101)
Machine only
(#951 075)
Complete
Welding
Amperage
Range
Rated Output
Amps Input at Rated Load Output, 50/60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
3 –350
250 A at 30 V, 100% Duty Cycle
29
26
15
13
10
10.3 9.9
300 A at 32 V, 60% Duty Cycle
35
32
16
16
13
12.7 12.1
180 A at 27.2 V, 100% Duty Cycle
35
32
—
15
12
7.4
225 A at 29 V, 60% Duty Cycle
47
43
—
21
17
9.8
9.1
500 A at 40 V, 100% Duty Cycle
75
68
39
34
27
27
26
600 A at 44 V, 60% Duty Cycle
97
88
51
44
35
35
34
360 A at 34 V, 100% Duty Cycle
82
74
—
37
30
17
16
450 A at 38 V, 60% Duty Cycle
115
104
—
52
42
24
22
SinglePhase
ThreePhase
SinglePhase
5 –700
Dimensions
Net
Weight
75 VDC
(10 –15 VDC**)
Machine H: 24 3⁄4 in (629 mm)
W: 13 3⁄4 in (349 mm)
D: 22 in (559 mm)
Complete H: 451 ⁄8 in (1146 mm)
W: 23 1⁄8 in (587 mm)
D: 43 3⁄4 in (1111 mm)
Machine
135 lb
(61 kg)
Complete
308 lb
(140 kg)
75 VDC
(10 –15 VDC**)
Machine H: 341 ⁄2 in (876 mm)
W: 13 3⁄4 in (349 mm)
D: 22 in (559 mm)
Complete H: 551 ⁄8 in (1400 mm)
W: 23 1⁄8 in (587 mm)
D: 43 3⁄4 in (1111 mm)
Machine
198 lb
(90 kg)
Complete
370 lb
(168 kg)
6.8
43
A FLE10 Cat P 44 TIG.qxd:TIG
11/3/09
11:13 AM
Page 1
TIG GAC/DC
TAW
MillerWelds.com
Syncrowave Series
®
Processes
• TIG (GTAW)
• Stick (SMAW)
• Pulsed TIG (GTAW-P)
(optional on 250 DX)
• Air Carbon Arc (CAC-A)
Squarewave output with AC balance control
features adjustable penetration and cleaning
action while increasing arc stability on
various aluminum alloys, and helps eliminate
tungsten spitting and arc rectification.
Syncro Start ™ Technology for customized arc starts, allows for more
precise arc starts and fine-tuning based on tungsten diameter and
material thickness.
120 V auxiliary power receptacle for
cooling system or small tools.
Dual digital meters allow for quick and easy viewing of actual and
preset values of amperage and voltage.
Syncrowave 200
®
Light Industrial
Comes With
See Literature No. AD/4.4
Not to scale.
Syncrowave 200
Runner shown.
HF arc starting provides non-contact arc starting that eliminates
tungsten or material contamination.
AC/DC TIG and Stick
Welding Capability
Aluminum Min. — 0.020 in (0.5 mm)
Steel Min. — 0.020 in (0.5 mm)
Aluminum Max. — 1/4 in (6.4 mm)
Steel Max. — 1/4 in (6.4 mm)
Stock Number
(#907 308) 208-230 V, 50/60 Hz
(#907 308-00-1) 208-230 V Runner
(#907 309) 460/575 V, 50/60 Hz
(#907 309-00-1) 460/575 V Runner
The world’s first and most reliable
conventional Squarewave TIG power source.
• Power source
• 8 ft (2.4 m) primary cord
(only with 208-230 V models)
• RFCS-14 remote foot control
• 12-1/2 ft (3.8 m) Weldcraft® WP17
TIG torch
• 15 ft (4.6 m) work lead with clamp
• 15 ft (4.6 m) lead w/electrode holder
• Flow gauge regulator with hose
• Cable and remote foot pedal holders
Cable management system uses
dual cable hangers and foot control
storage conveniently attached to the
power source side panels.
Auto-Postflow protects the
weld end zone and electrode by
optimizing postflow time based on
welding amperage.
Runner™ Model Includes Above Plus
• No. 39 Running Gear
See distributor for Miller accessories.
Welding
Amperage Range
Rated Output at
40% Duty Cycle
Amps Input at Rated Output, 60 Hz
208-230 V 460 V 575 V KVA
KW
Max. OpenCircuit Voltage
5 – 200
150 A at 26 V
54
6.0
80
27
22
Syncrowave 250 and 350
®
Welding Capability
Not to scale.
Aluminum Min. — 0.015 in (0.4 mm)
Steel Min. — 0.012 in (0.3 mm)
12.5
AC/DC TIG and Stick
See Literature No. AD/4.2
Coolmate™ 3X cooler (shown in
Complete Package). 3-gallon cooling
system features a flow indicator to
visually indicate system is working and
an external filter to stop objects from
entering the water-cooled torch cable.
Last procedure recall automatically
recalls the last procedure set-up when
switching polarity.
Machine only
Complete Package
250 DX Model
Aluminum Max. — 3/8 in (9.5 mm)
Steel Max. — 1/2 in (12.7 mm)
350 LX Model
Aluminum Max. — 1/2 in (12.7 mm)
Steel Max. — 5/8 in (15.9 mm)
*More packages are available — see our Web site or Literature No. AD/4.2.
**Add 12 3⁄4 inches height with Complete Package. ***Add 139 pounds with Complete Package.
Welding
Amp
Range
Model
Stock Number*
Syncrowave
250 DX
(#907 194) 200/230/460 V, 50/60 Hz, Machine only
(#907 195) 230/460/575 V, 50/60 Hz, Machine only
(#951 117) 200/230/460 V, 50/60 Hz, Complete
(#951 118) 230/460/575 V, 50/60 Hz, Complete
3–310
(#907 198) 200/230/460 V, 50/60 Hz, Machine only
(#907 199) 230/460/575 V, 50/60 Hz, Machine only
(#951 119) 200/230/460 V, 50/60 Hz, Complete
(#951 120) 230/460/575 V, 50/60 Hz, Complete
3–400
Syncrowave
350 LX
44
Line voltage compensation keeps
power source constant regardless of
fluctuations in input power (±10%).
Lift-Arc™ start provides DC arc starting
without the use of high frequency.
Built-in consumable storage drawer
located on front panel for easy access.
Dimensions
Net Weight
H: 301⁄8 in (765 mm)
W: 211⁄8 in (537 mm)
D: 211⁄2 in (546 mm)
238 lb
(108 kg)
Heavy Industrial
Syncrowave 250 DX and 350 LX
Come With
• Power source
(primary cord not included)
• (2) Dinse 50 mm connectors
Complete Package Includes
Above Plus
• No. 37 Running Gear
• Coolmate™ 3X cooler
• Coolant (4 gallons)
• RFCS-14 remote foot pedal
• 25 ft (7.6 m) water-cooled torch
(Syncro 250: Weldcraft® WP20)
(Syncro 350: Weldcraft® CS310)
• Torch accessory kit with tungsten
• 15 ft (4.6 m) work lead with clamp
• Regulator/flowmeter with hose
• Cable cover
Note: Stick electrode holder not included,
must be ordered separately.
See distributor for Miller accessories.
Rated Output
Amps Input at AC Balanced Rated Load, 1-Phase
(Syncro 250 DX, 60 Hz) (Syncro 350 LX, 50/60 Hz)
200 V 230 V 460 V 575 V KVA
KW
Max. OpenCircuit
Voltage
200 A at 28 VAC, 60% Duty Cycle
88
77
38
31
17.6
8.6
80
250 A at 30 VAC, 40% Duty Cycle
110
96
48
38
21.98
11.76
300 A at 32 VAC, 60% Duty Cycle
125
110
55
42
25
10.6
350 A at 34 VAC, 40% Duty Cycle
146
128
65
50
29.5
13.7
Dimensions**
H: 361⁄4 in
(921 mm)
W: 22 1⁄2 in
(572 mm)
D: 25 in
(635 mm)
Net
Weight***
378 lb
(172 kg)
496 lb
(225 kg)
A FLE10 Cat P 45 TIG.qxd:TIG
Call
11/5/09
10:02 AM
Page 1
AC/DC
G TAW
1-800-4-A-MILLER for more information.
TIG
Diversion TIG Welders
Personal Appeal. Professional Grade.
™
Leave it to Miller to take a professional-grade arc and put it in a package designed specifically
for personal users. Diversion AC/DC TIG welders contain all of the features you need —
and nothing more. Just simplicity combined with superior performance and honest value.
The Diversion series of TIG welders: Making welding easy, fun and affordable — with a TIG
arc quality that’s undeniably Miller.
Diversion 165 and 180
™
Welding
Capability
Not to scale.
Light Industrial
Process • TIG (GTAW)
Comes With
AC/DC TIG
See Literature No. AD/1.5
Aluminum Min. — 0.030 in (0.75 mm)
Steel Min. — 0.025 in (0.6 mm)
Aluminum Max. — 3/16 in (4.8 mm)
Steel Max. — 3/16 in (4.8 mm)
Easy-to-understand operator interface. Power
up, select material type, set material thickness
range and start welding!
Diversion 180
Inverter-based, AC/DC power source provides
a more consistent welding arc while using
less power.
HF start for non-contact arc starting that
eliminates tungsten and material contamination.
Fan-On-Demand™ cooling system only
operates when needed to reduce noise
and maintenance.
Portable — at 50 lb they can be taken anywhere.
Diversion 165
TIG Welding for Dummies
book, set-up and operation
DVD, Smith Argon regulator/
flow gauge with hose, and
welding project blueprint
(not shown) included with
each Diversion model.
Auto-Postflow protects the weld end zone and
electrode by optimizing postflow time based on
welding amperage.
Advanced Squarewave AC provides a fast
freezing weld puddle and deeper penetration.
The Diversion 180 model includes Miller’s
exclusive multi-voltage plug (MVP™) which
allows connection to 115 or 230 V receptacles
without tools — choose the plug that fits the
receptacle and connect it to the power cord.
• Power source with primary cord
and 50 A, 230 V plug (165 model)
• Power source with primary cord
and MVP™ plugs (180 model)
• 12-1/2 ft (3.8 m) Weldcraft® LS17
TIG torch with backcap, ceramic gas
cup, 3/32 in (2.4 mm) collet and
collet body, and 2% ceriated tungsten
• 12 ft (3.7 m) work lead with clamp
• Smith® Argon regulator/flow gauge
with hose
• TIG Welding for Dummies book
with content written by Miller
• Set-up and operation DVD
• Welding project blueprint for a
machine cart/cylinder rack
Most Popular Accessories
• Running Gear/Cylinder Rack
#770 187 (pg 82)
• Protective Cover #300 579 (pg 90)
• 125 A, Air-Cooled Standard
Torch Body #9LGC
• 125 A, Air-Cooled Pencil Torch Body
#9PLGC
• 125 A, Air-Cooled Flex Torch Body
#9FXLGC
• 150 A, Air-Cooled Flex Torch Body
#17FXLGC
• RFCS-RJ45 Remote Foot Pedal
#300 432
See your Miller distributor for other
popular Miller options and accessories.
*While idling.
Input
Power
Welding
Amperage Range
Rated Output
Amps Input at
Rated Output
KVA
KW
Max. OpenCircuit Voltage
Diversion 165
(#907 005)
230 VAC
10 – 165
60 A at 12.4 V, 100% Duty Cycle
8 (.20)*
1.8 (.04)*
1.2 (.02)*
80
150 A at 16 V, 20% Duty Cycle
23 (.20)*
5.3 (.04)*
3.7 (.02)*
165 A at 16.6 V, 15% Duty Cycle
25.5 (.20)*
5.9 (.04)*
4.2 (.02)*
Diversion 180
(#907 460)
115 VAC
60 A at 12.4 V, 100% Duty Cycle
11.3 (.88)*
1.3 (.1)*
1.2 (.03)*
125 A at 15 V, 35% Duty Cycle
26.5 (.88)*
3.1 (.1)*
3.0 (.03)*
60 A at 12.4 V, 100% Duty Cycle
5.6 (.44)*
1.3 (.1)*
1.2 (.03)*
150 A at 16 V, 20% Duty Cycle
16 (.44)*
3.7 (.1)*
3.6 (.03)*
180 A at 17.2 V, 10% Duty Cycle
20.5 (.44)*
4.7 (.1)*
4.6 (.03)*
Model/Stock Number
230 VAC
10 – 125
10 – 180
Dimensions
H: 17 in (433 mm)
W: 9 7⁄8 in (251 mm)
D: 23 7⁄8 in (608 mm)
Net
Weight
50 lb
(23 kg)
45
A FLE10 Cat P 46 MP Intro.qxd:MP Intro
11/5/09
10:03 AM
Page 1
Multiprocess
“
Now that we have standardized on Miller
equipment in many locations... It simplifies
the process. The operator is familiar with the
equipment. He knows what to expect in
various situations. This saves time and
improves first-pass weld quality.
John Meyer, Fabrication Coordinator
Gunderson Marine
Multiprocess Power Sources
and Packages for Demanding
Industrial Applications
Each Product Offers Three Package Options That Will Help Fit
Your Specific Welding Needs
”
GOOD
BEST
BETTER
MillerWelds.com/Multiprocess
Shopmate/22A
Power Source
Welding
Performance
Material
Mild Steel
Stainless Steel
Aluminum*
Material
Thickness
Gauge
(.020 –.125)
Sheet
(.125 –.375)
Plate
(.375 – 1 in)
Plate
(1+ in)
Wire Size
.030
.035
.045
.052
1/16
5/64
3/32
Process
Short Circuit
Pulsed Spray
Stick
TIG
CAC-A
ICON KEY
46
250 A
300 Amp
™
™
Dimension/S-74D
450 Amp
350 Amp
XMT
304 CC/CV
(Pg 48)
XMT
350 VS
(Pg 48)
XMT
350 CC/CV
(Pg 48)
XMT
350 MPa
(Pg 49)
Dimension
452
(Pg 47)
Dimension
NT 450
(Pg 50)
XMT
456 CC/CV
(Pg 48)
Dimension™
652
(Pg 47)
3/16"
®
Optional Optional 1/4"
®
1/4"
CAPABILITY:
Designed for
Capable of
*XR Push-Pull System recommended for best results.
5/16"
PROCESS QUALITY:
5/16"
5/16"
™
™
650 Amp
Dimension
302
(Pg 47)
®
XMT/SuitCase®
Shopmate
300 DX (1-Phase)
(Pg 47)
®
Dimension NT 450/S-74D
®
5/16"
Optional 5/16"
Good Better Best Optimized
3/8"
3/8"
A FLE10 Cat P 47 MP.qxd:Multiprocess
Call
11/5/09
10:04 AM
Page 1
Multiprocess
1-800-4-A-MILLER for more information.
Shopmate 300 DX
Light Industrial
Processes
™
See Literature No. DC/12.7
• MIG (GMAW)
• Flux Cored (FCAW)
• DC Stick (SMAW)
• DC TIG (DC GTAW)
An economical single-phase DC multiprocess power source that provides versatility and
outstanding arc performance in CV mode (MIG) and CC mode (Stick and TIG).
MIG Pkg Comes Complete With
Fan-On-Demand™ cooling system
operates only when needed.
Process selector switch is an
“operator-friendly” single process
switch that eliminates the confusion
of several switch combinations.
Line voltage compensation keeps
welding parameters constant even
when input voltages change ±10%.
Digital meters for presetting or
monitoring welding voltage in CV
mode and amperage in CC mode.
Stock Number
Built-in 14-pin connector
provides quick, direct
connection for 14-pin,
24 VAC Miller wire feeders
and accessories.
(#907 315) 200(208)/230 V
(#907 316) 230/460/575 V
(#951 076) 200(208)/230 V w/MIG Pkg
(#951 077) 230/460/575 V w/MIG Pkg
Amperage
Range
Voltage
Range
5 – 400
10 – 35
Rated Output
250 A at 30 VDC,
60% Duty Cycle
Dimension Series
Most Popular Accessories
Arc control adjusts inductance in MIG
mode and DIG in Stick mode to
optimize weld performance.
Built-in 10-pin connector for direct
hookup of Spoolmatic® spool guns.
Shopmate 300 DX MIG Package (#951 077) shown.
• Power source
• 22A wire feeder with Bernard® gun
• MIG kit
Lift-Arc™ start provides DC TIG arc
starting without the use of high
frequency. Starts the arc without
contaminating the weld with tungsten.
Max. OpenCircuit Voltage
Dimensions
(includes lift eye)
Net
Weight
66
80 VDC
H: 241 ⁄2 in (622 mm)
W: 19 in (483 mm)
D: 251 ⁄2 in (648 mm)
177 lb
(80.3 kg)
57
29
23
13
11.2
Heavy Industrial
Processes
See Literature No. DC/19.2
“Good!” multiprocess solution delivers dependable performance in demanding applications
and combines with the 70 Series wire feeder for a complete welding solution.
OR Build your own system by choosing machine, feeder,
gun, drive rolls, cables, etc. at MillerWelds.com/equiptoweld
DC multiprocess versatility with
excellent arc performance in CV
(MIG) and CC (Stick, TIG, CAC-A).
Digital voltage control (DVC)
enables operator to preset voltage
in the CV mode prior to welding.
Hot Start™ makes it easy to start
difficult electrodes.
• MIG (GMAW)
• Stick (SMAW)
• TIG (GTAW)
• Flux Cored (FCAW)
• Air Carbon Arc
Cutting and Gouging (CAC-A)
Most Popular Accessories
Line voltage compensation keeps
welding parameters constant even
when input voltages change ±10%
throughout the day.
Fan-On-Demand™ cooling system
operates only when needed. Reduces
contaminants drawn into the machine
Arc control for Stick applications
allows operators more flexibility when and reduces excess noise.
welding in tight areas where sticking Power efficient for exceptional return
on your investment.
electrodes is a problem.
Dimension 452 MIGRunner ™ Package
(#951 277) shown.
See your Miller distributor for other
popular Miller options and accessories.
Amps Input at Rated Load Output, 60 Hz
208 V 230 V 460 V 575 V KVA KW
™
MIG Power Source Solutions
• Shopmate Running Gear/
Dual Cylinder Rack #300 145
(pg 82)
• Shopmate 300 Kit #300 150
(pg 86)
Digital meters display voltage and
amperage while welding and also
display preset voltage in CV mode.
• SuitCase® X-TREME™ Wire Feeders
(pg 25)
• 70 Series Wire Feeders (pg 31)
• Standard Running Gear #042 886
(pg 82)
• Standard Cylinder Rack #042 887
(pg 82)
• Industrial MIG 4/0 Kit #300 390
(pg 86)
• Extension Cords (pg 91)
• Bernard® and Tregaskiss™ MIG Guns
When purchasing components separately
please see your Miller distributor or visit
MillerWelds.com/equiptoweld for other
popular Miller options and accessories.
*More models are available — see our Web site or Literature No. DC/19.2.
**Dimensions and weight are for power source only — includes lift eye and strain relief.
Welding
Mode
Amperage/
Voltage Range
(#903 216) 230/460/575 V, Machine only
(#951 272) 230/460/575 V, Stationary Pkg
(#951 276) 230/460/575 V, MIGRunner Pkg
CC
15 – 375 A
CV
10 – 32 V
Dimension
452
(#903 255) 230/460/575 V, Machine only
(#951 273) 230/460/575 V, Stationary Pkg
(#951 277) 230/460/575 V, MIGRunner Pkg
CC
20 – 565 A
CV
10 – 38 V
Dimension
652
(#903 379) 230/460/575 V, Machine only
(#951 274) 230/460/575 V, Stationary Pkg
(#951 278) 230/460/575 V, MIGRunner Pkg
CC
50 – 815 A
CV
10 – 65 V
Model*
Stock Number
Dimension
302
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
300 A at 32 VDC,
100% Duty Cycle
57.5
50
25
20
20
12.9
60 VDC
69
60
30
24
23.7 13.4
36 VDC
450 A at 38 VDC,
100% Duty Cycle
91
79
39
31
31.4 22
65 VDC
104
90
45
36
35.3 22.3
43 VDC
650 A at 44 VDC,
100% Duty Cycle
—
126
63
50.4
50
72 VDC
Rated Output
34.8
67 VDC
Dimensions**
Net
Weight**
H: 30 in (762 mm)
W: 23 in (585 mm)
D: 301 ⁄2 in (775 mm)
361 lb
(164 kg)
H: 30 in (762 mm)
W: 23 in (585 mm)
D: 38 in (966 mm)
424 lb
(192 kg)
H: 30 in (762 mm)
W: 23 in (585 mm)
D: 38 in (966 mm)
545 lb
(247 kg)
47
A FLE10 Cat P 48 MP.qxd:MP
11/3/09
11:20 AM
Page 1
Multiprocess
XMT Series
MillerWelds.com
Heavy Industrial
®
XMT 456
is 3-phase only.
304 CC/CV and 456 CC/CV — See Literature No. DC/18.8
350 CC/CV, 350 MPa and 350 VS — See Literature No. DC/18.83
Processes
The proven “Best!” performer in portable multiprocess inverter applications.
• MIG (GMAW)
• Pulsed MIG (GMAW-P)*
• Stick (SMAW)
• TIG (GTAW)
• Flux Cored (FCAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (Carbons — 304: 1/4 in,
350: 5/16 in, 456: 3/8 in)
*XMT 350 MPa. XMT CC/CV models with
optional control. Not available on VS model.
Most Popular Accessories
for non-VS Models
XMT 456 CC/CV
XMT 350 VS
XMT 350 CC/CV
XMT 304 CC/CV
• XR-AlumaFeed™ Feeder for
aluminum (XMT 350 MPa only)
#300 509 (pg 13)
• SuitCase® RC Feeders (pg 26)
• Spoolmatic® 30A/WC-24 (pg 28)
• XR™-Controls (pg 29)
• 22A and 24A Feeders (pg 30)
• S-74 MPa Feeder for steel (XMT
350 MPa only) #300 411 (pg 49)
• Optima™ MIG Pulse Control
#043 389 (pg 86)
• Current Sensor (XMT 456 only)
#194 807 (Field)
Wind Tunnel Technology ™ protects electrical
components and PC boards from contamination.
Process selector switch reduces the number of control
setup combinations without reducing any features.
Fan-On-Demand™ cooling system operates only when
needed, reducing noise, energy use and amount of
contaminants pulled through machine.
Large, dual digital meters are easy to view and
presettable to ease setting weld output.
• Spoolmatic® 30A/WC-115A
(with contactor) (pg 28)
Most Popular Accessories
for all Models
Adaptive Hot Start™ increases the output amperage at the
start of a weld if necessary, eliminating electrode sticking.
Pulsed MIG with optional Optima™ control reduces
spatter and distortion, allows better out-of-position
puddle control, and provides potential reduction of fume
particle emissions. Optima control can be used with
XMT CC/CV models only. Pulsed MIG is built-in on
XMT 350 MPa and is not available on XMT 350 VS.
Inverter arc control technology provides greater puddle
control for superior 6010 Stick electrode performance.
Lightweight, aerospace-grade aluminum case offers
protection with the benefit of reduced weight.
Line voltage compensation keeps power constant
even if power input varies by ±10%. XMT 350 models
further expand line voltage compensation to an amazing
+37% and -59% when operating on 460 VAC.
115 VAC auxiliary power provides 10 amps of circuitbreaker-protected power for water circulators, etc.
Standard on XMT 456 and optional on XMT 304,
XMT 350 CC/CV and XMT 350 MPa. Not available on
XMT 350 VS.
Lift-Arc™ allows TIG starting without the use of highfrequency. Starts the arc without contaminating the
weld with tungsten.
Input
Power
Amperage/
Voltage Ranges
Rated
Output
Amps Input at Rated Load Output, 60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
Max.OpenCircuit
Voltage
CC Mode: 5–400 A
CV Mode: 10–35 V
300 A at 32 VDC,
60% Duty Cycle
33.7 30.5 17
18.9 15.2 12.2 11.6
90 VDC
225 A at 29 VDC,
60% Duty Cycle
52.4 47.4 —
24.5 —
H: 17 in (432 mm)
79.5 lb
W: 121⁄2 in (318 mm) (36.1 kg)
D: 24 in (610 mm)
350 A at 34 VDC,
60% Duty Cycle
40.4 36.1 20.6 17.8 14.1 14.2 13.6
75 VDC
80 lb
H: 17 in (432 mm)
W: 121⁄2 in (318 mm) (36.3 kg)
D: 24 in (610 mm)
75 VDC
80 lb
H: 17 in (432 mm)
W: 121⁄2 in (318 mm) (36.3 kg)
D: 24 in (610 mm)
95 VDC
118 lb
H: 17 in (432 mm)
W: 141⁄2 in (368 mm) (53.5 kg)
D: 26 in (660 mm)
Model
Stock Number
XMT 304
CC/CV
(w/Dinse)
(#903 471) 208-230/460 V
(#903 471-01-1) 208-230/460 V w/Aux. Pwr.
(#903 473) 460/575 V
(#907 061) 208/230/460 V MIGRunner w/22A*
ThreePhase
XMT 350
CC/CV
(w/Dinse)
(#907 161) 208–575 V
(#907 161-01-1) 208–575 V w/Aux. Pwr.
(#951 099) 208–575 V w/SuitCase X-TREME 12VS*
(#907 233) 208–575 V MIGRunner w/22A*
(#907 423) 208–575 V MIGRunner w/S-74D*
ThreePhase
XMT 350
VS
(w/Tweco®)
(#907 224) 208–575 V
(CC/CV inverter ideal for construction — no remote
control, order mating Tweco connectors separately)
(#951 096) 208–575 V w/SuitCase X-TREME 8VS*
ThreePhase
48
• SuitCase® X-TREME™ VS Feeders
(pg 25)
• XMT® Rack (pg 54)
• Cylinder Cart #042 537 (pg 81)
• Universal Cart and Cylinder Rack
(XMT 304/350 only)
#042 934 (pg 81)
• MIGRunner™ Cart (XMT 304/350
only) #195 445 (pg 81)
• Running Gear Cylinder Rack
(XMT 456 only) #300 408 (pg 82)
• Coolmate™ Coolant System (pg 83)
• Protective Cover (XMT 304/350
only) #195 478 (pg 90)
• Bernard® Q-Gun™
See your Miller distributor for other
popular Miller options and accessories.
*Wire feeders include Bernard ® MIG gun.
**Duty cycle rating below achieved with 6 gauge input power cord (8 gauge cord supplied with unit).
XMT 456
(#907 010) 230/460 V
CC/CV
(#907 010-01-1) 230/460 V w/Remote On/Off
1
(w/Stud ⁄ 2") (#907 011) 575 V
Most Popular Accessories
for VS Model
SinglePhase
CC Mode: 5–425 A
CV Mode: 10–38 V
300 A at 32 VDC, 60.8 54.6 29.7 25.4 19.9 11.7 11.2
60% Duty Cycle**
SinglePhase
CC Mode: 5–425 A
CV Mode: 10–38 V
350 A at 34 VDC,
60% Duty Cycle
40.4 36.1 20.6 17.8 14.1 14.2 13.6
300 A at 32 VDC, 60.8 54.6 29.7 25.4 19.9 11.7 11.2
60% Duty Cycle**
SinglePhase
ThreePhase
11.3 7.6
CC Mode: 5–600 A
CV Mode: 10–38 V
450 A at 38 VDC, —
100% Duty Cycle;
565 A at 43 VDC,
60% Duty Cycle
50.8 31
27.8 24.4 21.2 19.2
Dimensions
Net
Weight
A FLE10 Cat P 49 MP.qxd:MP
Call
11/3/09
11:20 AM
Page 1
Multiprocess
1-800-4-A-MILLER for more information.
®
XMT 304 CC/CV Additional Features
Auto-Link® circuit automatically links the power source to primary voltage
being applied (230/460 or 460/575 VAC, single- or three-phase).
International-style weld disconnects provide high-quality weld cable
connections. (Two connectors supplied with each unit.)
Ultra-tough, polycarbonate-blended cover for control panel protects
front controls from damage.
®
XMT 350 Additional Features
CC/CV, MPa and VS models available. See MPa model below for
built-in Pulsed MIG features. VS model is capable of both CV and CC
operation, but has a simple four-position front panel without remote
control receptacle. Ideal for construction.
Reduced OCV operation — an internal dip switch enables reduced opencircuit voltage Stick welding capability. OCV is typically below 15 volts.
Auto Remote Sense™ enables unit to automatically use remote control if
connected to remote control receptacle (CC/CV and MPa models only).
Allows for any input voltage hook-up
(208 – 575 V) with no manual linking, providing
convenience in any job setting. Ideal solution
for dirty or unreliable input power.
Optional gas solenoid kit (#195 286) for TIG welding. Works with VS and
non-VS models.
®
XMT 456 CC/CV Additional Features
Unique case design helps protect internal components from dirt and dust.
To connect input power cord and/or set unit up for correct input power,
remove the easy-to-handle panel (1/3 case). The remaining two-thirds of
the case never needs to be removed!
Primary voltage display shows what primary voltage the power source is
set for without removing the side panels. Saves time and assures you that
the power source has been correctly set for available input voltage.
Optional 230/460 V model with remote on/off (#907 010-01-1) provides
ability to turn power source on or off when it is located away from your work.
®
XMT 350 MPa Additional Features
XMT 350 MPa takes the features of the XMT 350 CC/CV multiprocess
inverter and adds built-in Pulsed MIG capabilities.
• Easy-to-use Pulsed MIG, including programs for exotic alloys
• Eliminates need for separate pulse control pendant or other pulse controls
• Pulsed MIG works with voltage sensing, remote control and benchtop
wire feeders
Superior Pulsed MIG welding capabilities with simpleto-use multiprocess controls. Reliable inverter design
combines with the SuitCase® X-TREME™ feeders to provide
the industry’s “Best!” portable solution.
MPa — MIG; Pulsed; advanced Arc Control. Easy-to-use advanced arc
control enables an improved Pulsed MIG welding arc.
Built-in Pulsed MIG programs contain optimal parameters for steel,
metal core, stainless, aluminum, nickel, silicon bronze and copper nickel
wire. Just dial in wire and gas type. As easy to use as traditional MIG, the
MPa’s intuitive programming virtually eliminates the Pulsed MIG learning
curve for experienced MIG operators.
SharpArc® controls the arc in Pulsed MIG mode and gives total control
over the arc cone shape, puddle fluidity and bead profile.
*Wire feeders include Bernard ® MIG gun.
**Duty cycle rating below achieved with 6 gauge input power cord (8 gauge cord supplied with unit).
Model
Stock Number*
XMT 350
MPa
(w/Dinse)
(#907 366) 208–575 V
(#907 366-01-1) 208–575 V w/Aux. Pwr.
(#907 366-01-4) 208–575 V w/Tweco
(#951 079) 208–575 V w/SuitCase 8RC*
(#951 081) 208–575 V w/SuitCase X-TREME 8VS*
(#951 078) 208–575 V w/SuitCase 12RC*
(#951 080) 208–575 V w/SuitCase X-TREME 12VS*
(#951 294) 208–575 V w/XR-AlumaFeed and
air-cooled XR-Aluma-Pro Gun
Synergic Pulsed MIG — The XR-AlumaFeed™
feeder for aluminum welding or the S-74 MPa
for steel give you the benefit of a Synergic
Pulsed MIG system. As you increase/decrease
the wire feed speed, the pulse parameters
increase/decrease, matching the right amount
of power output to match the wire speed.
Additional systems available, please visit MillerWelds.com
Input
Power
Amperage/Voltage
Range
Rated
Output
Amps Input at Rated Load Output, 60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
Max.OpenCircuit
Voltage
ThreePhase
CC Mode: 5 – 425 A
CV Mode: 10 – 38 V
350 A at 34 VDC,
60% Duty Cycle
40.4 36.1 20.6 17.8 14.1 14.2 13.6
75 VDC
300 A at 32 VDC,
60% Duty Cycle**
60.8 54.6 29.7 25.4 19.9 11.7 11.2
SinglePhase
Dimensions
H: 17 in
(432 mm)
W: 121 ⁄2 in
(318 mm)
D: 24 in
(610 mm)
Net
Weight
80 lb
(36.3 kg)
49
A FLE10 Cat P 50 MP.qxd:MP
11/5/09
10:05 AM
Page 1
Multiprocess
MillerWelds.com
Dimension NT 450
Heavy Industrial
Processes
™
See Literature No. DC/19.5
A new generation of hybrid welding technology that improves arc starting and welding
performance. Combining this power source with 70 Series wire feeders offers a “Better!”
solution for industrial market applications.
• MIG (GMAW)
• Stick (SMAW)
• TIG (GTAW)
• Flux Cored (FCAW)
• Air Carbon Arc
Cutting and Gouging (CAC-A)
DC multiprocess flexibility with outstanding arc performance in all
welding processes.
Digital meters allow presetting of voltage or amperage prior to welding
in all modes for more precise welding control.
Electronic arc control with digital display gives operator added flexibility
on a variety of Stick electrodes.
Electronic inductance control with digital display reduces spatter and
gives operator added control on a larger variety of welding wires.
Line voltage compensation keeps welding parameters constant even
when input voltages change ±10%.
Fan-On-Demand™ cooling system operates only when needed. Reduces
contaminants drawn into the machine and reduces excess noise.
Dimension NT 450 (#907 256)
Purchase components separately.
See list at right for most popular
accessories.
Power efficient for exceptional return on your investment.
Help codes to help troubleshoot and service power source. Codes are
displayed on the volt/amp meters and help reduce service time.
Most Popular Accessories
• SuitCase® X-TREME™ Wire Feeders
(pg 25)
• 70 Series Wire Feeders (pg 31)
• Standard Running Gear #042 886
(pg 82)
• Standard Cylinder Rack #042 887
(pg 82)
MIG Power Source Solutions
OR
Build your own system by
choosing machine, feeder, gun,
drive rolls, cables, etc. at
MillerWelds.com/equiptoweld
• Industrial MIG 4/0 Kit #300 390
(pg 86)
Includes Smith® regulator/flowmeter
with 10 ft (3 m) gas hose, 10 ft
(3 m) 4/0 feeder weld cable with
lugs, and 15 ft (4.6 m) work cable
with 600-amp C-clamp.
• Remote Controls (pg 89/90)
• Extension Cords (pg 91)
• Air Filter Kit #042 939
• Bernard® and Tregaskiss™ MIG Guns
When purchasing components separately
please see your Miller distributor or visit
MillerWelds.com/equiptoweld for other
popular Miller options and accessories.
Dimension NT 450 Stationary Package
(#951 275) Stationary display without
running gear/cylinder rack.
Comes Complete With:
• Dimension NT 450 power source
• S-74D wire feeder with drive rolls
• Bernard® Q-Gun™
• Industrial MIG 4/0 Kit
(see listing at right for kit contents)
Dimension NT 450 MIGRunner ™ Package
(#951 279) MIGRunner system with
factory-installed running gear/cylinder rack.
Comes Complete With:
• Dimension NT 450 power source
• S-74D wire feeder with drive rolls
• Bernard® Q-Gun™
• Industrial MIG 4/0 Kit
(see listing at right for kit contents)
• Factory-installed running gear/cylinder rack
*While idling. **Dimensions and weight are for power source only — includes lift eye and strain relief.
Stock Number
(#907 256) 230/460/575 V, Machine only
(#951 275) 230/460/575 V, Stationary Pkg
(#951 279) 230/460/575 V, MIGRunner Pkg
50
Amperage
Range
Voltage
Range
Rated Output
Amps Input at Rated Output, 60 Hz
230 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
5 – 500 A
in CC mode
10 – 38 V
in CV mode
450 A at 38 VDC,
100% Duty Cycle
57
29
23
22.6 21.0
2.18* 1.04* 0.84* 0.87* 0.29*
80 VDC
Dimensions**
H: 321 ⁄2 in (826 mm)
W: 23 in (585 mm)
D: 38 in (966 mm)
Net
Weight
376 lb
(171 kg)
A FLE10 Cat P 51 MP.qxd:Multiprocess
11/3/09
11:22 AM
Page 1
Pipe Fabrication
Call
Multiprocess
1-800-4-A-MILLER for more information.
PipeWorx Welding System
™
Optimized for pipe fabrication shops.
Feeder
includes
drive rolls!
See Literature
No. PWS/2.0
Simple Process Setup
• The front panel was designed by welders for welders.
• Requires just a few basic steps to set up a new weld
process, resulting in less training time and minimizing
errors from incorrect setups.
• Memory feature stores 4 programs for each selection:
Stick, DC TIG, and MIG (left and right side of feeder).
Eliminates the need to remember parameters.
Multiprocess Machine
• Weld processes are optimized to deliver superior arc
performance and stability specifically for root pass,
fill and cap pipe welding.
• RMD™ and Pro-Pulse™.
Quick Process Changeover
PipeWorx Welding System (filler metal sold separately).
230/460 V system (#951 131) shown.
575 V system (#951 132) also available.
Now Available! Free CD showcasing the features and
benefits of the PipeWorx Welding System and new pipe
welding techniques. Visit the PipeWorx Welding System
page at MillerWelds.com/pipeworx to order your CD today.
RMD™ (Regulated Metal
Deposition) — Precisely
controlled short-circuit metal
transfer process provides a
calm, stable arc and weld
puddle for less chance of
RMD™ Carbon Steel
cold lap or lack of fusion,
less spatter and a higher quality root pass on pipe.
The stability of the weld process lessens the need for
puddle manipulation and is more tolerant to hi-lo
conditions, reducing training requirements. Weld bead
profiles are thicker than conventional root passes
which can eliminate the need for a hot pass. In some
stainless steel applications, it may be possible to
eliminate the backing (purge) gas to further improve
productivity and reduce welding costs.
• No need to manually switch polarity or cables and
hoses between processes. Simply push a process
selection button to choose a welding process.
PipeWorx “Quick-Select” technology automatically
selects the welding process, the correct polarity, cable
outputs and user programmed welding parameters.
• Quick process changeover eliminates set-up time for
switching cables and gas hoses. Also, reduces the risk
of weld reworks due to incorrect cable connection.
Streamlined System
• Wind Tunnel Technology™ and Fan-On-Demand™ provide
system protection in the dusty shop environment.
• All system components have been selected to meet the
needs of a pipe fabrication shop.
Pro-Pulse™ — Pulse welding
method that provides a
shorter arc length, narrower arc
cone and less heat input than
traditional spray pulse transfer.
Process is synergic, virtually
eliminating arc wander and
variations in tip-to-work
distances, providing easier
Pro-Pulse Stainless
puddle control and reducing
training time. Also improves fusion and fill at the toe of
the weld, for higher travel speeds and deposition. This
process coupled with RMD for root passes permits
procedures using the same wire and gas, eliminating
process switch-over time.
Heavy Industrial
Processes
• Stick (SMAW)
• DC TIG (GTAW) (HF and Lift-Arc™)
• MIG (GMAW)
• MIG RMD™ (GMAW MSC)
• Pro-Pulse™ (GMAW-P)
• Flux Cored (FCAW)
PipeWorx Welding System
Comes Complete With
• Power source with cable hangers
• Running gear and handles
• Dual feeder with drive rolls
• Cable kit with 25 ft (7.6 m) work
sense lead
• 15 ft (4.6 m) PipeWorx 300 guns
Most Popular Accessories
• Cable Kit #300 367
For feeder used on power source.
Includes feeder cable, weld cable
and 25 ft (7.6 m) work sense lead.
• Composite Cable Kit
25 ft (7.6 m) #300 454
50 ft (15.2 m) #300 456
For remote feeder applications.
Includes composite cable which
encases feeder cable, gas hose and
weld cable in protective sheath, and
either 25 or 50 ft work sense lead.
• PipeWorx Running Gear #300 368
Includes gas cylinder rack and
handles.
• Feeder Cart #300 467
For remote feeder applications.
Includes consumables drawer.
• PipeWorx Cooler #300 370
• PipeWorx Remote Feeder Interface
w/gun triggers and cable #300 597
• Spool Cover #057 607
For single or left side of dual feeder.
• Spool Cover #090 389
For right side of dual feeder.
• DSS-9 Dual Schedule Switch
#071 833
• RFCS-14 HD #194 744
• RPBS-14 On-Off Switch Remote
#300 666
• Bernard® PipeWorx™ Guns
15 ft (4.6 m) 250-15 #195 399
15 ft (4.6 m) 300-15 #195 400
15 ft (4.6 m) 400-15 #300 240
When purchasing components separately
please see your Miller distributor or visit
MillerWelds.com for other popular Miller
options and accessories.
*Dimensions and weight are for power source only.
Model/Stock Number
PipeWorx Welding System
(#951 131) 230/460 V
(#951 132) 575 V
PipeWorx Power Source only
(#907 382) 230/460 V
(#907 384) 575 V
Model/Stock Number
PipeWorx Feeder only
(#300 365) Single-wire model
(#300 366) Dual-wire model
Welding
Mode/Process
Amperage/
Voltage Range
Rated Output at
100% Duty Cycle
Amps Input at Rated
Output, 60 Hz, 3-Phase
230 V 460 V 575 V
CC: Stick
40 – 350 A
350 A at 34 VDC
36.8
22.5
CC/DC: TIG
10 – 350 A
350 A at 34 VDC
CV: MIG/Flux Cored
10 – 44 V
400 A at 44 VDC
53.6
31.1
Input
Power
Wire Speed
Wire Diameter Capacity
24 VAC,
11 A
50 –780 IPM
(1.3 –19.8 m/min)
.035 –.062 in (0.9 – 1.6 mm)
KVA
KW
18.9
230 V 14.8
460 V 18.0
575 V 19.0
230 V 13.7
460 V 13.7
575 V 13.8
26
230 V 21.5
460 V 24.7
575 V 25.9
230 V 20.0
460 V 19.9
575 V 19.7
Input Welding
Circuit Rating
Maximum Spool
Size Capacity
100 V, 750 A at
100% Duty Cycle
60 lb (27 kg)
Max. OpenCircuit
Voltage
90 VDC
Dimensions*
H: 28 in
(711 mm)
W: 19 1 ⁄2 in
(495 mm)
D: 31 3⁄4 in
(806 mm)
Net
Weight*
225 lb
(102 kg)
Dimensions
Net Weight
H: 14 in (356 mm)
W: 19 in (483 mm)
D: 29 in (737 mm)
Single: 65 lb (29.5 kg)
Dual: 90 lb (41 kg)
51
A FLE10 Cat P 52 MO Intro.qxd:MO Intro
11/3/09
11:40 AM
Page 1
Multioperator
“
Keeping it simple and easy is the key to
increasing overall operator efficiency
and reducing weld cost.
”
Matt Purcell, Weld Lead
Dakota Creek Industries
Mark VIII®-2
53
CST™ 280 Racks
53
XMT® 304 Rack
54
XMT® 350 VS Rack
XMT® 350
CC/CV Rack
3⁄ 16"
Lift eye
Steel, stainless
20 – 315 A
Up to 6 operators
Construction, fabrication, pipe, shipbuilding
3⁄ 16"
Lift eye
Steel, stainless
35 – 300 A
Up to 8 operators
Construction, fabrication, pipe, shipbuilding
5⁄ 16"†
Lift eye, optional
running gear
Steel, stainless
5 – 280 A
Up to 4 or 8 operators,
lightweight
Construction, maintenance/repair,
shipbuilding
** **
1⁄ 4"
Lift eye, optional
running gear
Steel, stainless
10 – 35 V
5 – 400 A
Up to 6 operators
Construction, fabrication, pipe,
maintenance/repair
54
5⁄ 16"
Lift eye, optional
running gear
Steel, stainless
10 – 38 V
5 – 425 A
Up to 6 operators
Construction, fabrication, pipe,
maintenance/repair
54
** **
5⁄ 16"
Lift eye, optional
running gear
Steel, stainless
10 – 38 V
5 – 425 A
Up to 6 operators
Construction, fabrication, pipe,
maintenance/repair
XMT® 350 MPa Rack 54
**
5⁄ 16"
Lift eye, optional
running gear
Steel, stainless
10 – 38 V
5 – 425 A
Up to 6 operators
Construction, fabrication, pipe,
maintenance/repair
3⁄ 8"
Lift eye,
optional trailer
Steel, stainless
15 – 600 A
Multioperator
engine drive
Construction, rental
PRODUCT KEY
*
DC TIG
Weldable Metals
MIG-P
Portability
Welding
Output
Range
66
Miller Du-Op™
(Engine Drive section)
52
CAC-A (1-Unit)
53
DC TIG-P
Mark VI™
Flux Cored
Product
Guide
Page
Class
Stick
MIG
3-Phase
MillerWelds.com/Multioperator
Special
Features
Typical Applications
CLASS:
Light Industrial
Industrial
Heavy Industrial
CAPABILITY:
Designed for this process
Capable of this process
*CC/CV models only. **With optional controls. †Two machines paralleled. For more detailed information, see individual specification sheets.
A FLE10 Cat P 53 MO.qxd:MO
Call
11/3/09
11:41 AM
Page 1
Multioperator
1-800-4-A-MILLER for more information.
Mark VI and Mark VIII -2
™
Heavy Industrial
®
See Literature
No. DC/9.8 and DC/10.0
Durable, heavy-duty multiple-operator welding systems drive four, six or eight modules
from a single main transformer.
Mark VI Features
Multiple capabilities CC or CC/CV. Versatility and outstanding arc welding in both
CV (MIG) and CC (TIG and Stick). CC/CV module has a high quality arc for welding
with cored wires. CC module has same great arc characteristic as the Gold Star® 302.
Four to six welding modules that can be paralleled for higher output.
Mark VIII-2
is CC only.
Processes
• Stick (SMAW)
• TIG (GTAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (3/16 in carbons)
• Flux Cored (FCAW) and
MIG Spray Transfer (GMAW)
with voltage-sensing feeder
• MIG (GMAW) with Mark VI
CC/CV units
Most Popular Accessories
Line voltage compensation keeps output constant, even if primary input power
varies by ±10%.
Optional Low OCV modules reduce maximum open-circuit voltage to 26 volts in
CC and CV modes when not welding.
Mark VIII-2 Features
Mark VI
Eight modules that can be paralleled for higher output.
MagAmp Technology provides excellent arc and puddle control.
Multiple CC capabilities. Stick, TIG, Air Carbon Arc cutting and
gouging, and Flux Cored welding with a voltage-sensing feeder.
Mark VIII-2
15 amp 115 VAC duplex receptacle allows operators the flexibility
to run grinders, drills, coolers, etc. from the power source.
Model
Stock Number
DC Welding Range,
Single Module
Mark VI-2
(4 CC Modules)
(#903 588) 230/460/575 V, 60 Hz
CC: 20 – 315 A
Mark VI CC
(6 CC Modules)
(#903 512) 230/460/575 V, 60 Hz
Mark VI CC/CV
(6 CC/CV Modules)
(#903 645) 230/460/575 V, 60 Hz
(#903 645-01-1) Low OCV Module
CC: 20 – 315 A
CV: 10 – 30 V
Mark VIII-2
(#901 348) 230/460/575 V
CC: 35 – 300
See your Miller distributor for other
popular Miller options and accessories.
Max. Open-Circuit
Voltage (DC)
Rated Welding Output
Amps Input
Single Module
250 A at 44 VDC, 60% Duty Cycle
At 750 Amps Output, 50/60 Hz
230 V 164
460 V 82.5
575 V 66.1
KVA
65.2
KW
41.9
CC: 75 VDC
At 800 Amps Output, 60 Hz
230 V 170
460 V 85
575 V 68
KVA
68
KW
48.6
CC: 80
Main Transformer
1500 A at 44 VDC, 25% Duty Cycle
750 A at 44 VDC, 100% Duty Cycle
Single Module
200 A at 40 VDC, 60% Duty Cycle
Main Transformer
1600 A at 40 VDC, 25% Duty Cycle
800 A at 40 VDC, 100% Duty Cycle
CST 280 Racks
• SuitCase® X-TREME™ VS
Wire Feeders (pg 25)
• Remote Controls (pg 90)
CC: 75 VDC, CV: 38 VDC
Low OCV modules: 26 VDC
™
See Literature No. DC/18.82
Rugged enclosure provides simple means for protecting and transporting multiple welding
power sources for construction, maintenance/repair and shipbuilding applications.
Light weight and small footprint for easy transportation.
The low weight enables the use of elevators to move the rack.
Top cover protects machines from falling debris.
Dimensions
Net
Weight
H: 65 in
(1.7 m)
W: 56 3⁄4 in
(1.4 m)
D: 341⁄4 in
(0.9 m)
Mark VI-2
1575 lb
(718 kg)
H: 70 1 ⁄4 in
(1.8 m)
W: 72 in
(1.8 m)
D: 40 in
(1 m)
4050 lb
(1837 kg)
Mark VI
1825 lb
(828 kg)
Heavy Industrial
Processes
• Stick (SMAW)
• TIG (GTAW)
• Air Carbon Arc
Cutting and Gouging (CAC-A)
(Paralleled CST 280s: 5/16 in
carbons)
Most Popular Accessories
• Dual Rack Kit #195 267
Lift eye simplifies crane or overhead lifting device transport.
CST 280
8-Pack
Rack
shown.
Lift truck fork pockets.
One main disconnect box with branched fusing for each machine.
Common output ground connection (for same polarity use only).
Optional dual rack kit connects two 4-pack CST racks to form an
8-pack rack, utilizing one input power cable and one lift.
Optional rack running gear available for moving the rack.
• 4-Pack Rack Running Gear
#195 114
• 8-Pack Rack Running Gear
#195 436
Model/Stock Number
Rack Capacity
Input Power to Rack
Welding Power Source
Dimensions
Net Weight
4-Pack Rack (#907 247) Tweco®-style
(#907 245) Dinse-style
4 units, 8 units with
optional dual rack kit
220-230/460-575 V,
60 Hz, Three-Phase
8 units
H: 50 3⁄4 in (1289 mm)
4-Pack W: 25 1⁄2 in (648 mm)
8-Pack W: 46 in (1168 mm)
D: 26 1⁄2 in (673 mm)
355 lb (161 kg)
8-Pack Rack (#907 365) Tweco®-style
CST 280s linked for 460-575 V with Tweco- or Dinse-style connectors.
The Dinse-style includes one set of male connectors; the Tweco-style
does not. See pg 36 for information on CST 280.
Empty Rack (#195 051)
4 units
Can contain any CST models.
Same as 4-Pack Rack
166 lb (75 kg)
—
640 lb (290 kg)
53
A FLE10 Cat P 54 MO.qxd:MO
11/3/09
11:41 AM
Page 1
Multioperator
MillerWelds.com
XMT 304 and 350 Racks
®
See Literature No. DC/18.81,
DC/18.8 and DC/18.83
XMT Rack conveniently houses multiple inverter power sources for multiple welders.
This is an ideal system for onsite applications including construction and shipbuilding.
Custom build your own system by mix and matching
Miller’s XMT® 304 CC/CV, 350 CC/CV, 350 MPa, 350 VS
and 456 CC/CV; and Invision™ 352 MPa, 456MP and
456P. (XMT® 456 CC/CV, Invision™ 456MP and 456P —
maximum of 4 units.)
Both 4-rack and 6-rack models are available with
two lift eyes for transportation and rugged skids for
dragging or pushing.
Lift truck side and end pockets in base enable loading
and work site repositioning with forklift.
Rack roof panel and power source shelves are
fabricated from galvanized steel and painted for added
protection in harsh environments.
Liquid-tight strain reliefs provided on both welding
power source and electrical junction box. Strain relief is
designed to resist salt water, alcohol, oil, grease and
common solvents.
Isolated work terminal provides a connection point for
common workpiece construction.
XMT 350 Rack shown.
Meets IP23 which is more stringent than IP23S or
IP23M ratings.
One easy connection allows up to six inverters to be
connected with one primary power drop.
Heavy Industrial
Processes
• MIG (GMAW)
• Pulsed MIG* (GMAW-P)
• Stick (SMAW)
• TIG and Lift-Arc TIG (GTAW)
• Pulsed TIG* (GTAW-P)
• Flux Cored (FCAW)
• Air Carbon Arc
Cutting and Gouging (CAC-A)
(XMT 304: 1/4 in carbons)
(XMT 350: 5/16 in carbons)
(XMT 456: 3/8 in carbons)
*With optional controls only — not
available with XMT 350 VS model.
Note: TIG processes not available with
Invision models.
Most Popular Accessories
• SuitCase® X-TREME™ VS Feeders
(pg 25)
• SuitCase® RC Feeders (pg 26)
• Remote Controls (pg 90)
• Rack Running Gear #195 114
• Fuse Kits
XMT 304/350 (20 A, 460 – 575 V)
4-Pk #220 766/6-Pk #220 765
XMT 304/350 (45 A, 208 – 230 V)
4-Pk #220 764/6-Pk #220 763
XMT 456 (30 A, 460 – 575 V)
4-Pk #220 767
All racks with factory-equipped power sources include
20 A fuses to provide primary power line protection for
each inverter power supply on 460 VAC. (575 VAC
operation, if applicable, also utilizes 20 A fuses.
Model/Stock Number
Welding Power Source
Input Power to Rack
Dimensions
Net Weight
XMT 304 Rack (#907 292)
XMT 304 CC/CV (4 Units with Dinse)
230/460 VAC, 60 Hz, Three-Phase (20 A fuses included)
XMT 304 Rack (#907 293)
XMT 304 CC/CV (4 Units with Dinse)
460/575 VAC, 60 Hz, Three-Phase (20 A fuses included)
560 lb (254 kg)
(4 Units)
XMT 304 Rack (#907 291)
XMT 304 CC/CV (6 Units with Dinse)
230/460 VAC, 60 Hz, Three-Phase (20 A fuses included)
XMT 304 Rack (#907 294)
XMT 304 CC/CV (6 Units with Dinse)
460/575 VAC, 60 Hz, Three-Phase (20 A fuses included)
XMT 350 Rack (#907 227)
XMT 350 VS (4 Units with Tweco)
XMT 350 Rack (#907 228)
XMT 350 VS (6 Units with Tweco)
208 – 575 VAC, 50/60 Hz,
Three-Phase (20 A fuses included)
H: 59 3⁄8 in
(1508 mm)
W: 43 in
(1092 mm)
D: 34 3⁄8 in
(873 mm)
XMT 350 Rack (#907 231)
XMT 350 CC/CV (4 Units with Dinse)
XMT 350 Rack (#907 232)
XMT 350 CC/CV (6 Units with Dinse)
XMT 350 Rack (#907 407)
XMT 350 CC/CV (4 Units with Tweco)
XMT 350 Rack (#907 406)
XMT 350 CC/CV (6 Units with Tweco)
XMT 350 Rack (#907 410)
XMT 350 MPa (4 Units with Tweco)
XMT 350 Rack (#907 411)
XMT 350 MPa (6 Units with Tweco)
Empty Rack (#195 466)
XMT 304 or 350, Invision 350 MPa (6 Units); XMT 456 CC/CV, Invision 456 (4 Units)
54
712 lb (323 kg)
(6 Units)
599 lb (272 kg)
(4 Units)
759 lb (344 kg)
(6 Units)
(Order required fuse kit separately)
279 lb (127 kg)
A FLE10 Cat P 55 Engine Intro.qxd:Engine Intro
11/3/09
11:42 AM
Page 1
Engine-Driven
“
Miller is the first company we’ve run
across that has a welding generator that
we feel comfortable recommending.
Mike Deason, CEO
M.T. Deason Company
”
Product
Guide
Blue Star ® 145
and 145 DX
Page
Class
Stick
MIG
Flux Cored*
AC TIG
DC TIG
PAC**
CAC-A
MillerWelds.com/EngineDriven
56
Portability
Weldable Metals
Optional lift eye, Steel
running gear
59 Blue Star ® 185 DX 56
Wildcat® 200
Bobcat ™ 225
56
57
Bobcat ™ 250
60
Steel
Welding
Amperage Engine
Range
Brand
Special Features
Typical Applications
4500
40–145 DC Kohler
Compact, portable
Maintenance, service trucks
6000
55–185 DC Kohler
Compact, portable
Maintenance, service trucks
6500
50–200 DC Subaru
Compact, lightweight
Maintenance, repair,
farm/ranch
50–225 AC Kohler,
50–210 DC Subaru
Cost-effective AC/DC Stick
Maintenance, farm/ranch,
construction
50–225 AC Kohler
50–210 DC
Backup power for pivot
irrigation
Farm/ranch
Steel, alum, stainless 11,000
3⁄ 16"
1-Ph /10,500
3-Ph /11,000
3⁄ 16"
11,000
40–250 CC Kohler,
12,000 with EFI 90–275 CV Subaru
Industry’s most popular
engine drive, optional EFI
Fab, maintenance,
farm/ranch, construction
3⁄ 16"
11,000
10–275 DC Kohler,
12,000 with EFI
Subaru
Industry’s best performing
engine drive, optional EFI
Fab, structural, maintenance,
repair, piping
Trailblazer®
275 DC
61 Trailblazer® 302
61
3⁄ 16"
11,000
30–225 AC Kohler,
12,000 with EFI 10–325 DC Subaru
Industry’s best performing
engine drive, optional EFI
Fab, structural, maintenance,
repair, piping
Trailblazer® 302
Air Pak™
62
3⁄ 16"
13,000
30–225 AC Kohler
10–350 DC
AC/DC, CC/CV, 26 CFM air,
battery charge/jump start
Service/maintenance,
construction
Steel, alum, stainless 11,000
40–250 CC Kubota
90–275 CV
Contractor’s choice,
AC/DC Stick, strong FCAW
Fab, maintenance, farm,
construction
Steel, alum, stainless 11,000
30–225 AC Kubota
10–325 DC
Pro’s choice,
premium arc quality
Fab, structural, maintenance,
repair, piping
Trailblazer® 302
Diesel
61 PipePro™ 304
66
Bobcat ™ 250
Diesel
Big
Blue®
300 Pro
60
3⁄ 16"
1⁄ 4"
1⁄ 4"
⁄
⁄
65 ⁄
66 ⁄
67 ⁄
67 ⁄
Big 40®
65
5 16"
Big Blue® 400
65
5 16"
Big Blue® 500
Miller Du-Op®
Big Blue® Turbo
Big Blue® Air Pak™
Why buy
a GAS
or DIESEL
engine?
PRODUCT KEY
3 8"
Lift eye,
optional
running gear,
trailer
Lift eye,
pickup mount,
optional trailer
Lift eye,
generally
mounted on
optional trailer
Steel, stainless
12,000
5–400 DC
XMT 304 arc characteristic
Pipe, structural
Steel, stainless
12,000
20–410 DC Caterpillar,
Deutz
Kubota
Low-speed engine,
compact, rugged, quiet
Pipe, structural, construction
AC/DC on Deluxe model
Steel, alum, stainless 5500
20–500 DC Caterpillar
Steel, stainless
5500
20–500 DC Deutz, Perkins Engine & process choice
Offshore, construction, rental
Construction, rental
Offshore, construction, rental
Steel, stainless
5500
20–650 DC Deutz, Perkins Engine & process choice
1 2"
Steel, stainless
5500
15–600 DC Deutz
Multioperator engine drive
Construction, rental
1 2"
Steel, stainless
5500
20–750 DC Deutz
Turbo for high altitude
Construction, mining
1 2"
Steel, alum, stainless 5500
20–750 DC Deutz
AC on Deluxe model
Repair, mining, railroad
Gas Advantages
EFI Advantages (vs. Carburetor Models)
Diesel Advantages
Lower product cost (by 50 –70%)
Smaller size and less weight
Less expensive engine repairs
Better warranties
Easier cold weather starting
12 – 27% better fuel economy
Reduced emissions (approx. 1/3 lower)
Easy starting in all climates (no choke)
Elimination of carburetor icing
Better high altitude performance
Uses 20 – 40% less fuel than carburetor gas
1-1/2 to 2-1/2 times the engine life
Required on some job sites for safety
Typically have longer maintenance intervals
Convenient if other equipment is diesel
Diesel
64 3⁄ 16"
Gas
Bobcat ™ 3 Phase
Lift eye,
pickup mount,
optional
running gear,
Std.
Generator
Pwr. (Watts)
CLASS:
Light Industrial
Industrial
Heavy Industrial
CAPABILITY:
Designed for this process
Capable of this process
New! or Improved! products appear in blue type. *If using self-shielded wire, use CV weld output. **With appropriate Spectrum, see engine-driven product descriptions.
For more detailed information, see individual specification sheets.
55
A FLE10 Cat P 56 Engine.qxd:Engine
11/3/09
11:42 AM
Page 1
Engine-Driven
MillerWelds.com
Blue Star Series
®
Light Industrial
Processes
145, 145 DX, 185 DX
See Literature No. ED/2.5
• Stick (SMAW) • TIG (GTAW)
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.
DX models include electric start, 5-gallon fuel
capacity, auto-idle and engine hour meter.
Receptacle covers improve reliability by
protecting receptacles from debris.
Accu-Rated™ peak generator power is
usable for maximum generator loads such as
plasma cutting, Millermatic® MIG welders and
motor starting.
Blue Star 185 DX
Blue Star 145
Gasoline Engines
Kohler CS10: Blue Star 145/145 DX
Kohler CS12.75: Blue Star 185 DX
1-cylinder, 4-cycle, overhead valve,
air-cooled
Note: Engines are warranted separately
by engine manufacturer.
Most Popular Accessories
• Millermatic® 140 Auto-Set™
#907 335 (pg 8)
• Millermatic® 180 Auto-Set™
#907 312 (pg 8)
• Lifting Eye #195 353 (pg 84)
• No. 38 Running Gear #195 352
(pg 84)
• Protective Cover #195 193 (pg 84)
• No. 2 Stick Cable Set (pg 89)
See your Miller distributor for other
popular Miller options and accessories.
Gasoline
*More models available — see our Web site or Literature No. ED/2.5.
Model
Stock Number*
Blue Star 145
(#907 266) Kohler Recoil Start, 10 HP at 3600 RPM
Blue Star 145 DX
(#907 267) Kohler Electric Start, 10 HP at 3600 RPM
Blue Star 185 DX
(#907 269) Kohler Electric Start, 12.75 HP at 3600 RPM
Wildcat 200
Welding
Mode/Process
Amperage
Range
CC/DC
(Stick/TIG)
40 –145
CC/DC
(Stick/TIG)
55 –185
Rated Output at 104˚F (40˚C)
Single-Phase Generator
Power at 104˚F (40˚C)
145 A at 25 V, 20% Duty Cycle
100 A at 25 V, 60% Duty Cycle
Peak: 4500 watts
Continuous: 4000 watts
185 A at 25 V, 20% Duty Cycle
130 A at 25 V, 60% Duty Cycle
Peak: 6000 watts
Continuous: 5500 watts
Dimensions
Net Weight
H: 223⁄4 in
(578 mm)
W: 22 3⁄4 in
(578 mm)
D: 31 5⁄8 in
(803 mm)
263 lb (119 kg)
Light Industrial
®
See Literature No. ED/3.0
309 lb (140 kg)
315 lb (143 kg)
Industrial
Processes
Compact, lightweight, durable and cost effective machine is designed for the contractor
and is great for maintenance/repair, farm and ranch applications.
Fully enclosed durable case provides a fully protected engine to
ensure long-term engine reliability.
Accu-Rated™ 6500 watts of usable peak power cranks out
enough power for many construction, maintenance/repair, and
farm/ranch applications. 5500 watts of continuous power.
12 hours of run time is provided by a 7-gallon fuel tank when
using a typical 1/8 in Stick electrode.
Tested and rated at 104˚F (40˚C) to ensure consistent operation
of the welder and generator in all climates.
Heavy duty construction ensures protection from rough handling
or the elements to keep you making money, rather than spending it.
Compact design takes up less truck space, is 20 inches wide to
fit on service truck tool boxes and is only 24 inches tall allowing
visibility out of the rear window when truck mounted.
• Stick (SMAW) • TIG (GTAW)
Gasoline Engine
Subaru EX40
1-cylinder, 4-cycle, overhead cam,
industrial, air-cooled
Note: Engine is warranted separately
by engine manufacturer.
Most Popular Accessories
• Millermatic® 140 Auto-Set™
#907 335 (pg 8)
• Millermatic® 180 Auto-Set™
#907 312 (pg 8)
• Spectrum® 375 X-TREME™
Plasma Cutter #907 339 (pg 72)
• Adapter Cord, Full KVA #300 517
(pg 84)
• Wildcat 200 Running Gear
#300 532 (pg 84)
• Protective Cover #300 496 (pg 84)
See your Miller distributor for other
popular Miller options and accessories.
Standard maintenance displays and front panel mounted
engine controls make the Wildcat easy to service and operate.
Gasoline
Note: See gas engine drive comparison chart on page 58.
*More models available — see our Web site or Literature No. ED/3.0.
56
Stock Number*
(#907 403) Subaru
14 HP at 3600 RPM
Welding Mode/Process
Amperage Range
Rated Output at 104˚F (40˚C)
Single-Phase Generator Power
at 104˚F (40˚C)
CC/DC
(Stick/TIG)
50 –200
150 A at 25 V, 100% Duty Cycle
200 A at 25 V, 20% Duty Cycle
Peak: 6500 watts
Continuous: 5500 watts
Dimensions
Net Weight
H: 24 3⁄4 in (629 mm)
W: 20 in (508 mm)
D: 35 1⁄2 in (902 mm)
345 lb (159 kg)
A FLE10 Cat P 57 Engine.qxd:Engine
Call
11/3/09
11:43 AM
Page 1
Engine-Driven
1-800-4-A-MILLER for more information.
Bobcat 3 Phase
Industrial
Processes
™
See Literature No. ED/4.33
• Stick (SMAW)
• MIG (GMAW)1
1
• Flux Cored (FCAW)
2
• AC /DC TIG (GTAW)
Designed for farm and ranch owners in need of single- and three-phase power to run 480 V
three-phase pivot irrigation systems or to provide backup power for home, farm and ranch.
With voltage-sensing feeder only.
With Dynasty ® 200 Series or
HF-251 (non-critical).
1
Accu-Rated™ 11,000 watts of
3-phase (480 V) for irrigation
pivot systems or Accu-Rated
10,500 watts of 1-phase
(120/240 V) for your house,
barn, or on the job tools.
2
Engines
Gasoline: Kohler CH 23
LP: Kohler CH 730
Twin-cylinder, 4-cycle, OHV,
industrial, air-cooled
Maintenance displays, fully
enclosed case, fuel gauge
and LP option.
Note: Engines are warranted separately
by engine manufacturer.
See distributor for Miller accessories.
Welding and power ratings
are at 104˚F (40˚C) —
highest in its class to ensure
reliable performance.
Bobcat 3 Phase is a 11,000
watt generator with Bobcat
225 weld output.
Gasoline/LP
*LP Tank Mounting Assembly (pg 84) sold separately.
Tank not included.
Stock Number
Welding Mode
Process
Amp/Volt Ranges
Rated Output at 104˚F (40˚C)
Generator Power at 104˚F (40˚C)
Dimensions
Net Weight
(#907 255) Kohler
23 HP at 3600 RPM
(#907 255-01-1)* Kohler LP
25 HP at 3600 RPM
CC/AC
Stick/TIG
50 –100 A
70 –150 A
85 – 225 A (210 DC)
225 A at 25 V, 100% Duty Cycle
H: 33 in (838 mm)
W: 20 in (508 mm)
D: 45 1⁄2 in (1156 mm)
540 lb
(245 kg)
19 – 28 V
200 A at 20 V, 100% Duty Cycle
1-Phase Peak: 10,500 watts
Continuous: 9500 watts
3-Phase (480 V) Peak: 11,000 watts
Continuous: 10,000 watts
CC/DC
CV/DC
MIG/FCAW
210 A at 25 V, 100% Duty Cycle
The GREEN Revolution
Starts by Owning BLUE
Electronic
Fuel Injection
Now, thanks to breakthrough work with our engine suppliers, Miller
is the exclusive provider of gas welder/generators with EFI technology.
EFI— Electronic Fuel Injection. It’s standard technology on
most cars. EFI optimizes the air/fuel ratio for all engine speeds
and all engine loads. It’s what enables V6 engines to deliver
small block V8 performance while getting better mileage.
Compared to carburetor models, Bobcats and Trailblazers
with EFI gas engines deliver a Win-Win performance:
• Up to 27% better fuel economy.
• Up to 27% longer run times for less refueling.
• Reduced emissions because EFI engines use less fuel.
• No choke required. EFI means easy starting in all
climates, at all altitudes and no carburetor icing.
SAVE UP TO $1,000 PER YEAR!
Here’s how Bobcat™ and Trailblazer® welder/generators
with optional EFI engines can save you money, help the
planet and improve job site performance.
Savings Advantage Comparison Chart
Carburetor Models
EFI Model
Fuel Use
—
12–27% less
Weekly Fuel Cost
(25 gal/week; $3.00 gas)
$75
$54.75 (a $20 savings —
$20 x 50 weeks = $1,000/yr!)
HC+NO2 emissions
—
33% lower
CO emissions
—
27% lower
Run time: 1/8 in 7018
17 hours
20 hours
Run time: welding at
140 A and 40% duty cycle
14.5 hours
17 hours
Run time: 2400 watts
(120 V, 20 A) continuous load
12 hours
15.2 hours
Total output at 3600 RPM
23 HP
25 HP
11,000 W peak power
9,500 W continuous
12,000 W peak power
10,500 W continuous
™
Accu-Rated power (same
for Bobcat and Trailblazer)
57
58
6,500 Watts
Good/Very Good
Fair
With voltage control set
near maximum
7 gallon
82.3 dB
No
No
Hours/Oil Change
No
No
Watts
Power Quality
Power While Welding
Fuel Capacity
Sound Levels at 23 ft (7 m)
Digital Meters with SunVision™
Stick: DIG/Adaptive Hot Start™
Maintenance Displays
Polarity Switch
14-pin Remote Receptacle
—
—
Millermatic® 180 and smaller
Dynasty® 200
Spectrum® 375 X-TREME™
MIG (All-In-One), Plug-In
TIG (AC/DC), Plug-In
Plasma Cutters (see chart on pg 70)
Millermatic® 212 and smaller
Dynasty® 200
Spectrum® 875 at 50 A and smaller
SuitCase® VS**
Spoolmate™ 3035/SGA 100C
12 gallon
75.5 dB (1/3 less noise)
No
No
Hours/Oil Change
Yes
No
Millermatic® 212 and smaller
Dynasty® 200
Spectrum® 875 at 50 A and smaller
SuitCase® VS and RC**
Spoolmatic® 30A/WC-24
12 gallon
75.5 dB (1/3 less noise)
Yes
Yes
Hours/Oil Change/Fuel/RPMs
No
Yes
11,000 Watts/12,000 with EFI
Very Good/Excellent
Excellent
Two generator system: one for
welding, one for generating power
— no interaction between tools
and the welding arc.
Excellent
—
Excellent
Excellent
Excellent
—
Unbeatable Stick,
wire, and DC TIG arc
performance and the two
generator system is ideal
for construction, fabrication,
and maintenance/repair
operations.
SuitCase® VS and RC**
Spoolmatic® 30A/WC-24
(325 Amps)
Millermatic® 212 and smaller
Dynasty® 200
Spectrum® 875 at 50 A and smaller
12 gallon
75.5 dB (1/3 less noise)
Yes
Yes
Hours/Oil Change/Fuel/RPMs
Yes
Yes
11,000 Watts/12,000 with EFI
Very Good/Excellent
Excellent
Two generator system: one for
welding, one for generating power
— no interaction between tools
and the welding arc.
Excellent
Very Good/Excellent
Excellent (325 Amps)
Excellent (325 Amps)
Excellent
Very Good
High output, unbeatable
arc performance, and the
two generator system
make this perfect for
construction, fabrication,
and maintenance/repair
operations.
UPGRADE
Trailblazer® 302 (pg 61)
*High Frequency Arc Starter and Stabilizer **VS = Voltage Sensing Feeder, RC = Remote Control Feeder
Millermatic® 212 and smaller
Dynasty® 200
Spectrum® 875 at 50 A and smaller
SuitCase® VS**
Spoolmatic® 30A/WC-115A
12 gallon
75.5 dB (1/3 less noise)
No
No
Hours/Oil Change/Fuel
Yes
No
11,000 Watts/12,000 with EFI
Very Good/Excellent
Good
Easier to fine tune arc with
voltage control near maximum
Very Good/Excellent
Very Good/Excellent
Good
Good
Very Good
Fair/Good
Rugged engine drive
is great for Stick and
Flux Cored welding and is
designed for maintenance/
repair operations,
construction, farm, ranch
and generator use.
UPGRADE
Trailblazer® 275 DC (pg 61)
Engine-Driven
Wire Feeders
Spool Guns
Accessories
Key Features
11,000 Watts
Very Good/Excellent
Fair/Good
With voltage control set
near maximum
Very Good
Very Good/Excellent
Fair
Fair
Good
Fair
Cost-effective,
multiprocess machine
primarily used for Stick
is great for farm, ranch,
stand-alone generator,
and maintenance/repair
operations.
UPGRADE
Bobcat™ 250 (pg 60)
11:44 AM
Generator
Very Good
—
See Accessories below
—
Good
—
Compact, lightweight,
durable, and cost-effective
machine is designed for
contractors, maintenance/
repair, and farm and ranch
applications.
UPGRADE
Bobcat ™ 225 (pg 59)
11/3/09
Stick – DC
Stick – AC (AC electrode)
MIG – Wire (Solid/FCAW), Steel
MIG – Wire, Aluminum w/Spool Gun
TIG – DC, Steel
TIG – AC, Aluminum w/H.F.*
Weld Performance
Product Description
Choose
the Right
Gas Engine
Drive
Wildcat® 200 (pg 56)
A FLE10 Cat P 58 Engine Chart.qxd:Engine
Page 1
MillerWelds.com
A FLE10 Cat P 59 Engine.qxd:Engine
Call
11/9/09
11:24 AM
Page 1
Engine-Driven
1-800-4-A-MILLER for more information.
Bobcat 225
Industrial
Processes
™
See Literature No. ED/4.4
Cost-effective, multiprocess machine primarily used for Stick welding is great for
farm/ranch, stand-alone generator, and maintenance/repair operations.
• AC/DC Stick (SMAW)
• MIG (GMAW)1
1
• Flux Cored (FCAW)
2
• AC /DC TIG (GTAW)
With voltage-sensing feeder only.
With Dynasty ® 200 Series or
HF-251 (non-critical).
1
2
Gasoline Engines
Kohler CH 23 or Subaru EH 65
V-twin-cylinder, 4-cycle, overhead
valve, industrial, air-cooled
Note: Engines are warranted separately
by engine manufacturer.
Most Popular Accessories
Versatile AC and DC Stick/TIG plus Wire
capabilities provide quality welds on all types
of metals. DC is smooth and easy to run while
AC Stick is used when arc blow occurs.
Note: AC TIG requires Dynasty 200 Series or
HF-251 (non-critical).
Fully enclosed case provides reduced sound
levels and fully protects the engine.
Maintenance displays show engine hours and
hours left before an oil change is due.
Accu-Rated™ 11,000 watts of usable peak
power cranks out enough power for most
applications: job site, farm/ranch, or home.
9500 watts of continuous power.
Typical Equipment Power Usage
Bobcats and Trailblazers will easily
start and run the following equipment:
Starting Watts Running Watts
Farm Equipment
Barn cleaner (5 HP)
11,600
3000
Silo unloader (5 HP)
12,200
4300
3400
1000
10,500
2800
Portable conveyer (1/2 HP)
Milker (5 HP)
Contractor Tools
Hand drill (1/2 in)
600
600
Circular saw (81/4 in)
1400
1400
Air compressor (11/2 HP)
8200
2200
Flood lights (vapor)
1250
1000
Refrigerator/freezer
2200
700
Sump pump
1300
800
Millermatic® 212 Auto-Set™
MIG welder, 230 V
6500
6500
Spectrum® 625 X-TREME™
30 A, 230 V, 1/2 in cut
6900
6900
Household
Welding/Cutting Equipment
• SuitCase® X-TREME™ Wire Feeders
(pg 25)
• Dynasty® 200 Series (pg 42)
• Spectrum® Plasma Cutters
375 X-TREME™ #907 339 (pg 72)
625 X-TREME™ #907 404 (pg 72)
• Adapter Cord, Full KVA #300 517
(pg 84)
• 1-Phase Full KVA Plug Kit
#119 172 (pg 84)
• Remote Oil Drain/Filter Kits (pg 84)
• All-Purpose Running Gear (pg 84)
#300 396 with Inner Tubes
#300 477 with Never Flat™ tires
Ten-degree skewed-rotor design for
smoother generator power — better power,
better performance.
Fuel capacity of 12 gallons means many
hours of run time before refueling.
EXCLUSIVE! Super-tough protective armor
with covers has high-impact resistance in all
temperatures and is chemical-resistant. Other
applications include: automotive bumpers,
tractor hoods and panels, lawn mower decks,
large structural parts, etc.
Output stud and receptacle covers are
required by OSHA and CSA for job site safety.
Welding and power ratings are at 104˚F
(40˚C) — highest in its class to ensure
reliable performance.
Heavy-duty construction. All internal
components are designed to handle the
harshest environments and will run better
and last longer.
• Protective Cover #195 333 (pg 84)
(for use without Running Gear or
Protective Cage)
• Protective Cover #195 529 (pg 84)
(for use with Running Gear)
• Protective Cage with Cable
Holders #195 331 (pg 84)
• HWY-1000 Trailer #195 013 (pg 85)
• Engine Tune-up Kits are available
from your Miller parts distributor.
See your Miller distributor for other
popular Miller options and accessories.
Gasoline
Note: See gas engine drive comparison chart on page 58.
*More models available — see our Web site or Literature No. ED/4.4.
Stock Number*
(#907 209) Kohler
23 HP at 3600 RPM
(#907 210) Subaru
23 HP at 3600 RPM
Welding
Mode
Process
Amp/Volt Ranges
Rated Output at 104˚F (40˚C)
CC/AC
Stick/TIG
50 –100 A
70 –150 A
85 – 225 A (210 DC)
225 A at 25 V, 100% Duty Cycle
19 – 28 V
200 A at 20 V, 100% Duty Cycle
CC/DC
CV/DC
MIG/FCAW
210 A at 25 V, 100% Duty Cycle
Single-Phase Generator
Power at 104˚F (40˚C)
Peak: 11,000 watts
Continuous: 9500 watts
Dimensions
Net Weight
H: 28 in (711 mm)
H: 33 in (838 mm)
to top of exhaust
W: 20 in (508 mm)
D: 45 1⁄2 in (1156 mm)
530 lb
(240 kg)
59
A FLE10 Cat P 60 Engine.qxd:Engine
11/9/09
11:25 AM
Page 1
Engine-Driven
Bobcat 250
MillerWelds.com
Industrial
(Gas, LP or Diesel)
™
See Literature No. ED/4.4
Heavy Industrial
Processes
Rugged engine drive is great for Stick and Flux Cored welding and is designed for
maintenance/repair operations, construction, farm/ranch, and generator use.
• AC/DC Stick (SMAW)
• MIG (GMAW)1
• Flux Cored (FCAW)1
2
• AC /DC TIG (GTAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (Carbons — rated 3/16 in
and capable 1/4 in)
• Optional Battery Charger
(replaces AC weld output)
With voltage-sensing feeder only.
With Dynasty ® 200 Series or
HF-251 (non-critical).
1
2
NEW! Electronic Fuel Injection (EFI)
Benefits vs Carburetor Models
• 12% to 27% better fuel economy!
• Reduced emissions — 33% lower HC+Nox levels
and 27% lower CO! (EPA 1000 Hour Certification)
• Easy starting in all climates with no choke required
• Elimination of carburetor icing
• Better high-altitude performance
(electric fuel pump is recommended)
• 12,000 watts of generator power and more
weld output
Bobcat 250
gas model
shown.
Optional EFI Model with
12,000 Watts and More Weld Power!
Accu-Rated ™– Not Inflated Generator Power
Miller’s Accu-Rated™ 11,000 watts (12,000 with EFI)
of usable peak power is delivered for a minimum of
30 seconds. Accu-Rated means peak power is
usable for maximum generator loads such as
plasma cutting, Millermatic® MIG welders and
motor starting. Accu-Rated peak power beats the
competition’s very short-duration peak or surge
power. Use your peak power, it’s more than a number.
Smooth Power –
Not Spike Power
Revolutionary
ten-degree skewedrotor design optimizes generator performance for
smoother power — not spiked power found with
other brands. Better power — better performance.
Competitor
Bobcat
Waveform
Comparison
Note: See gas engine drive comparison chart on page 58 and
diesel engine drive comparison chart on page 63.
*More models available — see our Web site or Literature No. ED/4.4.
**AC welding output is not available with Battery Charger option.
***LP Tank Mounting Assembly sold separately. Tank not included.
Diesel
Gasoline/LP
Stock Number*
60
(#907 211) Kohler, 23 HP at 3600 RPM
(#907 212) Subaru, 23 HP at 3600 RPM
(#907 211-02-1)** Kohler, 23 HP at 3600 RPM
w/12/24/36 V Battery Charger
(#907 450) Kohler EFI, 25 HP at 3600 RPM
(#907 211-03-1)*** Kohler LP
25 HP at 3600 RPM w/CSA Approval and GFCI
(#907 213) Kubota
19 HP at 3600 RPM
Welding
Mode
Versatile AC and DC Stick/TIG plus Wire capabilities
provide quality welds on all types of metals. DC is smooth
and easy to run while AC Stick is used when arc blow occurs.
Note: AC TIG requires Dynasty 200 Series or HF-251 (non-critical).
Tri-Cor ™ Technology is a redesigned stabilizer with added
iron core for smoother weld output, improved performance
and decreased spatter with 7018 electrodes. All without
sacrificing the excellent performance with 6010 electrodes.
Fuel capacity of 12 gallons means many hours of run time
before refueling.
EXCLUSIVE! Super-tough protective armor w/covers
has high-impact resistance in all temperatures and is
chemical-resistant. Other applications include: automotive
bumpers, tractor hoods and panels, lawn mower decks,
large structural parts, etc.
Welding and power ratings are at 104˚F (40˚C) —
highest in its class to ensure reliable performance.
Meter maintenance displays:
• Hour meter function
• Oil change interval
• Fuel gauge
• Diesel: High coolant temperature and low oil pressure
shutdowns
• Diesel: Low fuel shutdown — engine shuts down before
system runs out of fuel making restarts easy
Process
Amp/Volt
Ranges
Rated Output at 104˚F (40˚C)
Single-Phase Generator
Power at 104˚F (40˚C)
Peak: 11,000 watts
Continuous: 9500 watts
EFI Model
Peak: 12,000 watts
Continuous: 10,500 watts
CC/AC
CC/DC
Stick/TIG
40–100 A
60–140 A
80–200 A
100–250 A
250 A at 25 V, 100% Duty Cycle
275 A at 25 V, 60% Duty Cycle
EFI Model
250 A at 28 V, 100% Duty Cycle
275 A at 25 V, 100% Duty Cycle
CV/DC
MIG/FCAW
17–22 V
20–28 V
250 A at 28 V, 100% Duty Cycle
275 A at 25 V, 60% Duty Cycle
Gasoline/LP Engines
Gas: Kohler CH 23 or Subaru EH 65
EFI Gas: Kohler ECH 730
LP: Kohler CH 25
V-twin-cylinder, 4-cycle, overhead
valve, industrial, air-cooled
Diesel Engine
EPA Tier 4 Compliant! Kubota D722
3-cylinder, industrial, liquid-cooled
Note: Engines are warranted separately
by engine manufacturer.
Most Popular Accessories
• SuitCase® X-TREME™ Wire Feeders
(pg 25)
• Dynasty® 200 Series (pg 42)
• Spectrum® Plasma Cutters
375 X-TREME™ #907 339 (pg 72)
625 X-TREME™ #907 404 (pg 72)
• Adapter Cord, Full KVA #300 517
(pg 84)
• 1-Phase Full KVA Plug Kit
#119 172 (pg 84)
• Remote Oil Drain/Filter Kits (pg 84)
• LP Tank Mounting Assembly
#195 329 (pg 84)
• All-Purpose Running Gear
for Gas/LP models (pg 84)
#300 396 with Inner Tubes
#300 477 with Never Flat™ tires
• Protective Covers (pg 84)
• Protective Cage with Cable
Holders (pg 84)
#195 331 for Gas/LP models
#300 052 for Diesel models
• HWY-1000 Trailer #195 013 (pg 85)
• Engine Tune Up Kits are available
from your Miller parts distributor.
See your Miller distributor for other
popular Miller options and accessories.
Dimensions
Gas/LP Models
H: 28 in (711 mm)
H: 33 in (838 mm) to top of exhaust
W: 20 in (508 mm)
D: 45 1⁄2 in (1156 mm)
Diesel Model
H: 30 in (762 mm)
H: 34 1⁄4 in (870 mm) to top of exhaust
W: 20 in (508 mm)
D: 52 in (1321 mm)
Net
Weight
Gas/LP
Models
556 lb
(252 kg)
Diesel
Model
700 lb
(318 kg)
A FLE10 Cat P 61 Engine.qxd:Engine
Call
11/5/09
10:07 AM
Page 1
Engine-Driven
1-800-4-A-MILLER for more information.
Trailblazer 302 & 275 DC
®
(Gas, LP or Diesel)
See Literature No. ED/4.77
High output, unbeatable arc performance, and the two generator system make these
engine drives perfect for construction, fabrication, and maintenance/repair operations.
Heavy Industrial
Processes
• AC1/DC Stick (SMAW)
• MIG (GMAW)2
2
• Flux Cored (FCAW)
3
• AC /DC TIG (GTAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (rated 3/16 in carbons,
capable 1/4 in carbons)
302 model only.
With wire feeder.
3Both models with Dynasty 200 ® Series
or 302 model with HF-251.
1
2
Gasoline/LP Engines
NEW! Electronic Fuel Injection (EFI)
Benefits vs Carburetor Models
• 12% to 27% better fuel economy!
• Reduced emissions — 33% lower HC+Nox levels
and 27% lower CO! (EPA 1000 Hour Certification)
• Easy starting in all climates with no choke required
• Elimination of carburetor icing
• Better high-altitude performance
(electric fuel pump is recommended)
• 12,000 watts of generator power
Trailblazer 302
gas model
shown.
Optional EFI Model with 12,000 Watts!
Weld Power
DC TIG Arc End with Auto-Crater ™ (patent pending)
• Eliminates need for a remote control
• Maintains shielding gas coverage
• Eliminates tungsten and workpiece contamination
• Eliminates unwanted arc strikes outside the weld area
Accu-Rated™ 11,000 watts (12,000 with EFI) of usable
peak power cranks out enough power for most
applications: job site, farm/ranch, or home.
9,500 watts of continuous power (10,500 with EFI).
Generator Power
Two generators — one machine. Trailblazer Series
offers the only 2-generator system — one for welding,
and one for generating power—meaning no interaction
between tools and the welding arc, and it has the
strongest generator power while welding.
Superior arc performance
• Four preset DIG settings (Stick)
• Adaptive Hot Start ™ (Stick)
• Excellent MIG/FCAW arc performance
• Lift-Arc™ TIG with Auto-Crater™ and Auto-Stop™
Gasoline/LP
Note: See gas engine drive comparison chart on page 58 and
diesel engine drive comparison chart on page 63.
*More models available — see our Web site or Literature No. ED/4.77.
**LP Tank Mounting Assembly sold separately. Tank not included.
EXCLUSIVE! Super-tough protective armor with
covers has high-impact resistance in all temperatures
and is chemical-resistant. Other applications include:
automotive bumpers, tractor hoods and panels, lawn
mower decks, large structural parts, etc.
Welding
Mode
Process
Amp/Volt Ranges
Rated Weld Output
at 25 V at 104˚F (40˚C)
Model
Stock Number*
Trailblazer
275 DC
(#907 214) Kohler, 23 HP at 3600 RPM
(#907 215) Subaru, 23 HP at 3600 RPM
(#907 451) Kohler EFI, 25 HP at 3600 RPM
(#907 214-02-2)** Kohler LP, 25 HP at 3600 RPM
CC/DC
Stick/TIG
10 – 275 A
275 A at 100% Duty Cycle
CV/DC
MIG/FCAW
13 – 33 V, 10 – 275 A
275 A at 100% Duty Cycle
(#907 216) Kohler, 23 HP at 3600 RPM
(#907 217) Subaru, 23 HP at 3600 RPM
(#907 452) Kohler EFI, 25 HP at 3600 RPM
(#907 216-02-2)** Kohler LP, 25 HP at 3600 RPM
CC/AC
TIG/Stick
10 – 225 A
200 A at 60% Duty Cycle
CC/DC
Stick/TIG
10 – 300 A
280 A at 100% Duty Cycle
CV/DC
MIG/FCAW
13 – 35 V, 10 – 325 A
300 A at 100% Duty Cycle
Trailblazer
302
Diesel
Self-calibrating digital weld meters with
maintenance displays
• Preset and actual weld amperage/voltage
• Hour meter function
• Oil change interval
• Fuel gauge
• Engine RPMs
• Diesel: High coolant temperature and low oil pressure
shutdowns
• Diesel: Low fuel shutdown — engine shuts down
before system runs out of fuel making restarts easy
Trailblazer
302
(#907 218) Kubota 19 HP at 3600 RPM
Gas: Kohler CH 23 or Subaru EH 65
EFI Gas: Kohler ECH 730
LP: Kohler CH 25
V-twin-cylinder, 4-cycle, overhead
valve, industrial, air-cooled
Diesel Engine
EPA Tier 4 Compliant! Kubota D722
3-cylinder, industrial, liquid-cooled
Note: Engines are warranted separately
by engine manufacturer.
Most Popular Accessories
• SuitCase® X-TREME™ 12VS
Wire Feeder #951 184 (pg 25)
• Spoolmatic® 30A Aluminum
Spool Gun / WC-24 Control
#130 831 / #137 549 (pg 28)
• Dynasty® 200 Series (pg 42)
• Spectrum® Plasma Cutters
625 X-TREME™ #907 404 (pg 72)
875 #907 390-01-1 (pg 73)
• Adapter Cord, Full KVA #300 517
(pg 84)
• 1-Phase Full KVA Plug Kit
#119 172 (pg 84)
• Remote Oil Drain/Filter Kits (pg 84)
• LP Tank Mounting Assembly
#195 329 (pg 84)
• All-Purpose Running Gear
for Gas/LP models (pg 84)
#300 396 with Inner Tubes
#300 477 with Never Flat™ tires
• Protective Covers (pg 84)
• Protective Cage with Cable
Holders (pg 84)
#195 331 for Gas/LP models
#300 052 for Diesel models
• HWY-1000 Trailer #195 013 (pg 85)
• HF-251D-1 #042 388 (pg 90)
• Engine Tune Up Kits are available
from your Miller parts distributor.
See your Miller distributor for other
popular Miller options and accessories.
Single-Phase
Generator Power
at 104˚F (40˚C)
Peak:
11,000 watts
Continuous:
9500 watts
EFI Model
Peak:
12,000 watts
Continuous:
10,500 watts
Dimensions
Gas/LP Models
H: 28 in (711 mm)
H: 33 in (838 mm)
to top of exhaust
W: 20 in (508 mm)
D: 45 1⁄2 in (1156 mm)
Diesel Model
H: 30 in (762 mm)
H: 34 1⁄4 in (870 mm)
to top of exhaust
W: 20 in (508 mm)
D: 52 in (1321 mm)
Net
Weight
Gas/LP
Models
568 lb
(258 kg)
Diesel
Model
720 lb
(327 kg)
61
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Trailblazer 302 Air Pak
®
Heavy Industrial
Processes
™
See Literature No. ED/4.78
• AC/DC Stick (SMAW)
• MIG (GMAW)1
1
• Flux Cored (FCAW)
2
• AC /DC TIG (GTAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (rated 3/16 in carbons,
capable 1/4 in carbons using
integrated air compressor)
• Battery Charger/Jump Start
Powerful all-in-one tool is designed for repair and construction with unbeatable multiprocess
weld quality, integrated rotary screw air compressor, 13,000 watts of generator power for
job site tools, and battery charge/jump start.
With wire feeder.
With Dynasty 200 ® Series or
HF-251 (non-critical).
1
2
Gasoline Engine
Kohler CH 750
V-twin-cylinder, 4-cycle, overhead
valve, industrial, air-cooled
Note: Engine is warranted separately
by engine manufacturer.
Air Compressor
Most Popular Accessories
• SuitCase® X-TREME™ 12VS
Wire Feeder #951 184 (pg 25)
• Spoolmatic® 30A Aluminum
Spool Gun / WC-24 Control
#130 831 / #137 549 (pg 28)
• Dynasty® 200 Series (pg 42)
• Spectrum® Plasma Cutters
625 X-TREME™ #907 404 (pg 72)
875 #907 390-01-1 (pg 73)
• Adapter Cord, Full KVA #300 517
(pg 84)
• Remote Oil Drain/Filter Kits (pg 84)
• Protective Cover #300 379 (pg 84)
• Air Cooler with Separator #300 420
• 50 ft Air Hose with 1/2 in NPT
Swivel Fitting #300 571
Rotary screw air compressor
• Runs many tools at idle speed
• Delivers up to 26 CFM and 160 PSI of
air with no storage tank
• Gives 100% deliverable air
• Compressor is warranted by Miller for
3 years
• Air outputs rated at an industry high
104˚F (40˚C)
• Front panel air pressure adjustment
(80 –160 PSI)
• Screw compressor is designed for
more than 30,000 hours of operation
• Automatic overpressure shutdown
with indication
Now Includes
Battery Charge/
Jump Start!
NEW! Battery charge/jump start.
• For 12 and 24 volt batteries
• Adjustable 10 to 75 amps of charge current
• Up to 450 amps of jump start amperage
NEW! Optional Air Cooler with Separator.
Removes moisture, fully integrated. For
tools, blasters, plasma cutting, and
gouging. Effective when temperatures
are above freezing and easily bypassed
when below freezing.
Weld Power
• 25 ft Battery Charge/Jump Cables
with Plug #300 422
Size and weight advantage. By adding just 14 inches of length
to a Trailblazer, the Air Pak occupies up to 50% less truck bed
space and up to 25% less axle weight compared to using a
separate engine-driven air compressor.
Cutting and gouging advantage. Ample generator power for
plasma cutters and weld power for Carbon Arc gouging, plus
integrated air compressor delivers air for both.
EXCLUSIVE! Capable of running air tools at idle. Reduce noise
and fuel consumption by running impacts, decking punches, and
many other types of air tools at idle speed.
Industry-leading 13,000 watts of peak power is voltage regulated
and independent of weld settings. 11,000 watts of continuous power.
Generator Power
Two generators — one machine.
Trailblazer Series offers the only
2-generator system — one for welding,
and one for generating power — meaning
no interaction between tools and the
welding arc, and it has the strongest
generator power while welding.
• Protective Cage with Cable
Holders #300 473
• Engine Tune Up Kits are available
from your Miller parts distributor.
See your Miller distributor for other
popular Miller options and accessories.
Gas
*More models available — see our Web site or Literature No. ED/4.78. **Battery charge/jump cables (#300 422) must be ordered separately.
Stock Number*
(#907 447**) Kohler, 30 HP at 3600 RPM
with Battery Charger/Jump Start
(#907 447-00-4**) Kohler, 30 HP at 3600 RPM
with Battery Charger/Jump Start and Cooler/Separator
Air
Compressor
By Miller
62
Welding
Mode
Process
Amp/Volt
Ranges
Rated Weld Output
at 32 V at 104˚F (40˚C)
Single-Phase Generator
Power at 104˚F (40˚C)
CC/DC
Stick/TIG
10 – 300 A
280 A at 100% Duty Cycle
CV/DC
MIG/FCAW
13 – 35 V,
350 A
300 A at 100% Duty Cycle
350 A at 60% Duty Cycle
Peak: 13,000 watts
Continuous: 11,000 watts
CC/AC
TIG/Stick
10 – 225 A
225 A at 60% Duty Cycle
Net
Weight
Dimensions
H:
H:
W:
D:
28 in (711 mm)
341⁄2 in (876 mm) to top of exhaust
20 in (508 mm)
59 5⁄8 in (1514 mm)
Features
Free Air Delivery
at 3600 RPM
Free Air Delivery
at 3000 RPM
Free Air Delivery
at 2400 RPM (Idle)
Rotary screw with electric clutch for on/off. Oil change intervals 500 hours.
Life expectancy 30,000 hours.
26 cfm
(0.73 m3/min)
21 cfm
(0.59 m3/min)
17 cfm
(0.48 m3/min)
Working Pressure
Constant
80 – 160 psig
Duty
Cycle
100%
771 lb
(350 kg)
Oil
Capacity
1.75 qt
(1.7 L)
Very Good
Good
Very Good
Fair
3/16 in, 1/4 in
40 – 275 A, 17 – 28 V
MIG – Wire (Solid/FCAW), Steel
MIG – Wire, Aluminum with Spool Gun
TIG – DC, Steel
TIG – AC, Aluminum w/H.F.*
Carbon Arc Gouging (Rated, Capable of)
Amperage/Voltage Range
11,000 Watts
—
80.5 dB
700 lb
30 x 20 x 52 in
2400/3600 RPM
Not Available
Standard Generator Power
Optional Generator Power
Sound Level (Fully Loaded)
Weight
Size (H x W x D in Inches)
Height is without exhaust stack
Engine Speed (Idle/High)
Weld Meters
Digital — Preset and Weld Displays
1500/1800 RPM
32 x 26 x 56 in
1100 – 1208 lb
71 dB (almost 1/2 less noise)
—
12,000 Watts
20 – 410 A, 14 – 40 V
3/16 in, 1/4 in
Not Available
Excellent
Excellent
Excellent
Excellent
Analog — Weld Displays
1250/1800 RPM
43 x 28-1/2 x 64-1/2 in
1545 lb
73.8 dB (1/3 less noise)
15,000 Watts (3-Ph)/12,000 Watts (1-Ph)
5500 Watts
15 – 500 A, 14 – 40 V
5/16 in, 3/8 in
Fair/Good
Very Good
Excellent
Very Good
Very Good
Powerful, multiprocess machine is
great for Carbon Arc gouging and
welding for maintenance/repair
operations and construction.
Note: See the following pages for other diesel machines that may fit your applications. *High Frequency Arc Starter and Stabilizer
Digital — Preset and Weld Displays
2400/3600 RPM
30 x 20 x 52 in
720 lb
80.5 dB
—
11,000 Watts
10 – 325 A, 13 – 35 V
3/16 in, 1/4 in
Very Good
Excellent
Excellent
Excellent
Excellent
Low speed and quiet with
unbeatable arc performance make
this perfect for construction (pipe
and structural), maintenance/repair
operations, and fabrication.
• Powerful
• Quiet
• Powered by CAT
1-800-4-A-MILLER for more information.
Key Features
Very Good
Stick
Compact, lightweight, unbeatable
arc performance, and the
two-generator system make this
perfect for construction (pipe and
structural), maintenance/repair
operations, and fabrication.
• Low speed
• Quiet
• Unbeatable arc performance
• Most fuel efficient
Big 40® Deluxe (pg 65)
11:46 AM
Weld Performance
Rugged, compact, and
lightweight diesel engine drive is
great for Stick and Flux Cored
welding and is the lowest priced
diesel welder/generator.
• Compact
• Lightweight
• Unbeatable arc performance
Big Blue® 300 Pro (pg 64)
11/3/09
Product Description
• Compact
• Lightest weight
• Lowest price point
Trailblazer® 302 Diesel (pg 61)
Call
Choose the
Right Diesel
Engine Drive
Bobcat ™ 250 Diesel (pg 60)
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MillerWelds.com
Big Blue 300 Pro
®
See Literature No. ED/5.21
Reliable low-speed diesel with outstanding arc performance.
Ideal for construction, fabrication or pipewelding professionals.
Meter maintenance displays:
• Hour meter function
• Oil change interval
• High coolant temperature and low oil pressure shutdowns
• Low fuel shutdown — engine shuts down before system
runs out of fuel making restarts easy
The Vault — ultimate control board
reliability. Housed in a sealed vault,
sealed connections are made through
watertight plugs that make these
components impenetrable to dust
and moisture.
• Stick (SMAW)
• MIG (GMAW)
• Flux Cored (FCAW)
• TIG (GTAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (rated 3/16 in carbons,
capable 1/4 in carbons)
Diesel Engines
EPA Tier 4i Compliant Choices!
Caterpillar C1.5
3-cylinder, industrial, liquid-cooled
Deutz D 2008 L04
4-cylinder, industrial, liquid-cooled
Perkins 403D-15
3-cylinder, industrial, liquid-cooled
Note: Engines are warranted separately
by engine manufacturer.
Most Popular Accessories
Tailored arc control (DIG) allows arc characteristics to be
changed for specific applications and electrodes. Smooth
running 7018 or stiffer, more penetrating 6010.
Legendary Big Blue Reliability
with Pro Quality Arc!
Heavy Industrial
Processes
Improved arc starts and arc stability for excellent performance
in all applications.
Easy to use — simple controls make it easy to set-up and weld.
Quiet — only 71 dba (96 Lwa) at maximum output. Improves
work site communication and safety.
Compact design fits sideways in a standard pickup.
• SuitCase® X-TREME™ 12VS/12RC
(pg 25/26)
• Dynasty® 200 Series (pg 42)
• Spectrum® 875 (pg 73)
• Adapter Cord, Full KVA #300 517
(pg 84)
• 1-Phase Full KVA Plug Kit
#119 172 (pg 84)
• Protective Cover #195 301 (pg 84)
• Mid-Frame Trailer #195 481 (pg 85)
• PRHC-14 Remote #195 511 (pg 89)
See your Miller distributor for other
popular Miller options and accessories.
Optional stainless steel package available.
Diesel
Note: See diesel engine drive comparison chart on page 63.
*More models are available —
see our Web site or Literature No. ED/5.21.
Stock Number*
(#907 144) CAT, 21.7 HP at 1800 RPM
(#907 399) Deutz, 24.2 HP at 1800 RPM
(#907 242) Perkins, 21.7 HP at 1800 RPM
(#907 144-02-1) CAT w/Stainless Steel/120 V Block Heater
(#907 399-02-1) Deutz w/Stainless Steel/120 V Block Heater
CSA, IEC and NEMA compliant.
Welding
Mode
Amp/Volt
Ranges
Rated Output at
104˚F (40˚C)
Single-Phase Generator Power
at 104˚F (40˚C)
CC/DC
20 – 410 A
300 A at 32 V,
60% Duty Cycle
Peak: 12,000 watts
Continuous: 10,000 watts
CV/DC
14 – 40 V
We Could Talk About Our
True Blue Warranty...
®
…but we couldn’t say it any better than Ken.
Warranty issues are the big reason I switched to Miller. With my old
machines, I couldn’t get parts quickly, couldn’t get them fixed correctly
and the manufacturer never responded to my letters. Since they didn’t call me
or talk to me, I solved the problem — I started buying Miller.
“
Ken Stiles — President and Co-Owner, K.S. Mechanical
Sign up for one of Miller’s eNewsletters that is tailored to
fit your needs at MillerWelds.com/newsletters
64
”
Dimensions
Net Weight
H: 32 in (813 mm)
W: 261⁄4 in (667 mm)
D: 56 in (1422 mm)
CAT/Perkins
1100 lb (499 kg)
Deutz
1208 lb (548 kg)
A FLE10 Cat P 65 Engine.qxd:Engine
Call
11/3/09
11:48 AM
Page 1
Engine-Driven
1-800-4-A-MILLER for more information.
Big 40
®
Heavy Industrial
CC or CC/CV
See Literature No. ED/8.5
Processes
Superior CAT power with added features for the owner/operator compared to the Big Blue 400.
Deluxe Model has AC/DC polarity switch.
Designed and built with reliable,
heavy-duty industrial components to
allow it to operate in remote locations
without downtime.
Quiet — only 65 db (90 Lwa) at idle and
73 db (98 Lwa) at maximum output.
Automatic idle and engine gauges
standard on all models.
Hot Start ™ makes it easy to start all
types of Stick electrodes.
Meter maintenance displays:
• Hour meter function
• Oil change interval
• High coolant temperature and low oil
pressure shutdowns
• Low fuel shutdown — engine shuts
down before system runs out of fuel
making restarts easy
Big 40 CC/CV Deluxe model shown.
Deluxe model only.
Deluxe model with HF-251, or all models
with Dynasty ® 200 Series.
3CC/CV models only.
1
2
Arc-Drive enhances Stick welding,
especially on pipe, by focusing arc and
preventing electrode from going out.
5500-watt peak AC power independent
of weld settings means no interaction
between tools and the welding arc.
CSA, IEC and NEMA compliant.
Note: See diesel engine drive comparison chart on page 63.
Diesel
1
• AC /DC Stick (SMAW)
• AC2/DC TIG (GTAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (Carbons — rated 5/16 in
and capable 3/8 in)
• Stud
• MIG (GMAW)3
• Flux Cored (FCAW)3
Diesel Engine
EPA Tier 4i Compliant!
Caterpillar C2.2
4-cylinder, industrial, liquid-cooled
Note: Engine is warranted separately
by engine manufacturer.
See distributor for Miller accessories.
Model
Stock Number
Process
Amp/Volt
Ranges
Rated Output at 100%
Duty Cycle at 104˚F (40˚C)
Single-Phase Generator Power
at 104˚F (40˚C)
Big 40 CC
(#907 171) CAT, 33 HP at 1800 RPM
DC Stick/TIG
55 – 500 A
400 A at 36 V (14.4 kW)
Big 40 CC/CV
Deluxe Model
(#907 170-03-1) w/15,000 watts,
Weld Meters and AC/DC Polarity Switch
CAT, 33 HP at 1800 RPM
AC/DC
Stick/TIG/
MIG/FCAW
15 – 550 A (DC)
14 – 40 V (DC)
AC: 300 A at 32 V (9.6 kW)
DC: 400 A at 36 V (14.4 kW)
Peak: 5500 watts, Continuous: 4000 watts
Additional Generator Power for
Deluxe Model (While NOT Welding)
3-Phase: 15,000 watts or
1-Phase: 12,000 watts
25 – 350 A (AC)
Big Blue 400 and 500
®
CC or CC/CV
See Literature No. ED/10.8
Designed for fleet owners, construction contractors and rental companies who want a powerful
diesel welder/generator and place a premium on rugged reliability with proven performance.
Meter maintenance displays:
• Hour meter function
• Oil change interval
• High coolant temperature and low oil
pressure shutdowns
• Low fuel shutdown — engine shuts
down before system runs out of fuel
making restarts easy
Explore Your Passion,
CC/CV models have the vault for control
board reliability (see pg 64 for details).
Enclosed robust case design protects
internal components from impact, allows
air flow to cool and prolong the life of
the engine, and reduces sound levels.
Hot Start ™ makes it easy to start all
types of Stick electrodes.
Arc-Drive enhances Stick welding,
especially on pipe, by focusing arc and
preventing electrode from going out.
Build Your Business
Big Blue 500 CC/CV
Deluxe model shown.
Designed and built with reliable,
heavy-duty industrial components to
allow operation in remote locations,
without downtime.
5500-watt peak AC power independent
of weld settings means no interaction
between tools and the welding arc.
Quick and easy maintenance with
single-side access to oil level check, oil
fill, oil filter, fuel filter and air cleaner.
Net
Weight
Dimensions
H: 43 in (1092 mm)
W: 28 1⁄2 in (724 mm)
D: 64 7⁄16 in (1637 mm)
1545 lb
(701 kg)
Heavy Industrial
Processes
• Stick (SMAW) • TIG (GTAW)
• Air Carbon Arc Cutting
and Gouging (CAC-A)
(Carbons — 400: rated 5/16 in and
capable 3/8 in, 500: rated 3/8 in)
• Stud
• MIG (GMAW)*
• Flux Cored (FCAW)*
*CC/CV models only.
Diesel Engines
EPA Tier 4i Compliant Choices!
400 — Deutz D 2011 L03i
3-cylinder, industrial, air/oil-cooled
400 — Perkins 404D-22
4-cylinder, industrial, liquid-cooled
500 — Deutz D 2011 L04i
4-cylinder, industrial, air/oil-cooled
500 — Perkins 404D-22T Turbo
4-cylinder, industrial, liquid-cooled
Note: Engine is warranted separately
by engine manufacturer.
See distributor for Miller accessories.
CSA and NEMA compliant.
Story Here
Diesel
*More models are available — see our Web site or Literature No. ED/10.8.
**Adds Auto Idle, Weld Meters and Optional Generator Power.
Note: All models come standard with Engine Gauges.
Amp/Volt
Ranges
Rated Output
at 104˚F (40˚C)
Single-Phase Generator Power
at 104˚F (40˚C)
DC
Stick/TIG
55 – 500 A
(#907 327)** Deutz, 32.0 HP at 1800 RPM
(#907 329)** Perkins, 32.6 HP at 1800 RPM
DC
Stick/TIG/
MIG/FCAW
15 – 550 A
14 – 40 V
400 A at 36 V
(14.4 kW),
100% Duty Cycle
Peak: 5500 watts, Continuous: 4000 watts
Additional Generator Power for
Deluxe Model (While NOT Welding)
3-Phase: 15,000 watts or
1-Phase: 12,000 watts
H: 43 in (1092 mm)
W: 28 1⁄2 in (724 mm)
D: 64 7⁄16 in (1637 mm)
Deutz
1655 lb (751 kg)
Perkins
1545 lb (701 kg)
Big Blue
500 CC
(#907 181) Deutz, 48.6 HP at 1800 RPM
DC
Stick/TIG
55 – 600 A
Big Blue
500 CC/CV
Deluxe Model
(#907 331)** Deutz, 48.6 HP at 1800 RPM
(#907 333)** Perkins, 44.4 HP at 1800 RPM
DC
Stick/TIG/
MIG/FCAW
20 – 600 A
14 – 40 V
500 A at 40 V
(20 kW),
100% Duty Cycle
Peak: 5500 watts, Continuous: 4000 watts
Additional Generator Power for
Deluxe Model (While NOT Welding)
3-Phase: 20,000 watts or
1-Phase: 12,000 watts
H: 43 in (1092 mm)
W: 28 1⁄2 in (724 mm)
D: 64 7⁄16 in (1637 mm)
Deutz
1695 lb (769 kg)
Perkins
1565 lb (710 kg)
Model
Stock Number*
Process
Big Blue
400 CC
(#907 173) Deutz, 32.0 HP at 1800 RPM
(#907 175) Perkins, 32.6 HP at 1800 RPM
Big Blue
400 CC/CV
Deluxe Model
Dimensions
Net
Weight
65
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Engine-Driven
MillerWelds.com
PipePro 304
Heavy Industrial
Processes
®
See Literature No. ED/10.6
®
XMT 304 arc performance powered by a long-life Kubota diesel engine.
Designed for the professional pipe welder and mechanical contractor.
Patented Weld at Idle™ provides up to 5000 watts of weld power
(225 A at 23 V, 170 A at 30 V). When more power is needed the
machine automatically goes to high speed with no change in the arc.
Diesel Engine
Patented Dual Power Option™ operates on engine or 230 volt singleor three-phase electric input power which eliminates fuel cost, noise,
engine wear and emissions.
• SuitCase® X-TREME™ 12VS/12RC
#951 184/#951 188 (pg 25/26)
• Spectrum® Plasma Cutters
625 X-TREME™ #907 404 (pg 72)
875 #907 390-01-1 (pg 73)
• Full KVA Plug Kit
1-Phase #119 172 (pg 84)
3-Phase #007 470 (pg 84)
• Protective Cover #195 125 (pg 84)
• HWY-224 Trailer #043 805 (pg 85)
• PRHC-14 Remote #195 511 (pg 89)
High welding outputs to dominate larger diameter flux cored wires for
increased deposition and Air Carbon Arc gouging thru 1/4 in carbons.
Compact and lightweight design fits sideways in a standard pickup.
Toolless top and side access allows easy and faster maintenance with
little clearance space needed. Toolless remote oil drain is standard.
Diesel
Optional stainless steel package available.
Stock Number
(#903 731) Kubota, 26 HP, 3600/2500 RPM
(#903 731-01-2) Stainless Steel Package
(#903 731-01-3) with Dual Power
Most Popular Accessories
See your Miller distributor for other
popular Miller options and accessories.
Process
Amp/Volt Ranges
Rated Output at 104˚F (40˚C)
Generator Power at 104˚F (40˚C)
Dimensions
Net Weight
Stick/TIG
5 – 400 A
CV/DC
MIG/FCAW/
Pulsed MIG
10 – 34 V
300 A at 32 V,
60% Duty Cycle
Single-Phase or Three-Phase:
12,000 watts
H: 30 in (762 mm)
W: 24 in (610 mm)
D: 59 1⁄2 in (1511 mm)
910 lb
(412 kg)
Heavy Industrial
Processes
®
See Literature No. ED/10.9
Save fuel, reduce maintenance costs, increase productivity.
Deutz F3L914 EPA engine has 14% more horsepower.
Automatic engine shutdown protects engine if low oil pressure
or high coolant temperature occurs.
Shown with
portable wire feeder.
Diesel Engine
EPA Tier 4i Compliant!
Deutz D 914 L03i
3-cylinder, industrial, air-cooled
Note: Engine is warranted separately
by engine manufacturer.
Paralleling switch parallels both outputs to a single side for
double the amperage. This provides a safe and easy way to run
large electrodes, Stud weld or Air Carbon Arc gouge.
• SuitCase® X-TREME™ 12VS
#951 184 (pg 25)
• SuitCase® 8RC or 12RC with
remote voltage control (pg 26)
• HWY-224 Trailer #043 805 (pg 85)
• OFR-224 Trailer #043 802 (pg 85)
• HWY-430 Trailer #043 806 (pg 85)
• RCCS-14 Remote Contactor and
Current Control #043 688 (pg 90)
• RHC-14 Remote Hand Control
#129 340 (pg 90)
Standard CV allows MIG and Flux Cored welding without hassle
and expense of a CV module kit.
optional SuitCase 12RC
• Stick (SMAW)
• MIG (GMAW)
• Flux Cored (FCAW)
• TIG (GTAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (rated 3/8 in carbons)
Multiprocess capabilities performed independently at the
same time — each operator has a choice of Stick, TIG or MIG.
Hot Start ™ automatically provides additional amperage to start
electrode. This produces positive starts and reduces chance of
arc marking.
Diesel
Note: Engine is warranted separately
by engine manufacturer.
CC/DC
Designed for fleet owners and construction contractors who want a single low-speed
diesel engine to provide two independent high-quality multiprocess arcs.
66
EPA Tier 4i Compliant!
Kubota D1005
3-cylinder, industrial, liquid-cooled
Welding Mode
Miller Du-Op
Stock Number
(#907 317) Deutz
48 HP at 1800 RPM
*With optional Optima ™ Pulse Control.
Exceptional multiprocess arc. Excellent (uphill/downhill) bead (root),
hot pass, fill and cap control on Stick welding. DIG control changes
soft arc to stiff arc that prevents electrode sticking. Lift-Arc™ TIG for
DC welding without use of a HF unit. MIG arc runs in a variety of
modes with excellent results using any wire or flux core in the field.
Inductance control customizes weld puddle.
12,000 watt voltage-regulated generator power allows tools, inverter
welders or plasma cutters to run without affecting the arc while welding.
PipePro 304
shown with
Dual Power Option.
• MIG (GMAW)
• Pulsed MIG (GMAW-P)*
• Flux Cored (FCAW)
• DC Stick (SMAW)
• DC TIG (GTAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (1/4 in carbons)
Single range allows full range of operation in all processes
without walking back to switch ranges.
Process
Amp/Volt Ranges
Rated Output at 40% Duty Cycle
at 104˚F (40˚C)
Single-Phase Generator
Power at 104˚F (40˚C)
DC Stick/TIG/
MIG/FCAW
1 Welder: 15 – 600 A, 10 – 32 V
2 Welders: 15 – 300 A, 10 – 32 V
1 Welder: 550 A at 30 V (16.5 kW)
2 Welders: 275 A at 31 V (8.5 kW)
Peak: 5500 watts
Continuous: 4000 watts
Most Popular Accessories
See your Miller distributor for other
popular Miller options and accessories.
Dimensions
Net Weight
H: 47 5⁄8 in (1210 mm)
W: 311⁄4 in (794 mm)
D: 601⁄2 in (1537 mm)
2005 lb
(909 kg)
A FLE10 Cat P 67 Engine.qxd:Engine
Call
11/3/09
11:49 AM
Page 1
Engine-Driven
1-800-4-A-MILLER for more information.
Big Blue Air Pak
®
Heavy Industrial
Processes
™
See Literature No. ED/10.5
Designed for heavy construction or maintenance and repair contractors, this all-in-one
multiprocess welder/generator/compressor and optional AC weld/battery charge/jump-start
package sets the standard for power and performance.
Meter maintenance displays:
• Hour meter function
• Oil change interval
• High coolant temperature and low oil
pressure shutdowns
• Low fuel shutdown — engine shuts
down before system runs out of fuel
making restarts easy
Ingersoll-Rand ultra-reliable industrial
rotary screw air compressor. Belt-driven
with automatic belt tensioner.
Independent compressor controls
include an on/off switch for applications
not requiring compressed air.
Deluxe model
shown without the
Vandalism Lockout Kit.
Quiet — only 70 dB (95 Lwa) at idle and
79 dB (104 Lwa) at maximum output.
Hot Start ™ makes it easy to start all
types of Stick electrodes.
Arc-Drive™ enhances Stick welding,
especially on pipe, by focusing arc and
preventing electrode from going out.
Optional battery charge/jump start
for 12 and 24 volt batteries.
Note: Option includes AC weld.
CSA and NEMA compliant.
MSHA approved for miners with
purchase of certificate from Deutz dealer.
Diesel
* Comes complete with Engine Gauges, Auto Idle and 12 V Intake Manifold Heater.
** Cold Weather Model — Comes complete with Engine Gauges, Auto Idle, Weld Meters, Battery Lockout/Tagout Disconnect Switch,
12 V Intake Manifold Heater and 120 V Oil Pan Heater.
*** Deluxe Model — Comes complete with Engine Gauges, Auto Idle, Weld Meters, Battery Lockout/Tagout Disconnect Switch, 12 V Intake
Manifold Heater, 120 V Oil Pan Heater, Vandalism Lockout Kit, AC/DC/Battery Charge/Jump-Start Switch and Optional Generator Power.
Stock Number
(#907 062)*
Base Model
(#907 062-04-1)**
Cold Weather Model
(#907 062-07-1)***
Deluxe Model
Deutz
63.4 HP at 1800 RPM
Diesel Engine
EPA Tier 4i Compliant!
Deutz TD 2011 L04
Turbocharged, 4-cylinder, industrial,
liquid-cooled
Note: Engine is warranted separately
by engine manufacturer.
Most Popular Accessories
• Desiccant
Air Dry
System
#195 117
Eliminates moisture in the air
stream and prevents air line
freeze-ups in cold climates.
See your Miller distributor for other
popular Miller options and accessories.
Weld Output
Range
Weld Output Rated at 104˚F (40˚C)
NEMA Amperage and Voltage
Max. OpenCircuit Voltage
Single-Phase Generator
Power at 104˚F (40˚C)
CC/AC (Deluxe Model Only)
20–575 A
400 A at 36 V (14.4 kW), 100% Duty Cycle
64
CC/DC
20–750 A
600 A at 44 V (26.4 kW), 40% Duty Cycle
550 A at 42 V (23.1 kW), 60% Duty Cycle
500 A at 40 V (20 kW), 100% Duty Cycle
95
CV/DC
14–40 V
500 A at 40 V (20 kW), 100% Duty Cycle
56
Battery Charge/Jump Start
(Deluxe Model Only)
12/24 V
750 A, 12 V, Jump-Start
750 A, 24 V, Jump-Start
14/28
Peak: 5500 watts
Continuous: 4000 watts
Additional Generator
Power for Deluxe Model
(While NOT Welding)
3-Phase: 20,000 watts or
1-Phase: 12,000 watts
Features
Free Air Delivery
at 1850 RPM
Free Air Delivery
at 1235 RPM (Idle)
Ingersoll-Rand
CE55 G1
Rotary screw with electric clutch for on/off. Oil change intervals
500 hours (same as engine). Life expectancy 30,000 hours.
60 cfm
(1.70 m3/min)
40 cfm
(1.13 m3/min)
Big Blue Turbo
Working Pressure
Constant
100 psig
7 bar
See Literature No. ED/10.3
Similar to the Big Blue Air Pak, but without the air compressor.
Meter maintenance displays:
• Hour meter function
• Oil change interval
• High coolant temperature and low oil
pressure shutdowns
• Low fuel shutdown — engine shuts
down before system runs out of fuel
making restarts easy
Turbo engine provides superior
performance in high altitudes.
Highest output rating available on an
engine-driven welder: 20 – 750 A range,
600 amps at 100% duty cycle!
Duty
Cycle
100%
Dimensions
Weight
H: 43 in
(1092 mm)
W: 281⁄2 in
(724 mm)
D: 671⁄2 in
(1715 mm)
Base and
Cold Weather Models
Net: 1931 lb (876 kg)
Ship: 1982 lb (899 kg)
Oil
Capacity
5 qt
(4.7 L)
Deluxe Model
Net: 1956 lb (887 kg)
Ship: 2007 lb (910 kg)
Automatic Compressor
Shutdowns
Oil Temperature
Heavy Industrial
Processes
®
Diesel
Deluxe model only.
Deluxe model with HF-251, or all models
with Dynasty ® 200 Series.
1
2
Welding
Mode
Air
Compressor
Stock Number
(#907 157) Deutz,
63.4 HP at 1800 RPM
• AC1/DC Stick (SMAW)
• MIG (GMAW)
• AC2/DC TIG (GTAW)
• Flux Cored (FCAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (rated 1/2 in carbons)
• Stud
• Battery Charger/Jump Start1
Quiet — only 70 dB (95 Lwa) at idle and
79 dB (104 Lwa) at maximum output.
Hot Start ™ makes it easy to start all
types of Stick electrodes.
Arc-Drive™ enhances Stick welding,
especially on pipe, by focusing arc and
preventing electrode from going out.
5500-watt peak AC power independent
of weld settings means no interaction
between tools and the welding arc.
CSA and NEMA compliant.
• Stick (SMAW)
• MIG (GMAW)
• TIG (GTAW)
• Flux Cored (FCAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (rated 1/2 in carbons,
capable 5/8 in carbons)
• Stud
Diesel Engine
EPA Tier 4i Compliant!
Deutz TD 2011 L04
Turbocharged, 4-cylinder, industrial,
liquid-cooled
Note: Engine is warranted separately
by engine manufacturer.
See distributor for Miller accessories.
Welding Mode
Process
Weld Output Range
Rated Output at 104˚F (40˚C)
Single-Phase Generator Power at 104˚F (40˚C)
Dimensions
Net Weight
CC/DC
Stick/TIG
20 –750 A
CV/DC
MIG/FCAW
14 – 40 V
600 A at 44 V (26.4 kW),
100% Duty Cycle
Peak: 5500 watts
Continuous: 4000 watts
H: 43 in (1092 mm)
W: 281⁄2 in (724 mm)
D: 671⁄2 in (1715 mm)
1755 lb
(796 kg)
67
A FLE10 Cat P 68 Spot.qxd:Spot Intro
11/3/09
11:52 AM
Page 1
Spot Welders
Miller offers a wide variety
of both symmetrical and
asymmetrical tong and tip
configurations. Maximum
capabilities of spot welders
are obtained with minimum
tong lengths. Tips are
made of durable Class 2,
long-wearing copper alloy.
MillerWelds.com/SpotWelders
Work Capacity (Combined
thickness uncoated mild steel
using 6 in [152 mm] tongs)
Input
50/60 Hz
MSW-41 (#900 371)
MSW-41T (#901 345)
w/Timer
110 VAC
30 A
1/8 in (3.2 mm) or two pieces
of 20 gauge (1.8 mm)
galvanized steel
LMSW-52 (#900 377)
LMSW-52T (#901 357)
w/Timer
220 VAC
30 A
3/16 in (4.7 mm) or two pieces
of 16 gauge (3.0 mm)
galvanized steel
Hand lever locks tongs firmly on
material, ensuring positive, accurate fit-up.
Accommodates a wide variety of tongs
and tips.
Quick and easy adjustment for material
thickness.
• Gyro Bail #041 979 (pg 89)
• Spot Welder Pedestal #040 872
• Spot Welder Timer
MSW-41 #041 081
LMSW-52 #041 082
Note: Tongs/tips must be ordered
separately. One standard set of tips is
supplied with each set of tongs; see
diagram above.
See your Miller distributor for other
popular Miller options and accessories.
1.5 kVA at
50% Duty Cycle
5550 A
4500 A
3600 A
2.5 kVA at
50% Duty Cycle
6750 A
5800 A
4850 A
Dimensions
Net
Weight
1.6
H: 6 in (152 mm)
W: 3 3⁄4 in (95 mm)
D: 13 in (330 mm)
22 lb (10 kg)
34 lb (15 kg)
w/Timer
2.5
H: 6 in (152 mm)
W: 3 3⁄4 in (95 mm)
D: 16 in (406 mm)
30 lb (14 kg)
42 lb (19 kg)
w/Timer
See Literature
No. SW/3.1
SSW Series of water-cooled resistance spot welders offer the power needed for light
fabrication and sheet metal work.
Built-in squeeze/weld timer
makes it quick and easy to set
or adjust squeeze and/or weld
time in hundredths of a second.
Set-up/weld switch permits
checking of tong pressure
and alignment without making
a weld.
LED display makes it easy to
read and see timer settings.
Ten-step current control
adjusts output current with no
change in duty cycle.
Adjustable tong pressure nuts
to adjust tong pressure for
different thicknesses and
applications.
*Coolant system required to operate — order separately.
Tongs and tips must be ordered separately — see Lit. No. SW/3.1 for full range of tongs and tips.
Model/
Stock Number*
Input
50/60 Hz
Work Capacity (Combined thickness uncoated
mild steel using 6 in [152 mm] tongs)
SSW-2020 ATT (#903 826)
230 VAC, 90 A
1/4 in (6.3 mm)
SSW-2040 ATT (#903 827)
460 VAC, 45 A
68
Most Popular Accessories
Max OpenCircuit
Voltage
Water-Cooled Spot Welders
Rated Output
20 kVA at
40% Duty Cycle
Offset Tip
Note: Not recommended for welding
aluminum, copper or copper alloys.
Rated Output (Calibrated with standard-type tongs)
6 in (152 mm) 12 in (305 mm) 18 in (457 mm)
Rated Output
Flat Tip
• Resistance Spot Welding
Reversible for left- or right-hand
operation.
Model/Stock
Number*
Standard Tip
Process
See Literature No. SW/1.0
MSW and LMSW Series lightweight, air-cooled units are portable, easy to operate, and
provide a quick and effective means for spot welding mild, galvanized or stainless materials.
*Tongs and tips must be ordered separately —
see Lit No. SW/1.0 for full range of tongs and tips.
Optional Tong
See literature sheets
SW/1.0 and SW/3.1 for full
range of tongs and tips.
Air-Cooled Spot Welders
“T” models include timer panel with a
0 to 5 second weld timer and power on/off
switch. Timer panel can be mounted on
the optional SWP-2 pedestal or any other
convenient location. Includes 10 ft (3 m)
input power and interconnecting cords.
Standard Tong
Tongs and Tips
Process
• Resistance Spot Welding
Note: Not recommended for welding
aluminum, copper or copper alloys.
Comes Complete With
• Stationary welding head
• Remote foot switch
• 37-1/8 inch high all-steel pedestal
inclusive of controls and timer
• Air filter, regulator assembly
Note: Order tongs/tips separately to
match your applications.
Most Popular Accessories
• Coolant Systems (pg 83)
Coolmate™ 3, 115 VAC #043 007
Coolmate™ 3, 230 VAC #043 008
Coolmate™ V3 #043 009
Coolmate™ 4 #042 288
See your Miller distributor for other
popular Miller options and accessories.
Rated Output (Calibrated with standard-type tongs)
6 in (152 mm) 12 in (305 mm) 18 in (457 mm)
Max OpenCircuit Voltage
Net
Weight
12,500 A
3.55
185 lb
(84 kg)
10,500 A
9000 A
A FLE10 Cat P 69 Sub Arc.qxd:Sub Intro
11/3/09
11:53 AM
Page 1
Miller offers a wide array of versatile Sub Arc components,
including digital controllers, tractors, wire feed systems, torches,
and power sources. To learn more, visit MillerWelds.com/SubArc
Sub Arc
MillerWelds.com/SubArc
Sub Arc DC Series
Heavy Industrial
Processes
See Literature No. DC/19.8 and AY/12.0
Optimized for the Sub Arc process, the versatile
Sub Arc DC 650 and 1000 also provide Air Carbon
Arc cutting and gouging, Stick and Flux Cored
capabilities. This Series’ arc control provides stable
and consistent output regardless of electrode size,
electrode type or flux used.
Sub Arc DC 1000
Sub Arc DC 650
Amperage/
Voltage Range
CC/CV, DC,
Three-Phase
CC
50 – 815 A
CV
10 – 65 V
CC/CV, DC,
Three-Phase
CC
100 – 1250 A
CV
10 – 60 V
Stock Number
Description
Sub Arc
DC 650
(#907 338)
230/460/575 V
Sub Arc
DC 1000
(#907 342)
230/460/575 V
Automatic Weld Control
Most Popular Accessories
• Flux Hopper with Valve #194 775
(pg 89)
• Self-Propelled Tractor Pkgs (pg 89)
MT 1500 DX (Digital) #951 060
MT 1500 A (Analog) #951 061
• See additional Sub Arc Accessories
on page 89
See your Miller distributor for other
popular Miller options and accessories.
Welding
Mode
Model
• Submerged Arc (SAW)
• Flux Cored (FCAW) • Stick (SMAW)
• Air Carbon Arc Cutting and Gouging
(CAC-A) (1/2 in carbons)
Amps Input at Rated Output, 60 Hz
230 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
Dimensions (Includes
lift eye and strain relief.)
Net
Weight
650 A at 44 VDC,
100% Duty Cycle
126
63
50.4
50
34.8
72 VDC
545 lb
(247 kg)
1000 A at 44 VDC,
100% Duty Cycle
180
90
72
73
53
66 VDC
H: 271⁄4 in (692 mm)
W: 221⁄4 in (565 mm)
D: 36 in (914 mm)
Rated Output
HDC 1500 DX
HDC 1500 A
38 VDC
644 lb
(292 kg)
#300 438 With Digital Meters
#300 439 With Analog Meters
Reliable and flexible Miller digital and analog weld controls interface with AC or DC CC/CV power sources
that have remote contactor and output control capabilities. Internal power strips allow interfacing with
non-Miller power supplies. Run-in control ensures smoother arc starting and burnback control helps
prevent wire sticking on weld termination. Crater time, speed, and output rates can also be controlled
with these devices. See page 89 for more accessories. See Literature No. AY/12.0 for more details.
HDC 1500 A
HDC 1500 DX
Wire Drive Assemblies
RAD-400 shown.
RAD motors include
adapter plate which
allows mounting to
2-1/2, 4-1/4, and
4-5/8 inch bolt-hole
patterns.
RAD-400
RAD-780
SAW4
#195 265 Standard-speed, right-angle wire drive assembly for 1/8 in or larger wires.
#195 266 High-speed, right-angle wire drive assembly for 1/8 in or larger wires.
#300 481 Standard-speed assembly for smaller than 1/8 in wires.
Miller wire drive assemblies operate using 115-volt power and are available for a range of wire diameters.
Right angle wire drives (RAD) are designed for larger diameter wires while the SAW4 is optimized for
smaller diameters. The RAD-400 and SAW4 have a wire feed speed range of 20 – 400 inches per
minute (0.5 –10 MPM). The RAD-780 has a wire feed speed range of 20 – 780 IPM (0.5 –19.8 MPM).
Both RAD motors include an adapter plate that allows mounting to 2-1/2 inch (65.5 mm), 4-1/4 inch
(108 mm), and 4-5/8 inch (117.5 mm) bolt-hole patterns. See page 89 for recommended drive rolls.
OBT 600 #043 923 600-amp, 100% duty cycle torch used with 1/16 – 7/32 in (1.6 – 5.6 mm) wire.
OBT 1200 #043 900 1200-amp, 100% duty cycle torch used with 1/16 – 7/32 in (1.6 – 5.6 mm) wire.
Sub Arc Torches
OBT 600
OBT 1200
Miller offers a choice of torches for submerged arc welding: OBT 600 (600 amp maximum output) and
OBT 1200 (1200 amp maximum output). Both feature a concentric flux flow nozzle and have optional
body extensions available. OBT 1200 features a replaceable breakaway adapter end to prevent costly
damage should the torch run into an obstruction. See page 89 for torch body extensions and contact tips.
69
A FLE10 Cat P 70 Plas Intro.qxd:Plasma Intro
11/5/09
10:22 AM
Page 1
Plasma Cutters
“
If you can incorporate a plasma cutter into
your operation, it will save you half the
repair time. That’s worth a lot to a
contractor, a farmer or anybody.
”
Steve Young, Sr., Supervisor/Maintenance Manager
Murphy Concrete & Construction Co., Inc.
Cutting w/Engine Drives
Product
Guide
Page
Class
Gouging
Piercing
1-Phase
MillerWelds.com/PlasmaCutters
Spectrum® 125C
71
Spectrum® 375
71
Spectrum® 375
X-TREME™
72
Spectrum® 625
X-TREME™
72
Spectrum® 875
73
Engine-Driven
Welders
Rated Output/
Duty Cycle
Rated Cutting Thicknesses*
Mild
Stainless
Steel
Steel
Aluminum
Special Features
12 A at 35%
1/8 in
1/8 in
1/16 in
Built-in air compressor
HVAC, hobbyist, auto body, plumbing
27 A at 35%
3/8 in
3/8 in
1/4 in
115/230 V dual input voltage
Hobbyist, auto restoration, fabrication
27 A at 35%
3/8 in
3/8 in
1/4 in
Auto-Line™: 115 – 230 V, MVP™ plugs, only 18 lb
HVAC, maintenance, construction
40 A at 50%
5/8 in
1/2 in
3/8 in
Auto-Refire™, automatic air regulation, only 21 lb
body shops, prototyping
Maintenance, light construction,
60 A at 50%
7/8 in
7/8 in
5/8 in
Auto-Refire™, automatic air regulation, only 52 lb
Construction, maintenance/repair, fabrication
Typical Applications
Generator
Power
Spectrum 375 / 375 X-TREME
Steel Cut
Output Amp Setting**
Spectrum 625 X-TREME
Steel Cut
Output Amp Setting**
Steel Cut
Spectrum 875
Output Amp Setting**
Wildcat® 200
6.5 kW
3/8 in
27 A
3/8 in
30 A
Not Recommended
Not Recommended
Bobcat™, Trailblazer®
11 kW
3/8 in
27 A
5/8 in
40 A
1/2 in
45 A
PipePro® 304,
Big Blue® 300 Pro
12 kW
3/8 in
27 A
5/8 in
40 A
5/8 in
50 A
Big 40® CC/CV
15 kW (optional)
3/8 in
27 A
5/8 in
40 A
7/8 in
60 A
Big Blue® 500 CC/CV
20 kW (optional)
3/8 in
27 A
5/8 in
40 A
7/8 in
60 A
*Note on cut capacity ratings: The Spectrum Series rating system is designed to provide a guide to help our customers choose the right machine for their application.
Rated cut capacity is based on traveling approximately 10 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 cut is the maximum cut achieved in ideal conditions. Some factors that dictate 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 aluminum and other metals
with high thermal conductivity, cutting capacities may be derated as much as 30%.
PRODUCT KEY
70
CLASS:
Light Industrial
Industrial
Heavy Industrial
CAPABILITY:
Designed for this process
Capable of this process
*See note on cut capacity ratings above. **240 V, full KVA plug. Derate cut capacity with less generator power. For more detailed information, see individual specification sheets.
A FLE10 Cat P 71 Plasma.qxd:Plasma
Call
11/5/09
10:22 AM
Page 1
Plasma Cutters
1-800-4-A-MILLER for more information.
Spectrum Series ✓
®
Power Factor Correction (PFC)
(not available on 125C model). Uses
less energy by utilizing input power more
efficiently and increases productivity by
reducing nuisance circuit breaker trips.
Miller engine drive generator compatibility.
Industrial, heavy-duty work clamp.
LED indicators for easy troubleshooting.
Non-high-frequency arc starting does not
interfere with or damage controls or computers.
Miller Industrial-Grade Technologies/Features
Post-flow cooling circuitry extends life
of the consumable and torch by cooling
them with postflow air after the trigger
is released.
Built-in gas/air filter/regulator (either
internal or external depending on unit
and not available on Spectrum 125C).
Provides air filtration of airborne particles
5 microns and larger. Additional filtration
and water separation recommended.
Spectrum 125C
These technologies provide reliability
and performance others can’t match...
See why at MillerWelds.com/reliable
LVC™ line voltage compensation provides peak
performance power under variable input voltage
conditions for clean, steady cuts.
Wind Tunnel Technology™ prevents abrasive dust and
particles from damaging internal components.
Fan-On-Demand™ cooling system only operates when
needed, reducing the amount of airborne dust/dirt
pulled through the unit.
Light Industrial
Process • Air Plasma Cutting
125C Model Comes Complete With
®
See Literature No. PC/13.0
✓
Includes Industrial-Grade Technologies/Features (see above)
Mild Steel
Cutting Capability
Built-in, heavy-duty industrial piston-driven
compressor provides long life and superior airflow.
Not to scale.
Solid-state, constant-current design offers
consistent 12 amp cutting arc for continuous
quality cutting up to 3/16 in steel.
12 ga (2.7 mm) at 35 IPM
Electronic Pilot Arc Controller automatically
controls the pilot circuit to provide expanded metal
cutting ability without having to re-trigger the torch,
increasing productivity and extending tip life.
Rated
1/8 in (3.2 mm) at 10 IPM
35% duty cycle is tested at 104°F (40°C) to give
you the cutting power whenever you need it.
Stock Number
(#907 149) 115 V, 60 Hz
Amps Input at Rated Output, 60 Hz
120 V
KVA
KW
Rated Output at 104˚F (40˚C)
12 A at 110 VDC,
35% Duty Cycle
20
Spectrum 375
2.4
2.0
Dimensions
Net Weight with Torch
H: 13 1/2 in (343 mm)
W: 8 1/2 in (216 mm)
D: 16 in (406 mm)
50 lb (22.7 kg)
• ICE-12C hand-held torch with
20 ft (6.1 m) cable
• Heavy-duty work clamp with
20 ft (6.1 m) cable
• 10 ft (3 m) power cord
• Extra consumables
(2 electrodes, 2 tips)
375 Model Comes Complete With
• ICE-27C hand-held torch with
20 ft (6.1 m) cable
• Heavy-duty work clamp with
20 ft (6.1 m) cable
• 10 ft (3 m) power cord with
115 VAC, 20 A plug
• Extra consumables (3 electrodes,
3 tips and 1 air fitting)
• Built-in gas/air filter and regulator
Most Popular Accessories (pg 88)
• Protective
Cover
#195 144
®
See Literature No. PC/9.1
Mild Steel
Cutting Capability
Not to scale.
✓
Includes Industrial-Grade Technologies/Features (see above)
Dual input voltage allows either 115 or 230 VAC
input power and provides patented protection in case
of incorrect switch position.
1/4 in (6.4 mm) at 27 IPM
Rated
3/8 in (9.5 mm) at 14 IPM
Maximum Sever cut of
5/8 in (15.9 mm)
Electronic Pilot Arc Controller automatically
controls the pilot circuit to provide expanded metal
cutting capability without having to re-trigger the
torch, increasing productivity and extending tip life.
Pressure gauge and pressure knob for manual
adjustment of pressure to the torch.
*Recommended 30 A branch circuit for maximum performance.
Stock Number
(#903 891)
115/230 V, 60 Hz
Rated Output at
104˚F (40˚C)
Amps Input at Rated Output, 60 Hz, 1-Phase
115 V
230 V
KVA
KW
Compressor
Requirement
15 – 27 A at 90 VDC,
35% Duty Cycle
28*
4.5 CFM (128 L/min)
at 90 PSI (621 kPa)
14
3.3
3.2
Dimensions
H: 13 1⁄2 in (343 mm)
W: 8 1⁄2 in (216 mm)
D: 16 in (406 mm)
Net Weight
with Torch
55 lb (25 kg)
• Circle Cutting Guide #195 981
• Standoff
Roller
Guide
#194 883
• MIG Gloves
(pg 80)
• No. 30B Economy Cart with
Cord Wrap #300 511
• In-Line Air Filter Kit #228 926
(375 model only)
See your Miller distributor for other
popular Miller options and accessories.
71
A FLE10 Cat P 72 Plasma.qxd:Plasma
11/5/09
10:23 AM
Page 1
Plasma Cutters
MillerWelds.com
Spectrum 375 X-TREME
®
See Literature No. PC/9.2
✓
Mild Steel
Cutting Capability
Includes Industrial-Grade Technologies/Features (see pg 71)
Not to scale.
Allows for any input voltage
hook-up (115 – 230 VAC,
single-phase, 50/60 Hz) with no manual linking,
providing convenience in any job setting.
1/4 in (6.4 mm) at 27 IPM
Miller’s exclusive multi-voltage plug (MVP™)
allows connection to 115 or 230 V receptacles
without tools — choose the plug that fits the
receptacle and connect it to the power cord.
Rated
3/8 in (9.5 mm) at 14 IPM
Automatic air regulation automatically
compensates for input pressure variation to
provide constant recommended torch pressure
for optimum cutting performance.
Maximum Sever cut of
5/8 in (15.9 mm) —
cutting at 27 amps
(115 V, 20 A service
with 5-20P MVP or
230 V 6-50P MVP).
X-CASE™ provides the ultimate protection during
transport and storage. Additional space is ideal
for MVP plugs, consumables box, gloves, etc.
Shoulder strap allows the end user to easily
move from location to location.
Spectrum 375 X-TREME
includes X-CASE!
Stock Number
(#907 339)
115 – 230 V,
50/60 Hz
™
Input Power
Rated Output at 104˚F (40˚C)
Amps Input at
Rated Output,
50/60 Hz, 1-Phase
120 V (15 A)
20 A at 88 VDC, 35% Duty Cycle
20.6
2.5
2.3
120 V (20 A)
27 A at 92 VDC, 20% Duty Cycle
28.8
3.4
3.2
240 V
27 A at 92 VDC, 35% Duty Cycle
13.9
3.4
3.2
KVA
KW
Compressor
Requirement
4.5 CFM
(128 L/min)
at 90 PSI
(621 kPa)
Spectrum 625 X-TREME
®
Dimensions
H: 9 in (229 mm)
W: 51⁄2 in (140 mm)
D: 131⁄4 in (337 mm)
18 lb
(8.2 kg)
Rated
5/8 in (15.9 mm) at 12 IPM
Maximum Sever cut of
7/8 in (22.2 mm)
Automatic consumable detection detects
consumable type installed and adjusts gas
pressure to optimize cutting performance,
eliminating the need for a manual regulator.
Automatic air regulation automatically
compensates for input pressure variation to
provide constant recommended torch pressure
for optimum cutting performance.
X-CASE™ provides the ultimate protection during
transport and storage. Additional space is ideal for
MVP plugs, consumables box, gloves, etc.
Shoulder strap allows the end user to easily move
from location to location.
All Spectrum 625 X-TREME
models include X-CASE!
Stock Number
(#907 404)
208/230 VAC with 12 ft (3.7 m) Torch
(#907 404-01-1)
208/230 VAC with 20 ft (6.1 m) Torch
72
Rated Output
at 104˚F (40˚C)
Amps Input at Rated Output, 50/60 Hz
208 V
230 V
KVA
KW
Compressor
Requirement
40 A at 140 VDC,
50% Duty Cycle
33
6.0 CFM (170 L/min)
at 90 PSI (621 kPa)
30
6.8
6.6
• X-CASE™ for protection and storage
• ICE-27T hand-held torch with
12 ft (3.7 m) cable
• Heavy-duty work clamp with
12 ft (3.7 m) cable
• 10 ft (3 m) MVP™ power cord with
MVP™ plugs 5-15P (115 VAC, 15 A)
and 6-50P (230 V, 50 A)
• Consumables box with 3 electrodes
and 3 tips
• Built-in gas/air filter and regulator
625 Model Comes Complete With
• X-CASE™ for protection and storage
• ICE-40T hand-held torch with 12 ft
(3.7 m) or 20 ft (6.1 m) cable
• Heavy-duty work clamp with 12 ft
(3.7 m) or 20 ft (6.1 m) cable
• 12 ft (3.7 m) power cord
• Consumables box with 3 electrodes,
3 tips and deflector
• Built-in gas/air filter and regulator
Most Popular Accessories (pg 88)
• Circle Cutting Guide #195 981
See Literature No. PC/9.6
Auto-Refire™ provides ultimate convenience by
automatically controlling the pilot arc when cutting
expanded metal or multiple pieces of metal.
1/4 in (6.4 mm) at 60 IPM
375 Model Comes Complete With
• In-Line Air
Filter Kit
#228 926
™
Includes Industrial-Grade Technologies/Features (see pg 71)
Not to scale.
• Air Plasma Cutting
• Air Plasma Gouging with 625 model
Net Weight
with Torch
✓
Mild Steel
Cutting Capability
Light Industrial
Processes
Dimensions
Net Weight
with Torch
12 ft Torch
H: 9 in (229 mm)
W: 51⁄2 in (140 mm) 21 lb (10 kg)
1
D: 13 ⁄4 in (337 mm) 20 ft Torch
23 lb (11 kg)
• Standoff
Roller
Guide
#194 883
• Plasma Torch Consumable Kits
For ICE-27T #222 939
For ICE-40T #222 940
• MIG Gloves
(pg 80)
• X-CASE™ #300 184
• MVP™ Plugs (375 model only)
See your Miller distributor for other
popular Miller options and accessories.
A FLE10 Cat P 73 Plasma.qxd:Plasma
Call
11/5/09
10:23 AM
Page 1
Plasma Cutters
1-800-4-A-MILLER for more information.
Spectrum 875
Industrial
Processes
®
See Literature No. PC/9.8
Comes Complete With
✓
Mild Steel
Cutting Capability
Includes Industrial-Grade Technologies/Features (see pg 71)
Not to scale.
Auto Postflow calculates the length of postflow
time based on the amount of cutting time to
optimize consumable life and eliminate
excessive air usage.
1/2 in (12.7 mm) at 27 IPM
Rated
7/8 in (22.2 mm) at 10 IPM
Maximum Sever cut of
1-1/4 in (32 mm)
Most Popular Accessories (pg 88)
• Protective Cover
#300 388
Automatic air regulation compensates for
input pressure variation to provide constant
recommended torch pressure for optimum
cutting performance.
• No. 30B
Economy Cart
with Cord Wrap
#300 511
Patented
Ultra-Quick
Connect™ torch
and work cable
offers the fastest
plasma torch
and work cable
connection and
removal in the industry.
Rated Output
at 104˚F (40˚C)
Amps Input at Rated Output, 50/60 Hz
208 V
230 V
KVA
KW
Compressor
Requirement
(#907 390-01-1)
208/230 VAC with 20 ft (6.1 m) Torch
(#907 390-01-2)
208/230 VAC with 50 ft (15.2 m) Torch
60 A at 140 VDC
Duty Cycle:
208 V: 40%
230 V: 50%
47
6.75 CFM (191 L/min)
at 90 PSI (621 kPa)
9.9
• ICE-60T hand-held torch with
20 ft (6 m) or 50 ft (15.2 m) cable
• Heavy-duty work clamp with 20 ft
(6 m) or 50 ft (15.2 m) cable
• 10 ft (3 m) power cord
• Built-in gas/air filter and regulator
• Extra consumables
Auto-Refire™ provides ultimate convenience
by automatically controlling the pilot arc when
cutting expanded metal or multiple pieces
of metal.
Stock Number
42
• Air Plasma Cutting and Gouging
9.8
• RTI Filter and Bracket
#300 491
• Adapter
Cord
#300 517
Dimensions
H: 13 1⁄2 in (343 mm)
W: 8 3⁄ 4 in (222 mm)
D: 18 1⁄2 in (470 mm)
Net Weight
with Torch
20 ft 52 lb
(24 kg)
50 ft 61 lb
(28 kg)
Female
Receptacle
• 20 ft Cable
Cover #239 642
• 50 ft Cable
Cover #231 868
• Circle Cutting Guide #195 981
• MIG Gloves (pg 80)
See your Miller distributor for other
popular Miller options and accessories.
Inspire, Learn and Share!
MillerWelds.com Makes Welding Easy
Check out our Project Idea Gallery, with more than 700 inspiring projects.
Learn something new — with how-to articles, tech tips and videos
from the Improving Your Skills pages for MIG, TIG, Stick and Plasma.
Share your welding experiences with our growing list of 12,000 members
on our Welding Discussion Forums.
Get Ideas, Skills and Connections at MillerWelds.com/resources
Follow us:
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73
A FLE10 Cat P 74 Workstation Intro.qxd:Workstation
11/3/09
11:59 AM
Page 1
Workstations
“
Finally a workbench that is better than
one I can build, at a price I can afford.
Jim Wagner, Owner
Zero to 60 Garage
”
MillerWelds.com/ArcStation
ArcStation
™
The only workbench designed for welders.
Count on Miller to design the perfect workbench to make welding projects
faster and easier.
The new Miller ArcStation is the first-ever, all-in-one workstation designed
for welding and metalworking. It’s versatile. It’s affordable. And it comes in
two convenient table sizes and two tabletop configurations. Simply select
your frame size, approximately 30 x 30 inches or 30 x 60 inches, to meet
your space requirements and then select the top, either solid or X-Pattern,
to meet your needs. You can also customize your workbench with a wide
range of handy accessories.
Whether for the home shop or the fab shop, ArcStation’s the answer
you’ve been looking for.
ArcStation Makes Welding and Metalworking Easier!
No more welding on the floor or makeshift benches! ArcStation is just the
right height to work comfortably, with 360 degree access around the table.
It’s easy to clamp your work almost anywhere. And you can organize
equipment, tools and consumables into one convenient workspace.
You’ll get more done… better… faster… with less frustration.
74
This Isn’t Your Ordinary Workbench
ArcStation is properly engineered for the welding process,
with smart features designed for safety and convenience.
• Optional X-Pattern table top
with dust tray — makes
clamping and cleanup easy!
• Leveling feet — keep bench
rock-steady
• Work clamp lug — keeps
work clamps out of the way
• Lower shelf — provides a
convenient place to store
equipment, tools and raw
materials
Work Clamp Lug
Unmatched Miller Quality
Because it’s designed by Miller, you can depend on the
legendary quality of blue.
• Sturdy 1/8 in steel frame with
cross bar for added stability
• Solid 3/16 or 3/8 in steel tops
• Durable powder coat finish
• Sturdy pre-welded legs make
assembly easy
• Removable steel caps
close off the tubular legs
Pre-Welded Legs
A FLE10 Cat P 75 WorkStation.qxd:Workstation
Call
11/3/09
12:00 PM
Page 1
Workstations
1-800-4-A-MILLER for more information.
ArcStation 30 and 60 Series
™
See Literature No. WS/1.0
Miller’s 30 Series ArcStations are perfect for anyone who needs 360 degree access or has a small work envelope.
The 60 Series ArcStations are for those who need a larger work surface and sturdy all-purpose workbench.
Building Your Custom ArcStation is Easy!
• Choose
Select your frame size and top(s) for your
ArcStation. The ArcStation is a modular
system of base tables, which feature bolt
holes and open end tubes for connecting
different tops and accessories.
30S
• Accessorize
Personalize your ArcStation with your choice
of accessories. You can start with the basics
and add accessories as you go — even expand
or reconfigure your bench down the road.
60S
• Order
It’s simple to build your workbench your way
with Miller’s ArcStation configurator. It’s an
easy-to-use tool that walks you through your
options and helps you design your ideal
ArcStation. Print, save or email your
customized ArcStation. Build yours now at
MillerWelds.com/ArcStation. Call or visit your
local Miller distributor to place your order.
30SX
60SX
Build your own ArcStation and
check out the latest accessories at:
MillerWelds.com/ArcStation
Model/Stock Number
Steel Top
30S (#951 167)
(1) 29 x 29 x 3/16 in Solid
30SX (#951 168)
(1) 29 x 29 x 3/8 in X-Pattern
60S (#951 169)
(2) 29 x 29 x 3/16 in Solid
60SX (#951 170)
(1) 29 x 29 x 3/8 in Solid
(1) 29 x 29 x 3/8 in X-Pattern
1/8 in Steel Frame
Steel Leveling Feet
Dust Tray
Rear Stabilizing Bar
Tube Caps
Dimensions
Net Weight
H: 35 in (889 mm)
W: 29 in (737 mm)
D: 29 in (737 mm)
123 lb (56 kg)
H: 35 in (889 mm)
W: 58 in (1473 mm)
D: 29 in (737 mm)
230 lb (104 kg)
177 lb (80 kg)
318 lb (144 kg)
Most Popular Accessories
Miller’s ArcStation accessories allow you to get the most
out of your ArcStation.
7
1
10
2
6
5
3
4
1
2
3
4
Exclusive Clamp for X-Pattern Top #300 613
5
Quick-Remove Vise Kit (5 in vise/mount) #300 611
Quick-Remove Vise Mount (mount only) #300 612
6
7
Side Shelf #300 680*
8
Dust Tray (std with X-Pattern Top) #300 605
Tool Chest with Ball-Bearing Slides #300 610
Interior Shelf #300 679
Weld Curtain
30 Series (not shown) #300 685*
60 Series (shown) #300 686*
Convenience Kit #300 614 includes the following:
9
8
9
10
Tool Holder
10
Clamp Bar
Gun Holder
*Check for availability with your local Miller distributor.
Accessorized 60SX shown.
See your Miller distributor or MillerWelds.com for other
popular Miller options and accessories.
75
A FLE10 Cat P 76 Fume.qxd:Fume Intro
11/3/09
12:02 PM
Page 1
Fume Extraction
“
It does exactly what we wanted — a great job
pulling in the fume, the heavy duty brackets keep
the arm in place, and it fits well in the cells.
Paul Gitter, Foreman
Piping Systems Inc
”
MillerWelds.com/FumeExtraction
Choose the
Right Fume
Extractor
Fume Extractor
FILTAIR™ 130
FILTAIR™ MWX-S and MWX-D
Application
Portable, high-vacuum unit ideal for MRO,
contractors and intermittent welding
Mobile systems designed for manufacturing and
fabrication shops, schools and training facilities
Source/Submicron Capture
Yes
Yes
Filter Type
Manually cleanable filter
MWX-S: Self cleaning filter mechanism*
MWX-D: Disposable filter
Filter Media Area
16 ft2 (1.49 m2)
490 ft2 (45.52 m2)
CFM (Airflow)
132
875
Accessories
3 optional magnetic nozzles and a fume gun
—
*Self-cleaning filter mechanism is designed to increase productivity by greatly extending filter life, saving both filter costs and downtime.
FILTAIR 130
Processes
™
• Stick (SMAW) • Flux Cored (FCAW)
• MIG (GMAW) • TIG (GTAW)
See Literature No. AY/3.1
Portable weld fume extractor designed with 132 CFM
and a high-efficiency cartridge filter to collect weld fume
particles at the source.
Designed exclusively for welding applications.
Highest performing filter in the industry will last longer and capture the
smallest submicron (<1 micron) particles. Miller’s filter is manually cleanable
and the unit features a fume collection tray to minimize maintenance.
Comes With
• Filter • 8 ft collection hose
Most Popular Accessories
• Collection Hose
17 ft (5.2 m) #300 672
34 ft (10.4 m) #300 673
• Magnetic Nozzles
11.8 in (300 mm) width #300 669
23.6 in (600 mm) width #300 670
Less noise — One of the quietest portable systems in the industry at
68.5 dBA at 5 ft.
Easy to use — Adjustable airflow control allows you to change your airflow
capacity for different welding applications.
Portable and compact unit has castor wheels and handle bar to increase
portability, allowing operators to maneuver into small spaces or hard-to-reach
areas. Includes 20 ft power cord and an 8 ft collection hose.
Stock Number
Filter Media
Nominal Airflow
Sound Level
Motor
Input Power
Dimensions
Net Weight
(#300 595)
16 ft2 (1.49 m2)
132 CFM (62 L/sec)
68.5 dBA at 5 ft (1.5 m)
1 HP
115 VAC/1-Phase/60 Hz
at 11 A
H: 23 in (584 mm)
W: 12 in (305 mm)
D: 12 in (305 mm)
46 lb (92 kg)
76
• Flexible Funnel Magnetic Nozzle
#300 668
• Disposable Filter #300 671
• Bernard® Clean Air Gun Series
Ideal for almost any heavy-duty
MIG welding application. Attaches
to FILTAIR 130 with gun adaptor
and available in 400 and 600 A
models. Contact Bernard® at
1-800-946-2281 to order.
A FLE10 Cat P 77 Fume.qxd:TIG
Call
11/3/09
12:03 PM
Page 1
Fume Extraction
1-800-4-A-MILLER for more information.
FILTAIR Mobile Series
Processes
™
See Literature
No. AY/3.0
• Stick (SMAW)
• Flux Cored (FCAW)
• MIG (GMAW)
• TIG (GTAW)
MWX-S (self cleaning) and MWX-D (disposable filter) source capture systems feature
nanofiber filter technology for extended filter life, increased efficiency and cleaner air.
Comes With
• Filter
Most Popular Accessories
Designed exclusively
for welding
applications.
MWX-D
(disposable
filter) model
also available.
MWX-S (self-cleaning)
model with 10 ft
extraction arm shown.
Features Common to Both Models
Superior filter life from Miller’s exclusive MERV 15
nanofiber filter ensures capture of submicron weld
fumes, more holding capacity and the ability to maintain
low pressure drop—resulting in a longer lasting filter
and a cleaner work space.
MERV 15 rating of FILTAIR nanofiber filters is the highest
in the industry. Up to 95% of weld fumes are submicron
and FILTAIR filters capture 85 – 95% of these particles.
• Replacement FILTAIR Filters
Self-Cleaning Filter #300 540
Disposable Filter
#300 539
Nanofiber cartridge filter features
an ultra-thin surface webbing of
tiny fibers to capture weld fumes
on the surface of the filter instead
of within. This extends the filter life,
maintains longer lasting air flow,
and lengthens your maintenance
intervals. FILTAIR’s MERV 15* filter
provides higher efficiency and
longer filter life overall.
*MERV (Minimum Efficiency Reporting
Value) is between 1 and 16. A higher
MERV indicates a more efficient filter and
is more effective against submicron-sized
particles .30 to 1.0 micron.
Strong suction power of 875 CFM delivers long-lasting
airflow throughout the life of the filter.
Extraction arm is obstruction free so air can pass
through with less airflow resistance, giving you stronger
CFM (airflow).
MWX-S Self-Cleaning Model Additional Features
Miller’s nanofiber filter is surface loading.
Weld fume does not penetrate deep into the filter.
This enables particles to be easily released during
the cleaning process and keeps pressure drop low.
One-minute cleaning cycle operates with a push of a
button on the control panel.
Disposal drawer provides easy and convenient access
to empty out collected particles. Handle releases drawer
allowing it to slide out.
Note: Compressed air required to operate cleaning mechanism.
Air-Cleaning Efficiency with Specific Particulate Sizes
100%
MERV 15
Miller FILTAIR Nanofiber Filter
80%
Efficiency
Self-cleaning filter technology features an innovative
filter cleaning mechanism designed to increase
productivity and greatly extend filter life.
60%
RV
ME
40%
11
7- Competitive
Filters
20%
0
0.1 0.2
0.3
0.4
86% Weld Fume
(Exact % depends on process)
0.5
0.6
1
1.5
2
2.5
Particle Size (µm)
Model/Stock Number
Filter Media
Nominal Airflow
Extraction Arm Diameter
Sound Level
Motor
Input Power
Dimensions
Net Weight
MWX-S (Self-Cleaning) Models
(#951 178) 7 ft extraction arm
(#951 179) 10 ft extraction arm
(#951 180) 12 ft extraction arm
490 ft2 (45.52 m2)
875 CFM (413 L/sec)
8 in (203 mm)
Approximately
70 dBA at
5 ft (1.5 m)
1 HP,
3450
RPM
115 V/1-Ph/60 Hz
at approximately
12.5 A
H: 34 3⁄4 in (883 mm)
W: 313⁄4 in (806 mm)
D: 48 in (1219 mm)
300 lb
(136 kg)
MWX-D (Disposable Filter) Models
(#951 143) 7 ft extraction arm
(#951 144) 10 ft extraction arm
(#951 145) 12 ft extraction arm
238 lb
(108 kg)
77
A FLE10 Cat P 78 Protection Intro.qxd:Welding Protection
11/13/09
9:49 AM
Page 1
Welding Protection
“
Miller has made great strides in having the
safety gear available to us. It's definitely a
benefit to get everything from one source.
”
Bill Lancour,
Machinery and Welder Corporation
MillerWelds.com/WeldingProtection
We’re redefining welding protection with products that
provide optimal fit, comfort, performance and style,
resulting in safer, more productive work environments.
THAT’S THE ARC ARMOR DIFFERENCE.
™
Respiratory
Heat Stress
Available
1st Quarter
*MP-10 ™, Elite™ and Titanium™ Series.
78
PAPR
Powered Air-Purifying Respirator
#235 671
With Auto-Darkening Lens Assy
#237 811
Without Auto-Darkening Lens Assy
• Lightweight design provides all day
comfort
• Comfortable load-bearing shoulder
straps for extended wear
• Two air speeds for increased comfort
in varied working conditions
• Audible and vibrating alarms notify
user in noisy environments
• Low-profile blower design for
unrestricted movement
Half Mask
Available
1st Quarter
CoolBand™
CoolBelt™
Belt-Mounted Cooling System
#245 230
• Provides all-day comfort through
maximized airflow power
• Up to 17°F cooler under the hood
• Multiple airflow speeds eliminate
stagnant air and reduce fogging
• Lightweight design extends
wearability
• Compatible with most Miller
Helmets*
#245 642
• Lightweight, unique design ensures
optimal all day comfort
• 4-Point head strap allows for
convenient adjustability
• Patented low-profile filter design
provides maximum field of vision
• Flexible materials used to fit the
contours of one’s face and under the
welding helmet
Available
1st Quarter
Integrated Headgear Cooling System
#244 094
• Provides all-day comfort through
optimized airflow distribution
• Up to 8°F cooler under the hood
• Strategically placed air vents reduce
fogging
• Constant air movement removes
stagnant air
• Removable air deflector provides
airflow adjustability
• Compatible with most Miller
Helmets*
A FLE10 Cat P 79 Helmets.qxd:Apparel
Call
11/13/09
10:24 AM
Page 1
Welding Protection
1-800-4-A-MILLER for more information.
Head and Face
Hard Hat Adapter
#213 110 (XL and XLi)
#222 003 (All other Miller Series)
• Compatible with Fibre Metal
and MSA hats. Other brands
may also fit depending on
size and shape. Helmet and
hat not included.
Titanium™ Series
9400i
features
integrated
grinding shield.
1
2
3
4
1
2
3
9400i: #245 804
9400: #234 939
7300: #245 800
1600: #245 799
2x4 Auto-Darkening Lens
#770 660 (Shade 8)
#770 659 (Shade 9)
#770 226 (Shade 10)
• Fits all 2x4 inch windows
• 2 arc sensors
• Solar powered
• Light state shade #3
• 2-year warranty
4
Elite™ and Digital Elite™ Series
E: Elite Models
DE: Digital Elite Models
5 Black
E: #241 975 DE: #241 979
6 Stars and Stripes II™
E: #234 065 DE: #234 762
Safety Glasses
7 Vintage USA™
8
5
6
7
8
9
10
11
12
9
11
10
12
13
13
E: #237 838 DE: #236 340
Inferno™
E: #222 669 DE: #234 761
Wicked™
E: #241 464 DE: #241 462
Lucky’s Speed Shop™
E: #237 744 DE: #237 745
The Joker ™
E: #227 187 DE: #235 041
Maple Leaf ™
E: #222 670 DE: N/A
Camouflage
E: #227 188 DE: N/A
#238 979
(Black, clear lens)
#235 658
(Black, shade 5 lens)
#235 657
(Blue, shade 5 lens)
#235 659
(Orange, shade 5 lens)
• Form fitting orbital eye
coverage
• ANSI Z87.1 compliant
Available
1st Quarter
Performance™ Series
14
15
16
17
18
19
Model
22
Shade Type (all lenses
have light state 3)
20
Black: #232 035
America’s Eagle™: #232 036
Motorsports™: #232 039
Blue Rage™: #241 458
Fireball™: #234 514
Millermatic™ II: #232 037
Camouflage: #241 460
MP-10™ Series
Pro-Hobby™ Series
21
14
15
16
17
18
19
20
25
21 Black: #231 404
26 Black
22
23
24
25
27 Inferno™
6 Pack: #235 626
Each: #238 497
Fixed Shade Black: #231 703
American Eagle™ II: #231 405
Red Flame: #231 408
Millermatic™: #231 406
Camouflage: #231 407
23
24
Viewing Field
Arc
Sensors
Grind
Mode
Power
Control
Power Supply
6 Pack: #235 627
Each: #238 496
26
27
Lens Speed
(Seconds)
Sensitivity
Control
Delay
Control
TIG
Rating
Magnifying
Lens Holder
Weight
Titanium™
9400i and 9400
Variable Shade 8–13
3.85 x 2.38 in
(97 x 60 mm)
4
Yes
Auto-On
Auto-Off
Replaceable lithium batteries,
(2) 3000 hrs
1/20,000
Yes
.10–1.0 sec
5 amps
Yes
24 oz
(680 g)
Titanium™
7300
Variable Shade 8–13
3.85 x 1.85 in
(97 x 47 mm)
3
Yes
Auto-On
Auto-Off
Replaceable lithium batteries,
2000 hrs
1/20,000
Yes
.10–1.0 sec
5 amps
Yes
19 oz
(539 g)
Titanium™
1600
Passive Shade 10
4 x 4 in
(102 x 102 mm)
0
No
N/A
N/A
N/A
N/A
N/A
N/A
Yes
17 oz
(482 g)
Digital Elite™
Series
Variable Shade 8–13
(5–8 for cut mode)
3.85 x 2.38 in
(97 x 60 mm)
4
Yes
Manual-On
Auto-Off
Replaceable lithium batteries,
(2) 3000 hrs
1/20,000
Yes
.10–1.0 sec
5 amps
Yes
18 oz
(510 g)
Elite™
Series
Variable Shade 8–13
3.85 x 2.38 in
(97 x 60 mm)
4
Yes
Auto-On
Auto-Off
Replaceable lithium batteries,
(2) 3000 hrs
1/20,000
Yes
.10–1.0 sec
5 amps
Yes
18 oz
(510 g)
Performance™
Series
Variable Shade 8–13
3.85 x 1.85 in
(97 x 47 mm)
3
Yes
Auto-On
Auto-Off
Replaceable lithium batteries,
2000 hrs
1/20,000
Yes
.10–1.0 sec
5 amps
Yes
17 oz
(482 g)
Pro-Hobby™
Series
Variable Shade 8–12
3.85 x 1.57 in
(97 x 40 mm)
2
No
Manual-On
Auto-Off
Replaceable alkaline batteries,
(2) 2000 hrs
1/12,000
Yes
Slow/Fast
20 amps
Yes
16 oz
(454 g)
Pro-Hobby™
FS #10
Fixed Shade 10
3.70 x 1.37 in
(94 x 35 mm)
2
No
Auto-On
Auto-Off
Rechargeable solar cell
1/3,600
No
No
20 amps
Yes
16 oz
(454 g)
MP-10™ Series
Passive Shade 10
4 x 4 in
(102 x 102 mm)
0
No
N/A
N/A
N/A
N/A
N/A
N/A
Yes
18 oz
(510 g)
79
A FLE10 Cat P 80 Apparel.qxd:Helmets
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12:08 PM
Page 1
Welding Protection
MillerWelds.com
Hand and Body
Classic Cloth Jacket
INDURA® Cloth Jacket
Combo Jacket
Leather Jacket
• 9 oz flame-resistant cotton
• Barracuda-style collar
• Fold-in sleeve snaps
• High-visibility Miller logo
• INDURA® flame-resistant cotton
(flame resistant guaranteed
for life of jacket)
• Nomex® flame-resistant thread
• Allows for patented bib/apron attachment
• INDURA® flame-resistant cotton
(flame resistant guaranteed for
life of jacket)
• Premium top grain leather
• Allows for patented bib/apron attachment
• Premium top grain leather
• Expandable leather strategically
placed for optimal mobility
• Satin lined
• Tapered, athletic cut
H.D. MIG/Stick Gloves
TIG Gloves
MIG Gloves
Metalworker Gloves
• Developed for heavy-duty MIG
and Stick welding applications.
• Designed to meet the specific requirements
high quality TIG welding demands.
• Crafted specifically for medium-duty MIG
welding applications.
• Intended for daily demands of the
metalworker and material handler.
Jackets
and
Gloves
Classic Cloth Jacket
INDURA® Cloth Jacket
Combo Jacket
Leather Jacket
Small
#244 749
#231 072
#231 080
#231 088
Medium
#244 750
#231 073
#231 081
#231 089
Large
#244 751
#231 074
#231 082
#231 090
X-Large
#244 752
#231 075
#231 083
#231 091
2X-Large
#244 754
#231 076
#231 084
#231 092
3X-Large
#244 755
#231 077
#231 085
#231 093
4X-Large
#244 756
#231 078
#231 086
#231 094
5X-Large
#244 758
#231 079
#231 087
#231 095
H.D. MIG/Stick Gloves
TIG Gloves
MIG Gloves
Metalworker Gloves
#227 825
#227 813
#227 821
#227 817
#227 826
#227 814
#227 822
#227 818
#227 827
#227 815
#227 823
#227 819
#227 828
#227 816
#227 824
#227 820
#235 047
#235 048
#235 046
#235 049
—
—
—
—
—
—
—
—
—
—
—
—
Bib/Apron
#231 125
• Attaches with snaps across
the chest as a bib or along
the bottom as an apron
80
Welding Sleeves
Job-Site Tool Bag
Head Threads
Protection Paks
#231 096
• INDURA® flame-resistant
cotton/top grain leather
• 21 in (533 mm) length
#228 028
• Over 20 separate pockets
• Opening of 12 x 18-1/2 in
(305 x 470 mm)
• Bandannas have a sewn-in
sweatband
• Caps are reversible with a
low, soft bill
• See your distributor for
styles and sizes
• Starter Pak (includes
#231 404 Pro-Hobby™ helmet)
Large
#239 725
X-Large #239 726
2X-Large #240 885
• Performance Pak (includes
#232 035 Performance™ helmet)
Large
#240 886
X-Large #240 887
2X-Large #240 888
A FLE10 Cat P 81 Accessories Intro.qxd:Accessories
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Page 1
Contents
Accessories
Aluminum MIG Welding 27– 29
See Spoolmate, Spoolmatic, and
XR-Control System
Advanced Manufacturing
System Accessories 81
Carts, Cylinder Racks and
Running Gear 81–82, 84, 88
Controls
The right welding and cutting accessories increase convenience, save time
and money, perform better and help you meet the demands of any job. For
more information about accessories, visit MillerWelds.com/Accessories
See Advanced Manufacturing
System, MIG, TIG or Wire Feeder
Accessories, Polarity Switches/
Controls, and Remote Controls
Coolant Systems 83
Engine Drive Accessories 84–85
Generator Accessories
Maintenance
Package Expansions
Portability
Protection
Trailers
International-Style Connectors 86
Load Banks 86
Meters 86
MIG Accessories 86
Accessory Kits
Protective Covers
Pulsing Control
MillerWelds.com/Accessories
Aluminum MIG Welding
See Spoolmate, Spoolmatic and
XR-Control System on pages 27– 29.
Carts, Cylinder Racks and
Running Gear
See also Engine Drive Accessories
and Plasma Accessories.
Advanced Manufacturing
System Accessories
For adapters and drive motors,
visit MillerWelds.com.
Feeder Cart
#142 382
A low-profile,
creeper cart
which allows
the operator
to easily move the feeder around the
work area.
MIG Guns and Accessories 87
Plasma Cutter Accessories 88
Cable Covers
Cart
Cutting Guides
Filters
Plugs and Cords
Protective Covers
Torches
Polarity Switches/Controls 88
Remote Controls 89, 90
Spot Welder Gyro Bail 89
Stick Accessory Kits 89
Sub Arc Accessories 89
Consumables Handling
Control Accessories
Drive Assembly Drive Rolls
Torch Accessories and Tips
Welding Carriages
TIG Accessories 90
High-Frequency Arc Starters
Kits
Modules
Protective Covers
Remote Controls
Wire Feeder Accessories 91
Extension Cords and Kits
Power Supply Adapters
Secondary Contactor
Spool Adapter
Spool Gun Controls
Spoolmate 3035 Spool Gun
Turntable Assembly
Wire Straightener
Coolant Flow Switch #195 461
For Auto-Axcess. To ensure coolant is
flowing in the system. Lack of coolant
flow may cause damage to watercooled guns. Module allows wiring
into the peripheral connector port.
50 ft (15.2 m) cable with connector
and separate shell connector for
simple modification to desired length
in the field. It can be mounted on
Auto-Axcess or as desired elsewhere.
1/4-turn quick connection.
MCS-2 Motorized Cross Slide
#098 380 Control
#045 623 Adapter Plate*
Provides accurate weld head
adjustment with convenient motorized
control. Used to align the welding head
(gun) to the weld joint, by providing
vertical or horizontal adjustments,
based on mounting preferences.
*Required when using two slides.
Carrying Cart #056 301
For smaller Maxstars, CST 280,
XMTs, and wire feeders. Cart is
34 in high x 30 in wide x 17 in deep
(864 x 762 x 432 mm).
Cylinder Cart #042 537
For Invisions, CST 280, and XMTs.
Has adjustable handles and is slanted
for convenient access to power
source front panel controls. Carries
two 160 lb (72.6 kg) gas bottles or one
gas bottle and one Coolmate V3 for
TIG welding. Feeder mounted to tray
above power source. Accommodates
Coolmate 3 or 4 coolant systems.
Universal Cart and Cylinder Rack
#042 934
For Invision 352 MPa, CST 280,
Maxstar 200 Series, Dynasty 200
Series, Diversion 165 and 180, and
XMT 304 and 350. Also accommodates
gas cylinder up to 56 in (142.2 cm)
high measuring 6 to 9 in (15.2 to
22.8 cm) in diameter. Provides
storage for auxiliary items such as
electrodes, helmets and gloves.
MIGRunner ™ Cart #195 445
For AlumaFeed System, Invision 352
MPa, and XMT 304 and 350. Small
footprint and easily maneuverable,
with cylinder rack low enough that
you do not have to lift bottles.
Durable, heavy-duty ergonomic
handles are designed for comfort.
81
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Page 1
Accessories
MillerWelds.com
2-Wheel Trolley
Cart #300 480
For Maxstar 200
Series and Dynasty
200 Series to be
used with or
without Coolmate 1.
Easy-to-maneuver
two-wheel cart
features singlecylinder rack, chain for cylinder, straps
(quick and easy to detach and carry
machine), cable holders, torch holder,
storage area, and filler rod storage area.
Running Gear Cylinder Rack
#300 408
For Invision 352 with dual feeder,
Invision 456 models, Axcess 300 and
450, and XMT 456. Holds two large
gas cylinders and has gun cable
hangers and a consumable drawer in
front for easy access. A convenient
handle allows the cart to be pulled
easily through doorways. System
components including power
source, single or dual feeders, and
Coolmate™ V3 can be mounted to
the cart and secured.
Dual
EZ-Change™
Low Cylinder
Rack with
Elevated Gun
and Cable Rack
#300 337
For Millermatic
212 Auto-Set,
and 252. Allows
operators to
easily roll cylinders on and off the rack
with no lifting. Gun and cable rack keeps
cables off the floor and tangle free.
Elevated Gun and Cable Rack
#300 335
For Millermatic 212 Auto-Set, and 252.
For use with single cylinder rack.
(Included with Dual EZ-Change Low
Cylinder Rack.)
Dual
Cylinder Rack
#195 299
For Millermatic
350/350P.
Replaces single
cylinder rack.
No. 37 Running Gear #195 282
For Syncrowave 250 DX and 350 LX.
Includes two 10 in (254 mm) wheels,
two 5 in (127 mm) casters, twocompartment rack (for gas cylinder(s)
or Coolmate V3 coolant system), and
handles. Provides excellent mobility
and easy to install.
No. 39 Running Gear #300 009
For Syncrowave 200. Includes low
cylinder rack, two 8 in (203 mm)
wheels and two 4 in (102 mm) casters.
Has two-compartment, integrated filler
material storage and will accommodate
one gas cylinder up to 60 in (152 cm)
high and 9 in (23 cm) in diameter.
No. 20 Running Gear #041 581
For SRH-444. Includes four 8 in
(203 mm) poly/rubber-blend wheels
and a 30 in (762 mm) towing handle.
Runner™ Cart #300 244
For Maxstar 350 and 700, and
Dynasty 350 and 700 to be used with
or without Coolmate 3.5. Cart features
single cylinder rack, foot pedal holder,
(3) cable/torch holders, (2) TIG electrode
filler holders and a convenient drawer
for tungsten and consumable storage.
82
Small Running Gear/Cylinder Rack
#300 425
For Millermatic 140 Auto-Set, 180
Auto-Set, and 211 Auto-Set. Durable
construction. For gas cylinders no
larger than 7 in (178 mm) diameter,
maximum weight 75 lb (34 kg).
Shown with
optional
cylinder rack
(#042 887).
PipePro System Cart #300 334
For PipePro Welding System. Same as
#300 408 above, but is 4 inches taller
to accommodate the optional Process
Selector Control (#042 872).
No. 19 Running Gear #041 580
For Dialarc 250 AC/DC. Four 8 in
(203 mm) poly/rubber-blend wheels
with 30 in (762 mm) towing handle.
Running Gear/Cylinder Rack
#770 187
For Millermatic 140 Auto-Set, 180
Auto-Set, 211 Auto-Set, and Diversion
165 and 180. Heavy-duty construction.
For gas cylinders no larger than 7 in
(178 mm) diameter, maximum weight
100 lb (45 kg).
Shopmate 300 Running Gear/
Dual Cylinder Rack #300 145
For Shopmate 300/300 DX. The large
10 in (254 mm) rear wheels and 5 in
(127 mm) front casters on this running
gear provide excellent mobility on the
shop floor, making it easier to move
the power source. Very easy to install.
Handles double as a cable holder.
Holds two cylinders.
Standard Running Gear #042 886
For CP-302, Deltawelds, Gold Stars,
and Dimensions. The 10 in (254 mm)
rear wheels and 5 in (127 mm) front
casters on this running gear provide
excellent mobility on the shop floor,
making it easier to move the power
source. Very easy to install. Handles
double as a cable holder.
Standard Cylinder Rack #042 887
Installs on Standard Running Gear
(#042 886) only.
Thunderbolt XL
Running Gear
#043 927
Mounts easily to
unit and provides
convenient
portability.
Includes two
wheels, two feet
and a handle.
A FLE10 Cat P 83 Accessories.qxd:Accessories
Call
11/3/09
2:59 PM
Page 1
Accessories
1-800-4-A-MILLER for more information.
Coolant Systems
Coolmate 1
Coolmate 3
See Literature No. AY/7.2
Coolmate V3
Coolmate 3.5
Coolmate 3X
Coolmate 4
Includes wheels, handles
and dual cylinder rack.
Coolmate™ 3.5 #300 245
For Maxstar 350 and 700, and
Dynasty 350 and 700. Industrial,
3.5-gallon cooler designed for watercooled torches rated up to 600 A*.
Coolmate™ 1
#300 360 115 VAC
#300 459 230 VAC
For Maxstar 200 Series, Dynasty 200
Series, and Syncrowave 200. Light
industrial, 1-gallon cooler designed
for water-cooled torches on power
sources rated up to 200 A*.
Coolant
Sold in multiples of four in 1-gallon
recyclable plastic bottles. Miller coolants
contain a base of ethylene glycol and
deionized water to protect against freezing to
-37°F (-38°C) or boiling to 227°F (108°C).
Coolmate™ 4 #042 288
The best performer in its class —
industrial, 4-gallon cooler designed
for water-cooled torches rated up to
600 A*.
Coolmate™ 3
#043 007 115 VAC
#043 008 230 VAC
Economical, 3-gallon cooler designed
for water-cooled torches rated up to
500 A*.
Coolmate™ V3 #043 009
Vertical, 3-gallon cooler designed for
water-cooled torches rated up to 500 A*.
Coolmate™ 3X #300 419
For Syncrowave 250 DX and 350 LX.
Industrial, 3-gallon cooler designed
for water-cooled torches rated up to
500 A*. Includes wheels, handles and
dual cylinder rack.
Low-Conductivity Coolant
(Clear, Pre-Mixed) #043 810
For TIG and MIG applications. NOT
for use in push-pull systems or
systems where aluminum is in
coolant path/circuit.
Aluminum-Protecting Coolant
(Green, Pre-Mixed) #043 809
Primarily used in push-pull systems
where aluminum is in coolant
path/circuit and high frequency is
NOT used.
*May vary with torch design and cable length.
Miller coolant systems are backed by the best warranty in the industry — 1 full year.
Model
Motor Input Voltage
Maximum Current Draw
Maximum Cooling Capacity
IEC Cooling Capacity
Tank Capacity
Dimensions
Net Shipping Weight
Coolmate 1
115 VAC, 60 Hz
2.1 A (60 Hz)
0.65 A (50 Hz), 0.55 A (60 Hz)
1210 W (4120 BTU/hr)
1.1 qt/min (1 L/min)
1 gal
(3.8 L)
H: 8 in (203 mm)
W: 7 1 ⁄2 in (191 mm)
D: 23 3⁄4 in (603 mm)
29 lb (13 kg)
230 VAC, 50/60 Hz
2850 W (9700 BTU/hr)
1.8 qt/min (1.7 L/min)
115 VAC, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
2.5 A (50 Hz), 3.0 A (60 Hz)
1420 W (4840 BTU/hr)
1.1 qt/min (1 L/min)
3 gal
(11.4 L)
H: 13 1 ⁄4 in (337 mm)
W: 12 1 ⁄4 in (311 mm)
D: 23 1 ⁄4 in (584 mm)
43 lb (20 kg)
230 VAC, 50/60 Hz
3820 W (13,000 BTU/hr)
4.2 qt/min (4.0 L/min)
Coolmate V3
115 VAC, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
3820 W (13,000 BTU/hr)
4.2 qt/min (4.0 L/min)
1420 W (4840 BTU/hr)
1.1 qt/min (1 L/min)
3 gal
(11.4 L)
H: 33 in (838 mm)
W: 9 1 ⁄4 in (235 mm)
D: 9 1 ⁄4 in (235 mm)
54 lb (24 kg)
Coolmate 3.5
115 VAC, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
4140 W (14,000 BTU/hr)
5.0 qt/min (4.7 L/min)
1660 W (5660 BTU/hr)
1.1 qt/min (1 L/min)
3.5 gal
(13.2 L)
H: 11 3⁄4 in (298 mm)
W: 15 3⁄4 in (400 mm)
D: 26 in (660 mm)
70 lb (32 kg)
Coolmate 4
115 VAC, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
5500 W (18,000 BTU/hr)
5.9 qt/min (5.6 L/min)
1780 W (6070 BTU/hr)
1.1 qt/min (1 L/min)
4 gal
(15 L)
H: 16 1 ⁄4 in (413 mm)
W: 15 1 ⁄4 in (387 mm)
D: 18 3⁄4 in (476 mm)
40 lb (18 kg)
Coolmate 3X
115 VAC, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
4140 W (14,000 BTU/hr)
5.0 qt/min (4.7 L/min)
1660 W (5660 BTU/hr)
1.1 qt/min (1 L/min)
3 gal
(11.4 L)
H: 17 in (432 mm)
W: 27 in (686 mm)
D: 39 in (991 mm)
158 lb (72 kg)
Coolmate 3
83
A FLE10 Cat P 84 Accessories.qxd:Accessories
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2:59 PM
Page 1
Accessories
Engine Drive Accessories
All-Purpose Running Gear with
Protective Cage
#300 428 With inner tubes
#300 478 With Never Flat ™ tires
For Gas/LP Bobcats and Trailblazers
(except Air Pak model). Running gear
and rugged cage with cable holders
protects your investment and is easy
to move around flat surfaces.
See also Remote Controls and HF Arc
Starters on pages 89 and 90.
Generator Accessories
Female
Receptacle
Adapter Cord, Full KVA
#300 517 Field
For Bobcats, Trailblazers, Big Blue
300 Pro, and PipePro 304. NEMA
14-50P to NEMA 6-50R. Adapts engine
drive 120/240 V plug to common
Millermatic and Spectrum 240 V plug.
1-Phase Full KVA
Plug Kit #119 172
For Bobcats, Trailblazers,
Big Blue 300 Pro, and
PipePro 304. Used to
run plasma systems on engine drive
generator power.
MillerWelds.com
Gas Cylinder Mounting Assembly
#195 330
For Gas/Diesel Bobcats and Trailblazers
(except Air Pak model). Designed for
use with the All-Purpose Running
Gears (see note below), Protective
Cage, or by itself. Includes base tray
with bottle bracket, vertical support
rack and safety chain.
Note: Not recommended for diesel models
when equipped with All-Purpose Running
Gear. Cannot be used with LP Tank Mounting
Assembly or All-Terrain Running Gears.
All-Terrain Running Gear EZ
#300 572 With inner tubes
#300 574 With Never Flat ™ tires
For Gas Bobcats and Trailblazers
(except Air Pak model). Includes
two heavy-duty 15 in tires, two
10 in pneumatic tires with innertubes
and a rugged handle to provide
maximum maneuverability.
Note: Not for use with Gas Cylinder Mounting
Assembly or LP Tank Mounting Assembly.
3-Phase Full KVA Plug Kit
#165 963 For Bobcat 3 Phase.
#007 470 For PipePro 304.
Maintenance
Remote Oil Drain & Filter Kits
Rear Mounted (shown)
#300 106 Field For Kohler
#300 417 Field For Subaru
Oil can be drained from the rear of
the machine.
Front/Chassis Truck Mounted
#300 236 Field For Kohler
#300 418 Field For Subaru
Oil can be drained from the front of the
machine or below the truck, mounted
on the chassis.
LP Tank Mounting Assembly
#195 329
For LP Bobcats and Trailblazers.
Designed for use with the All-Purpose
Running Gears, Protective Cage, or by
itself. Includes bracket and clamp to
mount 33 and 43 lb tanks horizontally,
and hose with fittings to converter.
Note: Cannot be used with Gas Cylinder
Mounting Assembly or All-Terrain
Running Gears.
See also Trailers on page 85.
Package Expansions
84
All-Purpose Running Gear
#300 396 With inner tubes
#300 477 With Never Flat ™ tires
For Gas/LP Bobcats and Trailblazers
(except Air Pak model). Includes two
heavy-duty 15 in tires, two 8 in swivel
casters and a heavy-duty handle.
Recommended for all surfaces and
applications and is easy to move
around the jobsite.
#195 333
cover shown.
Protective Covers
Heavy-duty, water- and mildew-resistant
covers protect and maintain the finish of
welders. See MIG, Plasma Cutter, and
TIG Accessories for additional covers.
#195 193 For Blue Stars.
#300 496 For Wildcat 200.
#195 333 For Bobcats, and Trailblazer
302 and 275 DC (Gas)
without Protective Cage
or Running Gear.
#195 529 For Bobcats, and Trailblazer
302 and 275 DC (Gas)
with Running Gear.
#195 334 For Bobcat 250 Diesel and
Trailblazer 302 Diesel
without Protective Cage
or Running Gear.
#300 379 For Trailblazer 302 Air Pak.
#195 301 For Big Blue 300 Pro.
#195 125 For PipePro 304.
#194 683 For Big 40, and
Big Blue 400 and 500.
#195 159 For Big Blue Air Pak and
Big Blue Turbo.
Note: Not for use with Gas Cylinder Mounting
Assembly or LP Tank Mounting Assembly.
Lifting Eye
#195 353
For Blue Stars.
Portability
For Gas Bobcats and Trailblazers.
Makes servicing easy when mounted
in tight spots.
Cable Holder
#043 946
For Big 40,
Big Blue 400
and 500,
Big Blue Air
Pak, and Big
Blue Turbo.
All-Terrain Running Gear EZ with
Protective Cage
#300 573 With inner tubes
#300 575 With Never Flat ™ tires
For Gas Bobcats and Trailblazers
(except Air Pak model). Running gear
and rugged cage with cable holders
protects your investment and is easy
to move around the jobsite.
Protection
No. 38 Hand
Running
Gear
#195 352
For Blue
Stars.
Compact and balanced, lightweight
wheelbarrow-style running gear
designed for easy onsite mobility.
Wildcat 200 Running Gear
#300 532
For Wildcat 200. Running gear
designed for excellent portability on
the jobsite.
Protective Cage with Cable Holders
#195 331 For Gas/LP models
#300 052 For Diesel models
For Bobcats and Trailblazers
(except Air Pak model). Rugged cage
with cable holders protects your
investment. Works with Running Gear,
Gas Cylinder Mounting Assembly or
LP Tank Mounting Assembly.
Vandalism
Lockout Kit
#195 118 Field
For Big 40, Big Blue
400 and 500,
Big Blue Air Pak,
and Big Blue Turbo.
Lockable hinged
steel panels cover
and protect name plate gauges and
ignition switch (padlock included).
Also includes engine compartment
door lock and key.
A FLE10 Cat P 85 Accessories.qxd:Accessories
Call
11/3/09
3:00 PM
Page 1
Accessories
1-800-4-A-MILLER for more information.
Trailers
See Literature No. AY/20.0
HWY-1000 Trailer #195 013
For Wildcat 200, Bobcats, and Trailblazers (except Air Pak model). A 1000 lb
(454 kg) capacity highway trailer with welded steel tubing frame, heavy-duty
axle with roller bearing hubs and leaf-spring suspension. The HWY-1000
comes with jack stand, 2 in (50 mm) ball hitch, fenders and lights.
HWY-224 Trailer #043 805
OFR-224 Trailer #043 802
For Bobcats, Trailblazers, Big 40, Big Blue 400 and 500, PipePro 304, Miller
Du-Op, Big Blue Turbo, and Big Blue Air Pak. A 2650 lb (1202 kg) capacity
trailer with welded steel tubing frame, heavy-duty axle with roller bearing hubs
and leaf-spring suspension.
The HWY-224 highway trailer comes with jack stand, 2 in (50 mm) ball hitch,
fenders and lights. The OFR-224 off road trailer comes with jack stand and
2 in (50 mm) ball hitch.
Shown with hitch
(sold separately).
Shown with fenders,
lights and hitch
(sold separately).
Mid-Frame Trailer #195 481
For Big Blue 300 Pro. A 1424 lb (645 kg) capacity highway trailer with welded
steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring
suspension. Includes jack stand and safety chain. Order fenders, lights and
hitch separately.
HWY-430 Tandem Axle Trailer #043 806
For Big 40, Big Blue 400 and 500, Miller Du-Op, Big Blue Air Pak, and Big Blue
Turbo. Smooth riding with 3750 lb (1701 kg) capacity. Includes: hand-operated
parking brake, a self-actuating hydraulic brake system and a break-away
device to lock brakes if the trailer comes loose. It also includes jack stand,
fenders and lights. Order hitch separately.
Trailer Accessories
4 West Four-Wheel Steerable Off-Road Trailer #042 801
For Big 40, Big Blue 400 and 500, Miller Du-Op, Big Blue Air Pak, and Big Blue
Turbo. Heavy-duty 2570 lb (1166 kg) capacity trailer designed for use in
mines, quarries, and other rough terrain. Has narrow 22 ft (6.7 m) turning
radius. Includes 3 in lunette eye, universal hitch and safety chains.
Ball Hitch, 2 in (50 mm)
#195 493 For Mid-Frame.
#043 864 For HWY-430.
Cable Tree
#195 023 For HWY-1000 and
Mid-Frame.
#043 826 For HWY-224, OFR-224,
and HWY-430.
Provides an area to conveniently wrap
weld cables and extension cords.
Fender Kit #195 482
For Mid-Frame.
Light Kit #195 483
For Mid-Frame (requires fender kit
#195 482).
Lunette Eye 2-1/2 in (64 mm)
#043 824 For HWY-1000, Mid-Frame,
HWY-224, and OFR-224.
Lunette Eye 3 in (76 mm)
#043 863 For HWY-430.
Note: Trailers are shipped unassembled. *Width at outside of fenders. **Does not include tongue.
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)
HWY-1000
1500 lb
(680 kg)
1265 lb
(574 kg)
1000 lb
(454 kg)
18 1⁄2 in
(470 mm)
6 1⁄2 in
(165 mm)
50 in
(1270 mm)
Mid-Frame
1500 lb
(680 kg)
1666 lb
(755 kg)
1424 lb
(645 kg)
18 1⁄2 in
(470 mm)
6 1⁄2 in
(165 mm)
4 West
2000 lb/axle
(907 kg/axle)
3000 lb
(1361 kg)
2570 lb
(1166 kg)
21 1⁄4 in
(540 mm)
HWY-224
OFR-224
3500 lb
(1588 kg)
2960 lb
(1343 kg)
2650 lb
(1202 kg)
HWY-430
2200 lb/axle
(998 kg/axle)
4280 lb
(1941 kg)
3750 lb
(1701 kg)
Model
Dimensions
Net
Weight
4.8-12
L: 98 in (2489 mm)
W: 571⁄2 in (1461 mm)*
265 lb
(120 kg)
45 in
(1143 mm)
B78-13
L: 98 in (2489 mm)
W: 52 in (1321 mm)*
242 lb
(110 kg)
8 in
(203 mm)
551⁄4 in
(1403 mm)
B78-13
L: 91 in (2311 mm)**
W: 61 1⁄4 in (1556 mm)
430 lb
(195 kg)
181⁄2 in
(470 mm)
71⁄2 in
(191 mm)
52 in
(1321 mm)
B-78-13C
L: 105 in (2667 mm)
W: HWY– 61 in (1549 mm)*
OFR–581⁄2 in (1486 mm)
320 lb
(145 kg)
191⁄4 in
(489 mm)
81⁄2 in
(216 mm)
52 in
(1321 mm)
B78-13B
L: 1561⁄2 in (3975 mm)
W: 61 in (1549 mm)*
530 lb
(240 kg)
85
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Accessories
International-Style Connectors
For Invision 350 MPa, Maxstars,
Dynastys, Syncrowaves, and XMT 304
and 350. These power sources are
equipped with International-style connectors for secondary connections.
(Power source is shipped with two 50
mm male International-style plugs for
use with #4 to #1/0 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.
#042 418 50 mm
Accepts #4 to #1/0 AWG cable size.
Required if male plugs shipped with
power source must be replaced, or if
additional plugs are needed.
#042 533 70 mm
Accepts #1/0 or #2/0 AWG cable size.
Required if #1/0 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.
#042 419 50 mm
Accepts #4 to #1/0 AWG size cable.
#042 534 70 mm
Accepts #1/0 or #2/0 AWG size cable.
International/ Tweco®
Adapter #042 465
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 #042 466
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 ®/International
Adapter #195 116
One-piece adapter which
has a Tweco-style male plug (to power
source) on one end and a female Dinseor International-style receptacle (for
weld cable connection) on other end.
Tweco®-Style
Connector 50 mm
#195 115
Accepts #1/0 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.
86
MillerWelds.com
Thread Lock Connectors
#225 029
For Maxstar 700 and
Dynasty 700. Contains
two male connectors that
accept #1/0 to #4/0 AWG
size cable.
Air-Cooled TIG (GTAW) Torch Adapters
#195 234
For Maxstar 150. 25 mm
(small) International-style
flow thru for (WP17, WP9, WP50)
one-piece torch.
#194 722
For Syncrowave
200. 50 mm
Internationalstyle flow thru for (WP17, WP9,
WP50, WP23) one-piece torch.
#195 379 (WP26)
#195 378 (WP17, WP9,
WP50, WP23)
For CST 280,
Maxstar 200 and 350,
Dynasty 200 and 350,
and Syncrowave 250
and 350. 50 mm
International-style for
one-piece torch.
Water-Cooled TIG (GTAW)
Torch Adapters
#195 380
For Syncrowave
200. 50 mm
International-style
flow thru with gas
and water return
lines for (WP125,
WP24W, WP25,
and WP20) watercooled torch.
#195 377
For Maxstar 200
and 350, Dynasty
200 and 350, and
Syncrowave 250
and 350. 50 mm
International-style
with water return
line for (WP125,
WP24W, WP25, WP20, WP18, WP12,
CS310, CS410, WP22, WP27) watercooled torch.
Load Banks
LBP-350 #043 329
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
13 ft (4 m) 115 V power cord and has
seven 50 amp load switches, providing
a maximum capacity of 350 amps.
Welding Power Load
Bank #902 804
Designed to load
test the output of
transformer-type,
engine- or motordriven generator
welding power sources. This unit can
be used to test AC or DC welder
outputs, and to demonstrate welding
equipment to prospective customers.
Shopmate 300 MIG Kit #300 150
Includes 15 ft (4.6 m) 1/0 work cable
with clamp, 10 ft (3 m) 1/0 interconnecting cable, Smith® Ar/CO2
regulator with flowtube, 10 ft (3 m)
gas hose and consumable storage box.
Meters
Digi-Meter
#041 656
Used to monitor
welding voltage
and amperage of constant voltage and
constant current arc welding power
sources, and engine-driven welding
generators. This unit is not designed to
measure primary voltage and amperage.
Digital Meters
#043 812 Field For Gold Star models
AFTER serial #KG283595. Easy-toinstall, front-panel-mount, digital amp
and volt meters.
Protective Covers
#195 149
For Millermatic 140 Auto-Set, 180
Auto-Set, and 211 Auto-Set with MVP.
Meter Kits
#300 331 Field
For SuitCase X-TREME 8VS.
#195 165 Field For SuitCase 8RC
models BEFORE serial #LJ020185V.
#300 178 Field For SuitCase 12RC.
Weld Ammeter and Voltmeter Kit
#195 131 Field For Big 40, Big Blue
400 and 500, and Big Blue Air Pak.
Panel-mounted analog meters monitor
welding output.
MIG Accessories
Accessory Kits
#225 028
For Maxstar 700 and Dynasty 700.
50 mm thread lock-style for (WP125,
WP24W, WP25, WP20, WP18,
WP12, CS310, CS410, WP22, WP27)
water-cooled torch.
Industrial MIG 4/0 Kit with Dinse
Connector #300 405
Consists of Smith® regulator/flowmeter
with 10 ft (3 m) gas hose, 10 ft (3 m)
4/0 feeder weld cable with Dinse
connector on one end and a lug on the
other, and 15 ft (4.6 m) work cable
with Dinse connector on one end and
600-amp C-clamp.
Industrial MIG 4/0 Kit #300 390
Consists of Smith® regulator/flowmeter
with 10 ft (3 m) gas hose, 10 ft (3 m)
4/0 feeder weld cable with lugs, and
15 ft (4.6 m) work cable with 600-amp
C-clamp.
#195 142
For Millermatic 212 Auto-Set, 252 and
350/350P. Features side pocket.
Pulsing Control
Optima™ MIG Pulse
Control #043 389
For Invisions, XMTs
(except MPa and VS
models), and PipePro
304. A multipurpose,
microprocessor-based
pulse control for
synergic MIG
(wire welding or GMAW), manual MIG
pulsing or standard MIG welding.
Use this control with all above power
sources and any Miller wire feeder,
including automatic feeders and spool
guns. Includes 25 ft (7.6 m) cord with
14-pin plug.
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Accessories
1-800-4-A-MILLER for more information.
Call
MIG Welding Guns
M-10
M-15
Roughneck®
C-Series
M-25
FC-1260
Bernard®
Q-Gun™
FC-1150
Bernard®
Dura-Flux™
Tregaskiss™
TOUGH GUN™
*Rated duty cycle for MIGmatic and Roughneck guns using CO2 gas. Please see individual Literature Sheets for detailed specifications.
Model
Part Number
Cable Length
Process
Rated Output
Rated Duty Cycle*
Standard Wire Size
Max. Recommended Wire Size
MIGmatic™ M-Series guns are an ideal match for Miller integrated MIG packages and other Miller wire feeders. See Literature No. AY/15.0
M-10
#195 605
10 ft (3 m)
MIG, Flux Cored
100 Amps
100%
.030 –.035 in (0.8 – 0.9 mm)
.045 in (1.2 mm)
M-15
#169 589
10 ft (3 m)
MIG, Flux Cored
150 Amps
100%
.030 –.035 in (0.8 – 0.9 mm)
.045 in (1.2 mm)
#169 591
12 ft (3.7 m)
#169 593
15 ft (4.6 m)
#169 594
10 ft (3 m)
MIG, Flux Cored
250 Amps
100%
.030 –.035 in (0.8 – 0.9 mm)
3/64 in (1.2 mm)
#169 596
12 ft (3.7 m)
#169 598
15 ft (4.6 m)
#169 599
15 ft (4.6 m)
.035 –.045 in (0.9 –1.2 mm)
3/64 in (1.2 mm)
M-25
Roughneck ® C-Series guns are fully compatible with all current Miller wire feeders and are also adaptable to other major brands of welding equipment. See Literature No. AY/17.0
C-3010
#194 751
10 ft (3 m)
C-3012
#194 752
12 ft (3.7 m)
C-3015
#194 753
15 ft (4.6 m)
C-4010
#194 754
10 ft (3 m)
C-4012
#194 755
12 ft (3.7 m)
C-4015
#194 756
15 ft (4.6 m)
C-5010
#194 757
10 ft (3 m)
C-5012
#194 758
12 ft (3.7 m)
C-5015
#194 759
15 ft (4.6 m)
MIG, Flux Cored
300 Amps
100%
.035 –.045 in (0.9 –1.2 mm)
5/64 in (2.0 mm)
MIG, Flux Cored
400 Amps
100%
.035 –.045 in (0.9 –1.2 mm)
5/64 in (2.0 mm)
MIG, Flux Cored
500 Amps
100%
.052 –1/16 in (1.3 –1.6 mm)
1/8 in (3.2 mm)
Ironmate™ Series guns are ideal for feeding self-shielded (gasless) flux cored wires with portable as well as standard-type wire feeders. See Literature AY/16.0
FC-1260
#195 732
10 ft (3 m)
#195 729
15 ft (4.6 m)
FC-1260LM
(For Lincoln and Miller Wire Feeders)
#194 912
10 ft (3 m)
#194 911
15 ft (4.6 m)
FC-1150
#194 864
10 ft (3 m)
#194 863
15 ft (4.6 m)
Self-Shielded
Flux Cored
350 Amps
60%
1/16 – 3/32 in (1.6 – 2.4 mm)
3/32 in (2.4 mm)
Self-Shielded
Flux Cored
450 Amps
60%
3/32 –1/8 in (2.4 – 3.2 mm)
1/8 in (3.2 mm)
Bernard® Q-Guns™ and Dura-Flux™ guns — see Web site at bernardwelds.com
Tregaskiss™ TOUGH GUN™ Semi-Automatic MIG Torches — see Web site at tregaskiss.com/semiauto
MIG Gun Accessories
Roughneck C-Series
MIGmatic M-Series
Aluminum Conversion Kit #202 895
Allows 10 ft Roughneck guns to feed
3/64 –1/16 in aluminum wires.
Consumable Kits
For M-10 and M-15.
#234 607 .023 wire
#234 608 .030 wire
#234 609 .035 wire
For M-25.
#234 610 .030 wire
#234 611 .035 wire
#234 612 .045 wire
Contains contact tips, tip adapters,
nozzle adapters and a standard nozzle.
Consumable Kit #206 073
Contains contact tips, diffuser, nozzle,
nozzle insulator and gun hook.
Gun Hook #199 662
Enables Roughneck gun to be stored
between welds.
Locking Trigger Switch #199 661
Allows Roughneck trigger to be
locked during long welds.
Machine Adapter Kits
#199 663 For older Hobart and
Thermal products.
#199 664 For Lincoln products.
Adapts Roughneck guns to be used
with listed products.
Ironmate Series
.045 Conversion Kit #199 178
Allows FC-1260 and FC-1260LM guns
to feed .045 in self-shielded wire.
Bernard
Aluminum Gun Kits
#300 541 .035, 10 ft (3 m)
#300 542 .047, 12 ft (3.7 m)
#300 543 1/16, 12 ft (3.7 m)
For Axcess Systems and 70 Series.
These aluminum gun kits have
components designed specifically for
pushing aluminum wire. Includes
U-grooved .035, .047 or 1/16 in
drive rolls, plastic guides, specific
aluminum consumables, and a
10 or 12 ft Bernard® Q-Gun.™
87
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Accessories
MillerWelds.com
Plasma Cutter Accessories
MVP™ Adapter Plugs
Torches
Cable Covers
#239 642 20 ft
#231 867 25 ft
#231 868 50 ft
Cart
No. 30B Economy Cart with Cord
Wrap #300 511
For Spectrum 125C, 375, and 875.
This economical running gear includes
a cord wrap and provides mobility with
an angle for easy front panel access
and extra storage space.
Cutting Guides
Plasma Circle-Cutting Guides
#195 981
For ICE-12C, 27C, 27T, 40T, and 60T.
Cut straight lines or circles up to
12 in diameter.
Suction/Magnetic Pivot Base
#195 979
Add this to your cutting guide for
convenient attachment to all flat
surfaces. The extended arm accommodates holes up to 30 in diameter.
Filters
In-Line Air Filter Kit
#228 926
For Spectrum 375,
375 X-TREME,
625 X-TREME, and
875. Mounts between
the plasma unit and
input air line. Includes
male and female 1/4 in
NPT quick-disconnect
fitting and hose for easy on/off
connection. Removes water, oil, and
other particles as small as .825 micron
with 99.9% efficiency. Replaceable
filter element (#228 928).
Motor Guard Air Filter #042 306
For Spectrum 375, and 875. This filter
is equipped with a mounting bracket
that allows installation on the top, side,
or rear panel of most plasma cutters.
Replaceable filter element (#042 312).
RTI Filter and Bracket
#300 491
For Spectrum 375,
and 875. Dryer will
remove water, dirt and
oil as small as one
micron with 99.9%
efficiency. Includes an
auto drain feature.
Can be mounted on
plasma cutter or on
wall. Install as close as possible to
point of air consumption. Replaceable
filter element (#212 771).
#219 258
For power cable 6-50P
(230 V/50 A).
#219 261
For power cable 5-15P
(115 V/15 A).
#219 259
For power cable 5-20P
(115 V/20 A).
For Spectrum 375 X-TREME,
Millermatic 211 Auto-Set with MVP,
Millermatic Passport Plus, Maxstar
150 models, and Diversion 180. Allows
connection of machine to 115- or 230volt receptacles without tools — just
choose the plug that fits the receptacle.
Protective Covers
See your Miller distributor for complete
information on the following ICE
plasma torches and their consumables:
ICE-12C Hand-Held
For Spectrum 125C.
ICE-27C Hand-Held
For Spectrum 375.
ICE-27T Hand-Held
For Spectrum 375 X-TREME.
ICE-40T Hand-Held
For Spectrum 625 X-TREME.
ICE-60T Hand-Held
For Spectrum 875.
Plasma Torch Consumable Kits
#222 938 For ICE-12C.
#222 939 For ICE-27C and 27T.
#222 940 For ICE-40C and 40T.
#239 086 For ICE-60T.
#127 493 Empty consumable box.
Polarity Switches/Controls
#195 144
cover
shown.
#195 144 For Spectrum 125C and 375.
#300 388 For Spectrum 875.
Polarity Control #042 871
This dual-function control is designed
for use with dual wire feeders or any
application where electrical isolation
and/or polarity reversing of weld
current is required. Both functions
can be used at the same time.
AC/DC Polarity Reversing Switch Kit
#195 095 Field
For Big 40. Changes DC+ /AC/DCwithout using tools.
DC Polarity Reversing Switch Kit
#043 942 Field
For Big 40, and Big Blue 400 and 500.
Changes DC polarity without using tools.
Plugs and Cords
Female
Receptacle
Plasma Standoff Roller Guide
#194 883
Helps maintain recommended standoff
distance to maximize cutting
performance and improve tip life.
88
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.
#300 184 X-CASE for Spectrum 375
X-TREME and 625 X-TREME, and
Maxstar 150 models.
Process Selector Control #042 872
For CC, CV or CC/CV welding power
source. Provides easy way to change
welding process. Also includes features
of Polarity Control.
A FLE10 Cat P 89 Accessories.qxd:Accessories
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11/3/09
3:02 PM
Page 1
Accessories
1-800-4-A-MILLER for more information.
Remote Controls
Spot Welder Gyro Bail
See also TIG Accessories Remote
Controls on page 90.
PRHC-14 Hand
Control #195 511
For all solid-state
power sources
after serial
number JK674521.
Complete current
or voltage control brings 120 volts
GFCI power to work area in a single
cord. Housed in a durable light
aluminum case and includes 125 ft
(38 m) cord with plugs.
Remote On/Off Control
#042 869 Field
For Deltawelds, Gold Stars, and
Dimensions. 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.
RHC-3 Remote
Hand Amperage
Control
#040 056 20 ft (6 m) cord
#195 354 100 ft (30 m) cord
For Dialarc 250 AC/DC, SRH-444, and
Mark VIII-2. Optional remote control
facilities RF-10 (#041 111) required
for the Dialarc 250 AC/DC. Includes
cord and plug.
RHC-3GD34A
Remote Hand
Control #041 122
For Big 40 CC, and Big Blue 400 CC
and 500 CC. Remote hand amperage
control. Includes 20 ft (6 m) cord
and plug.
Remote Control Extension Cords
Remote Control Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15 m)
#122 975 75 ft (23 m)
For 14-pin remote controls/24 VAC wire
feeders. 14-pin plug to a 14-pin socket.
(Not for 115 V XR or 50 Series feeders.)
Remote Control Extension Kits
#043 725 25 ft (7.6 m)
#043 726 50 ft (15 m)
#043 727 75 ft (23 m)
Fully-loaded 14-pin extension cords
for remote controls or 24 V and
115 V feeders.
Shown with
MSW spot
welder.
Gyro Bail #041 979
For MSW and LMSW air-cooled spot
welders. Supports weight of welder.
Operates with boom and counterweight or from spring-loaded cable.
Spot welds in any position.
Stick Accessory Kits
Sub Arc Accessories
Torch Accessories and Tips
Consumables Handling
OBT 600 Torch Body Extensions
1 inch #043 967
2 inch #043 969
4 inch #043 973
6 inch #043 975
Flux Hopper with
Valve #194 775
25 lb (11 kg) capacity
hopper with automatic
flux valve and slag
screen. Contact
the following suppliers
for Miller-compatible
flux recovery systems.
Flux Recovery Systems
American Vacuum 1-800-321-2849
Invincible
1-800-282-6999
Weld Engineering 1-508-839-9875
Wire Reel #108 008
For 60 lb (27 kg) coil of wire. Requires
Spool Support Assembly (#119 438).
Wire Straightener #199 733
For RAD-400 or RAD-780 wire drive
assembly. For wires 1/16 – 7/32 in
(1.6 – 5.6 mm).
No. 2 Stick Cable Sets
#195 196 15 ft
#195 195 50 ft
Consists of either 15 or 50 ft electrode
cable with holder and work cable with
clamp. 200 A, 100% duty cycle.
Control Accessories
2/0 Stick Cable Set (50 ft) #173 851
Consists of 50 ft 2/0 electrode cable
with holder and 50 ft work cable with
clamp. 350 A, 100% duty cycle.
Control Cable Extensions
25 ft (7.6 m)
#043 725
50 ft (15 m)
#043 726
75 ft (23 m)
#043 727
14-pin welding power source control
cable extends distance between power
source and controller.
2/0 Stick Cable Set (100/50 ft)
#043 952
Consists of 100 ft 2/0 electrode cable
with holder and 50 ft work cable with
clamp. 300 A, 100% duty cycle.
Weld Cables
#195 457 Cable w/Electrode Holder
#195 458 Cable w/Work Clamp
Consists of a stud/Tweco® adapter and
10 ft 2/0 weld cable with a Tweco male
connector and either an electrode holder
or work clamp. Rated up to 400 A.
2/0 Weld Cable Extensions
#195 456 50 ft
#195 455 100 ft
For use with weld cables (#195 457)
and (#195 458).
Basic Cable Kit #195 308
For digital and analog HDC 1500
controllers. Includes 30 ft (9 m)
14-pin interconnect cable and 10 ft
(3 m) motor cable.
Motor Extension Cable #195 342
25 ft (7.6 m) extension for the motor
cable supplied in kit (#195 308).
OBT 1200 Torch Body Extension
#043 981
Overall length with extension is
9 inches. Actual length of extension
is 8-1/2 inches.
Torch Contact Tips
Wire Size
OBT 600
1/16 in (1.6 mm) #192 700
5/64 in (2.0 mm) #192 701
3/32 in (2.4 mm) #192 702
7/64 in (2.8 mm) #192 703
1/8 in (3.2 mm) #192 704
5/32 in (4.0 mm) #192 705
3/16 in (4.8 mm) #192 706
7/32 in (5.6 mm) #192 707
OBT 1200
#192 141
#199 026
#192 142
#200 771
#192 143
#192 144
#192 136
#200 756
Welding Carriages
Submerged Arc welding systems
employ two primary ways of traversing
the arc, wire and flux along the joint
to be fused: a Motorized Side Beam or
a Self-Propelled Tractor Package. Side
beam systems generally work well for
longitudinal welds less than eight feet
long. Welds over eight feet are better
suited to tractor systems.
Motorized Side Beam Systems
For more information contact Jetline
Engineering at (949) 951-1515. They
have extensive experience assembling
custom mechanized welding systems
— including Sub Arc systems.
Light-Duty Cross Slide #195 411
Allows 6 inches of travel adjustment.
Two units can be stacked to provide
vertical and horizontal movement.
Not recommended for tandem.
Heavy-Duty Cross Slide #300 482
Allows for 6 inches of travel adjustment
and has a load capacity of 200 pounds.
Recommended for tandem.
Drive Assembly Drive Rolls
V-knurled drive rolls for use with
hard-shelled cored wires.
SAW4 Recommended Drive Rolls
1/16 in (1.6 mm) #132 955
5/64 in (2.0 mm) #132 960
3/32 in (2.4 mm) #132 961
7/64 in (2.8 mm) #132 962
RAD-400 Recommended Drive Rolls
1/8 in (3.2 mm) #132 963
5/32 in (4.0 mm) #193 700
RAD-780 Recommended Drive Rolls
3/16 in (4.8 mm) #193 701
7/32 in (5.6 mm) #193 702
Miller Tractor Packages
MT 1500 DX (with HDC 1500 DX
Automatic Weld Control) #951 060
MT 1500 A (with HDC 1500 A
Automatic Weld Control) #951 061
Miller self-propelled tractor packages
include an HDC 1500 DX (digital) or
1500 A (analog) automatic weld control,
a travel system complete with a main
mounting mast and handle assembly,
a mounting arm for one wire reel,
vertical and horizontal 4 x 4 inch cross
slides, a control support arm and an
adjustable guide roll arm. See Literature
No.DC/19.9 for more information.
89
A FLE10 Cat P 90 Accessories.qxd:Accessories
11/3/09
3:02 PM
Page 1
Accessories
MillerWelds.com
TIG Accessories
Remote Controls
High-Frequency Arc Starters
and Stabilizers
#300 183 kit shown.
High Frequency Arc Starter/Stabilizer
HF-251D-1 #042 388 115 VAC
HF-251-2 #042 387 230 VAC
These portable 250 A, 60% duty cycle
units add high-frequency to the welding
circuit to help start arc when using the
TIG process.
Secondary Contactor Kit
#041 969 Field For HF-251D-1.
#041 906 Field For HF-251-2.
For power sources without a contactor.
Mounts inside HF-251 cabinet.
Kits
#195 054 kit shown.
Contractor Kits
#195 055 150 A TIG/Stick Package
with RCCS-14 Fingertip
#195 054 150 A TIG/Stick Package
with RFCS-14 HD
Foot Pedal
For Maxstar 200 SD and DX, and
Dynasty 200 SD and DX. Kit is an
all-in-one welding package and comes
complete with either a RCCS-14
fingertip control or RFCS-14 HD
foot control plus protective carrying
case, Weldcraft® 150 A TIG torch,
International-style torch adapter,
200 A Stick electrode holder with
15 ft (4.6 m) cable, 300 A work clamp
with 15 ft (4.6 m) cable, Smith® flow
gauge regulator with 12 ft (3.7 m) gas
hose, gas hose coupler, and AK-2
torch accessory kit.
Weldcraft® Water-Cooled Torch Kits
#300 185 250 A, WP20
#300 183 300 A, CS310
#300 186 400 A, WP18SC
For Maxstar and Dynasty 200/350/700,
and Syncrowave 250 DX/350 LX.
Each torch kit includes a 25 ft (7.6 m)
TIG torch, torch cable cover, work
clamp with 15 ft (4.6 m) cable
[12 ft (3.7 m) cable on 400 A kit],
Smith® regulator/flowmeter with 12 ft
(3.7 m) gas hose, torch adapter, and
torch accessory kit. See Lit. No. AD.5.0
for complete individual package details.
Modules
Pulser Module #300 548
For Syncrowave 250 DX effective with
serial #LE282983. For welding thin
materials. Provides a heating and
cooling effect of the weld puddle to
reduce heat input and control
distortion of the material. Provides
0.25 to 10 pulses per second.
Sequencer Module #300 547
For Syncrowave 250 DX and 350 LX
effective with serial #LE282983.
Provides a starting current higher or
lower than the welding current.
Provides final slope and final current
for trailing the weld. Provides a spot
timer for TIG spot application.
Protective Covers
RCC-14 (14-pin plug) #151 086
For all Miller solid-state power sources
AFTER serial number JK674521.
Side-to-side (east/west) rotary-motion
fingertip current/contactor control
fastens to TIG torch using two Velcro®
straps. Great for production or
contractors that need quick ramp-up.
Includes 26.5 ft (8 m) cord and plug.
RCCS-14 (14-pin plug)
#043 688 26.5 ft (8 m) cord
For all Miller solid-state power sources
AFTER serial number JK674521.
For Maxstar 200 Series.
For Dynasty 200 Series.
For Syncrowave 200.
For Syncrowave
250 DX/350 LX.
#300 579 For Diversion 165 and 180.
#195 478 For XMT 304 and 350.
North/south rotary-motion fingertip
current/contactor control fastens to
TIG torch using two Velcro® straps.
Great for applications that require a
finer amperage control. Includes cord
and plug.
RFC-23A #040 071
For Dialarc 250 AC/DC, Dialarc HF,
Gold Star 330 A/BP and 320 A/BP.
Foot pedal current/contactor control.
Includes 20 ft (6 m) cords and plugs.
RFCS-14 (14-pin plug)
#043 554 20 ft (6 m) cord
RFCS-5 (5-pin plug)
#043 716 20 ft (6 m) cord
For all Miller solid-state power sources
BEFORE serial #JK674521.
RFCS-6M (6-pin plug)
#195 183 13.25 ft (4 m) cord
#195 504 20 ft (6 m) cord
For Maxstar 150 STL and STH.
Foot pedal current/contactor control.
Includes cord and plug.
90
HD Conversion Kit #194 743
Kit provides the needed hardware to
convert your existing RFCS-14 foot
control to the heavy-duty version.
RCCS-6M (6-pin plug)
#195 184 13.25 ft (4 m) cord
#195 503 26.5 ft (8 m) cord
For Maxstar 150 STL and STH.
#195 478
cover
shown.
#195 321
#195 322
#300 059
#195 320
RFCS-14 HD (14-pin plug) #194 744
For all Miller solid-state power sources
AFTER serial #JK674521. Heavy-duty
foot pedal current/contactor control
with increased stability and durability
from larger base and heavier cord.
Reconfigurable cord can exit front, back
or either side of the pedal for flexibility.
Includes 20 ft (6 m) cord and plug.
RHC-14 (14-pin plug)
#129 340 20 ft (6 m) cord
#300 350 100 ft (30.5 m) cord
For all Miller solid-state power
sources AFTER serial #JK674521.
Miniature hand current/contactor
control. Dimensions: 4 x 4 x 3-1/4 in
(102 x 102 x 82 mm). Includes cord
and plug.
RMLS-14 (14-pin plug) #129 337
For all Miller solid-state power sources
AFTER serial #JK674521. Momentaryand maintained-contact rocker switch
for contactor control. Push forward for
maintained contact and backward for
momentary contact. Includes 26.5 ft
(8 m) cord and plug.
RMS-14 (14-pin plug) #187 208
For all Miller solid-state power sources
AFTER serial #JK674521.
RMS-6M (6-pin plug) #195 269
For Maxstar 150 STL and STH.
Momentary-contact switch for
contactor control. Rubber-covered
pushbutton dome switch ideal
for repetitive on-off applications.
Includes 26.5 ft (8 m) cord and plug.
RPBS-14 (14-pin plug) #300 666
For all Miller solid-state power sources
AFTER serial #JK674521. Attaches to
the TIG torch to remotely start and
stop the TIG welding process.
Includes 25 ft (7.6 m) cord and plug.
A FLE10 Cat P 91 Accessories.qxd:Accessories
Call
11/3/09
3:03 PM
Page 1
Accessories
1-800-4-A-MILLER for more information.
Wire Feeder Accessories
Extension Cords and Kits
Control Detachment Kits
#194 914 10 ft (3 m)
#194 913 25 ft (7.6 m)
For all S-74S and S-74D feeders,
and S-74DX feeders BEFORE serial
number LJ440752U.
#300 560 10 ft (3 m)
#300 562 25 ft (7.6 m)
For S-74DX feeders AFTER serial
number LJ440752U.
#194 995 25 ft (7.6 m)
For all D-74S and D-74D feeders,
and D-74DX feeders BEFORE serial
number LJ440752U.
#300 561 10 ft (3 m)
#300 563 25 ft (7.6 m)
For D-74DX feeders AFTER serial
number LJ440752U.
Allows separation of the control module
from the wire drive assembly and base.
Remote Control Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15 m)
#122 975 75 ft (23 m)
For 14-pin remote controls/24 VAC
wire feeders. 14-pin plug to a 14-pin
socket. (Not for 115 V XR or 50
Series feeders.)
Remote Control Extension Kits
#043 725 25 ft (7.6 m)
#043 726 50 ft (15 m)
#043 727 75 ft (23 m)
Fully-loaded 14-pin extension cords
for remote controls or 24 V and
115 V feeders.
Spoolmatic 15A/30A Extension Hose
and Cable Kits
#132 228 25 ft (7.6 m)
#132 229 50 ft (15 m)
Extends leads, etc. between
Spoolmatic gun and power source.
Power Supply Adapters
receptacle for direct connection of
wire feeder control cord. A short cord
with a 4-pin plug is hard wired to the
control. A 10 ft (3 m) interconnecting
cord with a 4-pin for connection to
PSA-2 and Hubbell connectors for
older-style Miller CV power sources is
included. Control can also be used with
competitive power sources requiring a
contact closure for contactor control.
See below for PSA-2 Extension Cord.
PSA-2 Extension Cord #047 813
25 ft (7.6 m) cord used to extend
the 10 ft (3 m) cord supplied with
the PSA-2 control (4-pin to 4-pin
connection).
Secondary Contactor
External Secondary Contactor
#108 921
For S-32S and S-32SL feeders. The
115 VAC/12 VDC secondary contactor,
rated at 250 amps, 60% duty cycle,
is designed for use with welding
power sources not having an output
contactor. It allows welding wire to be
electrically cold until operator is ready
to weld. The contactor can be used
with DC power sources operating
with electrode positive or negative.
Contactor will operate off 115 VAC or
can be connected to 12 VDC battery
of an engine driven welder without
115 VAC auxiliary power available.
Gun trigger switch controls contactor
and must remain closed while welding.
WC-115 Contactor Kit
#137 548 Field
Recommended for Spoolmatic gun and
WC-115A control when using power
sources without weld output contactor.
(This is installed in the WC-115A.)
Spoolmate 3035 Spool Gun
For more information see Lit. No.
M/1.5.
#146 236
Allows feeder to rotate as operator
changes work position. Reduces
strain and bending of gun cable.
Spool Adapter
#047 141
For use with 14 lb (6.4 kg) spool of
Hobart or Lincoln self-shielding wire.
Spool Gun Controls
For more information see Lit. No.
M/1.73.
WC-24 Weld Control #137 549
Packaged in a compact, lightweight,
non-metallic enclosure, the WC-24
easily mounts on the power source.
Designed for use with Miller CV power
sources supplying 24 VAC and 14-pin
receptacles, the control includes a
board-mounted potentiometer which
can alter the drive motor acceleration
rate to optimize arc starting
performance.
SGA 100C #043 857
SGA with contactor required to
connect Spoolmate 3035 spool gun
to CV engine drives like Miller’s
Bobcat. Includes 10 ft (3 m) 115 VAC
power cable and plug, 6 ft (1.8 m)
interconnecting cable, and 5 ft (1.5 m)
gas hose.
Turntable Assembly
Note: 25 ft Remote Contactor Cord
(#108 925) required.
Millermatic PSA Control #195 019
Required when using 24 VAC wire
feeder or XR-Control and gun with
Millermatic 252.
PSA-2 Control #141 604
Required when using SuitCase 8RC
and 12RC, 22A and 24A, and 70
Series wire feeders with power
sources having only 115 VAC
available. Control can be mounted on
wire feeder or positioned at power
source and is equipped with a 14-pin
WC-115A Weld Control
#137 546 Without contactor
#137 546-01-1 With contactor
Operates on 115 VAC, and designed
primarily for CC DC power sources.
Can also be used with CV power
sources or DC engine drives supplying
115 VAC. Used with a CC source, the
control circuit functions in a voltagesensing mode and with a CV source, it
functions as a constant-speed circuit.
Includes wire run-in and drive motor
acceleration controls which ensure
optimum arc starting performance.
SGA 100 #043 856
Required to connect Spoolmate 3035
spool gun to Millermatic 180 Auto-Set.
Allows connection to virtually any
similar MIG welder — Miller or other
brands. Includes 10 ft (3 m) 115 VAC
power cable and plug, 6 ft (1.8 m)
interconnecting cable, and 5 ft (1.5 m)
gas hose.
Wire Straightener
Spoolmate 3035 #195 016
This reliable, yet economical light
industrial spool gun provides 20 ft
cable reach and accessibility, with
smooth feeding of aluminum wire.
Lightweight (9.1 lb) and well-balanced
for operator comfort the 3035 is rated
at 150 amps at 60% duty cycle. It
handles aluminum, steel and stainless
wire from .023–.035 in (0.6 – 0.9 mm)
with a wire speed of 115 –715 IPM.
Includes cable sheath, spring strain
relief, clear spool canister and easyto-remove barrel assembly.
For 70 Series, and 20 Series.
#141 580
For .035 –.045 in (0.9 –1.1 mm) wire.
#141 581
For 1/16 –1/8 in (1.6 – 3.2 mm) wire.
Spoolmate 3035 Extension Kit
#194 996 25 ft (7.6 m)
Extends hose and cables between
Spoolmate gun and power source.
Gas Valve/Trigger Receptacle Kit
#300 338
Required to connect Spoolmate 3035
to Millermatic DVI2.
91
A FLE10 Cat P 92 ITW Intro.qxd:MIG Intro
11/5/09
10:31 AM
Page 1
Miller Recommended Brands
Comprised of a market-leading portfolio of best-in-class brands, Miller and the businesses
of ITW Welding work together to provide premium performance delivered through a breadth of
solutions encompassing welding, cutting, consumables, and accessories.
Together, we’re creating systematic value: serving more industries, applications and end-users, in
more global locations than ever before. These ITW businesses, owned by Illinois Tool Works Inc.,
share a common passion for excellence through innovation, customer service and reliability.
See the following pages for more information on:
1-800-757-8301
Contact Us: Phone:
Web: tempil.com
Tempil incorporates state of the art temperature indicator technology
to develop a wide range of temperature measurement products which
include temperature indicators, temperature strips, temperature labels,
temperature dots, and sterilization inks. These products are produced
in a wide range of configurations to meet the needs of applications
requiring accurate temperature measurement and temperature control.
1-949-951-1515
Contact Us: Phone:
Web: jetline.com
Jetline is your partner in welding automation, and is a leading supplier
of automated welding systems and components. Jetline applies proven
experience and innovative solutions to automated welding, and helps
manufacturing companies around the world to improve product quality
and increase productivity.
Contact Us:
1-847-657-5300
Contact Us: Phone:
Web: magnaflux.com
MAGNAFLUX is a leading worldwide supplier of magnetic particle, and
dye penetrant inspection equipment and associated chemical products
used for nondestructive testing.
Phone: 1-800-332-9448
or 937-332-5000
Web: welding.org
Provides skill and technical training to career-oriented students and
industry alike. The Institute is also the place to turn for books, DVDs,
and other resources related to welding training.
Illinois Tool Works, Inc. (NYSE: ITW), has $14.9 billion in revenues, and is a multinational manufacturer of a
diversified range of value-added industrial products and equipment. The Company consists of approximately
825 business units in 52 countries and employs some 60,000 people. ITWwelding.com
92
A FLE10 Cat P 93 Hobart.qxd:ITW Companies
11/13/09
10:29 AM
Page 1
Miller Recommended Brands
ATradition of
Filler Metal Excellence
Hobart Brothers Company is proud to be a
leading provider of superior welding filler
metals, technical education and customer
service for the welding industry. Our goal
is, and has always been, to find the right
stick electrode and solid or tubular wire to
improve your productivity and lower your
costs. Plus we promise to respond to your
orders quickly to ensure you get the fastest
possible delivery of your filler metals.
Our brands meet your needs.
Our Hobart® brand features stick
electrodes, and solid, flux-cored
and metal-cored wires designed for
mild and low alloy steel applications.
Each feature superior arc
performance, and selections are
available for fast-freezing or selfpeeling slag, low hydrogen weld
deposits, high deposition rates and
efficiencies, and X-ray quality welds.
Our premier Tri-Mark® brand of
gas-shielded, self-shielded and
low alloy flux-cored wires is
designed to provide superior
welding performance. The same
holds true for our mild steel and
low alloy metal-cored wires.
All Tri-Mark wires are designed to
improve weld quality, speed
productivity and offer the best
mechanical and chemical properties
for the job.
Contact Us: Address:
101 Trade Square East
Troy, OH 45373
McKay® brand stainless steel and
hard surfacing filler metals excel
on the most demanding applications.
Stainless steel stick electrodes,
spools, tubular wires and cutlengths provide excellent arc
characteristics, while McKay hard
surfacing products offer build-up or
overlay welds that meet or exceed
equipments’ impact and abrasion
resistance requirements.
Phone: 937-332-4000
Toll Free: 800-424-1543
Fax: 937-332-5224
Email: [email protected]
Web: Hobartbrothers.com
93
A FLE10 Cat P 94 Tregaskiss.qxd:ITW Companies
11/3/09
3:05 PM
Page 1
Miller Recommended Brands
Tregaskiss™ is a leading supplier of premium MIG welding guns, peripheral products, welding
consumables and accessories. Our tough products consistently last longer, resulting in fewer
replacements, reduced downtime, less rework and a better bottom line for our customers.
2 YEAR
WARRANTY ON
LSR UNICABLES
LIFETIME WARRANTY ON
HANDLES AND SWITCHES-
If you break it, we’ll
replace it free!
Straight handle
design is ergonomic
and allows trigger to
be mounted on the top
or bottom of the handle.
New TOUGH GUN
ThruArm™ Series
with patent-pending
LSR Unicables. Available for
ABB, FANUC, KUKA, Motoman
and OTC through arm robots.
ROBOTIC MIG GUNS
AND PERIPHERALS
TOUGH GUN™ Robotic MIG Guns offer the
performance and precision required for high-volume
production welding. Our TOUGH GUN Robotic
Peripherals complement the robotic MIG guns for a
durable and fully integrated robotic welding system.
SEMI-AUTOMATIC
MIG GUNS
TOUGH GUN Semi-Automatic MIG Guns are
known for their rugged durability in high-volume
production facilities.
Plus, our unique Double Life MIG Gun System doubles the life
of your air-cooled gun! Simply swap the trigger and gooseneck
from the worn front handle with the power pin on the rear handle.
COMMON
CONSUMABLE
PLATFORM
Tregaskiss™ MIG Guns share the same
high performance consumables so you
have less inventory and greater
production uptime.
TOUGH LOCK™ CONTACT TIP SYSTEM
WITH NEW DUAL TAPER TECHNOLOGY
Learn more about the cooling and locking benefits of our
new Dual Taper Technology at Tregaskiss.com/DualTaper
Contact Us: Canada and U.S.A.
Phone: 1-877-737-3111
Fax: 1-877-737-2111
94
International
Phone: +1-519-737-3000
Fax: +1-519-737-2111
Email: [email protected]
Web: Tregaskiss.com
QUICK LOAD™ LINER
Cut your liner replacement time by
more than 50% (as compared to
conventional liners) by loading your
liners from the front! Learn more at
Tregaskiss.com/QuickLoad
A FLE10 Cat P 95 Bernard.qxd:ITW Companies
11/3/09
3:06 PM
Page 1
Miller Recommended Brands
®
The Bernard Difference.
Bernard knows every welding application is different. That’s why
we engineer MIG and flux-cored products that can be customized
for your specific needs. Each of our products is built to improve
your welding productivity and performance.
Jump Liner
• Minimizes inventory and downtime for changeover
Neck
• Fixed, rotatable and multiple length options
improve operator comfort
All Guns are Not
Created Equal
Handle
• Ventilated to reduce heat and
increase operator comfort
Centerfire Consumables
• Built-in spatter shield protects diffuser,
improves gas flow
• Threadless contact tip mates securely
with diffuser for better conductivity
• Fits all Q-Guns — from 150 to 600 amps
Exceptional welding performance demands an
exceptional gun. Our Q-Gun™ MIG guns help
you achieve quality welds, increase productivity
and lower costs. Customize your Q-Gun using
our online configurator at Bernardwelds.com.
Trigger
• Designed and built to last
more than 1 million cycles
Centerfire™ Sets the Standard
Bernard developed its Centerfire consumables to save you time and money.
Our contact tips, nozzles and diffusers provide better arc starts, less spatter
and more consistent welds. Centerfire consumables also last up to three
times longer than competitive brands! Plus,
our unique conversion parts allow you
to convert most competitive guns to
Centerfire consumables, quickly and easily.
A Flux-Cored Gun Built
for the Way You Weld
Designed for self-shielded flux-cored
welding, the Dura-Flux™ gun is extremely
tough, yet comfortable to hold and use.
Handle
• Comfortable handle provides
excellent control
Cable
• Heavy-duty steel monocoil
cable withstands extreme
abuse to provide a
smooth, consistent
wire feed
Consumables
• Drop-in Centerfire consumables
last longer than other brands and
change out quickly
Trigger Guard
• Standard small trigger guard
improves maneuverability
compared to larger heat shields
• Optional heat shield available
Trigger
• Non-metallic trigger absorbs
less heat, reducing operator
discomfort
Contact Us: Address:
449 West Corning Road
PO Box 667
Beecher, IL 60401
Stay-Tite™ Technology
All Bernard guns feature long-lasting
power cable compression fittings and
necks with large tapered gun connections
to ensure optimal electrical conductivity
and product durability.
Phone: 708-946-2281
Toll Free: 800-946-2281
Fax: 708-946-6726
Email: [email protected]
Web: Bernardwelds.com
95
A FLE10 Cat P 96 Weldcraft.qxd:ITW Companies
11/3/09
3:06 PM
Page 1
Miller Recommended Brands
TheTIG Welder’s Choice
Crafter ™ Series
WP Series
Find best-in-class advantages in our Crafter Series:
• Designed for the
professional TIG welder.
• High-quality, long-lasting
components that help
reduce replacement costs.
• Ample cooling capacity
to improve productivity
on demanding jobs.
• Maneuverable,
easy-to-handle designs
that increase operator
comfort and arc-on time.
Expect the best with the WP Series, including:
• Innovative designs
and configurations for
improved versatility.
• Durable components that
withstand jobsite abuse
and increase productivity.
• A wide selection of
precision-machined
accessories designed for
trouble-free performance.
At Weldcraft, our top priority is manufacturing the best
and most innovative TIG torches and accessories in the
industry. Find out more about these premium products,
plus our full line of tungsten electrodes at Weldcraft.com
Contact Us: Address:
2741 North Roemer Road
Appleton, WI 54911
96
Phone: 920-882-6800
Toll Free: 800-752-7620
Fax: 920-882-6840
Email: [email protected]
Web: Weldcraft.com
A FLE10 Cat P 97 Smith.qxd:ITW Companies
11/3/09
3:07 PM
Page 1
Miller Recommended Brands
Premium Products
Built for a Lifetime
Six Reasons to Choose Smith
1. Smith’s Lifetime Warranty
It’s the longest and strongest in the business!
2. Products Engineered for Safety
Our torches feature exclusive technology to help
keep you safe.
3. Superior Cutting Tip Performance
We offer long-lasting cutting tips for even the most
challenging jobs.
4. Our Complete Product Line
Smith offers a complete line of oxy-fuel cutting, welding,
brazing and heating equipment, plus gas regulators.
5. Value
Our exceptional product quality and warranties offer
long-term cost savings!
6. Premium Built
Our products are proudly designed, assembled and
tested in Watertown, SD, USA!
Lifetime
Warranty Torches
Gas
Regulators
Specialty Gas
Regulators
Smith torches are so
durable and high performing
they carry a Lifetime Warranty.
And lifetime means lifetime!
We repair or replace any torch
for free — that’s how confident
we are in our product.
Achieving consistent welding and
cutting performance is important in
any application. So is finding
a durable product that saves
money. Smith has engineered
its gas regulators with such key
benefits in mind.
Complex applications require
comprehensive product lines.
Smith’s full line of specialty gas
regulators has been engineered
for general purpose, analytical,
high purity and corrosive gases,
and feature durable, highperforming and problem-solving
designs.
Our gas regulators feature highquality components that resist
corrosion, freezing and clogging to
provide accurate gas flow and
readings.
Contact Us: Address:
2601 Lockheed Avenue
Watertown, SD 57201
For precise pressure control on
even the most critical applications,
Smith offers over 10,000
configurations, most of which
ship within 24 hours!
Phone: 605-882-3200
Toll Free: 800-843-7912
Fax: 800-685-3370
Email: [email protected]
Web: Smithequipment.com
97
A FLE10 Cat P 98 MTE Glossary.qxd:MTE Glossary
11/5/09
10:32 AM
Page 1
Miller Technology Exclusives
MTE Glossary
For a complete listing of
welding terms, visit
MillerWelds.com/Dictionary
Automatic Start at Idle™ — Idles engine
immediately when started, extending
engine life and reducing fuel consumption
and noise.
Accu-Pulse® — MIG process that
delivers precise control of the arc even
over tack welds and in tight corners.
Provides optimum and precise molten
puddle control.
Auto-Refire™ — Automatically controls
the pilot arc when cutting expanded
metal or multiple pieces of metal, without
manual retriggering.
Accu-Rated™ Power — The standard for
measuring engine-driven generator power.
Guarantees delivery of all power promised.
Accu-Set™ — Patented amperage indicator
on Thunderbolt® models provides accurate
heat control with infinite amperage control.
Active Arc Stabilizer ™ — Enhances arc
starts and provides a softer arc throughout
all ranges, with less puddle turbulence
and less spatter.
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.
Advance Active Field Control
Technology ™ — A simple and reliable
patented way of accurately controlling an
engine drive’s generator weld output.
Alumination™ Technology — Gives
you the ability to use the extended reach
of a push-pull system to feed your
aluminum wire. Available on Invision™
MPa Plus System.
Aluminum Pulse Hot Start ™ —
Automatically provides more arc power to
eliminate a “cold start” that is inherent with
aluminum starts. Available on Millermatic®
350P and AlumaFeed™ System.
Arc-Drive™ — Automatically enhances
Stick welding, especially on pipe, by
focusing the arc and preventing the
electrode from going out.
Auto-Crater™ — Allows a TIG arc on
Trailblazer® Series to crater-out, allowing
time for addition of filler, without the loss
of shielding gas. Eliminates the need for
a remote control at arc end.
Auto-Gun Detect™ — Automatically
detects and recalls the voltage, wire feed
speed, and timer on the active gun —
either the MIG gun, spool gun, or pushpull gun on the Millermatic® Reach Wire
Feeder, 252, 350 and 350P.
Auto Remote Sense™ — Automatically
switches machine from panel to remote
control with remote connected. Available
on Delta-Fab™ System, XMT® 350,
Dimension™ NT 450, and Trailblazer®
Series. Eliminates confusion and need
for panel/remote switch.
Auto-Set™ — Sets the MIG welder
automatically to the proper parameters.
Operator only needs to set the wire
diameter and material thickness, and go!
Available on Millermatic® 140 Auto-Set,
180 Auto-Set, 211 Auto-Set with MVP™,
and 212 Auto-Set™.
Auto Speed™ — On the Trailblazer® 302
Air Pak™, in the Auto Speed mode of the
Speed Control Switch, the engine speed
will be auto-selected depending upon
total power needed.
Auto Stop™ — Allows a TIG arc to be
stopped without the loss of shielding gas
on Trailblazer® Series.
Axcess® File Management — Software
that turns a standard Palm™ handheld or
PC into a remote pendant control for all
Axcess systems. Allows e-mailing, storage,
and transfer of welding programs.
Blue Lightning™ — High frequency arc
starter for non-contact arc initiation.
Provides more consistent arc starts
compared to traditional HF arc starters.
Available on Maxstar® 200 (except STR)
and larger models and Dynasty® models.
Dual Power Option™ — Gives the option
on the PipePro® 304 engine drive to use
230 volt single- or three-phase electric
input power, eliminating engine wear,
noise and emissions, as well as fuel costs.
Dual Voltage Input —
See MVP™ (Multi-Voltage Plug).
Engine Save Start ™ — Idles engine 3–4
seconds after starting on Trailblazer® 275
DC and 302. Extends engine life and
reduces fuel consumption.
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.
Extended AC Balance™ (30 – 99%) —
Controls the amount of oxide cleaning
(amperage time in Electrode Negative)
on Dynasty® 350 and 700. Essential for
high quality aluminum welds.
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.
EZ-Access™ — Consumable compartment
and parameter chart in flip-down
compartment on front of Millermatic® 212
Auto-Set™ and 252. Set weld parameters
right the first time with fast access to the
set up chart.
98
EZ-Change™ — Low cylinder rack allows
operators to easily roll cylinders on and
off of rack — no need to lift cylinders.
Available on Millermatic® 212 Auto-Set™
and 252.
SharpArc® — Optimizes the size and
shape of the arc cone, bead width and
appearance, and puddle fluidity. Available
on the Millermatic® 350/350P and
XMT® 350 MPa.
Fan-On-Demand™ — Internal power source
cooling system only works when needed,
keeping internal components cleaner.
Smart Fuel Tank — Tank’s design
minimizes chance of fuel backflow.
FasTip™ Contact Tip — Patented, singleturn for quick change — no tools needed!
Gun-On-Demand ™ — Allows you to use
either a standard gun or a Spoolmatic®
gun on the Millermatic® 212 Auto-Set™
without flipping a switch. The machine
senses which gun you are using when
you pull the trigger.
Hot Start™ — Used on some Stick
(SMAW) machines to make it easier to
start difficult-to-start electrodes. Used
for arc starting only.
Lift-Arc™ — This feature allows TIG arc
starting without high frequency. Starts
the arc at any amperage without
contaminating the weld with tungsten.
Low OCV Stick™ — Reduces OCV on
several Maxstar ® and Dynasty® models
when power source is not in use, eliminating need for add-on voltage reducers.
LVC™ (Line Voltage Compensation) —
Keeps the output of a power source
constant, regardless of minor
fluctuations in input power.
MVP™ (Multi-Voltage Plug) —
Allows connection of Millermatic®
Passport™ Plus, 211 Auto-Set™ with
MVP, Maxstar® 150 models, Diversion™
180, or Spectrum® 375 X-TREME™ to
115- or 230-volt receptacles without
tools — just choose the plug that fits
the receptacle.
Profile Pulse™ — Pulsed MIG process
which produces a stacked dime bead
profile without the operator having to
manually manipulate his welding torch
to do so. Appearance is similar to an
aluminum TIG weld.
Pro-Pulse™ — On the PipeWorx™ Welding
System, easier-to-use pulse welding
method than conventional pulse for
out-of-position pipe welding applications.
Offers precise arc and puddle control
even in narrow weld joints, providing
optimum molten puddle control for
out-of-position welding.
Regulated Metal Deposition (RMD™) —
Precisely controlled short-circuit transfer
technology, available on PipeWorx™
Welding System and as an option on
Axcess® models. For spatter reduction,
up to 20% reduced heat input, or filling
gaps. Reduces weld training and
improves weld quality.
Smooth Start ™ — Provides a smooth,
spatter free start to the MIG weld on
Millermatic® 140 and 180 models.
SunVision™ — Allows easy reading of
digital meters in direct sunlight or
shade on SuitCase® VS models and
Trailblazer® Series.
SureStart® — Provides consistent
Axcess® arc starts by precisely
controlling power levels for specific
wire and gas combinations.
Syncro Start ™ — Allows selectable
customized arc starts on Syncrowave®
200, 250 DX and 350 LX.
Tip Saver Short Circuit Protection™ —
Shuts down output when the MIG contact
tip is shorted to the work on Millermatic®
140 Auto-Set ™, 180 Auto-Set ™, and 211
Auto-Set ™ with MVP. Extends contact tip
life and protects machine. Trigger Reset
permits quick reset at gun rather than
at machine.
Torch Detection™ — Syncrowave® 250
DX and 350 LX detect if TIG torch is
water- or air-cooled.
Tri-Cor ™ Technology — Stabilizer
design on the Bobcat ™ 250 that delivers
smoother welds and decreased spatter
with E7018 electrodes, without sacrificing
performance with E6010 electrodes.
Ultra-Quick Connect™ — Offers the fastest
plasma torch and work cable connection
and removal in the industry. Available on
Spectrum® 875.
WaveWriter ™ File Management —
Includes all Axcess® File Management
functions, plus a simple, graphical
wave-shaping program for the most
demanding Pulsed MIG applications.
Weld at Idle™ — Allows PipePro® 304
to automatically weld at a quieter, lower
RPM, using less fuel. When more output
is required, the machine goes to high
speed without a change in the arc.
Wind Tunnel Technology™ — Internal
air flow on many Miller inverters,
that protects electrical components and
PC boards from contamination,
significantly improving reliability.
A FLE10 Cat P 99 Literature-Index.qxd:Online-Index
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Literature Sheets/Index
Miller Product Literature Sheets
Use this catalog to help compare and select power sources. To obtain detailed
product literature sheets visit our Web site at MillerWelds.com, see your Miller
distributor or call 1-800-4-A-MILLER. These sheets provide ordering information,
control features, options and recommended accessories. They also provide complete
specifications, including cCSAus, CE, CCC, IEC, CSA, UL and NEMA listings.
In a hurry? Check our Web site, or upon request, our 800-number operators can also
fax the literature directly to you. Simply ask for a literature sheet by product name.
MillerWelds.com and 1-800-4-A-MILLER (1-800-426-4553) are also your direct line
to locating your nearest Miller distributor sales and service provider. Operators are
on-duty from 8:30 AM to 5:00 PM (eastern time). At all other times an automated
service is available.
In 1993 we became the first U.S.
welding equipment manufacturer to
be registered to the world's highest
quality standard — ISO.
Miller has a long history of being
the first to meet the changing needs
of welders in a variety of industrial
and non-industrial markets.
To further demonstrate Miller’s commitment to its
customers, we back all our equipment with the
best coverage in the industry — the True Blue®
Warranty. And that's The Power of Blue®.
Index
A
B
C
D
AlumaFeed Welding System. . . . . 13
Arc Armor Welding Protection. . . . 78
ArcStation Workstation . . . . . . . . 74
Auto-Axcess Systems. . . . . . . . . . 22
Automation Components . . . . . . . 22
Axcess Systems . . . . . . . . . . . . . 20
Big 40 . . . . . . . . . . . . . . . . . . . . 65
Big Blue 300 Pro . . . . . . . . . . . . . 64
Big Blue 400. . . . . . . . . . . . . . . . 65
Big Blue 500. . . . . . . . . . . . . . . . 65
Big Blue Air Pak . . . . . . . . . . . . . 67
Big Blue Turbo . . . . . . . . . . . . . . 67
Blue Star Series . . . . . . . . . . . . . 56
Bobcat 225 . . . . . . . . . . . . . . . . . 59
Bobcat 250 . . . . . . . . . . . . . . . . . 60
Bobcat 250 Diesel . . . . . . . . . . . . 60
Bobcat 3 Phase . . . . . . . . . . . . . . 57
Coolant Systems . . . . . . . . . . . . . 83
CP-302. . . . . . . . . . . . . . . . . . . . 16
CST 280 . . . . . . . . . . . . . . . . . . . 36
CST 280 Rack . . . . . . . . . . . . . . . 53
Delta-Fab System . . . . . . . . . . . . 16
Deltaweld Series. . . . . . . . . . . . . 17
Dialarc 250 AC/DC. . . . . . . . . . . . 34
New! or Improved!
products appear in blue type.
D
Dimension NT 450. . . . . . . . . . . . 50
Dimension Series . . . . . . . . . . . . 47
Diversion 165 . . . . . . . . . . . . . . . 45
Diversion 180 . . . . . . . . . . . . . . . 45
Dynasty 200 Series . . . . . . . . . . . 42
Dynasty 350 . . . . . . . . . . . . . . . . 43
Dynasty 700 . . . . . . . . . . . . . . . . 43
F FILTAIR Fume Extraction . . . . . . . 76
. . . . . . . . . . . . . . . . . . 98
G Glossary
Gold Star Series . . . . . . . . . . . . . 34
H Helmets . . . . . . . . . . . . . . . . . . . 79
MPa Plus System . . . . . . 18
I Invision
Invision 456MP/456P . . . . . . . . . 19
VI . . . . . . . . . . . . . . . . . . . 53
M Mark
Mark VIII-2 . . . . . . . . . . . . . . . . . 53
Maxstar 150 S. . . . . . . . . . . . . . . 35
Maxstar 150 STL/STH . . . . . . . . . 39
Maxstar 200 STR. . . . . . . . . . . . . 35
Maxstar 200 Series . . . . . . . . . . . 40
Maxstar 350 . . . . . . . . . . . . . . . . 41
Maxstar 700 . . . . . . . . . . . . . . . . 41
Miller Du-Op. . . . . . . . . . . . . . . . 66
Millermatic 140 Auto-Set . . . . . . . . 8
Millermatic 180 Auto-Set . . . . . . . . 8
211 Auto-Set w/MVP. . . 9
M Millermatic
Millermatic 212 Auto-Set . . . . . . . 10
S
Sub Arc DC 650/1000 . . . . . . . . . 69
SuitCase 8RC . . . . . . . . . . . . . . . 26
SuitCase 12RC . . . . . . . . . . . . . . 26
SuitCase X-TREME 8VS . . . . . . . . 25
SuitCase X-TREME 12VS . . . . . . . 25
Syncrowave 200 . . . . . . . . . . . . . 44
Syncrowave 250 DX. . . . . . . . . . . 44
Syncrowave 350 LX . . . . . . . . . . . 44
T
22A/24A. . . . . . . . . . . . . . . . . . . 30
Thunderbolt XL 225 AC . . . . . . . . 34
Thunderbolt XL AC/DC . . . . . . . . . 34
Trailblazer 275 DC. . . . . . . . . . . . 61
Trailblazer 302 . . . . . . . . . . . . . . 61
Trailblazer 302 Air Pak. . . . . . . . . 62
Trailblazer 302 Diesel . . . . . . . . . 61
Millermatic 252 . . . . . . . . . . . . . 11
Millermatic 350/350P . . . . . . . . . 12
Millermatic Passport Plus . . . . . . . 9
Millermatic Reach Wire Feeder . . 10
P
R
S
PipePro 304 . . . . . . . . . . . . . . . . 66
PipeWorx Welding System . . . . . . 51
R-115. . . . . . . . . . . . . . . . . . . . . 30
70 Series . . . . . . . . . . . . . . . . . . 31
70 Series Swingarcs . . . . . . . . . . 32
74 MPa Plus . . . . . . . . . . . . . . . . 18
S-32S/S-32SL . . . . . . . . . . . . . . 30
Shopmate 300 DX . . . . . . . . . . . . 47
Spectrum 125C . . . . . . . . . . . . . . 71
Spectrum 375 . . . . . . . . . . . . . . . 71
Spectrum 375 X-TREME . . . . . . . . 72
Spectrum 625 X-TREME . . . . . . . . 72
Spectrum 875 . . . . . . . . . . . . . . . 73
Spoolmate 100 Series . . . . . . . . . 27
Spoolmate 200 Series . . . . . . . . . 27
Spoolmate 3035 . . . . . . . . . . . . . 91
Spoolmatic 15A/30A . . . . . . . . . . 28
Spot Welders . . . . . . . . . . . . . . . 68
SRH-444 . . . . . . . . . . . . . . . . . . 34
W Wildcat 200 . . . . . . . . . . . . . . . . 56
304/350 Racks . . . . . . . . . . 54
X XMT
XMT Series. . . . . . . . . . . . . . . . . 48
XR-Aluma-Pro Gun . . . . . . . . . . . 29
XR-Aluma-Pro Plus Gun . . . . . . . . 18
XR-A/XR-W Guns . . . . . . . . . . . . 28
XR-Controls . . . . . . . . . . . . . . . . 29
99
A FLE10 CoverBk 2.qxd:Cat CoverBk
11/3/09
3:15 PM
Page 1
Strike it Rich at MillerWelds.com
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81
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