Big Blue® 600Pro

Big Blue® 600Pro
Issued Dec. 2015 • Index No. ED/11.5
Big Blue 600 Pro
®
Heavy Industrial
Applications
Quick
Specs
Diesel Engine-Driven
Welder/AC Generator
Processes
Heavy construction
Structural steel
Mining maintenance
Maintenance and repair rigs
Pipe welding
Output Range
Stick (SMAW)
MIG (GMAW)
Flux-cored (FCAW)
DC TIG (GTAW)
Air carbon arc (CAC-A)
3/8-inch (9.5 mm) carbons
Air plasma cutting and gouging with
optional Spectrum models
DC stick/TIG 20–600 A
DC MIG/FCAW 14–44 V
Generator Output Rated at 104°F (40°C)
3-phase 27,000 watts peak, 20,000 watts continuous
1-phase 15,000 watts peak, 12,000 watts continuous
Heavy-duty low-speed T4F
industrial diesel engine.
The cleanest, greenest diesel power
available. Utilizes diesel oxidation
catalyst (DOC) technology to keep
the air clean with NO exhaust
aftertreatment maintenance.
Electronic engine display
simultaneously displays
fuel level, engine hours, coolant
temperature, oil pressure, battery
volts, and engine rpm. Also tracks
oil change intervals and displays
engine diagnostics for quick and
easy servicing.
Low OCV stick (VRD) reduces the
open-circuit voltage to 15 volts
when the welding power source is
not in use. This feature is now built
into the Big Blue 600 Pro for
increased operator safety without
compromising arc starts.
The vault — ultimate control board
reliability. See page 4.
Thermal overload protection
prevents machine damage if the
duty cycle is exceeded or airflow
is blocked.
Infinite arc control allows the arc
characteristics to be changed for
specific applications in stick, MIG
and FCAW.
Remote oil drain prevents spills and
makes servicing easy.
Auto Remote Sense™ (ARS)
detects if a remote control is
plugged into the 14-pin receptacle
and eliminates confusion of a
remote/panel switch.
Deluxe model shown.
Standard features include digital
preset weld meters, automatic idle,
120-volt block heater and automatic
glow plugs.
Welder/generator is warranted by Miller for three years, parts and labor.
Engine is warranted separately by engine manufacturer.
Miller Electric Mfg. Co.
Equipment Sales US and Canada MillerWelds.com
An ITW Welding Company
1635 West Spencer Street
P.O. Box 1079
Appleton, WI 54912-1079 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
Specifications (Subject to change without notice.)
Weld
Output
Range
Weld Mode/
Process
Max. OpenCircuit
Voltage
Weld Output
Rated at 104°F (40°C)
CC/DC
(Stick/TIG)
20–600 A
CV/DC
(MIG/FCAW)
14–44 V
500 A at 40 V, 100% duty cycle*
550 A at 42 V, 60% duty cycle
600 A at 42 V, 40% duty cycle
92 VDC
15 VDC**
Generator Power Output
Rated at 104°F (40°C)***
3-phase:
27,000 watts peak,
20,000 watts continuous
1-phase:
15,000 watts peak,
12,000 watts continuous
Dimensions
Weight
H: 46 in. (1,168 mm)
W: 28.5 in. (724 mm)
D: 69.5 in. (1,765 mm)
Add 7.5 in. (191 mm) to
heights for exhaust pipe
Net: 1,750 lb. (793.8 kg)
Add 51 lb. (23 kg) for
ship weight
Add 165 lb. (75 kg)
when fuel tank is full
*Meets NEMA and IEC ratings. **Sense voltage for stick and Lift-Arc™ TIG. ***Will operate either 60 hertz or 50/60 hertz power tools, lights, etc.
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
Engine Specifications (Engines warranted separately by the engine manufacturer.)
Engine Brand
Features
HP
Type
Engine Speeds
Sound Levels at 23 ft. (7 m)
Capacities
Automatic Engine
Shutdown
Kubota
V2403
EPA Tier 4 Final
compliant, includes
120 V block heater
48.9
Four-cylinder,
liquid-cooled
industrial diesel
Idle: 1,350 rpm
Weld: 1,800 rpm
Idle: 65.9 dB (90.7 Lwa)
Weld: 74.3 dB (99.1 Lwa)
Fuel: 25 gal. (95 L)
Oil: 10 qt. (9.5 L)
Coolant: 9 qt. (8.5 L)
Low oil pressure,
high coolant temperature,
low fuel level
Performance Data
Fuel Consumption Curve
Simultaneous Welding and Power
2.50
Total Aux. Power Available (Watts)
US Gal./Hr.
2.25
2.00
Weld Amperes
1-Phase*
1.75
No Weld Output
16,000
20,000
1.50
200 A at 28 V
16,000
20,000
300 A at 32 V
13,000
18,000
400 A at 36 V
9,000
12,500
500 A at 40 V
4,500
5,750
600 A at 42 V
4,000
0
- or -
3-Phase
1.25
1.00
0.75
0.50
Idle
0.25
0.00
0
50
100
150
200
250
300
350
DC Weld Amperes at 100% Duty Cycle
2
400
450
500
*Single-phase listings include 4,000 watts from the exciter stator.
Function Guide
1. Weatherproof Lexan® nameplate is super
durable and resists cracking and fading.
Color coded for ease of operation.
2. Self-calibrating digital weld meters with
fault code indication display preset or
actual weld parameters.
3. Adjustable arc control adjusts DIG when
process control is in stick mode and adjusts
inductance when process control is in
FCAW or MIG mode. The amount of DIG
determines how much amperage (heat)
varies with stick arc length. Inductance
determines the “wetness” of the weld puddle.
4. Amperage/voltage adjust control
5. Hot Start ™ provides positive stick electrode
starts making it easy to start all types of
electrodes and it also works great for bead
tie-ins.
6. Great FCAW/MIG performance and arc
starts make the Big Blue® 600 Pro arc the
best in its class. Easy to run all wires from
.023-inch solid wires to large-diameter
1/8-inch flux-cored wires.
1
15
2
3
4
5
6
16
17
7
8
9
10
11
12
7. Lift-Arc™ TIG with Auto-Stop™.
8. 50 A, 240 V, three-phase receptacle
13
14
(For matching plug, order #254 140.)
18
9. 50 A, 120/240 V receptacle
(For matching plug, order #119 172.)
10. 20 A, 240 V receptacles
11. 20 A, 120 V receptacles with ground fault
12. 50 A circuit breaker
13. 20 A, 240 V circuit breaker
14. 20 A, 120 V circuit breakers
15. Electronic engine display can display fuel
level, engine hours, coolant temperature,
oil pressure, battery volts, and engine rpm
simultaneously or one at a time. Also tracks
oil change intervals and displays engine
diagnostics for service technicians.
16. Engine control switch is used to start
engine and then select between auto idle
and high speed lock. Glow plug operation
is controlled by the engine control module
and automatically occurs as needed by
ambient conditions.
17. Standard 14-pin receptacle for simple
connection of remote controls and wire
feeders. It features Auto Remote Sense™
which automatically switches from panel to
remote amperage/voltage (A/V) control with
remote connected. Eliminates confusion of
the panel/remote A/V switch.
18. Optional polarity reversing switch changes
DC polarity without the use of tools.
19. Weld output terminals
19
Arc Start with Lift-Arc
™
Touch or scratch
Lift at any angle
Shielding
gas
Arc
Shielding
gas
• Reduces or eliminates sticking
• Reduces or eliminates electrode/work
contamination
• Low open-circuit voltage
Workpiece
Arc End with Auto-Stop
™
For Auto-Stop, lift up to terminate arc
While welding
Shielding
gas
Arc
Workpiece
Lift up
until arc
ends
Arc ends
without
flare
Move back
down to
maintain gas
coverage
• Eliminates need for a
remote control
• Maintains shielding gas
coverage
• Eliminates tungsten and
workpiece
contamination
• Eliminates unwanted
arc strikes outside the
weld area
3
What Makes Miller Industrial Engine Drives So
®
Superior circuit board design
Our critical circuit boards are engineered to carry low power and low
heat to reduce thermal stress and minimize expansion and contraction.
In contrast, our competitor’s boards carry high power and high heat,
making them more vulnerable to failure.
“The vault” makes upgrading to Miller CC/CV
units worry-free
Concerns with circuit board reliability have resulted in some operators
steering clear of CC/CV welder/generators — even though they offer a
superior arc and multiple welding processes. Miller circuit board
reliability isn’t a concern since all Big Blue multiprocess industrial engine
drives feature the Vault.
Created out of two aluminum halves sealed with silicone, as well as
watertight harness connections, the Vault provides a clean circuit board
environment, protecting the electronics — and controlling output —
in heavy industrial applications. No other competitor protects their
electronics with a sealed vault, leaving critical circuit boards exposed to
harsh elements that can disrupt the machine’s electronics, and therefore,
its operation.
Rigorous testing for
tough, real-world
conditions
To prove our machines go to the
limit, Miller industrial engine drives
are put to the test in very extreme
environmental conditions.
• Airborne dust and sand.
Critical components are exposed
to abusive airborne particles in a
special testing chamber for weeks,
helping make sure they’ll operate
while facing extreme levels of dirt,
dust or sand on the jobsite.
• Humidity and corrosion.
Inside our Houston testing room,
critical components are subjected to extended moisture and corrosive
salt exposure to ensure they’ll run even when exposed to humid
climates, corrosive coastal environments, and driving rain.
• Temperature extremes. Miller industrial engine drives are tested
to ensure performance in scorching heat. All Miller engine-driven
machines are weld rated at 104 degrees Fahrenheit, but actual tests are
conducted up to 122 degrees Fahrenheit to assure peak performance.
• Jobsite/over-the-road abuse. Miller industrial engine drives are
shaken for hours on transportation bed simulators, subjected to severe
vibration, and test-dropped and jerked to ensure they’ll withstand the
stresses that can shut down competitive machines.
• Continuous operation. Miller industrial engine drives run day and
night, in all weather conditions, to assure they’ll perform without
interruption in the field.
Why industrial engine
drive customers
choose Miller
The ultimate test of Miller reliability
is how it performs in the field. Read
stories demonstrating our superior
reliability at MillerWelds.com.
4
?
Genuine Miller Accessories
®
Polarity Reversing Switch Kit
#301 112 Field
Changes DC polarity without the use of tools.
Female
Receptacle
Full KVA Adapter Cord #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.
Full KVA Plug Kit Field
#119 172 1-phase,
120/240 VAC, 50 A plug
(NEMA 14-50P)
#254 140 3-phase,
240 VAC, 50 A plug
(NEMA 15-50P)
Engine Filter Kit #273 293 Field
Includes all filters required for proper engine
maintenance. Oil filter, primary and secondary
fuel filter, primary air filter, and safety element.
Spark Arrestor Kit
#195 012 Field
Prevents particles
from leaving the
muffler that could
potentially start a fire. Mandatory when
operating on California grasslands, brush, or
forest-covered land, and in all national forests.
For other areas, check your state and local laws.
Meets U.S. Forest Service standard 5100-1B.
FA-1D Lockable Flame Arrestor
Fuel Cap #043 947 Field
Fuel cap can be padlocked to
prevent vandalism. A built-in flame
arrestor prevents flames or sparks
from entering the fuel tank.
Vandalism Lockout Kit
#399 802 Field
Lockable hinged steel panels
cover and protect name plate
gauges and ignition switch
(padlock included).
Cable Holder
#043 946 Field
Saddle-bag-style cable
holder. Convenient wraparound storage of coiled
cable for transportation.
Stores 100 feet of 2/0 cable
on each side.
Note: For best results do not weld when cable is coiled!
Protective cover cannot be used with cable holder.
Protective Cover
#301 113
Blue waterresistant canvas
cover resists stains
and mildew, and
protects the finish
of your welder.
Note: Protective cover cannot be used with cable holder.
Stick (SMAW) Welding
Weld Leads
2/0 Stick Cable Set, 50 ft. (15 m) #173 851
Consists of 50-foot (15 m) 2/0 electrode cable
with holder, and 50-foot (15 m) work cable with
clamp. 350 A, 100% duty cycle.
2/0 Stick Cable Set, 100/50 ft. (30.5/15 m)
#043 952
Consists of 100-foot (30.5 m) 2/0 electrode
cable with holder, and 50-foot (15 m) work
cable with clamp. 300 A, 100% duty cycle.
Spoolmatic® 30A Spool Gun #130 831
Air-cooled, 200-amp, one-pound spool gun for
aluminum MIG. See Lit. Index No. M/1.73.
WC-24 Control #137 549
Use with Spoolmatic 30A.
XR™ Wire Feeders and Guns
Push-pull system designed to handle difficult-tofeed soft alloy wires such as aluminum. See Lit.
Index Nos. M/1.7 to M/1.74.
MIG (GMAW)/Flux-Cored (FCAW) Guns
Miller produces a complete line of dependable
MIG guns. See Lit. Index Nos. AY/15.0, AY/16.0
and AY/17.0.
MIG (GMAW) or Flux-Cored (FCAW) TIG (GTAW) Welding
Dynasty® 200 Series
For premium portable
AC/DC TIG arc quality.
See Lit. Index No. AD/4.8.
SuitCase® X-TREME™ 8VS Wire Feeder
#951 582
SuitCase® X-TREME™ 12VS Wire Feeder
#951 543
Lightweight, voltage-sensing wire feeders include
secondary contactor, gas valve, drive roll kit and
Bernard™ Q300 MIG gun. See Lit. Index No. M/6.42.
SuitCase® 12RC Wire
Feeder #951 580
Lightweight and flexible
enough to run a variety of
wires up to .062-inch
diameter. Includes
remote voltage control,
drive roll kit and Bernard™
Q300 MIG gun. See Lit.
Index No. M/6.5.
HF-251D-1 #042 388
115 V. High-frequency
arc starter and stabilizer.
See Lit. Index AY/5.0.
Plasma Cutting
Spectrum 375 X-TREME and 625 X-TREME shown.
Spectrum® 375 X-TREME™ #907 529
See Lit. Index No. PC/9.2.
Spectrum® 625 X-TREME™ #907 579
See Lit. Index No. PC/9.6.
Spectrum® 875 #907 583
See Lit. Index No. PC/9.8.
The Spectrum 375 X-TREME and 625 X-TREME
come complete with protective X-CASE™
(not shown).
5
Genuine Miller Accessories (Continued)
®
Extension Cables for 14-Pin Remote Controls
or 24 VAC Wire Feeders
#242 208 025 25 ft. (7.6 m)
#242 208 050 50 ft. (15.2 m)
#242 208 080 80 ft. (24.4 m)
Remote Controls
Wireless Remote Hand
Control #300 430
For remote current,
voltage and contactor
control. Receiver plugs
directly into the 14-pin
receptacle of Miller
machine. 300-foot
(91.4 m) operating range. Wireless antenna kit
#300 749 recommended.
RHC-14 Hand Control #242 211 020
Miniature hand control for remote current,
voltage and contactor control. Dimensions:
4 x 4 x 3.25 inches (102 x 102 x 82 mm).
Includes 20-foot (6 m) cord and 14-pin plug.
Wireless Antenna Kit #300 749
Optional when improved reception is desired.
Mounting Specifications
Trailers and Hitches (Note: Trailers are shipped unassembled.)
H
A
4 holes
Front panel
B
C
D
4 West Four-Wheel Steerable
Off-Road Trailer #042 801
A heavy-duty 2,570-pound (1,166 kg) capacity
trailer designed for use in mines, quarries, and
other rough terrain. Has narrow 22-foot (6.7 m)
turning radius. Includes 3-inch (76 mm) lunette
eye, universal hitch and safety chains.
HWY-224 Trailer #043 805
A 2,650-pound (1,202 kg) capacity trailer for
highway use. Welded steel tubing frame,
heavy-duty axle with roller bearing hubs and
leaf-spring suspension. Includes jack stand,
2-inch (50 mm) ball hitch, fenders and lights.
E
F
G
A. 29.812 in. (757 mm)
B. 27.5 in. (699 mm)
C. 1 in. (25 mm)
D. 11.625 in. (295 mm)*
E. 46.375 in. (1,178 mm)*
F. 58 in. (1,473 mm)*
G. 69.5 in. (1,765 mm)
H. .562 in. (14 mm) dia.
Cable Tree #043 826
Provides an area to conveniently wrap weld
cables and extension cords.
Height:
46 in. (1,168 mm) to top of cover
Add 7.5 in. (191 mm) to heights for exhaust pipe
(Exhaust measurement subject to change.)
Width:
28.5 in. (724 mm) (mounting brackets turned in)
30.75 in. (781 mm) (mounting brackets turned out)
Dual Hitch #300 831
2-inch (50 mm) ball hitch and 3-inch (76 mm)
lunette eye in one reversible assembly.
*With mounting brackets in center position.
Dimensions vary with location of mounting brackets.
Trailer Specifications (Subject to change without notice.)
Gross Axle
Weight Rating
Gross Vehicle
Weight Rating
Net
Payload
Height
of Bed
Road
Clearance
Track (Center
to center of
tires)
Standard Tires
(Standard rating
or P-size rating)
4 West
2,000 lb./axle
(907 kg/axle)
3,000 lb.
(1,361 kg)
2,570 lb.
(1,166 kg)
21.25 in.
(540 mm)
8 in.
(203 mm)
55.25 in.
(1,403 mm)
HWY-224
3,500 lb.
(1,588 kg)
2,960 lb.
(1,343 kg)
2,650 lb.
(1,202 kg)
18.5 in.
(470 mm)
7.25 in.
(184 mm)
52 in.
(1,321 mm)
Model
*Does not include tongue. **Width at outside of fenders.
6
Dimensions
Net
Weight
B78-13
Length: 91 in. (2,311 mm)*
Width: 61.25 in. (1,556 mm)
430 lb.
(195 kg)
B78-13
Length: 105 in. (2,667 mm)
Width: 59.5 in. (1,511 mm)**
320 lb.
(145 kg)
Typical Installations
Electrode Hot
Remote control
Stick (SMAW) Basic Equipment
RHC-14
Wireless remote hand control
Wireless antenna kit
#242 211 020
#300 430
#300 749
14-pin
RHC-14
or
Stick electrode
Wireless
remote
hand control
Work
Flux-Cored/MIG (FCAW/GMAW)
Basic Equipment
SuitCase® X-TREME™ 8VS
SuitCase® X-TREME™ 12VS
Voltage-sensing feeder
SuitCase
X-TREME
8VS/12VS
#951 582
#951 543
Flux-cored or MIG gun
Work
TIG torch
with valve
Lift-Arc TIG (GTAW) Basic Equipment
™
Lift-Arc TIG
Work
Remote On/Off Required
Remote control
Stick (SMAW) Basic Equipment
RHC-14
Wireless remote hand control
Wireless antenna kit
#242 211 020
#300 430
#300 749
14-pin
RHC-14
or
Stick electrode
Wireless
remote
hand control
Work
Flux-Cored/MIG (FCAW/GMAW)
Basic Equipment
®
SuitCase 12RC
14-pin
Flux-cored or MIG gun
SuitCase
12RC
#951 580
Work
Spoolmatic 30A gun
Aluminum MIG (GMAW) Basic Equipment
®
Spoolmatic 30A
WC-24
#130 831
#137 549
14-pin
WC-24
Work
Plasma Basic Equipment
Spectrum® 375 X-TREME™ #907 529
Spectrum® 625 X-TREME™ #907 579
Spectrum® 875
#907 583
Cutting torch
Spectrum
Work
7
Ordering Information
Equipment and Options
Stock No.
Description
#907 695
#907 695 001
Base model with 240-volt 3-phase power
Deluxe model with polarity reversing switch and vandalism lockout kit
Polarity Reversing Switch Kit
#301 112
Changes DC polarity without the use of tools
Full KVA Adapter Cord
#300 517
®
Big Blue 600 Pro
EPA Tier 4 Final compliant engine
Qty.
Field Accessories
Full KVA Plug Kits
See page 5
Engine Filter Kit
#273 293
Spark Arrestor Kit
#195 012
Includes air, oil and fuel filters
FA-1D Lockable Flame Arrestor Fuel Cap
#043 947
Padlock NOT included
Vandalism Lockout Kit
#399 802
Lockable front control panel and engine compartment
Cable Holder
#043 946
Stores up to 200 feet of 2/0 cable
Protective Cover
#301 113
Canvas cover — will not fit over machine with cable holder attached
Stick Welding Leads
#173 851
#043 952
2/0, 350 A, 100% duty cycle, 50 ft. (15 m) stinger, 50 ft. (15 m) work clamp
2/0, 300 A, 100% duty cycle, 100 ft. (30.5 m) stinger, 50 ft. (15 m) work clamp
SuitCase® X-TREME™ 8VS
#951 582
With Bernard™ Q300 MIG gun. See Lit. Index No. M/6.42
SuitCase® X-TREME™ 12VS
#951 543
With Bernard™ Q300 MIG gun. See Lit. Index No. M/6.42
SuitCase® 12RC
#951 580
With Bernard™ Q300 MIG gun. See Lit. Index No. M/6.5
Spoolmatic 30A Spool Gun
#130 831
Requires WC-24 Control. See Lit. Index No. M/1.73
WC-24 Control
#137 549
MIG/Flux-Cored Welding
®
See Lit. Index No. M/1.5
XR™ Wire Feeder Control and Guns
See Lit. Index Nos. M/1.7 to M/1.74
MIG (GMAW) and Flux-Cored (FCAW) Guns
See Lit. Index Nos. AY/15.0, AY/16.0 and AY/17.0
TIG Welding
Dynasty® 200 Series
HF-251D-1
See Lit. Index No. AD/4.8
#042 388
115-volt high-frequency arc starter and stabilizer. See Lit. Index No. AY/5.0
Spectrum® 375 X-TREME™
#907 529
Includes X-CASE™. See Lit. Index No. PC/9.2
Spectrum® 625 X-TREME™
#907 579
Includes X-CASE™. See Lit. Index No. PC/9.6
Spectrum 875
#907 583
See Lit. Index No. PC/9.8
Plasma Cutting
®
Remote Controls
Wireless Remote Hand Control
#300 430
Wireless Antenna Kit
#300 749
RHC-14 Hand Control
#242 211 020
Extension Cables
See page 6
Trailers and Hitches
4 West Four-Wheel Steerable Trailer
#042 801
Trailer with lunette eye, universal hitch and safety chains. For off-road use
HWY-224 Trailer
#043 805
Trailer with lights, fenders and 2-inch (50 mm) ball hitch. For highway use
Cable Tree
#043 826
Trailer-mounted cable holder for HWY-224
Dual Hitch
#300 831
Combination 2-inch (50 mm) ball hitch and 3-inch (76 mm) lunette eye in
one reversible assembly for HWY-224
Date:
Distributed by:
© 2015 Miller Electric Mfg. Co.
Total Quoted Price:
Price
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