Miller Full-Line Catalog

Miller Full-Line Catalog
Full-line Catalog
MillerWelds.com
2017
EU•CE Edition
with you
with you
When imagination meets determination,
we can do anything.
It begins with a spark of inspiration That inspiration builds to an idea —
and then, a plan.
Work begins. Challenges are overcome. And soon, we’ve built something
new for ourselves and for our world.
The wonder of your imagination. The power of your determination.
The capabilities of Miller products. Together, we build.
MillerWelds.com/webuild
New from Blue
13
XMS®425 MPa
18
SuitCase®12RC
45
Maxstar®400
Dynasty®400
15
Continuum Systems
16
Auto-Continuum Systems
31
Dimension 650
34
XMT®350 FieldPro System
45
Maxstar®800
Dynasty®800
61
External Cladding Head
™
™
™
™
Shop with expert advice and attention
Visit your local Miller distributor for in-depth knowledge and one-on-one
assistance in product selection. MillerWelds.com/wheretobuy
Help me choose
Finding the welding equipment that’s right for you doesn’t have to be complicated. Follow the steps below.
1
Pick the right process for the metals
to be welded.
MIG (GMAW) Process skill level Low Moderate High
Metal type
S Steel
SS Stainless Steel
Ni Nickel Alloys
AL Aluminium
CI Cast Iron
CB Copper/Brass
Ti Titanium
Mg Magnesium Alloys
EC All Electrically Conductive
S SS Ni AL CB
process to learn
• Easiest
welding speeds possible
• High
better control on thinner metals
• Provides
welds possible with no slag
• Cleaner
• Same equipment can be used for flux-cored welding
Pulsed MIG (GMAW-P) S SS Ni AL CB
Flexibility and productivity — nearly all metals can
• be
welded in all positions
Larger
diameter electrode wires for higher
• deposition
rates
no spatter
• Virtually
• Welds thin to thick metals
TIG (GTAW) AC AL Mg DC S SS Ni CB Ti
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) AC AL Mg DC S SS Ni CB Ti
More control on thin metals
Less heat distortion on thin metals
•
•
Submerged Arc (SAW) S SS
Flux-cored (FCAW) S SS
work as well as stick on dirty or rusty material
• Can
Out-of-position
welding
• Deep penetration
for welding thick sections
• Increased metal deposition
rate
•
Stick (SMAW) S SS Ni CI
suited for windy, outdoor conditions
• Well
More
forgiving when welding on dirty or rusty metal
•
4
High deposition rates can enhance weld speed
• and
production
Excellent
properties for high-quality
• code and mechanical
X-ray requirements
• Improves welding operator comfort and appeal
Air Carbon Arc Cutting and Gouging (CAC-A) AC CB DC S SS AL CI
Wide variety of metals
Removes discontinuities or inferior welds
•
•
Power icons
Input power
Does your machine need to be self-powered, or will AC power
be available at the location where it’s primarily used?
locations where an electrical hookup is not practical,
• For
consider a diesel-powered engine-driven welder/generator
Output power
Light industrial products are suitable for the hobbyist or
occasional light industrial user. They are designed to be easy
to operate, are affordably priced and typically have a low duty
cycle and lower-rated output.
Industrial products are suitable for applications that do not
require high-volume production. They typically have a 60 percent
duty cycle and/or rated output of 300 amps. Industrial products
are an appropriate choice for professional welders.
Heavy industrial products are suited to high-volume
production and/or welding of thicker materials. They typically
have a duty cycle of 60 to 100 percent and a rated output of
at least 300 amps. Heavy industrial products are 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.
Portability
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.
engine-driven welding generators fit in the back of a truck,
• Many
enabling them to be driven to wherever the welding is needed.
Heavy-duty trailers are also available for engine drives.
3
Check out the Product Guides.
The Product Guides (at the start of each major section) briefly
describe and compare power sources within that section.
Product
Guide
Flux-cored*
Three-phase power
Check to see if the machine you’re considering requires
three-phase power and whether its voltage requirements
are met by the electrical service at the intended location.
Pulsed MIG
Single-phase power
Check to see if the machine you’re considering requires
single-phase power, and whether its voltage requirements
are met by the electrical service at the intended location.
MIG
you’re considering:
Out in the field, you may need an engine-driven welder/generator
to supply AC power to run tools and lights, or supply 12-volt
DC power to charge automotive batteries and jump-start
vehicles. Miller®welder/generators are packed with power;
larger units even offer option packages that add 10 to 20 kW
of generator power.
Class
locations where AC power is available, you need to
• For
know its type — and whether it’s a match for the machine
Generator power
1-Phase
to supply welding and generator power.
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
Unit requires single-phase
input power
Unit requires three-phase
input power
Unit supplies alternating current
weld output
Unit supplies direct current
weld output
Page
2
Evaluate your needs: input power, output
power, generator power and portability.
MigMatic® 175
7
MigMatic® 220
7
MigMatic® 220 DX
7
MigMatic® 250
7
MigMatic® 250 DX
7
Portability
Installed
running gear
Installed
running gear
Weldable
Metals
Welding
Output Ranges
Special Features
Typical Applications
Steel, stainless
30–150 A, 15–21 V
Thermal overload protection, fan-cooled,
Euro torch connection
Light fabrication, hobby, auto body repair
Steel, stainless,
aluminium
30–200 A, 15–21 V
Adjustable run-in, burnback and spot timer,
thermal overload protection
General fabrication, auto body repair,
trailer fabrication
30–200 A, 15–21 V
Synergic interface for simple user setup,
weld meters
30–250 A, 15–24 V
Adjustable run-in, burnback and spot timer,
thermal overload protection
Steel, stainless,
aluminium
General fabrication, auto body
trailer fabrication
S
About duty cycles
Duty cycle is an indication of how long a power source
can continuously weld (at a specific amperage and voltage)
in a 10-minute period of time before it needs to cool down.
For example, a machine with a 60 percent duty cycle at
300 amps and 32 volts of welding output can be used
(at 300 amps and 32 volts) for 6 minutes out of a 10-minute
period. When comparing two similar-sized power supplies it
is important to pay close attention to both the amperage
and voltage values that determine the rated load.
4
Go to product descriptions.
(Specifications are subject to change without notice.)
Colored bullets indicate output power classification.
Power icons indicate power supplied or required (see
descriptions above). Listing of recommended processes.
Color-coded sections are
identified by a primary
process icon and title.
MIG
GMAW
MigMatic 175
®
Light industrial
See literature DCM/13.0 UK
Processes
Manual mode allows for simple manual setting of parameters for
welding on a broad range of applications.
Thermal overload protection shuts down the power source output if
the main transformer or rectifier overheats.
Industrial dual-gear-driven system features a no-tool, quick-change
reversible drive roll (0.8/1.0 mm) and an easy-to-set tension
adjustment knob.
Traditional tapped design and laminated inductor provide a stable,
smooth arc for consistent weld quality.
Stock Number
(029015550)
230 V, 50/60 Hz
Welding
Output Ranges
Rated Output
30–150 A
15–21 V
150 A at 21 VDC,
30% duty cycle
IP
Rating
Amps Input at Rated Output
230 V
Max. OpenCircuit Voltage
Wire Feed
Speed
IP21S
21
34
1.8–18 mpm
(70–708 ipm)
For more product specifications, give the product
name and literature number to your distributor,
visit us on the Web at MillerWelds.com.
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
Power cord with plug
• Work
with clamp
• Runningcablegear/bottle
rack
• 0.8/1.0
mm drive roll
•
Most popular accessories
• Bernard MIG gun Q2010TE3EEQ
™
Wire Type and Diameter Capacity
Dimensions
Solid steel 0.6–0.8 mm (.023–.030 in.)
Aluminium 0.8–1.0 mm (.030–.040 in.)
Flux-cored 0.6–0.8 mm (.023–.030 in.)
H: 561 mm (22.1 in.)
W: 447 mm (17.6 in.)
D: 769 mm (30.25 in.)
Net
Weight
43.3 kg
(95.5 lb.)
Brief listing of most popular
accessories. Refer to pages
listed for more details.
5
MIG
GMAW
3-Phase
1-Phase
Flux-cored*
Pulsed MIG
MIG
Class
Product
Guide
Page
Also see Multiprocess section for machines that can MIG weld.
MigMatic® 175
7
MigMatic® 220
7
MigMatic® 220 DX
7
MigMatic® 250
7
MigMatic® 250 DX
7
MigMatic® 300
8
MigMatic® 300 DX
8
MigMatic® 380
8
MigMatic® 380 DX
8
XPS 350
9
XPS 450
9
AlumaFeed™ 350
Aluminium System
11
AlumaFeed™ 450
Aluminium System
11
Deltaweld® 402
13
Deltaweld® 602
13
Installed
running gear
Installed
running gear
Weldable
Metals
Welding
Output Ranges
Special Features
Typical Applications
Steel, stainless
30–150 A, 15–21 V
Thermal overload protection, fan-cooled,
Euro torch connection
Light fabrication, hobby, auto body repair
Steel, stainless,
aluminium
30–200 A, 15–21 V
Adjustable run-in, burnback and spot timer,
thermal overload protection
General fabrication, auto body repair,
trailer fabrication
30–200 A, 15–21 V
Synergic interface for simple user setup,
weld meters
30–250 A, 15–24 V
Adjustable run-in, burnback and spot timer,
thermal overload protection
Steel, stainless,
aluminium
Synergic interface for simple user setup,
weld meters
30–300 A, 15–28 V
Industrial two-gear drive system, spot timer,
digital meter
General fabrication, trailer fabrication, construction
Synergic interface for simple user setup,
digital meter, run-in and burnback
30–350 A, 15–32 V
Industrial four-gear drive system, spot timer,
digital meter
General fabrication, trailer fabrication, construction
Synergic interface for simple user setup,
digital meter, run-in and burnback
Most metals
Fan-On-Demand,™ dual digital meters,
115-volt aux power socket, step voltage control
Structural steel, trailer manufacturing,
general fabrication
Profile Pulse,™ lightweight feeder with
multiple gun options
Heavy industrial aluminium production/fabrication,
truck and shipbuilding
Fan-On-Demand,™ dual digital meters,
115-volt aux power socket, tried and tested
Structural steel, trailer manufacturing,
general fabrication
5–425 A, 10–38 V
Advanced pulse and double-pulsed inverter
with simplified user interface
Heavy manufacturing and production,
aluminium fabrication
Push/pull gun capability, optimised with
74 MPa Plus wire feeder
Heavy manufacturing and production,
aluminium fabrication
30–350 A, 15–32 V
30–450 A, 15–34 V
Optional
running gear
Aluminium
5–425 A, 10–38 V
15–600 A, 10–38 V
Deltaweld® 852
13
XMS® 425 MPa
Welding System
13
Invision™ 352
MPa Plus System
14
5–425 A, 10–38 V
Invision™ 450
MPa Plus System
14
15–600 A, 10–38 V
Continuum™ 350
Steel, stainless 20–400 A, 10–44 V
Advanced arc performance, Welding Intelligence
20–600 A, 10–44 V
15 Steel, stainless 20–400 A, 10–44 V
Available for EtherNet/IP, DeviceNet and
16 Lift eye
analogue protocol
20–600 A, 10–44 V
16 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.
Auto-Continuum™ 350
Auto-Continuum™ 500
Product Key
Most metals
30–375 A, 10–32 V
30–575 A, 10–38 V
30–825 A, 10–44 V
™
15
™
See aluminium MIG solutions chart (page 10) and industrial MIG solutions chart (page 12) for additional information.
6
General fabrication, auto body repair,
trailer fabrication
Continuum™ 500
Portability
Mid-to-high volume manufacturing
Fixed and flexible automation
MIG
GMAW
MigMatic 175
®
Light industrial
See literature DCM/13.0 UK
Processes
Manual mode allows for simple manual setting of parameters for
welding on a broad range of applications.
Thermal overload protection shuts down the power source output if
the main transformer or rectifier overheats.
Industrial dual-gear-driven system features a no-tool, quick-change
reversible drive roll (0.8/1.0 mm) and an easy-to-set tension
adjustment knob.
Traditional tapped design and laminated inductor provide a stable,
smooth arc for consistent weld quality.
Stock Number
(029015550)
230 V, 50/60 Hz
Welding
Output Ranges
Rated Output
30–150 A
15–21 V
150 A at 21 VDC,
30% duty cycle
IP
Rating
Amps Input at Rated Output
230 V
Max. OpenCircuit Voltage
Wire Feed
Speed
IP21S
21
34
1.8–18 mpm
(70–708 ipm)
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
cord with plug
• Power
Work
cable
with clamp
• Running gear/bottle
• 0.8/1.0 mm drive rollrack
•
Most popular accessories
• Bernard MIG gun Q2010TE3EEQ
™
Wire Type and Diameter Capacity
Dimensions
Solid steel 0.6–0.8 mm (.023–.030 in.)
Aluminium 0.8–1.0 mm (.030–.040 in.)
Flux-cored 0.6–0.8 mm (.023–.030 in.)
H: 561 mm (22.1 in.)
W: 447 mm (17.6 in.)
D: 769 mm (30.25 in.)
MigMatic 220/220 DX and 250/250 DX
®
Net
Weight
43.3 kg
(95.5 lb.)
Light industrial
220/220DX
See literature DCM/9.0 UK (220/220 DX) and DCM/10.0 UK (250/250DX)
250/250DX
Processes
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
cord with plug
• Power
m work cable with clamp
• 3Running
gear/bottle rack
• 0.8/1.0 mm
drive roll
•
Weld Ready packages include
above plus
• Bernard
™
MIG gun Q2010TE3EEQ
MigMatic 220 and 220DX shown.
Manual mode allows for simple manual setting of
parameters for welding on a broad range of applications.
Thermal overload protection shuts down the power
source output if the main transformer or rectifier
overheats.
Industrial dual-gear-driven system features no-tool,
quick-change reversible drive roll (0.8/1.0 mm) and
an easy-to-set tension adjustment knob.
Professional wire drive motor withstands even the
most demanding applications.
Superior arc control technology provides the operator
with state-of-the-art welding performance on a wide
variety of materials.
Model/Stock Number
MigMatic 220
(029015520) 230 V, 50/60 Hz
(029083116) Weld Ready package
Welding
Output Ranges
Rated Output
30–200 A
15–21 V
30–250 A
15–24 V
Traditional tapped design (10 steps) and laminated
inductor provide a stable, smooth arc for consistent
weld quality.
Adjustable run-in control allows the operator to
optimize arc starting with a variety of different wires.
Adjustable burnback control reduces wire stubbing,
arc flaring and prevents wire burnback to protect
contact tips.
Spot weld timer provides consistent spot welds every
time. (Base models only.)
Synergic user interface with digital display to simplify
setup and offer precise settings for welding a variety of
materials. (DX models only.)
IP
Rating
Amps Input at Rated Output
230 V
400 V
Max. OpenCircuit Voltage
Wire Feed
Speed
220 A at 28 VDC,
25% duty cycle
IP23S
34
—
40
1.0–20 mpm Solid steel
(39–787 ipm) Stainless
Aluminium
Flux-cored
0.6–1.2 mm (.023–.047 in.)
0.8–1.0 mm (.030–.040 in.)
0.8–1.2 mm (.030–.047 in.)
0.9–1.2 mm (.035–.047 in.)
240 A at 26 VDC,
35% duty cycle
IP23S
27
16
43
1.0–20 mpm Solid steel
(39–787 ipm) Stainless
Aluminium
Flux-cored
0.6–1.2 mm (.023–.047 in.)
0.8–1.0 mm (.030–.040 in.)
0.8–1.2 mm (.030–.047 in.)
0.9–1.2 mm (.035–.047 in.)
MigMatic 220DX
(029015521) 230 V, 50/60 Hz
(029083117) Weld Ready package
MigMatic 250
(029015524) 230/400 V, 50/60 Hz
(029083115) Weld Ready package
MigMatic 250DX
(029015525) 230/400 V, 50/60 Hz
(029083118) Weld Ready package
Wire Type and Diameter Capacity
Dimensions
H: 712 mm
(28 in.)
W: 480 mm
(18.88 in.)
D: 920 mm
(36.19 in.)
Net
Weight
66 kg
(152 lb.)
73 kg
(161 lb.)
7
MIG GMAW
MigMatic® 300/300 DX and 380/380 DX
See literature DCM/11.0 UK (300/300 DX) and DCM/12.0 UK (380/380DX)
Industrial
Processes
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
cord with plug
• Power
5
m
work
cable with clamp
• Running gear/bottle
• Two 0.6–0.8 mm driverackrolls
• (300 models)
Four 1.0–1.2 mm drive rolls
(380 models)
Weld Ready packages include
above plus
• Bernard
™
MIG gun Q3015TE3EEQ
MigMatic 380 and 380 DX shown.
Manual mode allows for simple manual setting of
parameters for welding on a broad range of applications.
Traditional tapped design (20 steps) and laminated
inductor provide a stable, smooth arc for consistent
weld quality.
Thermal overload protection shuts down the power
source output if the main transformer or rectifier
overheats.
Adjustable run-in control allows the operator to
optimize arc starting with a variety of different wires.
Industrial dual-gear-driven system features no-tool,
quick-change reversible drive rolls and an easy-to-set
tension adjustment knob.
Adjustable burnback control reduces wire stubbing,
arc flaring and prevents wire burnback to protect
contact tips.
Professional wire drive motor withstands even the
most demanding applications.
Spot weld timer provides consistent spot welds every
time. (Base models only.)
Superior arc control technology provides the operator
with state-of-the-art welding performance on a wide
variety of materials.
Synergic user interface with digital display to simplify
setup and offer precise settings for welding a variety of
materials. (DX models only.)
Model/Stock Number
MigMatic 300
(029083119) 400 V, 50 Hz Weld Ready pkg
(029015540) 400 V, 50 Hz
Welding
Output
Ranges
Rated
Output
IP
Rating
Amps Input at
Rated Output
230 V 400 V
Max.
Open-Circuit
Voltage
30–300 A
15–28 V
300 A at
28 VDC,
35% duty
cycle
IP22S
35
20
30–350 A
15–32 V
350 A at
29 VDC,
35% duty
cycle
IP22S
40
23
MigMatic 300 DX
(029015541) 400 V, 50/60 Hz
(029083120) 400 V, 50/60 Hz Weld Ready pkg
MigMatic 380
(029015547) 230/400 V, 50/60 Hz
(029083121) 400 V, 50 Hz Weld Ready pkg
(029015542) 400 V, 50 Hz
MigMatic 380 DX
(029083122) 400 V, 50/60 Hz Weld Ready pkg
(029015543) 400 V, 50/60 Hz
8
Net
Weight
Wire Feed Speed
Wire Type and Diameter Capacity
Dimensions
43
1.3–26 mpm
(51–1,024 ipm)
Solid steel
Stainless
Aluminium
Flux-cored
0.6–1.2 mm (.023–.047 in.)
0.8–1.0 mm (.030–.040 in.)
0.8–1.2 mm (.030–.047 in.)
0.9–1.4 mm (.035–.055 in.)
H: 825 mm
(32.5 in.)
W: 471 mm
(18.5 in.)
D: 1,066 mm
(42 in.)
88 kg
(194 lb.)
43
1.3–26 mpm
(51–1,024 ipm)
Solid steel
Stainless
Aluminium
Flux-cored
0.6–1.2 mm (.023–.047 in.)
0.8–1.0 mm (.030–.040 in.)
0.8–1.2 mm (.030–.047 in.)
0.9–1.4 mm (.035–.055 in.)
H: 825 mm
(32.5 in.)
W: 471 mm
(18.5 in.)
D: 1,066 mm
(42 in.)
102.6 kg
(227 lb.)
GMAW
XPS Series
MIG
Industrial
See literature DCM/42.0 UK
Processes
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
power cord
• Industrial
Work
cable
with clamp
• Factory-installed
running gear
•
Most popular accessories
ST -44 Series Wire Feeders (pg 20)
• 029007406
Base model
Traditional tapped transformer power source.
Simple and precise with 30 voltage steps (XPS 350) or
40 voltage steps (XPS 450). Provides the operator with
a superior range and arc performance for even the most
demanding applications.
®
Two inductance terminals and laminated inductor
provides a stable, smooth arc operators appreciate.
•
Standard 14-pin connection to Miller wire feed units
connects to a variety of Miller wire feeders.
•
•
•
Thermal overload protection shuts down the power source
output if the main transformer or rectifier overheats.
029007404 Digital model
ST®-24 Series Wire Feeders (pg 20)
029007395 Base model
029007397 Digital model
Cylinder Rack 058066064 (pg 63)
Cylinder/Cooler Rack 058066065
(pg 63)
HydraCool® 1 028042103 (pg 64)
Optional 115-volt auxiliary power receptacles.
Auxiliary power for water-cooling unit.
Optional Fan-On-Demand™ cooling system operates only
when needed, reducing noise, energy use and amount of
contaminants pulled through machine.
Optional dual digital meters with hold function display
clear, precise readings of arc voltage and amperage.
XPS 450 shown.
Welding
Output Ranges
Rated Output
(029015531) 400 V, 50 Hz
(029015528) 400 V, 50 Hz with aux power,
digital meters and Fan-On-Demand
30–350 A
15–32 V
(029015535) 230/400 V, 50 Hz with aux power,
digital meters and Fan-On-Demand
(029015532) 400 V, 50 Hz with aux power
(029015529) 400 V, 50 Hz with aux power,
digital meters and Fan-On-Demand
30–450 A
15–34 V
Model
Stock Number
XPS 350
XPS 450
IP
Rating
Amps Input at Rated Output, 50 Hz
230 V
400 V
Max. OpenCircuit Voltage
350 A at 32 VDC,
45% duty cycle
IP22
—
23
38
450 A at 37 VDC,
45% duty cycle
IP22
56
32
47
Dimensions
Net Weight
H: 930 mm (37 in.)
W: 570 mm (22.5 in.)
D: 860 mm (34 in.)
125 kg
(275 lb.)
153 kg
(337 lb.)
9
MIG
GMAW
Choose the Right Industrial Aluminium MIG Solution
For additional aluminium MIG solutions see push-pull guns and controls on pages 26–27.
AlumaFeed® Synergic Aluminium
Welding System (page 11)
Invision™ MPa Plus System
(page 14)
AlumaPower 450 MPa and XR-AlumaFeed
with XR-Aluma-Pro gun shown.
Invision 352 MPa and D-74 MPa Plus feeder with
XR-Aluma-Pro and Bernard BTB Gun 400 A guns shown.
Dedicated heavy-industrial-fabrication solution for
aluminium welding, with advanced features that can handle
larger weldments. Its lightweight push-pull feeder can
easily be carried up to 30.5 meters from the power source.
Versatile, heavy-industrial advanced system for large,
high-duty-cycle aluminium and steel weldments. Features
push and/or push-pull bench feeder for easy switchover
between solid, aluminium and tubular wires.
Power Source
AlumaPower ™ 350 MPa or 450 MPa
Invision 352 MPa or 450 MPa
Feeder
Single-wire XR-AlumaFeed — portable feeder can be carried
up to 30.5 meters from power source
Single- or dual-wire 74 MPa Plus — stationary feeders can
be mounted up to 30.5 meters from power source
Input Voltage
Three-phase
Three-phase
Rated Output
350 MPa: 350 A at 60% duty cycle
450 MPa: 450 A at 100% duty cycle
352 MPa: 350 A at 60% duty cycle
450 MPa: 450 A at 100% duty cycle
Primary Connection
350 MPa: Auto-Line™ — Allows for any primary input
voltage (230–575 V, three-phase, 50 or 60 Hz) with no
manual linking. Also adjusts for voltage spikes within the
entire range.
450 MPa: 400 V only, 50 or 60 Hz
352 MPa: Auto-Line™ — Allows for any primary input
voltage (230–575 V, three-phase, 50 or 60 Hz) with no
manual linking. Also adjusts for voltage spikes within the
entire range.
450 MPa: 400 V only, 50 or 60 Hz
Aluminium Wire Diameters
0.9–1.6 mm (.035–1/16 in.)
0.9–1.6 mm (.035–1/16 in.)
Gun Capability
XR-Aluma-Pro™ or XR™-Pistol
XR-Aluma-Pro™ Plus, XR™-Pistol Plus or standard MIG gun
Profile Pulse™
Yes — achieve a “stacked dime” appearance quickly and
easily without gun manipulation
Yes — achieve a “stacked dime” appearance quickly and
easily without gun manipulation
Synergic Pulsed MIG
Yes — “one-knob” control, only need to change wire feed
speed to weld different material thicknesses
Yes — “one-knob” control, only need to change wire feed
speed to weld different material thicknesses
MIG
Spray transfer MIG — for aluminium wires
Conventional MIG — modes for aluminium, steel and
other wires
Built-In Pulsed Programs
Aluminium
Aluminium, steel, stainless and others
Portability
Lightweight, portable feeder with handle — can be carried
up to 30.5 meters from power source
Stationary feeder — can be mounted up to 30.5 meters
from power source
Trigger Hold
Yes — reduces operator fatigue from holding trigger
Yes — reduces operator fatigue from holding trigger
Trigger Schedule Select
Yes — allows operator to switch between two preset weld
conditions by tapping the trigger
Yes — allows operator to switch between two preset weld
conditions by tapping the trigger
Program Locks
Yes — prevents unintended changes to the welding program
weld parameters
Yes — prevents unintended changes to the welding program
weld parameters
Flow Meter
Yes — allows flow to be set at feeder even when gas supply
is a long distance away
—
MIG Modes
Features
10
ALUMINIUM
GMAW
®
AlumaFeed
MIG
Heavy industrial
Synergic Aluminium Welding System
Processes
See literature DC/34.0
Dedicated aluminium system for the most advanced MIG and synergic pulsed MIG performance.
Aluminium MIG (GMAW)
• Aluminium
pulsed MIG (GMAW-P)
•
AlumaFeed System consists of
the following (sold separately)
350 MPa power source
• AlumaPower
(907420003) OR 450 MPa power
source (907526)
feeder
• XR-AlumaFeed
XR-Aluma-Pro OR XR -Pistol Grip
• push-pull
MIG gun
3 cooling system with
• Coolmate
coolant (water-cooled systems only)
• Universal trolley
Most popular accessories
Push-Pull Guns (pg 26)
• XRUniversal
018035028 (pg 63)
• MIG Kit forTrolley
Trolley
• 058066129Universal
(pg 63)
3 Mounting Brackets for
• Coolmate
Universal Trolley 028066301 (pg 63)
3 043007 (pg 64)
• Coolmate
043810 (pg 64)
• Coolant
Cables (pg 66)
• Extension
247831025 7.6 m (25 ft.)
™
™
™
™
AlumaPower 350 MPa and XR-AlumaFeed with
XR-Aluma-Pro gun air-cooled system shown.
™
™
•
•
AlumaPower ™ 350 model allows
for any input voltage hookup
(230–575 V, three-phase) with no manual linking,
providing convenience in any job setting. Ideal solution
for dirty or unreliable power. 450 model is 400 V only,
three-phase.
Built-in MIG and pulsed MIG programs automatically
set the optimal parameters for a wide variety of wires
making it easy to set up and use.
Synergic pulsed MIG. As wire speed increases/decreases,
pulse parameters also increase/decrease to match the
right amount of power needed, eliminating the need to
make additional adjustments.
Synchronized, true push-pull wire feed system for
precise wire feeding and arc performance.
247831050 15 m (50 ft.)
247831080 24.4 m (80 ft.)
1.6 mm (1/16 in.) Liner and
Wire Kit for Gun 230708
1.6 mm (1/16 in.) Drive Roll Kit for
Control Box 195591
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.
Parameter and system locks enhance quality assurance
and protect weld consistency.
Trigger schedule select allows operator to change
between two sets of weld parameters.
Fan-On-Demand™ cooling system operates only when
needed, reducing noise, energy use and amount of
contaminants pulled through machine.
Note: All systems come set up out of the box to run 1.2 mm wire. 1.6 mm consumables not included — order separately above.
See aluminium solutions comparison chart on page 10.
Welding
Output Ranges
Rated Output
AlumaPower 350 MPa
(907420003)
230–575 V
with auxiliary power
5–425 A
10–38 V
AlumaPower 450 MPa
(907526) 400 V
with auxiliary power
15–600 A
10–38 V
XR-AlumaFeed
Wire Feeder
14-pin compliant, but
only operates synergically
w/MPa power sources
Input Power
Input Welding Circuit Rating
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
24 VAC,
5 A,
50/60 Hz
400 A at 100% duty cycle
System duty cycle is limited
to gun rating
1.3–22.9 mpm
(50–900 ipm)
0.9–1.6 mm (.035–1/16 in.)
Requires wire kit (230708) for gun and drive roll kit
(195591) for control box to run 1.6 mm (1/16 in.) wire
305 mm (12 in.)
H: 406 mm (16 in.)
W: 241 mm (9.5 in.)
D: 540 mm (21.25 in.)
19.2 kg
(42.5 lb.)
Model
IP
Rating
Amps Input at Rated Load Output, 60 Hz
230 V
400 V
460 V
575 V
KVA
KW
Max. OpenCircuit Voltage
Dimensions
Net Weight
350 A at 34 VDC,
60% duty cycle
IP23
36.1
20.6
17.8
14.1
14.2
13.6
75 VDC
H: 432 mm (17 in.)
W: 318 mm (12.5 in.)
D: 610 mm (24 in.)
36.3 kg
(80 lb.)
450 A at 36.5 VDC,
100% duty cycle
IP23
—
29.8
—
—
21.6
18.3
90 VDC
H: 438 mm (17.25 in.)
W: 368 mm (14.5 in.)
D: 689 mm (27.125 in.)
55.3 kg
(122 lb.)
11
MIG
GMAW
Choose the Right Industrial MIG Solution
Deltaweld® with
74S/D Feeder
XMS® 425 MPa with
XMS® MPa Feeder
Invision™ with
74 MPa Plus Feeder
Continuum™
System
(page 13)
(page 13)
(page 14)
(page 15)
Feature
Basic
and easy to use
• Simple
Digital
meters
power
• source provideonaccurate
•
weld parameter indication
74D feeder adds voltage
control and digital meters
on feeder for point-of-use
control
Advanced MIG
power source
• Multiprocess
Synergic
pulsed
and
• double-pulsed programs
functionality for
• USB
increased ease of
advanced system with
• More
optimized weld programs
•
for steel and aluminium
Push-pull gun for aluminium
(optional)
generation advanced
• Next
welding solution
productivity through
• Improves
weld quality, ease of use and
system flexibility
adding/saving weld programs
water cooler
• Integrated
(optional)
Weldable
Metals
Steels
Steels and aluminium
Steels and aluminium
Steels
MIG Processes
arc
• Short
Spray
•
arc
• Short
Spray
• Pulsed MIG
•
arc
• Short
Spray
• Pulsed MIG
• Profile Pulse — provides
• TIG appearance with MIG
arc
• Short
Accu-Pulse
popular
• for full range—ofmost
material
®
™
productivity
•
•
•
thicknesses
Versa-Pulse™ — fast, low-heat,
low-spatter for thin material;
ideal for automation
RMD® — designed to fill gaps,
and for thin material
High-deposition MIG —
increased deposition rates
on thicker materials
Special Models
—
—
Dedicated aluminium models
available (see AlumaFeed®
System, page 11)
Semi-auto and automation
packages available
(see pages 15 and 16)
Welding
Intelligence™
(see page 53)
Optional Insight Core™
—
Optional Insight Core™
Standard Insight Core™
and optional
Insight Centerpoint™
Input Power
380/400/440 V, 3-phase
Auto-Line™ 230–575 V,
3-phase
352: Auto-Line™ 230–575 V,
3-phase
450: 400 V, 3-phase
Auto-Line™ 230–575 V,
3-phase
Recommended
Wire Diameters
402: 0.6–1.6 mm
602: 0.6–2.0 mm
852: 0.8–2.4 mm
0.6–1.8 mm
352: 0.6–1.6 mm
452: 0.6–2.0 mm
0.9–2.0 mm
Bernard™ Gun
Included
with Feeder
Yes
Yes
Yes
Yes
12
MIG
GMAW
Industrial
402 model
Heavy industrial
602/852 models
®
Deltaweld Series
See literature DC/16.2
Industry standard for heavy-industrial MIG welding. Designed for manufacturing operations,
with 100 percent duty cycle for extended arc-on time.
Processes
(GMAW) • Flux-cored (FCAW)
• MIG
Air
carbon
(CAC-A)
• (Deltaweld arc452:gouging
6 mm carbons)
Line voltage compensation ensures consistent weld performance
even when primary power varies.
Fan-On-Demand™ cooling system operates only when needed.
Reduces contaminants drawn into the machine and excess noise
in work areas.
Digital meters are easy to read and display preset and actual
voltage and amperage.
Remote control capability allows operators fine tuning capability
at an extended distance.
115-volt power for tools and coolant systems.
Thermal overload protection light indicates power shutdown.
Helps prevent machine damage if the duty cycle is exceeded or
airflow is blocked.
Material specific output studs provide the flexibility to produce
the optimal arc characteristics for aluminium, stainless steel and
all other materials.
Deltaweld 602 shown with optional S-74D wire feeder and
standard running gear with cylinder rack.
(Deltaweld 652: 10 mm carbons)
Most popular accessories
Series Feeders (pg 20)
• 70Standard
• (pg 63) Running Gear 042886
Cylinder Rack 042887
• Standard
(pg 63)
Cables (pg 66)
• Extension
242208025 7.6 m (25 ft.)
242208050 15 m (50 ft.)
242208080 24.4 m (80 ft.)
IP
Rating
Amps Input at Rated Output, 50/60 Hz
380 V 400 V 440 V KVA KW
Max. OpenCircuit Voltage
Dimensions
(Includes lift eye and strain relief)
300 A at 32 VDC,
100% duty cycle
IP21
27
25
23
16.9
12.9
42 VDC
30–575 A
10–38 V
450 A at 38 VDC,
100% duty cycle
IP21
39
37
33
25.1
21.1
48 VDC
H: 762 mm (30 in.)
W: 585 mm (23 in.)
402 D: 775 mm (30.5 in.)
602/852 D: 966 mm (38 in.)
30–825 A
10–44 V
650 A at 44 VDC,
100% duty cycle
IP21
58
54
50
38.2
34.2
54 VDC
Model/Stock Number
Welding
Output Ranges
Rated Output
Deltaweld 402
(907357) 380/400/440 V, 50/60 Hz
30–375 A
10–32 V
Deltaweld 602
(907358) 380/400/440 V, 50/60 Hz
Deltaweld 852
(907359) 380/400/440 V, 50/60 Hz
147 kg (323 lb.)
174 kg (384 lb.)
214 kg (472 lb.)
Industrial
XMS® 425 MPa Synergic Welding System
Processes
See literature DCM/17.5
Enhanced double-pulsed and pulsed MIG capabilities
reduce spatter and distortion, improve bead shape and
provide better out-of-position weld puddle control.
Simple user interface reduces the number of control
setup combinations for all processes and programs
(including double-pulsed and pulsed MIG capabilities)
without minimizing features or welding performance.
Large, dual digital meters are easily preset to the
desired weld output, and provide easy-to-view current
and voltage measurements during welding to ensure
optimal control of the weld bead.
Integrated water-cooling system provides efficient
cooling with low-flow shutdown for both MIG and TIG
applications.
Inverter arc control technology provides class-leading
welding performance on a variety of material, while
line voltage compensation (LVC™) maintains constant
power even when primary power input varies from
+/- 10 percent.
Multiprocess power source. MIG, synergic MIG,
synergic pulsed and double-pulsed MIG, Lift-Arc™ TIG
and stick processes.
XMS 425 MPa Weld Ready water-cooled package shown
includes power source, feeder, cooler, trolley, feeder swivel,
handle kit and Bernard™ E 4215 MIG torch.
Net Weight
Double-pulsed MIG (GMAW-DP)
• Pulsed
MIG (GMAW-P)
• MIG (GMAW)
(FCAW)
• Lift-Arc TIG (GTAW)
• Flux-cored
•
• Stick (SMAW)
™
Power source
comes complete with
power cord
• Industrial
• Work cable with clamp
Weld Ready package includes
above plus
MPa wire feeder w/feeder swivel
• XMS
Bernard
torch
• XMS MPawater-cooled
cooler with coolant
• Universal trolley
with handle kit
•
Most popular accessories
Trolley 018035028 (pg 63)
• Universal
Kit for Universal Trolley
• Handle
058066130 (pg 63)
MPa Cooler 028042109
• XMS
Coolant
043810 (pg 64)
• Feeder Swivel
• Interconnecting028066300
Cable Assembly
• (Water-Cooled) (pg
66)
air-cooled MIG gun
• Bernard
Q4015TE3EEQ
water-cooled MIG gun
• Bernard
E4215-45-5-445-Q
™
™
™
Welding
Output Ranges
Rated Output
IP Rating
Amps Input at Rated Load Output, 50/60 Hz
230 V 400 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
XMS 425 MPa
(029015507) 230–575 V, 50/60 Hz
(029083123) Weld Ready package
5–425 A
10–38 V
350 A at 34 VDC,
60% duty cycle
IP23S
36.1
75 VDC
XMS MPa Wire Feeder
(029007427)
Input Power
IP Rating
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
24 VAC, 7 A, 50/60 Hz
IP23S
1.27–25.4 mpm
(50–1,000 ipm)
0.6–1.8 mm
(.023–.068/.072 in.)
305 mm (12 in.)
15 kg (33 lb.)
H: 425 mm (16.7 in.)
W: 235 mm (9.3 in.)
D: 700 mm (27.6 in.)
18 kg
(40 lb.)
Model/Stock Number
20.6
17.8
14.1
14.2 13.6
Dimensions
Net Weight
H: 597 mm (23.5 in.)
W: 349 mm (13.7 in.)
D: 560 mm (22 in.)
52.5 kg
(116 lb.)
13
MIG GMAW
Invision MPa Plus System
Heavy industrial
™
See literature DC/23.6
Processes
MIG and synergic pulsed MIG system with optimized weld programs for both steel and aluminium.
(GMAW) • Flux-cored (FCAW)
• MIG
MIG (GMAW-P)
• Pulsed
carbon arc gouging (CAC-A)
• Air(Invision
352: 6 mm carbons)
(Invision 450: 8 mm carbons)
Invision MPa System consists of
the following (sold separately)
352 MPa power source
• Invision
(907431002) OR 450 MPa power
source (907524)
Series MPa Plus feeder
• 70XR-Aluma-Pro
• push-pull MIG gunPlus OR XR -Pistol Plus
3 cooling system with
• Coolmate
coolant (water-cooled systems only)
• Universal trolley
Most popular accessories
Push-Pull Guns (pg 26)
• XRUniversal
018035028 (pg 63)
• MIG Kit forTrolley
Trolley
• 058066129Universal
(pg 63)
3 Mounting Brackets for
• Coolmate
Universal Trolley 028066301 (pg 63)
3 043007 (pg 64)
• Coolmate
043810 (pg 64)
• Coolant
Cables (pg 66)
• Extension
247831025 7.6 m (25 ft.)
™
Recommended Aluminium Solution
Dedicated XR Plus guns work with MPa
Plus feeders to coordinate wire feed
speed of the gun and the feeder. This
provides optimized aluminium feeding
and welding performance. See page 26
for stock numbers.
Invision 352 MPa with S-74 MPa Plus feeder shown.
Invision 352 model allows for any
input voltage hookup (230–575 V,
three-phase) with no manual linking, providing
convenience in any job setting. Ideal solution for dirty
or unreliable power. 450 model is 400 V, three-phase.
Built-in MIG and pulsed MIG programs automatically
set the optimal parameters for a wide variety of wires
making it easy to set up and use.
Synergic pulsed MIG. As wire speed increases/
decreases, pulse parameters also increase/decrease
to match the right amount of power needed,
eliminating the need to make additional adjustments.
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.
Easy to set up. Select wire diameter, wire type and gas
being used, set your wire speed and strike an arc.
Wind Tunnel Technology.™ Air flow that protects internal
components, greatly improving reliability.
Fan-On-Demand™ cooling system operates only when
needed, reducing noise, energy use and amount of
contaminants pulled through machine.
™
™
™
™
™
•
247831050 15 m (50 ft.)
247831080 24.4 m (80 ft.)
1.6 mm (1/16 in.) Liner and
Wire Kit for Gun 230708
Note: See aluminium solutions comparison chart on page 10.
Welding
Output Ranges
Rated Output
IP Rating
Amps Input at Rated Load Output, 60 Hz
230 V
400 V
460 V
575 V
KVA
KW
Max. OpenCircuit Voltage
Dimensions
Net Weight
Invision 352 MPa
(907431002) 230–575 V
with auxiliary power
5–425 A
10–38 V
350 A at 34 VDC,
60% duty cycle
IP23
36.1
20.6
17.8
14.1
14.2
13.6
75 VDC
H: 432 mm (17 in.)
W: 318 mm (12.5 in.)
D: 610 mm (24 in.)
36.3 kg
(80 lb.)
Invision 450 MPa
(907524) 400 V
with auxiliary power
15–600 A
10–38 V
450 A at 36.5 VDC,
100% duty cycle
IP23
—
29.8
—
—
21.6
18.3
90 VDC
H: 438 mm (17.25 in.)
W: 368 mm (14.5 in.)
D: 689 mm (27.125 in.)
55.3 kg
(122 lb.)
Model
14
MIG
GMAW
Continuum Systems
Heavy industrial
™
See literature DCM/41.0 UK
Processes
MIG (GMAW-P)
• Accu-Pulse
• Versa-Pulse
• RMDMIG (GMAW)
• MIG (GMAW)
• High-deposition
(FCAW)
• Flux-cored
Air
carbon
arc gouging (CAC-A)
•
®
Next generation of advanced industrial welding solutions improves productivity through
weld quality, ease of use and system flexibility.
™
More power — better reliability
Weld Ready package includes
the following
Up to 26 percent more welding output
(than competitive models) for demanding
industrial applications.
power source
• Continuum
single-wire feeder
• Continuum
water-cooled torch
• Bernard
cooler with coolant
• Continuum
• Universal trolley
Most popular accessories
MIG Guns (pg 23/24)
• Bernard
water-cooled torch
• Bernard
E4215-45-5-445-Q
Centerpoint Software (pg 55)
• Insight
Running Gear/Cylinder
• Continuum
Rack 301264 (pg 63)
Trolley 018035028 (pg 63)
• Universal
Integrated Cooler 301214
• Continuum
Mounts to bottom of Continuum
™
Power source design
Smart and powerful digital design has the fast
response needed to deliver the most stable
welding performance for better welding results.
Flexible to meet current and future needs with
integrated expansion capabilities.
Welding Intelligence.™ Increase productivity,
improve quality and manage costs with Insight
Core™ (standard) and Insight Centerpoint™
(optional) welding information management
systems (see pages 54 and 55).
™
™
™
Feeder design
™
Tru-Feed technology provides precise feeding
operation for stable arc performance.
Low-inertia motor provides faster response
for the best arc starts with the least amount
of spatter
Balanced-pressure drive-roll design and
tensioners feed wire in its truest and straightest
form for consistent feedability, resulting in better
welding performance
New user interface makes the system easy to
set up and adjust with minimal training.
•
•
Continuum 350 shown with Continuum single-wire feeder,
Bernard BTB Gun 400 A and Continuum running gear/cylinder
rack. Filler metal sold separately.
®
•
•
power source. Does not require
external power.
Coolant 043810 (pg 64)
Continuum Control/Motor Cables
263368003 0.9 m (3 ft.)
263368015 4.6 m (15 ft.)
263368020 6.1 m (20 ft.)
263368025 7.6 m (25 ft.)
263368050 15 m (50 ft.)
263368080 24.4 m (80 ft.)
263368100 30.5 m (100 ft.)
Continuum Processes
Best For
Standard
Spray
High-Deposition
MIG
Accu-Pulse
Versa-Pulse Short Circuit
Deposition
A
A
A
B
D
D
Gap Filing
D
D
B
B
A
A
Low Heat Input
D
C
B
A
A
A
A
B
B
B
Low Spatter
A
A
A
B
C
B
Thick Metals
A
A
A
C
D
D
B
A
A
A
A
A
B
Out-of-Position Welds
Thin Metals
Increased Travel Speed
A
A
Ratings A, B, C, and D are relative values.
An “A” rating indicates a best fit between
your performance needs and process.
A “blank” rating indicates that the process
is not recommended for that application.
RMD
Accu-Pulse is the most popular process for
majority of industrial welding applications.
Versa-Pulse is a fast, low-heat, low-spatter
process designed for thin-material applications.
RMD is a low-heat modified short-circuit
process designed to fill gaps with
thin-material applications.
High-deposition MIG provides increased
deposition rates over standard spray on
thicker materials.
C
HOT
COLD
Note: As the technological advances offered by Continuum extend beyond the capability of Axcess® systems, the two systems are not compatible.
Continuum systems are designed to allow future upgradability, to expand with your operation’s needs.
*While idling.
Welding
Output Ranges
20–400 A
10–44 V
Rated Output
350 A at 31.5 VDC,
100% duty cycle
IP Rating
IP23
Continuum 500
(907648) 230–575 V
(029083125) Weld Ready package
20–600 A
10–44 V
500 A at 39 VDC,
100% duty cycle
IP23
Continuum Feeder
(301195010) Single-wire model
(301199010) Dual-wire model
Input
Power
50 VDC
Model/Stock Number
Continuum 350
(907645) 230–575 V
(029083124) Weld Ready package
Input Welding
Circuit Rating
500 A at
100% duty cycle
IP Rating
IP23
Amps Input at Rated Output, 50/60 Hz, 3-Phase
230 V 380 V 400 V 460 V 575 V KVA KW
36.7 21.8 20.8 18.8 14.6 14.4 13.8
0–1* 0–1* 0–1* 0–1* 0–1* 0.8* 0.17*
Max. OpenCircuit Voltage
75 VDC
58.7 34.9
0–1* 0–1*
75 VDC
Wire Feed Speed
Standard:
1.3–25.4 mpm
(50–1,000 ipm)
33.2
0–1*
28.9
0–1*
23.3
0–1*
Wire Diameter Capacity
0.9–2.0 mm
(.035–5/64 in.)
23.1 21.9
0.8* 0.17*
Maximum Spool
Size Capacity
457 mm (18 in.),
27 kg (60 lb.)
Dimensions
(Includes lift eye)
H: 691 mm (27.187 in.)
W: 444 mm (17.5 in.)
D: 714 mm (28.125 in.)
Dimensions
H: 351 mm (13.812 in.)
Single W: 414 mm (16.312 in.)
Dual W: 432 mm (17 in.)
D: 754 mm (29.687 in.)
Net Weight
57.6 kg
(127 lb.)
67.1 kg
(148 lb.)
Net Weight
Single 19.5 kg (43 lb.)
Dual 27.9 kg (61.5 lb.)
15
MIG GMAW
Auto-Continuum Systems
Heavy industrial
™
See literature AUM/90.0 UK
Processes
MIG (GMAW-P)
• Accu-Pulse
• Versa-Pulse
• RMDMIG (GMAW)
• MIG (GMAW)
• High-deposition
• Flux-cored (FCAW)
Most popular accessories
Centerpoint Software (pg 55)
• Insight
Drive Motor Mounting Brackets
• Wire
301276 ABB 1600
®
Next generation automation welding solution delivers advanced arc performance to improve
throughput and weld quality.
More power — better reliability. Up to 26 percent
more welding output (than competitive models) for
demanding industrial applications.
Improve work environment and reduce spatter.
Versa-Pulse and Accu-Pulse processes reduce fume
generation, and by precisely controlling the welding
arc they also reduce spatter size and quantity. Fume
generation can be reduced up to 50 percent over
traditional CV MIG.
Versa-Pulse is a fast, low-heat, low-spatter process
for high-speed automation on thin materials and is
great for gap filling
Accu-Pulse is better for out-of-position welds,
provides higher deposition rates and is designed
for thicker materials than Versa-Pulse
Easy communication from robot to power source.
Designed for easy integration with fixed and
flexible automation.
Fleet standardization. Auto-Continuum can be used
for both automation and hand-held applications.
Welding Intelligence.™ Increase productivity, improve
quality and manage costs.
Insight Core™ (standard) is a simplified, Internetbased welding information solution that reports
cell productivity and weld parameter verification
(see page 54)
Insight Centerpoint™ (optional) is an advanced,
real-time feedback solution to ensure consistent
weld quality and actively detects a bad weld when
it happens, reducing rework costs and improving
quality (see page 55)
™
®
•
•
•
Auto-Continuum
500 shown with
robot arm (not
included) and
Auto-Continuum
wire drive motor
assembly.
Closeup of Auto-Continuum
wire drive motor assembly
(left-hand drive).
®
™
•
•
•
301277 ABB® 2600
300483 FANUC® 100 and 120 IC
300013 FANUC®/KUKA®/Motoman®
301282 KUKA® KR5 HW
301275 KUKA® KR16 HW
300375 Motoman® EA1400
300376 Motoman® EA1900
Motor Control Cables
263368025 7.6 m (25 ft.)
263368050 15 m (50 ft.)
263368080 24.4 m (80 ft.)
263368100 30.5 m (100 ft.)
EtherNet/IP™ Communication Cables
300734 3 m (9.8 ft.)
300735 5 m (16.4 ft.)
300736 10 m (32.8 ft.)
DeviceNet Communication Cables
300020 2.7 m (9 ft.)
300021 6.1 m (20 ft.)
DeviceNet to Analog Adapter 301427
Adapts DeviceNet to analog
communication.
•
•
Note: As the technological advances offered by Auto-Continuum extend
beyond the capability of Axcess® systems, the two systems are not
compatible. Continuum systems are designed to allow future upgradability,
to expand with your operation’s needs.
*While idling.
Model
Auto-Continuum 350
Auto-Continuum 500
Stock Number
(907660) EtherNet/IP™
(907660001) DeviceNet
(907661) EtherNet/IP™
(907660001) DeviceNet
Auto-Continuum Wire Drive Motor Assembly
(301207) Left-hand drive
(301208) Right-hand drive
IP
Rating
IP23
Amps Input at Rated Output, 50/60 Hz, 3-Phase
230 V 380 V 400 V 460 V 575 V KVA KW
36.7 21.8 20.8 18.8 14.6 14.4 13.8
0–1* 0–1* 0–1* 0–1* 0–1* 0.8* 0.17*
Max. OpenCircuit Voltage
75 VDC
IP23
58.7 34.9
0–1* 0–1*
75 VDC
Welding
Output Ranges
20–400 A
10–44 V
Rated Output
350 A at 31.5 VDC,
100% duty cycle
20–600 A
10–44 V
500 A at 39 VDC,
100% duty cycle
Input Power
50 VDC
Input Welding Circuit Rating
500 A at 100% duty cycle
IP Rating
IP23
33.2
0–1*
28.9
0–1*
23.3
0–1*
Wire Feed Speed
Standard:
1.3–25.4 mpm
(50–1,000 ipm)
23.1 21.9
0.8* 0.17*
Wire Diameter Capacity
0.9–2.0 mm
(.035–5/64 in.)
Maximizing throughput. Minimizing costs.
Automated welding applications require flexible, repeatable solutions that
maximize production uptime and throughput while minimizing costs.
This is why industrial manufacturers rely on Tregaskiss and its proven
track record of delivering reliable and resilient robotic MIG welding guns
and peripherals. See page 25 for more information.
Visit Tregaskiss.com to configure a robotic gun for your welding application today.
16
Dimensions
(Includes lift eye)
H: 691 mm (27.187 in.)
W: 444 mm (17.5 in.)
D: 717 mm (28.22 in.)
Dimensions
H: 222 mm (8.75 in.)
W: 254 mm (10 in.)
D: 254 mm (10 in.)
Net Weight
59.4 kg
(130 lb.)
69 kg
(150 lb.)
Net Weight
7.5 kg (16.5 lb.)
Wire Feeders
Wire Types
Flux-cored Flux-cored
Dual-shld Self-shld
Alum.
Product
Guide
Page
Class
MIG
Pulsed MIG*
Flux-cored**
Portable
Power Source
Required
Hard
Also see MIG, MIG Guns and Multiprocess sections for wire feeding options.
Typical Applications
CC/CV
CV** 0.6–2.0 mm (.023–5/64 in.)
203 mm (8VS model) or 305 mm (12VS model)
diameter spool capacity, lightweight, powered by
arc voltage
Construction, site fabrication,
field maintenance
ArcReach® SuitCase®
8/12
18
CC/CV
CV** 0.6–2.0 mm (.023–5/64 in.)
203 mm (8 model) or 305 mm (12 model)
diameter spool capacity, powered by arc voltage,
remote voltage control without a control cord
Construction, site fabrication,
field maintenance
SuitCase® 12RC
18
CV
0.6–2.0 mm (.023–5/64 in.)
Standard remote voltage control, powered by
14-pin control cord, 305 mm diameter
spool capacity
Field maintenance,
site fabrication
I-24A/ST®-24 Series
20
CV
0.6–2.0 mm (.023–5/64 in.)
Adjustable run-in and burnback, optional meters,
remote voltage control and coolant fittings
for ST-24
Heavy and light manufacturing,
fabrication
ST®-44 Series
20
CV
0.6–2.0 mm (.023–5/64 in.)
Adjustable run-in and burnback, optional meters,
remote voltage control and coolant fittings
Heavy and light manufacturing,
fabrication
70 Series S/D —
Singles and Duals
20
CV
0.6–3.2 mm (.023–1/8 in.)
Low-speed motor recommended
for 2.4 mm and 3.2 mm wires
Four drive roll, remote voltage control
(optional field kit for “S” model, standard
on “D” model)
Heavy and light manufacturing,
fabrication
70 Series MPa Plus —
Singles and Duals
20
CV
0.6–2.0 mm (.023–5/64 in.)
XR-Aluma-Pro™ Plus or XR™-Pistol Plus guns for
feeding soft wires
Manufacturing requiring
multiple wire types
70 Series
22
Remote Configurations —
Singles and Duals
CV
***
0.6–2.0 mm (.023–5/64 in.)
Control box, cables and wire drive motor
assemblies for generic booms or
fixed automation
Heavy and light manufacturing,
fabrication
Product Key
Bench
Special Features
18
Portable
Wire Diameter Capacity
SuitCase® X-TREME ™
8VS/12VS
Class:
Light industrial
Industrial
Heavy industrial
Capability:
Designed for this process
Capable of this process
New! or Improved! products appear in blue type.
*Requires MPa inverter power source. **Certain self-shielded wires require CV output. Miller recommends a CV power source whenever possible.
***74S and 74D models are capable of aluminium welding and 74 MPa Plus models are designed for aluminium welding.
17
Wire Feeders
PORTABLE
SuitCase® Series
Portable Feeders
Portable SuitCase feeders that set
the standard for performance and
provide extreme reliability to stand
up to the demands of construction
and fabrication.
SuitCase Series Features
X-TREME ArcReach
8VS 12VS 8
12 12RC
Feature
Remote voltage control
(control cable required)
Remote voltage control
without a cord
Digital meters
Impact-resistant case
Gas purge
Wire jog
Standard
SuitCase X-TREME 8VS
shown with optional meters
SuitCase
X-TREME 12VS
PORTABLE!
ArcReach
SuitCase 12
SuitCase 12RC/12RC Euro
Models include male Tweco® connector installed on weld cable
and reversible dual size (1.2 and 1.6 mm) VK drive rolls.
Optional
Setting the standard for performance
Unique and durable case
Heavy-duty drive motor with tachometer control provides wire feed speed
that is accurate and consistent from the start of the weld to the finish and
from one weld to the next. Consistent wire feed speed is very important with
large-diameter cored wire, because small changes in wire feed speed make
large changes in deposition rates.
Impact-resistant, flame-retardant case provides strength and durability,
and protects components and welding wire from moisture, dust and
other contaminants.
Front panel has trigger hold, wire jog, and gas purge for easy operator
access (except 12RC).
Wide voltage range for small and large wires with no contactor chatter or
arc outages.
Ultra-low drag inlet guide pins make loading
the wire easy and does not deform the wire
on the way into the drive rolls improving wire
feeding performance.
Scaled wire pressure knob provides easy
adjustment and consistent pressure on the
drive rolls and wire.
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 (optional on 8VS).
18
Built-in slide rails allow you to drag the feeder into position for welding.
Innovative feeder door design allows you to change wire while feeder is
standing upright or laying down.
Case is available in two sizes (except 12RC).
Extreme reliability
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.
Gun locking tab works with guns and Euro-adapter
having corresponding locking grooves to prevent
gun from being pulled out if the feeder is dragged
by the gun.
Gas inlet recessed into back of case is
protected from incidental contact by the weld
cable, ensuring consistent and contaminant-free
shielding gas delivery to the gun. Double-filtered
gas valve helps keep dirt from clogging and
affecting gas flow.
PORTABLE
Wire Feeders
Heavy industrial
™
SuitCase® X-TREME 8VS and 12VS See literature M/6.42
Use with CC (except 12RC model) and CV,
DC power sources.
Voltage-sensing feeders designed to run off of arc voltage from almost any welding power
source. 8VS model is sized for a 203 mm spool of wire, can be carried to remote welding sites
and fits through a 356 mm manhole/manway. 12VS model is sized for an 203 or 305 mm spool
of wire. 305 mm spools are the most common in structural steel and fabrication.
Processes
• MIG (GMAW) • Flux-cored (FCAW)
Suggested power sources
Series (pg 31)
• Dimension
XMT
Series
(pg 32–35)
• Big Blue Series
(pg 57/58)
•
™
®
®
Note: Full functionality of ArcReach is only
available with ArcReach power sources.
RC feeder requires power source with
14-pin connector.
ArcReach® SuitCase® 8 and 12 See literature M/6.55
Suggested guns
• Bernard Guns (pg 23/24)
Most popular accessories
Cables
• Extension
(12RC only, 1 required) (pg 66)
Kit 300343
• Flowmeter
• Shielding Gas Filter 195189
™
Remote control of the power source without a cord. With a SuitCase ArcReach
feeder and ArcReach power source you can change output voltage at the feeder, and save a trip
to the power supply. No extra control cable to purchase, maintain, string or unstring — saving time
and money.
SuitCase® 12RC See literature WFM/60.0 UK
Standard remote voltage control with a control cord. For applications where the feeder is within
30.5 meters of the power source and control cords are acceptable.
Wire Feed Speed
Wire Type and Diameter Capacity
Maximum Spool
Size Capacity
330 A at
60% duty cycle
IP23
Solid wire 0.6–1.4 mm (.023–.052 in.)
Flux-cored 0.8–2.0 mm (.030–5/64 in.)
203 mm (8 in.),
6.4 kg (14 lb.)
H: 324 mm (12.75 in.)
W: 184 mm (7.25 in.)
D: 457 mm (18 in.)
13 kg
(28 lb.)
425 A at
60% duty cycle
IP23
1.3–19.8 mpm
(50–780 ipm)
Actual range in
CC mode is
dependent on arc
voltage applied
Solid wire 0.6–1.4 mm (.023–.052 in.)
Flux-cored 0.8–2.0 mm (.030–5/64 in.)
305 mm (12 in.),
20 kg (45 lb.)
H: 394 mm (15.5 in.)
W: 229 mm (9 in.)
D: 533 mm (21 in.)
15.9 kg
(35 lb.)
Operates on
open-circuit voltage
and arc voltage:
14–48 VDC/
110 max. OCV
330 A at
60% duty cycle
IP23
Solid wire 0.6–1.4 mm (.023–.052 in.)
Flux-cored 0.8–2.0 mm (.030–5/64 in.)
203 mm (8 in.),
6.4 kg (14 lb.)
H: 324 mm (12.75 in.)
W: 184 mm (7.25 in.)
D: 457 mm (18 in.)
13 kg
(28 lb.)
425 A at
60% duty cycle
IP23
1.3–19.8 mpm
(50–780 ipm)
Actual range in
CC mode is
dependent on arc
voltage applied
Solid wire 0.6–1.4 mm (.023–.052 in.)
Flux-cored 0.8–2.0 mm (.030–5/64 in.)
305 mm (12 in.),
20 kg (45 lb.)
H: 394 mm (15.5 in.)
W: 229 mm (9 in.)
D: 533 mm (21 in.)
15.9 kg
(35 lb.)
24 VAC, 10 A,
50/60 Hz
425 A at
60% duty cycle
IP23
1.3–17.8 mpm
(50–700 ipm)
Solid wire 0.6–1.4 mm (.023–.052 in.)
Flux-cored 0.8–2.0 mm (.030–5/64 in.)
305 mm (12 in.),
20 kg (45 lb.)
H: 394 mm (15.5 in.)
W: 229 mm (9 in.)
D: 533 mm (21 in.)
14.1 kg
(31 lb.)
Input Power
SuitCase X-TREME 8VS
(300877)
Operates on
open-circuit voltage
and arc voltage:
14–48 VDC/
110 max. OCV
ArcReach
SuitCase X-TREME 12VS
(300876)
ArcReach SuitCase 8
(301456)
ArcReach SuitCase 12
(301457)
SuitCase 12RC
(301121)
(301121E) w/Euro gun connection
Input Welding
Circuit Rating
IP Rating
Model/Stock Number
Increase, improve
and maximize
Dimensions
Net
Weight
Increase Productivity
No time-consuming trips to the power source.
Exclusive Miller®technology uses the weld cables to
communicate changes in voltage settings. With an
ArcReach system, voltage and wire-feed-speed controls
are conveniently located at the operator’s fingertips —
right at the point of use — not back at the power source.
By eliminating control cables to the feeder, cabling is
streamlined and operators work at maximum efficiency.
Improve Weld Quality
Reduces costly “work arounds”.
Improve Worker Safety
Reduces operator hazards and injuries.
Maximize Efficiency
Reduces costly cord set up, maintenance
and repair.
Learn more at MillerWelds.com/arcreach
19
Wire Feeders
BENCH
I-24A and ST ® Series
Industrial Bench Feeders
70 Series
Heavy-Industrial
Bench Feeders
Designed for manufacturing,
our popular bench feeders
are available in three series with
multiple models to fit your needs.
D-74 MPa Plus
S-74D
ST-44 D
ST-24
ST Series models include 1.0/1.2 mm reversible drive rolls
and 70 Series models include 1.2 mm drive rolls.
I-24A, ST Series and 70 Series Features
Feature
Trigger hold
Adjustable run-in control
Automatic run-in control
Digital meters
Remote voltage control
Preflow/postflow
Spot control
Quick-connect
coolant fittings
Dual-wire models
Rotatable drive assembly
Accu-Mate™
Dual schedule control
Trigger program select
Trigger dual schedule
Sequence control
Locks and limits
Weld programs
Trigger schedule select
Push-pull capability
Synergic pulsed MIG
Profile Pulse™
I-24A
ST Series
24
44
74S
70 Series
74D 74MPA
4
Trigger hold allows the operator to make long welds without having to hold the trigger
continuously. Reduces operator fatigue.
Miller® standard, quick-change drive rolls save time.
Easy loading and threading of welding wire without having to release the drive roll
pressure arm.
Additional features for 70 Series feeders
Available in dual-wire models which allows two different wire types to be available on
one feeder, avoiding downtime from changing spools and drive rolls.
Toolless rotatable drive assembly allows operator to rotate the drive housing, allowing a
straight path for wire flow.
Quick-release drive-roll pressure arm allows drive roll change without losing spring
preload setting.
High-torque permanent-magnet motor, sealed ball bearing gear drive and solid-state
speed and brake control are maintenance free for long life.
Standard Optional
I-24A, ST-24 and ST-44 See literature M/6.91x (I-24A), WFM/4.0 UK (ST-24) and WFM/51.2 UK (ST-44)
Simple and cost-effective feeders for industrial manufacturing and fabricating.
Industrial, four-roll gear-driven, cast aluminium drive system with
heavy-duty motor. Provides exceptional feed performance, reliability
and wire speeds ranging from 1.3–20 meters per minute.
Optional features for ST Series
Scaled wire pressure knob.
Remote voltage control enables precise remote operation of the welding
power source arc voltage.
Adjustable run-in and burnback controls allow the operator to set the
optimum arc starts and stops, reducing wire stubbing, arc flaring or wire
burning back. ST Series only.
Euro-style or US-style torch connections ensure exceptional performance
and reliability for various style torches.
Standard 14-pin connection. Connects to any Miller® CV power source with
a 14-pin receptacle.
20
Dual digital meters display clear, precise readings of arc voltage, wire feed
speed and/or amperage. Can be set to hold last reading.
Quick-connect coolant fittings provide easy hook up for water-cooled
torches, no tools required!
BENCH
Wire Feeders
Industrial
I-24/ST Series
Heavy industrial 70 Series
74S and 74D See literature WFM/30.0 UK
Use with CV, DC
power sources.
Standard, simple feeders for most heavy-industrial applications, with the 74D providing
increased accuracy and control of the most common weld parameters.
Processes
Digital meters (74D models only) ensure accuracy
when presetting and reading actual voltage, amperage
and wire feed speed.
Suggested power sources
Remote voltage control (74D models only) allows you
to set both voltage and wire feed speed at the feeder,
saving time and increasing weld quality because optimal
weld parameters are easy to set.
(GMAW) • Flux-cored (FCAW)
• MIG
MIG (GMAW-P) with MPa Plus
• Pulsed
feeder and optional MPa power source
Series (pg 13)
• Deltaweld
MPa Series (pg 14)
• Invision
Series (pg 31)
• Dimension
• XMT Series (pg 32–35)
Suggested guns
Guns (pg 23/24)
• Bernard
Plus and XR -Pistol
• XR-Aluma-Pro
Plus (see chart below)
®
™
™
®
74 MPa Plus See literature WFM/30.0 UK
™
™
Adds features for weld control and programs, plus push-pull aluminium capabilities.
Optimized with Invision™ MPa or XMT® MPa power sources.
Adjustable run-in control for improved arc starts.
Dual schedule control allows the operator to switch
between two preconfigured welding parameters
without readjusting the machine, saving time and
enhancing quality.
Trigger schedule select saves time when switching
between two weld settings by simply tapping gun trigger.
Trigger program select provides the ability to access
any of the four active programs.
Sequence control gives the operator the ability to
adjust all of the welding parameters: preflow, run-in,
weld time, crater, burnback and postflow.
Locks and limits for restricting or limiting operator
adjustments, such as voltage and wire feed speed
parameters.
Four weld program memories allow operators to
recall up to four previously used processes and their
weld settings.
Accu-Mate™ properly seats the MIG gun power pin for
best feeding performance.
Push-pull capability provides consistent, versatile
and dependable aluminium wire feeding over
greater distances.
™
Most popular accessories
Recommended
aluminium solution.
Dedicated XR Plus guns
(gooseneck and pistol grip)
work with MPa Plus feeders
to coordinate wire feed speed of
the gun and the feeder. This provides
optimized aluminium feeding and welding performance.
See chart below for gun models and stock numbers.
Straightener (pg 66)
• Wire
Bail 058435
• Hanging
Wire
Reel
• Spool CoversAssembly 108008
• 057607 For I-24 and 70 Series
single-wire models
and left side of
dual-wire models
090389 For right side of
dual-wire models
Additional features when used with
Invision MPa or XMT MPa power sources
Synergic pulsed MIG. As wire speed increases/decreases,
pulse parameters also increase/decrease to match the
right amount of power needed, eliminating the need to
make additional adjustments.
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.
*Requires wire kit (230708) to run 1.6 mm (1/16 in.) wire.
Maximum Spool
Size Capacity
IP
Rating
Wire Feed
Speed
Dimensions
Net Weight
24 VAC, 4 A,
50/60 Hz
IP21
1.9–16.5 mpm
(75–650 ipm)
0.6–2.0 mm (.023–5/64 in.)
305 mm (12 in.),
15 kg (33 lb.)
H: 279 mm (11 in.)
W: 273 mm (10.75 in.)
D: 597 mm (23.5 in.)
12 kg (26 lb.)
ST-24 (029007395) Base model
ST-24 (029007396) w/voltage control
and coolant fittings
ST-24 (029007397) w/meters,
voltage control and coolant fittings
24 VAC, 4 A,
50/60 Hz
IP23
1.3–20 mpm
(51–790 ipm)
0.6–1.6 mm (.023–1/16 in.)
305 mm (12 in.),
15 kg (33 lb.)
H: 279 mm (11 in.)
W: 273 mm (10.75 in.)
D: 597 mm (23.5 in.)
16.6 kg (36.5 lb.)
ST-44 Series
ST-44 (029007406) Base model
ST-44 D (029007404) w/meters,
voltage control and coolant fittings
24 VAC, 5 A,
50/60 Hz
IP23
1.3–20 mpm
(51–790 ipm)
0.6–2.0 mm (.023–5/64 in.)
305 mm (12 in.),
15 kg (33 lb.)
H: 420 mm (16.5 in.)
W: 220 mm (8.65 in.)
D: 650 mm (25.5 in.)
ST-44 18 kg (40 lb.)
ST-44 D 20 kg (44 lb.)
70 Series
(Single-wire
models)
S-74S (300616002)
S-74D (300617002)
S-74 MPa Plus (300577)
24 VAC, 10 A,
50/60 Hz
IP23
1.3–19.8 mpm
(50–780 ipm)
26 kg (58 lb.)
D-74D (300620002)
D-74 MPa Plus (300578)
27 kg (60 lb.)
coil with optional
wire reel assembly
(108008)
H: 356 mm. (14 in)
W: 318 mm (12.5 in.)
D: 711 mm (28 in.)
70 Series
(Dual-wire
models)
0.6–3.2 mm (.023–1/8 in.)
Low-speed motor recommended for
2.4 and 3.2 mm wires (factory option)
MPa Plus model
Hard wire 0.6–2.0 mm (.023–5/64 in.)
Aluminium* 0.9–1.6 mm (.035–1/16 in.)
H: 356 mm (14 in.)
W: 533 mm (21 in.)
D: 889 mm (35 in.)
39.5 kg (87 lb.)
Model
Stock Number*
Input Power
I-20 Series
I-24A (186493)
ST-24 Series
Wire Type and Diameter Capacity
Optional Push-Pull Gun (For MPa Plus feeders only)
Welding Current Rating
IP Rating
Wire Feed Speed
Wire Type and Diameter Capacity
Dimensions
Net Weight
XR-Aluma-Pro Plus (Water-cooled)
(300003001) 4.6 m (15 ft.)
(300004001) 7.6 m (25 ft.)
400 A at 100% duty cycle
IP23
1.8–23 mpm
(70–900 ipm)
Aluminium*
0.8–1.6 mm (.030–1/16 in.)
H: 127 mm (5 in.)
W: 64 mm (2.5 in.)
L: 432 mm (17 in.)
1.3 kg (2.9 lb.)
H: 187 mm (7.375 in.)
W: 48 mm (1.875 in.)
L: 270 mm (10.625 in.)
1.1 kg (2.4 lb.)
XR-Pistol Plus (Water-cooled)
(300757) 7.6 m (25 ft.)
(300758) 10.6 m (35 ft.)
21
Wire Feeders
70 Series Remote Configurations
Heavy industrial
Use with CV, DC power sources.
Processes
See literature WFM/30.0 UK
(GMAW) • Flux-cored (FCAW)
• MIG
MIG (GMAW-P) with MPa Plus
• Pulsed
control box and optional MPa power
Remote wire feeder control box and wire drive assembly for non-Miller boom applications.
source
Suggested power sources/guns
Note: MPa Plus wire drive motor assemblies and control
cables are only for use with MPa Plus control boxes.
S-74 MPa
Plus shown.
Single-wire control box
300881 S-74S
300882 S-74D
300738 S-74 MPa Plus
Gun NOT included.
Must be ordered separately.
Wire drive motor assembly
300904
Standard left-hand drive
300740001 MPa Plus left-hand drive
Motor control cable
Standard: 11 conductor
MPa Plus: 14 conductor
•
MPa Plus drive can be used with push-only guns OR
XR-Aluma-Pro™ Plus and XR™-Pistol Plus push-pull guns.
Motor control cable
11 conductor
• Same as 70 Series
Most popular accessories
Control Cable (11 conductor)
• Motor
254935010 3 m (10 ft.)
254935025 7.6 m (25 ft.)
For push-only gun configurations.
MPa Plus Motor Control Cable
(14 conductor)
254864010 3 m (10 ft.)
254864025 7.6 m (25 ft.)
For MPa Plus configurations only —
single-wire or left side of dual-wire.
Motor control cable
Standard: 11 conductor
MPa Plus: 14 conductor
Base 195369
• Feeder
For use with spooled wire.
Gun NOT included.
Must be ordered separately.
Push-only wire drive motor assembly
300741001 Standard right-hand drive
300741 MPa Plus right-hand drive
D-74D
shown.
Dual-wire control box
300886 D-74S
300887 D-74D
300739 D-74 MPa Plus
Gun NOT included.
Must be ordered separately.
Wire drive motor assembly
300904
Standard left-hand drive
300740001 MPa Plus left-hand drive
MPa Plus drive can be used with push-only guns OR
XR-Aluma-Pro™ Plus and XR™-Pistol Plus push-pull guns.
Engineered for Simplicity. Built for Durability.
Your welders select the Bernard
gun handles, triggers and necks
that are the most comfortable and
effective for accessing their welds.
Management enjoys the resulting
increase in productivity, longer
gun life, and a reduced parts
inventory with consumables
designed to work across all of your
welding guns.
For more information see pages
23/24, or contact your local welding
distributor or Bernard directly.
A Division of Miller Electric Mfg. Co.
Visit BernardWelds.com to configure a hand-held gun for your welding application today.
22
23
Flux-cored Flux-cored
Dual-shld Self-shld
24 CV** CV** Wire Diameter Capacity
Available Cable Lengths
Typical Applications
0.6–3.2 mm (.023–1/8 in.)
2.4, 3, 3.7, 4.5, 6, or 7.6 m
Heavy industrial steel fabrication
0.6–3.2 mm (.023–1/8 in.)
2.4, 3, 3.7, 4.5, 6, or 7.6 m
Heavy industrial steel fabrication
Bernard™ Dura-Flux™ Gun
with Fixed Liner
24
CV**
1.6–2.4 mm (1/16–3/32 in.)
2.4, 3, 3.7, 4.5, 6, or 7.6 m
Heavy industrial steel fabrication
Bernard™ Dura-Flux™ Gun
with Replaceable Liner
24
CV**
1.2–2.0 mm (.045–5/64 in.)
2.4, 3, 3.7, 4.5, 6, or 7.6 m
Heavy industrial steel fabrication
26
0.8–1.6 mm (.030–1/16 in.)
4.5, 7.6 or 10.6 m
Heavy industrial aluminium fabrication
26
0.8–1.6 mm (.030–1/16 in.)
Pistol: 4.5 or 9 m
Pistol-Pro: 4.5, 7.6 or 10.6 m
Heavy industrial aluminium fabrication
XR™ Controls
27
0.8–1.6 mm (.030–1/16 in.)
—
Heavy industrial aluminium fabrication
Product Key
Aluminium
XR-Aluma-Pro™ Push-Pull Guns
XR™-Pistol Push-Pull Guns
Steel
Bernard™ Clean Air™
Fume Extraction Guns
Alum.
Bernard™ BTB MIG Guns
Wire Types
Hard
Product
Guide
Page
Class
MIG
Pulsed MIG*
Flux-cored**
MIG Guns
Class:
Light industrial
Industrial
Heavy industrial
Capability:
Designed for this process
Capable of this process
*Requires MPa inverter power source. **Certain self-shielded wires require CV output. Miller recommends a CV power source whenever possible.
™
Bernard Semi-Automatic Guns
ITW Welding offers rugged and reliable Bernard welding guns that have been customized to
match the performance of many of its industrial wire feeders and power sources.
Heavy industrial
Processes
• MIG (GMAW) • Flux-cored (FCAW)
Suggested feeders
Feeder (pg 15)
• Continuum
Series (pg 18)
• SuitCase
ST Series and 70 Series
• I-24A,
Feeders (pg 20)
™
®
BTB Air-Cooled MIG Guns
See Bernard literature SP-BTB
Our rugged Bernard BTB (Best of the Best) MIG guns bring together all the best features and
options from our former Q-Gun,™ S-Gun™ and T-Gun™ MIG guns into a single, flexible gun series.
Most popular consumables
TOUGH LOCK Consumable Series
Diffusers (amps)
404-18-25 200, 300, 400 SD
404-26-25 300, 400, 500, 600 HD
Copper Nozzles (inches)
401-4-62 5/8 ID, 1/8 Rec., SD
401-6-62 5/8 ID, 1/8 Rec., HD
401-5-62 5/8 ID, 1/4 Rec., HD
401-5-75 3/4 ID, 1/8 rec., HD
B Series handle
(small or large)
O Series handle
(small or large)
T Series handle
(small or large)
To configure your BTB MIG gun from the following array of options visit BernardWelds.com/ConfigureMyGun
Compatible with two high-performance consumable lines — TOUGH LOCK™ and Centerfire™
(see page 24 for more information)
Compatible with Universal Conventional or front-loading QUICK LOAD™ liners (see page 25 for more information)
Fixed or rotatable aluminium armored necks in various lengths and angles to optimize weld access
Choice of seven different handles with various trigger options for a comfortable, ergonomic fit
Internal cable connections are compression fit (instead of crimped) to optimize conductivity, reduce heat and
increase gun life
Optional ultra-heavy-duty steel monocoil cable provides extra reinforcement and high pinch/kink resistance
One year manufacturer’s warranty with lifetime warranty on rear strain relief
•
•
•
•
•
•
•
For more detailed information, visit
Contact Tips (mm)
403-14-35-25 0.9 SD
403-20-35-25 0.9 HD
403-14-45-25 1.2 SD
403-20-45-25 1.2 HD
403-20-52-25 1.4 HD
403-20-116-25 1.6 HD
Centerfire Consumable Series
Diffusers (amps)
DS-1 200, 300, small
D-1 400, 500, 600, large
Brass Nozzles (inches)
NS-1218B 1/2 ID, 1/8 rec., small
Copper Nozzles (inches)
NS-5818C 5/8 ID, 1/8 rec., small
N-5818C 5/8 ID, 1/8 rec., large
N-5814C 5/8 ID, 1/4 rec., large
N-3414C 3/4 ID, 1/4 rec., large
Contact Tips (mm)
T-035 0.9
T-045 1.2
T-052 1.4
T-062 1.6
BernardWelds.com
23
MIG Guns STEEL
Bernard Semi-Automatic Guns
™
Industrial-duty fume extraction and flux-cored welding solutions built for the way you weld.
Heavy industrial
Processes
• MIG (GMAW) • Flux-cored (FCAW)
Suggested feeders
Feeder (pg 15)
• Continuum
SuitCase
Series
• I-24A, ST Series and(pg 7018)Series
• Feeders (pg 20)
™
Fume Extraction MIG Gun
See Bernard literature SP-CLA (Clean Air ™ gun)
Maintaining a clean working environment is important
and Bernard understands the need for a reliable fume
extraction solution. Extract fumes at the weld bead
using our Clean Air fume extraction MIG gun.
Clean Air
Clean Air ™ gun
Available in 300-, 400-, 500- and 600-amp models
Compatible with TOUGH LOCK and Centerfire consumables
Ergonomic, lightweight handle with rear swivel improves operator
comfort
•
•
•
Dura-Flux Self-Shielded
Flux-Cored Guns See Bernard literature SP-DF
™
Replaceable
power cable liner
For structural steel applications, bridge construction
and heavy equipment repair, Bernard offers two types
of 350-amp self-shielded flux-cored guns.
Dura-Flux gun with replaceable power cable liner
Replaceable power cable liner allows quick and easy power
cable maintenance
Quik Tip consumables provide excellent heat transfer and
electrical conductivity
Dura-Flux gun with fixed power cable liner
Ultra-heavy-duty steel monocoil power cable is highly resistant
to kinking
Centerfire consumables are easy to use and high performing,
providing better arc starts, less spatter and more consistent welds
•
•
Fixed power
cable liner
•
•
For more detailed information, visit
BernardWelds.com
Bernard Welding Consumables (cutaways shown)
TOUGH LOCK™
Centerfire™
See Bernard literature SP-TLC
See Bernard literature SP-CFC
•
contact tip (no tools required to replace
• Drop-in
tip or nozzle) means quick changeover and
•
Dual-taper technology keeps consumables
locked from tip to neck for improved weld
consistency, positive electrical conductivity
and maximized heat dissipation
Consumables run cooler, improving
performance and extending life
reduced downtime
shield within nozzle holds tip in place,
• Spatter
protects diffuser and directs gas evenly with
reduced turbulence
mates securely with contact tip for
• Diffuser
better conductivity
24
®
Most popular consumables
TOUGH LOCK Consumable Series
Diffusers (amps)
404-18-25 200, 300, 400 SD
404-26-25 300, 400, 500, 600 HD
Copper Nozzles (inches)
401-4-62 5/8 ID, 1/8 Rec., SD
401-6-62 5/8 ID, 1/8 Rec., HD
401-5-62 5/8 ID, 1/4 Rec., HD
401-5-75 3/4 ID, 1/8 rec., HD
Contact Tips (mm)
403-14-35-25 0.9 SD
403-20-35-25 0.9 HD
403-14-45-25 1.2 SD
403-20-45-25 1.2 HD
403-20-52-25 1.4 HD
403-20-116-25 1.6 HD
Centerfire Consumable Series
Diffusers (amps)
DS-1 200, 300, small
D-1 400, 500, 600, large
Brass Nozzles (inches)
NS-1218B 1/2 ID, 1/8 rec., small
Copper Nozzles (inches)
NS-5818C 5/8 ID, 1/8 rec., small
N-5818C 5/8 ID, 1/8 rec., large
N-5814C 5/8 ID, 1/4 rec., large
N-3414C 3/4 ID, 1/4 rec., large
Contact Tips (mm)
T-035 0.9
T-045 1.2
T-052 1.4
T-062 1.6
MIG Guns
Industrial
Tregaskiss Robotic Guns
™
•
Process MIG (GMAW)
Compatible robots
Air-Cooled MIG Guns
• Panasonic
• ABB
• COMAU
• FANUC
• Kawasaki
• KUKA
• Motoman
Daihen
• OTC
• Reis (CA3 only)
Most popular accessories
GUN I.C.E. (Integrated
• TOUGH
Cooling Enhancer) Technology —
®
Compatible with most robotic welding systems, fully configurable TOUGH GUN robotic MIG
guns are engineered for accurate, reliable and repeatable performance that maximizes
production uptime and throughput.
™
®
®
®
®
™
®
®
TOUGH GUN TA3 MIG Gun
See Tregaskiss literature SP-TA3
™
™
Designed for welding applications where the gun runs
internally through the robot arm.
Available in 350-amp models at 100 percent duty cycle with mixed gases.
Available as a complete package from the power pin to the contact tip.
Re-engineered neck clamp improves durability and consistency of
clamping force.
Easy maintenance with minimal downtime.
•
•
TOUGH GUN CA3 MIG Gun
TOUGH GUN TT3E
reamer shown with
TOUGH GUN CA3
MIG gun.
See Tregaskiss literature SP-CA3
Designed for welding applications where the gun runs external
to the robot arm.
Available in 385-amp models at 100 percent duty cycle with mixed gases.
Replaceable unicable reduces downtime through faster repair and
extended service life.
Cable guide minimizes stress on cable connection as the robot articulates.
Re-engineered neck clamp improves durability and consistency of
clamping force.
Easy maintenance with minimal downtime.
GUN TT3 Reamers
• TOUGH
TT3A Analog
For more information or to configure your Tregaskiss
robotic gun online, visit Tregaskiss.com/ConfigureMyGun
•
Tregaskiss Liners
adds water-cooling to air-cooled guns
for a boost in duty cycle.
Neck Checking Fixture
Reamer Lubricator
TT3E Ethernet
Two models available — TT3A (analog)
and TT3E (Ethernet) model enhanced
with digital Ethernet communication
for better integration. Reamers provide
automated spatter removal to help
extend the life of your robotic MIG
guns and consumables, increasing
both production uptime and
throughput while benefiting your
bottom line. Designed to operate
reliably in even the harshest welding
environments.
NEW! TOUGH GUN Reamer Stand —
custom height, quick installation,
easy on the budget.
TOUGH GARD Multi-Feed System
•
Most popular consumables
TOUGH LOCK Consumables
• (see
Tregaskiss literature TLC/1.0)
QUICK LOAD Liners (see Tregaskiss
• literature
QLL/1.2)
LOAD Liner AutoLength System
• QUICK
(see Tregaskiss literature QLL/1.2)
™
AutoLength pin cutaway shown.
™
QUICK LOAD™ Liner AutoLength™ System
See Tregaskiss literature QLL/1.2
™
QUICK LOAD Liners
See Tregaskiss literature QLL/1.2
This innovative front-loading liner is a two-piece
system with the retainer installed inside the
power pin on first use.
Requires less than half the time and effort to
replace compared to conventional liner
Compatible with Tregaskiss TOUGH GUN
robotic and automatic air-cooled MIG guns,
and Bernard™ BTB MIG Guns
•
•
Pair your QUICK LOAD liner with an AutoLength pin to
reap the benefits of the revolutionary QUICK LOAD
Liner AutoLength System. Minimize downtime, wire
feeding and quality issues commonly associated with
short liner length.
Reduces issues caused by short liners
Decreases burn-backs caused by misalignment
between the liner and contact tip
Accommodates liner movement during welding
Improves wire feeding by enhancing wire alignment
with the contact tip
Spring-loaded module allows for up to 2.54 cm
(1 in.) forgiveness if the liner is too short
™
•
•
•
•
•
25
MIG Guns ALUMINIUM
XR Push-Pull Guns
Heavy industrial
™
Use with CC/CV, DC power sources.
Processes
XR-Aluma-Pro and XR-Pistol guns work in conjunction with an XR Control or XR-AlumaFeed
to provide the best solution for push-pull applications.
(GMAW) with aluminium wire
• MIG
(capable of other wires with optional
hardwire kits)
MIG (GMAW-P) with optional
• Pulsed
pulsing power source
Threaded quick-change 360-degree rotatable head tubes are available in different bends and lengths
for even those hard-to-reach welds. Over 30 different styles to fit your application and welder’s preference.
Wire tension settings (except XR-Pistol). 4000- or 5000-specific tension settings ensure the very best
wire feeding performance and arc consistency.
Heavy-duty construction. All internal components are designed to provide long lasting performance and
feeding precision.
XR-Aluma-Pro
™
Suggested power sources
These power sources require
XR-AlumaFeed® (pg 11) OR
XR™ Control (pg 27)
AlumaPower™ MPa (pg 11)
Invision™ MPa (pg 14)
XMT® Series (pg 32–35)
•
•
•
Most popular accessories
• Hardwire Liner Kit 198377
See literature M/1.71
Robust professional-grade gun has the
highest duty cycle rating in its class.
Easy access to drive assembly and removable
toolless head tube reduce service time, by allowing
a simple means of changing drive rolls and head
tube — or performing routine maintenance without
disassembly of gun.
XR-Aluma-Pro
PORTABLE!
™
XR -Pistol See literature M/1.73
Reliable, cost-effective gun for
light- to medium-industrial applications.
XR-Pistol
™
XR -Pistol-Pro See literature M/1.74
Exceptional aluminium welding results for
heavy-industrial applications.
XR-Pistol-Pro
Most durable motor and drive design improves
feedability and arc consistency while helping reduce
downtime and maintenance costs.
Easy access to drive assembly and removable
toolless head tube reduce service time, by allowing
a simple means of changing drive rolls and head
tube — or performing routine maintenance without
disassembly of gun.
*Dependent on control box used. **Requires wire kit (230708) to run 1.6 mm (1/16 in.) wire.
Model
4.6 m (15 ft.)
Cable Length
7.6 m (25 ft.) 9 m (30 ft.)
XR-Aluma-Pro (Water-cooled)
(300003)
(300004)
XR-Pistol (Air-cooled)
(198127)
XR-Pistol (Water-cooled)
(198129)
26
10.6 m (35 ft.)
Welding Current Rating
IP
Rating
Wire Feed
Speed*
Wire Type and
Diameter Capacity
Dimensions
—
(300265)
400 A at 100% duty cycle
IP23
1.8–23 mpm
(70–900 ipm)
Aluminium**
0.8–1.6 mm
(.030–1/16 in.)
H: 127 mm (5 in.)
W: 64 mm (2.5 in.)
L: 432 mm (17 in.)
1.3 kg (2.9 lb.)
—
(198128)
—
200 A at 100% duty cycle
IP23
(198130)
—
400 A at 100% duty cycle
IP23
1.8–22.2 mpm
(70–875 ipm)
Aluminium
0.8–1.6 mm
(.030–1/16 in.)
H: 187 mm (7.375 in.)
W: 48 mm (1.875 in.)
L: 270 mm (10.625 in.)
1 kg (2.2 lb.)
—
Gun Only
Net Weight
1.1 kg (2.4 lb.)
ALUMINIUM
XR Control
MIG Guns
Heavy industrial
™
Use with CC/CV, DC power sources.
See literature M/1.7
Standard aluminium wire feeding system for fabrication and manufacturing, consisting of a
control box and push-pull gun. Beneficial for difficult-to-feed wire types.
XR-S
XR-S
PORTABLE!
Includes both 0.9 mm and factory-installed 1.2 mm drive rolls.
Order 1.6 mm control box drive roll kit (195591) separately.
(GMAW) with aluminium and
• MIG
other soft alloy wires
MIG (GMAW-P) with optional
• Pulsed
pulsing power source
Suggested guns
Simple, cost-effective push-pull feeder for
industrial applications.
XR-D
Processes
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.
Digital meters ensure accuracy when presetting
and reading actual wire feed speed or voltage.
Trigger hold for making long weldments without
hand fatigue.
Adjustable wire run-in control allows arc start fine
tuning. Reduces wire stubbing or arc flaring which
can result in contact tip burnback.
• Push-pull guns (pg 26)
Suggested power sources
MPa (pg 11)
• AlumaPower
MPa (pg 14)
• Invision
• XMT Series (pg 32–35)
Most popular accessories
Cables (pg 66)
• Extension
• Gas Flowmeter Kit 246127
™
™
®
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
XR-D (additional features)
Adds basic programmable weld
sequencing that allows adjustments for
preflow, postflow, start, and crater
providing higher quality welds.
Model/Stock Number
XR-S (300601)
XR-D (300687)
Input Power
IP Rating
Wire Feed Speed
Wire Type and Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
24 VAC,
50/60 or 100 Hz
IP23
1.3–23 mpm
(50–900 ipm)
Aluminium 0.8–1.6 mm (.030–1/16 in.)
Requires drive roll kit (195591) to run
1.6 mm (1/16 in.) wire
305 mm (12 in.)
H: 406 mm (16 in.)
W: 235 mm (9.25 in.)
D: 540 mm (21.25 in.)
19.2 kg
(42.5 lb.)
Feeding aluminium –
choose the right gun solution
Push-only Guns
UPGRADE
Push-pull Guns
23–24
26
Known as standard MIG guns, these guns are only used
for occasional aluminium work.
•Typically used with hard wire or flux-cored wires in
general manufacturing
•For aluminium, guns should be limited to 3.7 meter
lengths and configured with correct aluminium liner and
consumables
Preferred guns for industrial production work with the
best overall aluminium wire feedability.
•Built for longevity
•Great arc starts and performance
•Higher amp ratings
•Air- and water-cooled models
•Work in conjunction with designated wire feeders
Learn more at MillerWelds.com/aluminum
27
People like you use their talent and tools
to make our world a better place.
Miller celebrates those who build dreams, security, industry, adventure,
performance…everything that makes a positive difference in our lives.
Together, we build with you.
Multiprocess
Power Source
Welding
Performance
200 A
450 Amp
350 Amp
650 A
MPi 220P
(1-Phase)
XMT®
350 CC/CV
XMT®
350 MPa
Dimension™
562
XMT®
450 CC/CV
XMT®
450 MPa
Dimension™
812
Dimension™
650
(pg 30)
(pg 32)
(pg 32)
(pg 31)
(pg 32)
(pg 32)
(pg 31)
(pg 31)
Mild Steel
Material
Stainless Steel
Aluminium*
Gauge
(0.5–3.0 mm)
Material
Thickness
Sheet
(3.0–9.5 mm)
Plate
(9.5–25 mm)
Plate
(25+ mm)
0.6 mm
6 mm
6 mm
6 mm
8 mm
8 mm
10 mm
10 mm
0.8 mm
1.0 mm
Wire Size
1.2 mm
1.4 mm
1.6 mm
2.0 mm
2.4 mm
Short Circuit
Pulsed Spray
Process
Stick
TIG
CAC-A
Icon Key
Capability:
Designed for
Capable of
Process Quality: Good Better Best
New! or Improved! products appear in blue type. *XR push-pull system recommended for best results.
Optimized
29
Multiprocess
MPi 220P
Industrial
See literature DCM/9.5 UK
Processes
(GMAW) • Pulsed MIG (GMAW-P)
• MIG
(FCAW) • Stick (SMAW)
• Flux-cored
• TIG (GTAW)
Synergic welding mode offers the simplicity of single knob
control. The machine will select the correct voltage and amperage
based on the wire feed speed (WFS) set by the operator.
Weld Ready package includes
the following
source
• Power
Bernard
• Work cableMIGwithgunclampQ2010TE3EEQ
•
Most popular accessories
WP-17VS4BXEY3GL
• TIG150Torch
amps DC/100 amps AC,
Note: Complete material library to select from for the targeted market segment.
™
Large graphical display guides user through process and
parameter setup with ease and high visibility.
Durable cast aluminium feedhead incorporates dual-groove
quick-change drive roll and spring-loaded tension arm with
calibrated tension knob, all designed to make setup easier
and faster.
60% duty cycle
MIG gun Q2010TE3EEQ
• Bernard
200-amp gun with 3 m cable
™
Thermal overload protection shuts down unit and activates
over temperature light if airflow is blocked or duty cycle is
exceeded. Automatically resets when fault is corrected and
unit cools.
Adjustable Hot Start™ for stick arc starts. Adjust the optimal
start current for the application. The current automatically
increases the output amperage at the start of a weld.
Built-in upslope/downslope function for TIG helps provide
better arc starts and reduces craters.
Built-in run-in/crater/burnback function for MIG helps
provide better arc starts and reduces craters.
Adjustable preflow and postflow gives operator better control
of the gas parameters affecting weld zone.
Selectable trigger configuration allows the operator to choose
standard or 2T trigger method.
Stock Number
(059016014)
230 V, 50/60 Hz
(029083114)
Weld Ready package
Welding Mode
Welding Output Ranges
Rated Output
IP Rating
Max. Open-Circuit Voltage
Dimensions
Net Weight
MIG
2–200 A, 15–24 V
180 A at 23.0 VDC, 35% duty cycle
140 A at 21.0 VDC, 60% duty cycle
110 A at 17.5 VDC, 100% duty cycle
IP22S
35
H: 365 mm (14.4 in.)
W: 237 mm (9.3 in.)
D: 548 mm (21.6 in.)
16 kg (35 lb.)
Stick
5–200 A, 20.2–28 V
170 A at 26.8 VDC, 35% duty cycle
130 A at 25.2 VDC, 60% duty cycle
100 A at 24.0 VDC, 100% duty cycle
65
TIG
5–200 A, 10–18 V
180 A at 17.2 VDC, 35% duty cycle
130 A at 15.2 VDC, 60% duty cycle
100 A at 14.0 VDC, 100% duty cycle
65
Engineered for Simplicity.
Built for Durability.
Design the perfect MIG guns for all your welds!
Improve welding productivity by choosing the neck length and angle, handle
shape and trigger style that allows welders to comfortably and efficiently reach
all your welds.
Plus, longer gun life and shared parts and consumables will help to simplify
inventory and minimize costs across our shop.
For additional information, please
contact your local welding distributor.
To request a catalog, please call or
complete our online request form.
BernardWelds.com
30
A Division of Miller Electric Mfg. Co.
Multiprocess
Heavy industrial
Dimension 562 and 812
™
See literature DC/19.2
Processes
Multiprocess performance in a reliable package. Designed for heavy-industrial applications,
with 100 percent duty cycle for extended arc-on time.
(GMAW) • Flux-cored (FCAW)
• MIG
(SMAW) • TIG (GTAW)
• Stick
carbon arc cutting and gouging
• Air(CAC-A)
(carbons — 562: 6 mm,
812: 10 mm)
Most popular accessories
Built-in arc control for stick welding allows operators more
flexibility when welding in tight areas where sticking electrodes
is a problem.
Line voltage compensation ensures consistent weld
performance even when primary power varies.
Fan-On-Demand™ cooling system operates only when needed.
Reduces contaminants drawn into the machine and excess
noise in work areas.
X-TREME Feeders (pg 18)
• SuitCase
Series Feeders (pg 20)
• 70Standard
• (pg 63) Running Gear 042886
Cylinder Rack 042887
• Standard
(pg 63)
• Extension Cables (pg 66)
™
®
Digital meters are easy to read and display preset and actual
voltage and amperage.
115-volt power for tools and coolant systems.
Dimension 562 shown with 70 Series feeder, MIG gun,
weld cable and work cable (components sold separately).
Model/Stock Number
Welding Output
Ranges
Dimension 562
(907360) 380/400/440 V, 50 Hz
CC mode: 20–565 A
Dimension 812
(907361) 380/400/440 V, 50 Hz
CC mode: 50–815 A
CV mode: 10–38 V
Rated Output
IP Rating
Amps Input at Rated Output, 60 Hz
380 V 400 V 440 V KVA KW
Max. OpenCircuit Voltage
Dimensions
(Includes lift eye and strain relief)
450 A at 36.5 VDC,
100% duty cycle
IP23S
48
46
41
31.4 22
65 VDC
52.5
51
46
35.3 22.3
43 VDC
H: 762 mm (30 in.)
W: 585 mm (23 in.)
D: 966 mm (38 in.)
192 kg
(424 lb.)
650 A at 44 VDC,
100% duty cycle
IP23S
77
73
66
50
72 VDC
H: 762 mm (30 in.)
W: 585 mm (23 in.)
D: 966 mm (38 in.)
247 kg
(545 lb.)
34.8
67 VDC
CV mode: 10–65 V
Dimension 650
Net Weight
Heavy industrial
™
See literature DCM/40.0 UK
Processes
Developed for harsh environmental conditions and output requirements that range from
power-intensive to precise.
All aluminium construction helps the machine resist corrosion
for long life.
Exclusive protection input inductor protects machine’s
performance and reliability from “dirty” input power.
(GMAW) • Flux-cored (FCAW)
• MIG
Stick
(SMAW) • TIG (GTAW)
• Submerged
(SAW)
• Air carbon arcarccutting
gouging
• (CAC-A) (rated 10 mmandcarbons)
Most popular accessories
X-TREME Feeders (pg 18)
• SuitCase
Series Feeders (pg 20)
• 70Bernard
Guns (pg 23/24)
• Universal MIG
Trolley
018035028 (pg 63)
• Dimension 650 Running
• 301307 (pg 63) Gear
Cables (pg 66)
• Extension
242208025 7.6 m (25 ft.)
™
™
Wind Tunnel Technology ™ protects internal components,
greatly improving reliability.
Fan-On-Demand™ reduces power consumption and
improves reliability.
High-quality performance in all welding processes, from thick
to thin metals.
242208050 15 m (50 ft.)
242208080 24.4 m (80 ft.)
Arc control available in the stick and wire modes for easier fine
tuning of tough-to-weld materials and out-of-position applications.
Reduced size and weight results in an easier-to-handle
package that exceeds the welding performance of larger,
heavier machines. Dimension 650 is 3.5 times lighter than
the Dimension 812 and also uses 40 percent less floor space.
High electrical efficiency and excellent power factor
mean that you can get more welding done using less power.
Dimension 650 uses 32 percent fewer amps than the
Dimension 812.
Stock Number
(907618) 380/460 V, 50/60 Hz
Welding Output
Ranges
CC mode: 20–815 A
CV mode: 10–44 V
SAW mode: 10–65 V
Rated Output
IP Rating
Amps Input at Rated Output, 50/60 Hz
380 V
460 V
KVA
KW
Max. OpenCircuit Voltage
Dimensions
(Includes lift eye and strain relief)
650 A at 44 VDC,
100% duty cycle
IP23
53.2
87 VDC
H: 716 mm (28.187 in.)
W: 424 mm (16.687 in.)
D: 803 mm (31.625 in.)
42.8
34
30.7
Net Weight
71.7 kg
(158 lb.)
31
Multiprocess
XMT® Series
Portability and excellent multiprocess
arc performance make the XMT family
the most popular in the industry.
With many models to choose from
the XMT family has the right solution
for your business.
XMT 450
XMT 350
Input power choices
Reliability
(350 models) allows for any input voltage hookup
(230–575 V, three-phase) with no manual linking,
providing convenience in any job setting. Ideal solution for dirty or
unreliable input power.
Wind Tunnel Technology.™ Air flow that protects internal components, greatly
improving reliability.
Fan-On-Demand™ cooling system operates only when needed, reducing noise,
energy use and amount of contaminants pulled through machine.
Standard hookup (450 models). 400 V only, three-phase.
Welder friendly control panel
Advanced features for the professional welder
Process selector switch reduces the number of control setup combinations
without reducing any features.
Adaptive Hot Start™ makes starting stick electrodes easy without
creating an inclusion.
Ultra-tough, polycarbonate-blended cover protects front controls from damage.
Infinite arc control available in the stick and wire modes for easier
fine tuning of tough-to-weld materials and out-of-position applications.
Large, dual digital meters are easy to view and presettable to ease setting
weld output.
Lift-Arc™ provides arc starting that minimizes contamination of the
electrode and without the use of high frequency.
Output connector choices
Welding Intelligence™ system. XMT 14-pin
models are Insight Core capable to monitor
weld voltage, amperage, and arc-time and percentage.
Dinse-style weld disconnects (350 models) provide high-quality weld cable
connections. Machines come with two Dinse connectors.
Weld studs (450 models).
14-pin receptacle provides a quick, direct connection to Miller® wire feeders.
Capable of remote voltage control.
Choose the Right XMT
350 Amp
XMT 350 CC/CV
Input Power
Primary Operating Range
Weld Output
Carbon Arc Gouging
Net Weight
Output Connector
Pulsed MIG
14-pin Compliant
Insight Core Capable
(requires Insight Core
14-pin module)
32
—
450 Amp
XMT 350 MPa
XMT 450 CC/CV
XMT 450 MPa
3-phase
3-phase
Auto-Line (230–575 V)
400 V
350 A at 34 VDC
(3-phase input power at 60% duty cycle)
UPGRADE
450 A at 38 VDC
(3-phase input power at 100% duty cycle)
Rated: 6 mm
UPGRADE
Rated: 8 mm
36.3 kg (80 lb.)
55.3 kg (122 lb.)
Dinse
1/2 in. stud
UPGRADE
Yes
—
UPGRADE
Yes
Yes
Yes
(pg 54)
Yes
(pg 54)
Yes
Multiprocess
Heavy industrial
®
XMT 350 CC/CV and 450 CC/CV
Processes
(GMAW) • Pulsed MIG (GMAW-P)*
• MIG
(SMAW) • TIG (GTAW)
• Stick
(FCAW)
• Flux-cored
Air
carbon
arc cutting and gouging
• (CAC-A) (carbons
— 350: 6 mm,
See literature DCM/43.0 UK (350) and DC/18.94 (450)
Flexibility and simplicity make this the most
popular model. It has the core multiprocess
capabilities along with the flexibility of a
14-pin for spool guns, feeders, and remote
controls.
450: 8 mm)
*Only XMT MPa models.
Most popular accessories
(pg 11)
• XR-AlumaFeed
X-TREME Feeders (pg 18)
• SuitCase
Feeders (pg 20)
• 70XR Series
Control
(pg 27)
• Universal Trolley
(pg 63)
• Coolmate Coolant018035028
(pg 64)
• HydraCool CoolantSystem
(pg 64)
• Coolant 043810 (pgSystem
• Protective Cover (XMT 64)
• 195478 (pg 65) 350 only)
Valve Kit
• Gas
195286 XMT 350
®
®
Strong weld output for increased capabilities.
More output for larger wires and stick electrodes.
™
™
™
™
XMT® 350 MPa and 450 MPa
300928 XMT 450
See literature DCM/43.0 UK (350) and DC/18.94 (450)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Built-in pulse programs for manufacturing and fabrication applications that have benefits for
standard steels, high-strength steels and aluminium.
Pulse programs provide reduced heat affected zone,
weld in all positions, great for thick-to-thin metal, good
gap filling ability and faster travel speeds and deposition.
SharpArc® controls the arc in pulsed MIG mode and
gives total control over the arc cone shape, puddle
fluidity and bead profile.
Additional features when using a 70 Series MPa Plus feeder or XR-AlumaFeed® feeder.
Synergic pulsed MIG.
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,
eliminating the
need to make
additional
adjustments.
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.
Added capabilities with Insight Core.™ When using an
MPa Plus feeder, wire deposition is added to the Insight
Core capabilities.
*Optional 115-volt auxiliary power provides 10 amps of circuit-breaker protected power for coolant systems, etc.
**Duty cycle rating below achieved with 6-gauge input power cord (8-gauge cord supplied with unit).
Input
Power
Welding
Output Ranges
Rated Output
XMT 350 CC/CV
(907161011) 230–575 V w/auxiliary power*
XMT 350 MPa
(907366011) 230–575 V w/auxiliary power*
3-phase
5–425 A
10–38 V
XMT 450 CC/CV
(907525) 400 V w/auxiliary power*
3-phase
15–600 A
10–38 V
450 A
350 A
Model/Stock Number
XMT 450 MPa
(907468) 400 V w/auxiliary power*
IP
Rating
Amps Input at Rated Load Output, 60 Hz
230 V 400 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
350 A at 34 VDC,
60% duty cycle
IP23
36.1 20.6 17.8 14.1
14.2 13.6
75 VDC
H: 432 mm
(17 in.)
W: 318 mm
(12.5 in.)
D: 610 mm
(24 in.)
36.3 kg
(80 lb.)
43 kg
(94.8 lb.)
w/aux power
450 A at 38 VDC,
100% duty cycle
IP23
—
32.1 —
—
22
90 VDC
55.3 kg
(122 lb.)
—
32.1 —
—
22.2 19.2
H: 438 mm
(17.25 in.)
W: 368 mm
(14.5 in.)
D: 689 mm
(27.125 in.)
18.9
Dimensions
Net
Weight
33
Multiprocess PIPE WELDING
XMT ® 350 FieldPro System
™
See literature DC/18.96
XMT 350 FieldPro shown with optional
ArcReach Smart Feeder, ArcReach SuitCase 12
and ArcReach SuitCase 8 feeders.
Remote control of the power source
without a cord.
More jobsite productivity and efficiency
Cable Length Compensation (CLC™) ensures that the voltage a weld
operator sets is the voltage they get by automatically adjusting voltage
based on weld cable length
•
Exceptional arc performance
Regulated Metal Deposition (RMD®) and pulsed MIG are fully supported,
enabling operators to use these advanced processes in the field for faster,
more-efficient welds
Common weld failures can be minimized with stick stops that are specifically
programmed to eliminate arc strikes outside of the heat-affected zone
•
•
More operator control
Weld operators can Adjust While Welding (AWW™) to change weld
parameters while the arc is on
Inadvertent parameter changes by other jobsite workers can be easily
avoided because connecting an ArcReach accessory from the power source
automatically locks out the power source’s panel controls
Return to a previous weld process faster because the power source is
restored to its previous settings once the ArcReach accessory is removed
Decrease the chance of an incorrect weld process being used because
Auto-Process Select™ automatically sets the power source to the correct
weld process based on the polarity applied to the weld accessory
•
•
•
•
Increased uptime
No more expenses related to maintaining or replacing easily damaged
control cords because the weld cables are used to communicate weld
parameters between the wire feeder and power source
•
PipeWorx 350 FieldPro System
™
See literature PWSM/6.5 UK
Simplicity-driven performance for
your pipe construction site.
PipeWorx 350 FieldPro shown with optional
FieldPro Remote, ArcReach Smart Feeder,
ArcReach SuitCase 12 and ArcReach
SuitCase 8 feeders.
Remote control of the power source
without a cord.
Complete control at the weld joint
Remote reduces weld defects by automatically setting correct
• FieldPro
polarity for each welding process — without the need to manually
swap cables
the need to “get by” with less than optimal settings without
• Eliminates
control cables, and allows for easy setup of a new weld process with the
•
touch of a button
Total remote control of welding processes and parameters improves safety
by limiting jobsite movement and reducing slip, trip and fall hazards
34
Arc performance optimized for critical pipe welding
arc performance like the PipeWorx 400 welding system,
• Industry-leading
but in a field-ready package
multiprocess system provides conventional stick, TIG, flux-cored and
• True
MIG welding, as well as the advanced technologies of RMD and pulsed MIG
Feeder delivers excellent RMD and pulsed MIG welding 200 feet from
• Smart
the power source with no control cables. RMD and pulse processes help
®
reduce weld failures and eliminate backing gas on some stainless and
chrome-moly applications
New durability standard for field construction
Designed and built to withstand the harshest field environments
•
PIPE WELDING
Multiprocess
Heavy industrial
®
How ArcReach Works
Processes
(SMAW) • DC TIG (GTAW)
• Stick
(GMAW) • Flux-cored (FCAW)
• MIG
(GMAW-P)
• RMD
• Pulsedarc MIG
Air
carbon
cutting
and gouging
• (CAC-A)
ArcReach
feeder or
remote
XMT 350 FieldPro systems
(components sold separately)
MIG/flux-cored system consists of
XMT 350 FieldPro power source
ArcReach SuitCase® 8 or 12 feeder
with drive rolls, work sense lead
and clamp
RMD/pulse system consists of
XMT 350 FieldPro power source
ArcReach Smart Feeder with drive
rolls, work sense lead and clamp
•
•
•
•
ArcReach
power source
PipeWorx 350 FieldPro systems
(components sold separately)
MIG/flux-cored system consists of
PipeWorx 350 FieldPro power source
ArcReach SuitCase® 8 or 12 feeder
with drive rolls, work sense lead
and clamp
RMD/pulse system consists of
PipeWorx 350 FieldPro power source
ArcReach Smart Feeder with drive
rolls, work sense lead and clamp
Stick/TIG system consists of
PipeWorx 350 FieldPro power source
FieldPro Remote with work sense lead
and clamp (301176)
•
•
ArcReach technology uses the existing weld cable to communicate welding control information between the
feeder or remote and the power source. This technology eliminates the need for control cords, and their associated
problems and costs. Learn more at MillerWelds.com/arcreach
•
•
Advanced Technologies of FieldPro Systems
RMD® (regulated metal deposition)
Higher quality root pass
Calm stable arc
Less spatter
RMD carbon steel
More tolerant of hi-lo conditions
Reduced training requirements
Less chance of cold lap or lack of fusion reducing rework
Can eliminate the need for a hot pass
Can eliminate backing/purge gas in some stainless
applications
Pulsed MIG
Less heat input than traditional
spray pulse transfer
Shorter arc length
Narrower arc cone
Improved fusion and fill at the
toes of the weld resulting in:
Pulsed MIG stainless
- Faster travel speeds
- Higher deposition rates
Less training time required because pulsed MIG:
- Virtually eliminates arc wander
- Is easier to control the puddle
- Compensates for tip to work variations automatically
When used with RMD, it is possible to use one wire
and one gas for all passes
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Most popular accessories for
both FieldPro systems
PipeWorx 250-15 MIG Gun
• Bernard
Q2015TF2DEL Euro connection
™
™
Q2015TF2DML Miller connection
PipeWorx 300-15 MIG Gun
• Bernard
Q3015TF2DEL Euro connection
™
™
Q3015TF2DML Miller connection
•
PipeWorx Memory Card, Accu-Power 300667
Displays instantaneous power during welding to meet the new
ASME requirement for calculating heat input on complex
waveform processes (RMD and pulsed MIG).
•
*Welding with the Smart Feeder requires the XMT 350 FieldPro or PipeWorx 350 FieldPro to be hooked up to three-phase power.
Welding Output
Ranges
Rated Output at
60% Duty Cycle
IP
Rating
Amps Input at Rated Output, 60 Hz
230 V 380 V 400 V 460 V 575 V
KVA
KW
Max. OpenCircuit Voltage
Three-phase
CC mode: 5–425 A
CV mode: 10–38 V
350 A at 34 VDC
IP23
36.1
23.4 20.6 17.8 14.1
14.2
13.6
75 VDC
H: 432 mm (17 in.)
W: 318 mm (12.5 in.)
D: 610 mm (24 in.)
42.2 kg
(93 lb.)
Three-phase
CC mode: 10–350 A
CV mode: 10–44 V
350 A at 34 VDC
IP23
36.1
27.1 25.9 17.8 14.1
15.0
14.4
75 VDC
H: 432 mm (17 in.)
W: 305 mm (12 in.)
D: 559 mm (22 in.)
45.4 kg
(100 lb.)
Power Source/Stock Number
Input Power
XMT 350 FieldPro
(907730002) 230–575 V
PipeWorx 350 FieldPro
(907633) 230–575 V
Wire Feeder
Model/Stock Number
Input Power
Input Welding
Circuit Rating
IP
Rating
Wire Feed Speed
Wire Diameter Type and Capacity
Maximum Spool
Size Capacity
Dimensions
Dimensions
Net
Weight
Net
Weight
ArcReach SuitCase 8 (301456)
Operates on open-circuit
voltage and arc voltage:
14–48 VDC/110 max. OCV
330 A at
60% duty cycle
IP23
1.3–19.8 mpm
(50–780 ipm)
dependent on arc voltage
Solid wire 0.6–1.4 mm (.023–.052 in.)
Flux-cored 0.8–2.0 mm (.030–5/64 in.)
203 mm (8 in.),
6.4 kg (14 lb.)
H: 324 mm (12.75 in.)
W: 184 mm (7.25 in.)
D: 457 mm (18 in.)
13 kg
(28 lb.)
ArcReach SuitCase 12 (301457)
Operates on open-circuit
voltage and arc voltage:
14–48 VDC/110 max. OCV
425 A at
60% duty cycle
IP23
1.3–19.8 mpm
(50–780 ipm)
dependent on arc voltage
Solid wire 0.6–1.4 mm (.023–.052 in.)
Flux-cored 0.8–2.0 mm (.030–5/64 in.)
305 mm (12 in.),
20 kg (45 lb.)
H: 394 mm (15.5 in.)
W: 229 mm (9 in.)
D: 533 mm (21 in.)
15.9 kg
(35 lb.)
ArcReach Smart Feeder (301177)
Operates on open-circuit
275 A at
voltage and arc voltage:
60% duty cycle
14–48 VDC/110 max. OCV*
IP23
1.3–12.7 mpm
(50–500 ipm)
dependent on arc voltage
0.9–1.1 mm (.035–.045 in.)
305 mm (12 in.),
15 kg (33 lb.)
H: 457 mm (18 in.)
W: 330 mm (13 in.)
D: 546 mm (21.5 in.)
23 kg
(50 lb.)
35
Multiprocess PIPE WELDING
PipePro® XC Welding System
Heavy Industrial
See literature PWSM/5.0
Processes
(SMAW) • MIG (GMAW)
• Stick
• Flux-cored (FCAW) • RMD
Most popular accessories
PipePro Dura-Flux Gun
• Bernard
301011 3 m (10 ft.)
PipeWorx 250-15 MIG Gun
• Bernard
Q2015TF2DEL Euro connection
Designed specifically to meet the rugged demands of pipeline applications.
System is optimized to provide excellent arc performance using the Hobart® Fabshield®
family of self-shielded FCAW filler metals.
™
™
™
Q2015TF2DML Miller connection
PipeWorx 300-15 MIG Gun
• Bernard
Q3015TF2DEL Euro connection
™
•
•
•
Q3015TF2DML Miller connection
Feeder Control Cable
(one required per system)
300845 10 m (32 ft.)
300846 20 m (64 ft.)
RHC-14 Remote Control (pg 65)
242211020 6 m (20 ft.)
242211100 30.5 m (100 ft.)
Work Sense Lead
300947 5 m (16 ft.)
300461 7.6 m (25 ft.)
300462 15.2 m (50 ft.)
Wireless Hand Control
300430 (pg 66)
PipeWorx 400XC shown with optional PipePro XC Feeder with Bernard PipePro Dura-Flux gun
and PipePro XC RMD Feeder with Bernard PipeWorx 250-15 gun.
Power source features
Feeder features
PipeWorx 400XC power source is able to perform
simple stick (SMAW) welding to advanced RMD®
welding. The arc performance and ease-of-use is
optimized to provide quality and productivity, while
simplifying welding training.
Temperature — power source rating is based on
50°C ambient
Moisture — meets IP23 standards. Horizontal control
boards are potted
Shock and vibration — the power source base is
designed with shock mounts to reduce vibration when
mounted on tractors
Dust — Wind Tunnel Technology™ circulates air over
components that require cooling (not electronic
circuitry). Fan-On-Demand™ cooling system operates
only when needed. This reduces the amount of
airborne contaminants in the machine
PipePro XC feeder is uniquely designed to operate
with the PipePro 400XC power source to perform the
self-shielded flux-cored weld process for fill and cap
pass welding on pipelines. This economical solution
optimizes the weld process using the Hobart Fabshield
family of self-shielded wires.
PipePro XC RMD feeder provides the most versatile
welding solution when used with the PipePro 400XC
power source. It can provide MIG and RMD (solid wire
and metal-cored wire), and flux-cored (self-shielded
or gas-shielded wires). All welding processes are
optimized for pipe welding.
•
•
•
•
Equipped with a memory card reader to provide new
capabilities into the future.
Stores weld parameters for all welding processes
Enables the use of custom programs for future
applications
Provides range locks
Provides Accu-Power™ (instantaneous power display)
Provides diagnostic information and operational
information in a text file format
•
•
•
•
•
Power Source/
Stock Number
PipePro 400XC
(907675) 380/400 V
Wire Feeder/
Stock Number
PipePro XC (300794)
SuitCase XC RMD
(300844)
36
Gun features
Bernard PipePro Dura-Flux gun is uniquely designed
to perform self-shielded flux-cored with the PipePro
400XC system for onshore pipeline applications. The
gun features a dual schedule switch to enable two sets
of welding parameters — wire feed speed and voltage.
Bernard PipeWorx 250-15 gun is designed by welders
to reduce fatigue and improve visibility of the puddle on
the root pass.
Bernard PipeWorx 300-15 gun provides a heavy-duty
solution to producing root, fill and cap welds on pipe.
Welding
Mode/Process
Welding
Output Ranges
Rated Output at
100% Duty Cycle
IP
Rating
Amps Input at Rated Output, 50/60 Hz
380 V 400 V
KVA
380 V 400 V
KW
380 V 400 V
Max. OpenCircuit Voltage
CC: Stick
40–350 A
350 A at 34 VDC
IP23
23.5
22.7
15.7
13.2
80 VDC
CV: MIG/
flux-cored
10–39 V
400 A at 34 VDC
27.1
25.7
15.9
13.2
Dimensions
H: 375 mm
(14.75 in.)
W: 464 mm
(18.25 in.)
D: 686 mm
(27 in.)
Net
Weight
56.7 kg
(125 lb.)
Input Power
Input Welding Circuit Rating
IP Rating
Wire Feed Speed
Wire Diameter Type and Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
24 VAC, 9 A
100 V, 500 A at
100% duty cycle
IP23
1.3–12.7 mpm
(50–500 ipm)
0.9–2.0 mm (.035–5/64 in.)
15 kg (33 lb.)
H: 438 mm (17.25 in.)
W: 203 mm (8 in.)
D: 508 mm (20 in.)
15.2 kg
(33.5 lb.)
PIPE WELDING
PipeWorx 400 Welding System
Multiprocess
Heavy industrial
Processes
See literature PWS/2.0
(SMAW) • DC TIG (GTAW)
• Stick
(GMAW) • Flux-cored (FCAW)
• MIG
(GMAW-P)
• RMD
• Pulsedarc MIG
Air
carbon
cutting
and gouging
• (CAC-A)
Optimized for pipe fabrication shops.
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 four programs for each selection:
stick, DC TIG, and MIG (left and right side of feeder) —
eliminates the need to remember parameters
•
•
PipeWorx 400 welding system
shown. All components are
sold separately.
System consists of
(components sold separately)
400 power source with
• PipeWorx
cable hangers (907534)
feeder with drive rolls (300950)
• Dual
4.6 m (15 ft.) PipeWorx 300 guns
• Two
(Q3015TF2DEL or Q3015TF2DML)
gear with gas cylinder rack
• Running
and handles (300368)
•
True multiprocess machine
Weld processes are optimized to deliver superior arc
performance and stability specifically for root, fill, and
cap passes on pipe
RMD® and pulsed MIG increase quality and productivity
•
Most popular accessories
PipeWorx 250-15 MIG Gun
• Bernard
Q2015TF2DEL Euro connection
™
•
Quick process changeover
push a process selection button to choose a
• Simply
welding process
setup time and reduces the risk of weld
• Eliminates
reworks due to incorrect cable connections
“Quick Select” technology automatically
• PipeWorx
selects the welding process, the correct polarity,
Q2015TF2DML Miller connection
PipeWorx 300-15 MIG Gun
• Bernard
Q3015TF2DEL Euro connection
™
Q3015TF2DML Miller connection
cable outputs, gas solenoid, and user-programmed
welding parameters
400 Insight Module
• PipeWorx
301304
Cable Kit
• Composite
300454 7.6 m (25 ft.)
Single-system design
One machine designed to perform all of your pipe
welding needs
Simplified and optimized specifically for pipe welding
•
•
300456 15.2 m (50 ft.)
Cooler 300370
• PipeWorx
Control Bracket 300676
• Foot
Dual Schedule Switch
• DSS-9
071833
• RFCS-14 HD 194744 (pg 65)
Advanced Technologies of PipeWorx 400 Welding System
RMD® (regulated metal deposition)
Higher quality root pass
Calm stable arc
Less spatter
RMD carbon steel
More tolerant of hi-lo conditions
Reduced training requirements
Less chance of cold lap or lack of fusion reducing rework
Can eliminate the need for a hot pass
Can eliminate backing/purge gas in some stainless
applications
•
•
•
•
•
•
•
•
PipeWorx Memory Card, Accu-Power 300667
Displays instantaneous power during welding to meet the new
ASME requirement for calculating heat input on complex
waveform processes (RMD and pulsed MIG).
Wireless Hand Control
300430 (pg 66)
Pulsed MIG
Less heat input than traditional
spray pulse transfer
Shorter arc length
Narrower arc cone
Improved fusion and fill at the
toes of the weld resulting in:
Pulsed MIG stainless
- Faster travel speeds
- Higher deposition rates
Less training time required because pulsed MIG:
- Virtually eliminates arc wander
- Is easier to control the puddle
- Compensates for tip to work variations automatically
When used with RMD, it is possible to use one wire
and one gas for all passes
•
•
•
•
•
•
Power Source/
Stock Number
Welding
Mode/Process
Welding
Output Ranges
Rated Output at
100% Duty Cycle
IP
Rating
Amps Input at Rated Output, 50/60 Hz
380 V 400 V
KVA
380 V 400 V
KW
380 V 400 V
Max. OpenCircuit Voltage
PipeWorx 400
(907534) 380/400 V
CC: Stick
40–400 A
400 A at 36 VDC
IP21
26.3
25.5
17.6
17.8
16.5
16.5
90 VDC
CC/DC: TIG
10–350 A
350 A at 24 VDC
19
18.1
12.4
12.5
9.7
9.8
CV: MIG/flux-cored
10–44 V
400 A at 34 VDC
27.1
25.7
18.0
18.0
15.5
15.6
Wire Feeder/
Stock Number
PipeWorx Feeder
(300949) Single-wire model
(300950) Dual-wire model
Dimensions
H: 724 mm
(28.5 in.)
W: 495 mm
(19.5 in.)
D: 806 mm
(31.75 in.)
Net
Weight
102 kg
(225 lb.)
Input Power
Input Welding Circuit Rating
IP Rating
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
24 VAC, 11 A
100 V, 750 A at 100% duty cycle
IP21
1.3–19.8 mpm
(50–780 ipm)
0.9–1.6 mm
(.035–.062 in.)
27 kg (60 lb.)
H: 356 mm (14 in.)
W: 483 mm (19 in.)
D: 737 mm (29 in.)
Single
30 kg (65 lb.)
Dual
41 kg (90 lb.)
37
Miller recommends
ITW Orbital Cutting & Welding
Orbital cutting,
beveling &
welding machines
for high-purity
process piping,
e.g.
Applications,
e.g.
«
orbital (TIG)
welding power
sources and
orbital welding
heads
pharmaceutical,
biotechnology
& chemical
industry
«
food & beverage
industry
«
pipe cutting &
beveling
machines
semiconductor
industry
«
»
aerospace
industry
tube facing
machines
«
»
heating,
ventilation &
air conditioning
industry
pipe end prep
machines
«
«
p owe r
generation
industry
«
Applications,
e.g.
Portable weld
prep machine
tools for
industrial
applications,
e.g.
oil, gas &
petrochemical
industry
NEW DynaPrep »
MDSF split
frames for
heavy duty form
tooling & pipe
weld preparation
«
HDSF
heavy duty split
frames - built
for big jobs in
the field
power
generation
industry
«
The ITW ORBITAL CUTTING & WELDING
division with its brands ORBITALUM TOOLS and
E.H. WACHS provides global customers one
source for the finest in pipe & tube cutting,
beveling and orbital welding products.
»
pipeline
distribution
TRAV-L-CUTTER
portable milling
machines
«
«
LCSF
low clearance
split frames
off-shore
«
»
WORLDWIDE SALES & SERVICE:
EP 424
ID mount end
prep machines
EUROPE, ASIA, AFRICA
& MIDDLE EAST:
Orbitalum Tools GmbH
Josef-Schuettler-Str. 17
78224 Singen, Germany
Tel. +49 (0) 77 31 - 792 0
[email protected]
www.orbitalum.com
NORTH AMERICA:
E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire, IL 60069, USA
Tel. +1 847 537 8800
Toll Free 800 323 8185
[email protected]
www.ehwachs.com
«
SDB / FF
small diameter
bevelers & flange
facers
»
Stick
SMAW
STi 160
40
STi 203
40
STR® 400/400C
42 42 42 42 42 6 mm
42 8 mm
42 10 mm
Portability
Shoulder strap
Handle, shoulder strap,
optional carts
41
STR® 500/500C
Special Features
Typical Applications
Steel,
stainless
15–150 A
4–150 A (w/PFC)
VRD device, dual fan technology
MRO, ship installation/repair, farm/ranch
4–150 A
VRD device, dual fan technology, meters
MRO, ship installation/repair, farm/ranch
5–200 A
Meters with preset, Lift-Arc™ TIG
Maintenance/repair, fabrication
Steel,
stainless
Running gear
41
Blue Thunder® 253
Blue Thunder® 343
Blue Thunder® 403
Blue Thunder® 443
Gold Star® 402
Gold Star® 652
Gold Star® 852
Product Key
CAC-A
39
Welding
Amperage
Range (DC)
Lift eye, running gear
Lift eye,
optional running gear
20–400 A
Rugged and simple design
Construction, fabrication, pipe, steel erection
20–500 A
Rugged and simple design
Construction, fabrication, pipe, steel erection
30–220 A
Rugged and simple design
Construction and repair
50–320 A
Rugged and simple design
Construction and repair
60–400 A
Rugged and simple design
Construction and repair
60–420 A
Rugged and simple design
Construction and repair
15–395 A
Built-in arc control
Steel erection, pipe, fab, shipbuilding, foundries
20–590 A
Built-in arc control
Steel erection, pipe, fab, shipbuilding, foundries
50–850 A
Built-in arc control
Steel erection, pipe, fab, shipbuilding, foundries
Class:
Light Industrial
Industrial
Heavy Industrial
Capability:
Designed for this process
*Constant-current (stick) machines can utilize voltage-sensing wire feeders for some flux-cored applications.
Si 160 and Si 160 PFC
3-Phase
Si 160/160 PFC
Weldable
Metals
1-Phase
Product
Guide
Page
Class
Stick
DC TIG
Flux-cored*
Also see Multiprocess and TIG sections for machines that can stick weld.
Capable of this process
Light industrial
•
See literature DC/27.05 UK
Process Stick (SMAW)
Comes complete with
Inverter-based, DC power source with simple-to-use interface providing only the necessary
controls in a compact machine.
• 3 m (10 ft.) power cord
Weld Ready package includes
above plus
m (10 ft.) electrode cable with
• 3holder
• 3 m (10 ft.) work cable with clamp
Most popular accessories
• Stick Welding Cable Kit 058066079
Portable with adjustable shoulder strap. Easy to transport at
under 6.2 kg (13.7 lb.).
Dual fan technology. An optimised power source cooling system
which enables the machine to operate at a lower temperature,
thus increasing its performance and life cycle.
Thermal overload protection with indicator light helps prevent
machine damage if the duty cycle is exceeded or airflow is blocked.
VRD function is a simple design that reduces the open-circuit
voltage to 20 volts when the welding power source is not in use.
Best-in-class stick arc characteristics for those demanding jobs.
Si 160 shown.
Preset Hot Start™ for stick arc starts automatically increases the
output amperage at the start of a weld should the start require it.
Prevents the electrode from sticking and creating an inclusion.
Innovative PFC (power factor control) allows taking full advantage
of the available input amps resulting in the required welding current
without power leakage (Si 160 PFC model).
*VRD sense voltage for stick.
Model
Stock Number
Si 160
(059016011)
230 V, 50/60 Hz
(029083126)
Weld Ready package
Si 160 PFC
(059016016)
230 V, 50/60 Hz
(029083112)
Weld Ready package
Welding
Mode
Welding Amperage
Range
Rated Output
IP
Rating
Amps Input at Rated
Output, 50/60 Hz
KVA
KW
Stick
15–150 A
100 A at 24.0 VDC, 100% duty cycle
IP23
Scratch
start TIG
15–150 A
Stick
4–150 A
Scratch
start TIG
4–160 A
20
4.5
2.8
150 A at 26.0 VDC, 25% duty cycle
30
7.0
4.8
100 A at 14.0 VDC, 100% duty cycle
13
3.0
2.0
150 A at 16.0 VDC, 25% duty cycle
21
4.8
3.2
13.7
3.1
2.8
150 A at 26.0 VDC, 25% duty cycle
22.1
5.0
4.8
100 A at 14.0 VDC, 100% duty cycle
13
3.0
2.0
160 A at 16.4 VDC, 20% duty cycle
22
5.1
3.5
100 A at 24.0 VDC, 100% duty cycle
IP23
Max. OpenCircuit Voltage
85 V
(20 V)*
70 V
(20 V)*
Dimensions
H: 245 mm
(9.65 in.)
W: 145 mm
(5.75 in.)
D: 380 mm
(15 in.)
Net
Weight
5.2 kg
(11.5 lb.)
6.2 kg
(13.7 lb.)
39
Stick
STi 160
SMAW
Light industrial
See literature DC/27.15 UK
Processes
Inverter-based, DC power source with simple-to-use interface providing only the necessary
controls in a compact machine.
Portable with adjustable shoulder strap. Easy to transport at
6.0 kg (13.2 lb.).
Dual fan technology. An optimised power source cooling system
which enables the machine to operate at a lower temperature,
thus increasing its performance and life cycle.
Thermal overload protection with indicator light helps
prevent machine damage if the duty cycle is exceeded or airflow
is blocked.
VRD function is a simple design that reduces the open-circuit
voltage to 20 volts when the welding power source is not in use.
Digital meter with presetting shows preset current before
welding and actual value during welding.
Full-function remote control connector for precise amperage
control for critical welds on thin materials.
Lift-Arc™ start provides TIG arc starting without the use of high
frequency or the risk of tungsten contamination.
Adjustable Hot Start™ for stick arc starts. Adjust the optimal
start current for the application. The current automatically
increases the output amperage at the start of a weld.
Adjustable Arc Force™ prevents sticking. Adjust the optimal arc
force value. Adjustable arc force supports positional welding by
increasing the output amperage.
• Stick (SMAW) • TIG (GTAW)
Comes complete with
• 3 m (10 ft.) power cord
Weld Ready package includes
above plus
m (10 ft.) electrode cable with
• 3holder
• 3 m (10 ft.) work cable with clamp
Most popular accessories
Fingertip Control (pg 65)
• RCCS-6M
195184 4 m (13.25 ft.)
•
•
•
•
•
195503 8 m (26.5 ft.)
RFCS-6M Foot Control (pg 65)
195183 4 m (13.25 ft.)
195504 8 m (26.5 ft.)
RMS-6M On/Off Control
195269 (pg 65)
Stick Welding Cable Kit 058066079
Dinse-style Flow Thru Adapter
195234
6-pin Remote Plug 217796
*VRD sense voltage for stick and Lift-Arc TIG.
Stock Number
(059016012)
230 V, 50/60 Hz
(029083127)
Weld Ready package
Welding
Mode
Welding Amperage
Range
Rated Output
IP
Rating
Amps Input at Rated Output,
50/60 Hz
KVA
KW
Stick
4–150 A
100 A at 24.0 VDC, 100% duty cycle
IP23
20
4.5
2.8
150 A at 26.0 VDC, 25% duty cycle
30
7.0
4.8
100 A at 14.0 VDC, 100% duty cycle
13
3.0
2.0
150 A at 16.0 VDC, 25% duty cycle
21
4.8
3.2
TIG
STi 203
15–150 A
Max. OpenCircuit Voltage
70 V
(20 V)*
Dimensions
Net Weight
H: 245 mm (9.65 in.)
W: 145 mm (5.75 in.)
D: 380 mm (15 in.)
6.0 kg
(13.2 lb.)
Industrial
See literature DC/29.65 UK
Processes
Inverter-based, DC power source with simple-to-use interface providing only the necessary
controls in a compact machine.
Portable with adjustable shoulder strap. Easy to transport at
17 kg (37.5 lb.).
Digital meter with presetting shows preset current before
welding and actual value during welding.
Remote amperage control provided through 14-pin receptacle
on front of machine. This permits use of standard remote
amperage control devices.
Lift-Arc™ start provides TIG arc starting without the use of high
frequency or the risk of tungsten contamination.
Adaptive Hot Start™ for stick arc starts automatically increases the
output amperage at the start of a weld should the start require it.
Prevents the electrode from sticking and creating an inclusion.
DIG control allows the arc characteristics to be changed for
specific applications and electrodes. Lower the DIG setting for
smooth running electrodes like E7018 and increase the DIG
setting for stiffer, more penetrating electrodes like E6010.
• Stick (SMAW) • TIG (GTAW)
Comes complete with
• 3 m (10 ft.) power cord
Most popular accessories
Fingertip Control
• RCC-14
151086 (pg 65)
Fingertip Control
• RCCS-14
043688 (pg 65)
HD Foot Control
• RFCS-14
194744 (pg 65)
Hand Control
• RHC-14
242211020 (pg 65)
Remote Control (pg 65)
• SHRC-14
058040019 5 m (16.4 ft.)
•
058040020 10 m (32.8 ft.)
058040021 20 m (65.6 ft.)
Stick Welding Cable Kit 058066040
*VRD sense voltage for stick and Lift-Arc TIG.
Stock Number
(059016015)
400 V, 50/60 Hz
40
Welding
Mode
Welding Amperage
Range
Stick
5–200 A
200 A at 18 V,
40% duty cycle
TIG
5–200 A
200 A at 28 V,
40% duty cycle
Rated Output
IP
Rating
Amps Input at Rated Output, 50/60 Hz
380 V
400 V
440 V
KVA
KW
IP23
8.7
8.3
7.5
5.73
4.2
13.5
12.8
11.5
8.86
6.51
Max. OpenCircuit Voltage
85 V
(12 V)*
Dimensions
Net Weight
H: 345 mm (13.6 in.)
W: 190 mm (7.5 in.)
D: 460 mm (18.1 in.)
17 kg
(37.5 lb.)
Stick
SMAW
Industrial
®
STR 400/500 Series
Processes
(SMAW) • TIG (GTAW)
• Stick
carbon arc cutting and gouging
• Air(CAC-A)
(carbons — 500 C: 10 mm)
Comes complete with
m (8 ft.) power cord (no plug)
• 2.4
running gear with
• Industrial
rubber tyres
Most popular accessories
Additional features of
400 C/500 C models.
STR 400 C
STR 400
Easy-to-use interface allows the operator to select the correct range to
suit the desired electrode.
Auto Hot Start™ makes it easier to start difficult-to-start stick electrodes.
(400 C/500 C models have Adjustable Hot Start.)
Auto remote current control automatically detects remote current
controls for easier setup.
Enclosed circuit board provides additional protection from contaminants
resulting in longer service life.
Superior performance arc control technology provides a smooth,
low-spatter class-leading arc suitable for a wide variety of applications.
Lifting eyelets provide a safe means of lifting the power source.
115 V/10 A and 48 V/32 A auxiliary power receptacles provide power
for ancillary devices.
Help code display provides simple and convenient indication of primary
input power phase loss.
Model/Stock Number
Amperage
Range
Voltage
Range
IP
Rating
STR 400 (059016017) 400 V, 50/60 Hz
20–400 A
28.8–36 V
Rated Output
KVA
KW
Max. OpenCircuit Voltage
IP22
240 A at 29.6 VDC, 100% duty cycle
305 A at 32.2 VDC, 60% duty cycle
400 A at 36.0 VDC, 35% duty cycle
22.8
19.8
82 V
20–500 A
20.8–40 V
IP22
300 A at 32.0 VDC, 100% duty cycle
380 A at 35.5 VDC, 60% duty cycle
500 A at 40.0 VDC, 35% duty cycle
32.5
28.2
STR 400 C (059016025) 380 V, 50/60 Hz
STR 500 (059016019) 400 V, 50/60 Hz
STR 500 C (059016020) 380 V, 50/60 Hz
Welding process selection control
knob to select weld process. The
weld process selected determines
weld output on/off control.
Stick cellulosic function. Use with
cellulosic electrodes to provide
outstanding arc stability and
penetration. It’s ideal for welding in
all positions.
Adjustable Hot Start™ for stick arc
starts. Adjust the optimal start current
for the application. The current
automatically increases the output
amperage at the start of a weld.
Adjustable Arc Force™ (DIG control)
prevents sticking. Adjust the optimal
arc force value. Adjustable arc force
supports positional welding by
increasing the output amperage.
Stick gouging process allows the use
of gouging electrodes for arc stability
and penetration. It’s ideal for welding
in all positions (500 C model only).
70 V
80 V
72 V
Remote Hand Control
• RHC-14
242211020 (pg 65)
Welding Cable Kits
• Stick
058066045 5 m (16.5 ft.)
058066046 10 m (33 ft.)
058066047 15 m (50 ft.)
058066048 20 m (66 ft.)
Dimensions
Net Weight
H: 730 mm (28.7 in.)
W: 620 mm (24.4 in.)
D: 1,120 mm (44.1 in.)
132 kg (291 lb.)
H: 730 mm (28.7 in.)
W: 620 mm (24.4 in.)
D: 1,120 mm (44.1 in.)
164 kg (362 lb.)
145 kg (320 lb.)
174 kg (384 lb.)
ELGA STAINLESS
STEEL WELDING
CONSUMABLES
At Elga we are passionate about
welding and this is reflected by
our unique offering to the market.
When you use Elga’s best-in-class
stainless steel welding consumables,
you will enjoy the most advanced
and productive products.
www.elga.se
41
Stick SMAW
Blue Thunder® Series
Industrial
•
See literature MN/77.1
Process Stick (SMAW)
Most popular accessories
DC power source, with a rugged simple design for maximum durability and ease of use.
Welding Cable Kits
• Stick
058066045 5 m (16.5 ft.)
Superior performance arc control technology provides the
operator with a smooth and low-spatter, class-leading arc
suitable for a wide variety of applications.
Fan-cooled design provides efficient cooling in the most
demanding environments.
Industrial-rated components and construction designed for
long-lasting, trouble-free performance.
Lifting eyelets provide a safe means of lifting the power source.
Industrial running gear designed for a variety of terrain.
Includes handle/cable carrier and rubber tyres for smooth and
easy manoeuverability.
Easy-to-use interface allows the operator to select the correct
range to suit the desired electrode.
Ergonomic design. Angled controls make reading and
parameter adjustments easier.
Quick-connect weld terminals provide simple, convenient and
robust connection of weld cables.
Blue Thunder 343 shown.
058066046 10 m (33 ft.)
058066047 15 m (50 ft.)
058066048 20 m (66 ft.)
Welding Amperage
Range
Rated Output
IP
Rating
Amps Input at Rated Output, 50 Hz
230 V 380 V 400 V 520 V KVA KW
Max. OpenCircuit Voltage
Blue Thunder 253
(029016230) 230/400 V, 50 Hz
30–220 A
220 A at 29 VDC, 35% duty cycle
IP22S
36
–
21
–
14.6 12
59–66 VDC
Blue Thunder 343
(029016232) 230/400 V, 50 Hz
50–320 A
320 A at 33 VDC, 35% duty cycle
IP22S
55
—
32
—
22
18
56–68 VDC
Blue Thunder 403
(029016234) 230/400 V, 50 Hz
60–400 A
400 A at 36 VDC, 35% duty cycle
IP22S
73
–
42
–
28
23
66–73 VDC
Blue Thunder 443
(029016236) 230/400 V, 50 Hz
(029016237) 380/520 V, 50 Hz
60–420 A
420 A at 37 VDC, 45% duty cycle
IP22S
80
47
47
34
32
26
70–78 VDC
Model/Stock Number
Gold Star Series
®
Model/Stock Number
Welding
Amperage Range
See literature DC/8.1
80 kg
(176 lb.)
105 kg
(231 lb.)
115 kg
(254 lb.)
H: 650 mm (25.5 in.)
W: 410 mm (16.125 in.)
D: 1,150 mm (45.25 in.)
175 kg
(386 lb.)
Processes
Built-in arc control lets you get in tight without sticking
the electrode.
Hot Start™ makes it easy to start difficult stick electrodes such
as E-6010 and E-7018.
Enclosed circuit boards provide additional protection from
contaminants resulting in longer service life.
Thermal overload protection light indicates power shutdown.
Helps prevent machine damage if the duty cycle is exceeded
or airflow is blocked.
Fan-On-Demand™ cooling system operates only when needed,
reducing noise, energy use and the amount of contaminates
pulled through the machine.
115 V duplex receptacle provides 15 amps of auxiliary power.
Power efficient for exceptional value and return on
your investment.
Remote control capability.
Optional digital volt and amp meters. Easy to install,
front-panel mount. 300359 for models after KG283595 and
300321 for models after MF100119C.
Rated Output
(SMAW) • TIG (GTAW)
• Stick
carbon arc cutting and
• Airgouging
(CAC-A) (carbons —
•
•
402: 6 mm, 602: 8 mm
852: 10 mm)
Flux-cored (FCAW)
MIG spray transfer (GMAW) with
voltage-sensing feeder
Most popular accessories
Running Gear 042886
• Standard
(pg 63)
Cylinder Rack 042887
• Standard
(pg 63)
Cables (pg 66)
• Extension
242208025 7.6 m (25 ft.)
242208050 15 m (50 ft.)
242208080 24.4 m (80 ft.)
Wireless Foot Control
300429 (pg 66)
IP
Rating
Amps Input at Rated Output, 60 Hz
380 V 400 V 440 V
KVA
KW
Max. OpenCircuit Voltage
Dimensions
(Includes lift eye and strain relief)
H: 762 mm (30 in.)
W: 585 mm (23 in.)
402 D: 775 mm (30.5 in.)
602/852 D: 966 mm (38 in.)
Gold Star 402
(907362) 380/400/440 V, 50 Hz
15–395 A
300 A at 32 VDC,
60% duty cycle
IP21
35
33
31
24.5
13.8
72 VDC
Gold Star 602
(907363) 380/400/440 V, 50 Hz
20–590 A
450 A at 38 VDC,
60% duty cycle
IP21
54
51
47
35.5
23.3
72 VDC
Gold Star 852
(907364) 380/400/440 V, 50 Hz
50–850 A
650 A at 44 VDC,
60% duty cycle
IP21
75
71
65
49.4
36
72 VDC
42
Net Weight
H: 650 mm (25.5 in.)
W: 410 mm (16.125 in.)
D: 980 mm (38.5 in.)
Heavy industrial
Rugged, reliable performance and superior arc characteristics.
Gold Star 602 shown.
Dimensions
Net Weight
160 kg
(352 lb.)
183 kg
(404 lb.)
229 kg
(505 lb.)
TIG
GTAW
43
Maxstar® 210 DX
44
Maxstar® 280 DX
44
Maxstar® 400
45
Maxstar® 800
45
Dynasty® 210 DX
CAC-A
Welding
Amperage
Range
Net
Weight
Generator
Power
Requirement
—
0.5–4.0 mm
4–160 A
4 mm
—
0.05–6.4 mm
1–210 A
0.5–300 PPS
6.0 kg (13.2 lb.)
7 kW
0.1–500 PPS
17.2 kg (38 lb.)
5 mm
5 mm
5 mm
0.1–9.5 mm
1–280 A
9 kW
0.1–500 PPS
21.3 kg (47 lb.)
11 kW
8 mm
6 mm
6 mm
6 mm
0.3–15.9 mm
8 mm
8 mm
8 mm
10 mm
0.5–25.4 mm
3–400 A
0.1–5,000 PPS
61 kg (134 lb.)
12 kW
5–800 A
0.1–5,000 PPS
90 kg (198 lb.)
32 kW
5 mm
5 mm
4 mm
4 mm
—
0.3–6.4 mm (alum.)
0.05–6.4 mm (steel)
2–210 A (AC)
1–210 A (DC)
0.1–500 PPS
21.3 kg (47 lb.)
9 kW
5.5 mm
5 mm
5 mm
5 mm
5 mm
0.3–9.5 mm (alum.)
0.1–9.5 mm (steel)
2–280 A (AC)
1–280 A (DC)
0.1–500 PPS
23.6 kg (52 lb.)
12.5 kW
45
8 mm
8 mm
6 mm
6 mm
6 mm
0.4–15.9 mm (alum.)
0.3–15.9 mm (steel)
3–400 A
0.1–500 PPS (AC)
0.1–5,000 PPS (DC)
61 kg (134 lb.)
13 kW
45
8 mm
8 mm
8 mm
8 mm
10 mm
0.5–25.4 mm
(aluminium/steel)
5–800 A
0.1–500 PPS (AC)
0.1–5,000 PPS (DC)
90 kg (198 lb.)
35 kW
4 mm
3.2 mm
3.2 mm
5 mm
5 mm
4 mm
5 mm
5 mm
8 mm
8 mm
44
4 mm
Dynasty® 280 DX
44
Dynasty® 400
Dynasty® 800
Product Key
Capability:
All models Some models
Pulse Capability
New! or Improved! products appear in blue type.
STH 160 and STH 160 L
Light industrial
See literature DC/27.25 UK
Processes
Inverter-based, DC power source with simple-to-use interface providing only the necessary
controls in a compact machine.
STH 160 shown.
AC/DC (Alum./Steel)
STH 160/160 L
Material
Thickness
Range (TIG)
Max. Electrode Diameter
E6010/11 E6013 E7018 E7024
DC (Steel)
Product
Guide
Page
TIG
Pulsed TIG
Stick
CAC-A
Also see Multiprocess section for machines that can TIG weld.
Portable with adjustable shoulder strap. Easy to transport at
6.0 kg (13.2 lb.).
Dual fan technology. An optimised power source cooling system
which enables the machine to operate at a lower temperature, thus
increasing its performance and life cycle.
Thermal overload protection with indicator light helps prevent
machine damage if the duty cycle is exceeded or airflow is blocked.
VRD function is a simple design that reduces the open-circuit
voltage to 20 volts when the welding power source is not in use.
Digital meter with presetting shows preset current before welding
and actual value during welding.
Full-function remote control connector for precise amperage
control for critical welds on thin materials.
Built-in pulsing capabilities allow the operator to select from four
fixed pulse frequencies to satisfy the application.
Lift-Arc™ start provides TIG arc starting without the use of high
frequency or the risk of tungsten contamination.
HF start for non-contact arc starting that eliminates tungsten or
material contamination.
Adjustable Hot Start™ for stick arc starts. Adjust the optimal start
current for the application. The current automatically increases the
output amperage at the start of a weld.
Adjustable Arc Force™ prevents sticking. Adjust the optimal arc force
value. Adjustable arc force supports positional welding by increasing
the output amperage.
Low stick output process (STH 160 L only) allows limiting of the
maximum input line current.
(SMAW) • TIG (GTAW)
• Stick
• Pulsed TIG (GTAW-P)
Comes complete with
• 3 m (10 ft.) power cord
Weld Ready package includes
above plus
ft.) WP-17S4NXXF TIG torch
• 43 mm (13
• holder(10 ft.) electrode cable with
• 3 m (10 ft.) work cable with clamp
Most popular accessories
Fingertip Control (pg 65)
• RCCS-6M
195184 4 m (13.25 ft.)
•
•
•
•
•
195503 8 m (26.5 ft.)
RFCS-6M Foot Control (pg 65)
195183 4 m (13.25 ft.)
195504 8 m (26.5 ft.)
RMS-6M On/Off Control
195269 (pg 65)
Stick Welding Cable Kit 058066079
Dinse-style Flow Thru Adapter
195234
6-pin Remote Plug 217796
*VRD voltage.
Model
DC
STH 160
STH 160 L
Stock
Number
Welding
Mode
Welding
Amperage Range
(059016013)
230 V, 50/60 Hz
(029083128)
Weld Ready package
Stick
4–150 A (160)
4–100 A (160 L)
(059016021)
230 V, 50/60 Hz
(029083113)
Weld Ready package
TIG
4–160 A
Rated Output
IP
Rating
Amps Input at
Rated Output, 50/60 Hz
KVA
KW
100 A at 24.0 VDC, 100% duty cycle
IP23
20
4.5
2.8
150 A at 26.0 VDC, 25% duty cycle
30
7.0
4.8
100 A at 14.0 VDC, 100% duty cycle
13
3.0
2.0
160 A at 16.4 VDC, 20% duty cycle
22
4.8
3.5
Max. OpenCircuit Voltage
70 V
(20 V*)
Dimensions
H: 245 mm (9.65 in.)
W: 145 mm (5.75 in.)
D: 380 mm (15 in.)
Net
Weight
6.0 kg
(13.2 lb.)
43
TIG GTAW
Maxstar® and Dynasty® 210 DX/280 DX
Maxstar/Dynasty
210 DX models
Industrial
Maxstar is DC only
See literature DCM/37.0 UK (Maxstar 210 DX) and DCM/35.0 UK (Maxstar 280 DX),
and literature ADM/11.0 UK (Dynasty 210 DX) and ADM/9.0 UK (Dynasty 280 DX)
Processes
• TIGPulsed(GTAW)
• Stick (SMAW)
• TIG (GTAW-P)
Power source comes with
m (8 ft.) power cord (no plug)
• 2.4
50 mm Dinse-style connectors
• Two
reference guide
• Quick
(Dynasty models only)
210 DX TIG Welding Capability
Steel
Max. 6.4 mm (1/4 in.)
Aluminium
(Dynasty only)
Min. 0.05 mm (0.002 in.)
Min. 0.3 mm (0.012 in.)
Max. 6.4 mm (1/4 in.)
Weld Ready packages include
above plus
280 DX TIG Welding Capability
Max. 9.5 mm (3/8 in.)
Max. 9.5 mm (3/8 in.)
Steel
Aluminium
(Dynasty only)
Min. 0.1 mm (0.004 in.)
Min. 0.3 mm (0.012 in.)
(26.2 ft.) WP-280S8AAFD
• 8TIGmtorch
m (16.4 ft.) work cable with clamp
• 5Small
Runner cart
• Coolmate
1.3 with coolant
•
™
™
Most popular accessories
Dynasty 280 DX
Maxstar 210 DX
Allows for any input
voltage hook-up
(210 models: 120–480 V,
280 models: 230–575 V) with no manual linking,
providing convenience in any job setting. Ideal solution
for dirty or unreliable power.
Blue Lightning ™ high-frequency (HF) arc starter for
non-contact arc initiation. Provides more consistent
arc starts and greater reliability compared to traditional
HF arc starters.
Lift-Arc™ provides AC or DC arc initiation without the use
of high frequency.
Hot Start™ adaptive control provides positive arc starts
without sticking.
Auto-postflow adjusts length of postflow time based
on amperage setting, shielding your tungsten and
eliminating the need to set postflow time.
Pro-Set™ eliminates the guesswork when setting weld
parameters. Use Pro-Set when you want the speed,
convenience and confidence of preset controls. Select
the feature and adjust until Pro-Set appears on display.
Sleep timer conserves electricity. This programmable
feature will power down the machine if it sits idle for a
specified time.
Update and expand. Front panel memory card data
port provides the ability to easily update software and
expand product features.
Cooler power supply (CPS) is an integrated 120-volt
dedicated-use receptacle for the Coolmate™ 1.3. Not
available on Maxstar 210 DX.
Cooler-On-Demand™ feature operates the auxiliary
cooling system only when needed, reducing noise,
energy use, and airborne contaminants pulled through
the cooler. Not available on Maxstar 210 DX.
Runner Cart 301318 (pg 63)
• Small
Trolley 018035026 (pg 63)
• MH
1.3 300972 (pg 64)
• Coolmate
Coolant
043810
• Remote Controls (pg(pg65)64)
• 043688 RCCS-14 fingertip control
™
194744 RFCS-14 HD foot control
Dynasty welders add AC TIG capabilities and
the following AC features
Wireless Foot Control
300429 (pg 66)
Waveforms for advanced squarewave, soft squarewave,
sine wave and triangular wave.
Balance control provides adjustable oxide removal,
essential for creating the highest quality aluminium welds.
Frequency controls the width of the arc cone and can
improve directional control of the arc.
AC/DC Dynasty
DC Maxstar
*Refer to owner’s manual for 208-volt output ratings and duty cycle. **Sense voltage for low OCV stick and Lift-Arc™ TIG.
44
Model/
Stock Number
Welding
Process
Input Power
Welding
Amp Range
Rated Output at
60% Duty Cycle
IP
Rating
Amps Input at Rated Load Output, 50/60 Hz
120 V 230 V 240 V 400 V 460 V 480 V
KVA
KW
Maxstar 210 DX
(907684001)
TIG
3-phase
1–210 A
210 A at 18.4 V
IP23
—
—
12
7
—
6
5.2
4.9
1-phase
1–210 A
210 A at 18.4 V
IP23
—
—
20
12
—
10
4.9
4.9
1-phase (120 V)
1–150 A
125 A at 15 V
IP23
22
—
—
—
—
—
2.6
2.6
3-phase
5–210 A
160 A at 26.4 V
IP23
—
—
13
8
—
6
5.5
5.2
1-phase
5–210 A
160 A at 26.4 V
IP23
—
—
22
13
—
11
5.3
5.3
1-phase (120 V)
5–100 A
90 A at 23.6 V
IP23
23
—
—
—
—
—
2.8
2.8
3-phase
1–280 A
235 A at 19.4 V
IP23
—
15
—
9
7
—
6.2
6.0
1-phase
1–280 A
235 A at 19.4 V*
IP23
—
26
—
15
13
—
6.0
6.0
3-phase
5–280 A
200 A at 28 V
IP23
—
18
—
10
9
—
7.2
7.0
1-phase
5–280 A
180 A at 27.2 V*
IP23
—
27
—
15
13
—
6.2
6.2
3-phase
1–210 A
210 A at 18.4 V
IP23
—
—
12
7
—
6
5.2
4.9
1-phase
1–210 A
210 A at 18.4 V
IP23
—
—
20
12
—
10
4.9
4.9
1-phase (120 V)
1–150 A
125 A at 15 V
IP23
22
—
—
—
—
—
2.6
2.6
3-phase
5–210 A
160 A at 26.4 V
IP23
—
—
13
8
—
6
5.5
5.2
1-phase
5–210 A
160 A at 26.4 V
IP23
—
—
22
13
—
11
5.3
5.3
1-phase (120 V)
5–100 A
90 A at 23.6 V
IP23
23
—
—
—
—
—
2.8
2.8
3-phase
1–280 A (DC)
2–280 A (AC)
235 A at 19.4 V
IP23
—
17
—
10
9
—
7.0
6.7
1-phase
235 A at 19.4 V*
IP23
—
30
—
17
15
—
6.9
6.8
3-phase
5–280 A
200 A at 28 V
IP23
—
20
—
11
10
—
8.2
7.9
180 A at 27.2 V*
IP23
—
31
—
17
15
—
7.1
7.0
Stick
Maxstar 280 DX
(907539002)
(029083131)
Weld Ready pkg
Dynasty 210 DX
(907686003)
(029083130)
Weld Ready pkg
TIG
Stick
TIG
Stick
Dynasty 280 DX
(907514002)
(029083132)
Weld Ready pkg
TIG
Stick
1-phase
Max. OpenCircuit Voltage
80 VDC
(11 VDC**)
Dimensions
H: 346 mm
(13.6 in.)
W: 219 mm
(8.6 in.)
210 D: 495 mm
(19.5 in.)
280 D: 569 mm
(22.5 in.)
60 VDC
(11 VDC**)
80 VDC
(11 VDC**)
60 VDC
(11 VDC**)
Net
Weight
17.2 kg
(38 lb.)
22.7 kg
(50 lb.)
H: 346 mm
(13.6 in.)
W: 219 mm
(8.6 in.)
D: 569 mm
(22.5 in)
22.7 kg
(50 lb.)
25 kg
(55 lb.)
TIG
GTAW
Maxstar and Dynasty 400 and 800
Heavy industrial
See literature DCM/24.8 UK (Maxstar) and ADM/50.0 UK (Dynasty)
Processes
®
®
Maxstar is DC only
• TIGPulsed(GTAW)
• Stick (SMAW)
• Air carbonTIG arc(GTAW-P)
and gouging
• (CAC-A) (carbonscutting
— 400: 6 mm,
800: 10 mm)
TIG Welding Capability
800 Max.
25.4 mm (1 in.)
800 Max.
25.4 mm (1 in.)
400 Max.
15.9 mm (5/8 in.)
400 Max.
15.9 mm (5/8 in.)
Steel
Aluminium
(Dynasty only)
400 Min.
0.3 mm (0.012 in.)
400 Min.
0.4 mm (0.015 in.)
800 Min.
0.5 mm (0.020 in.)
800 Min.
0.5 mm (0.020 in.)
400 models come with
m (8 ft.) power cord (no plug)
• 2.4
Two
mm Dinse-style connectors
• Setup50video
and reference guide
•
Weld Ready packages for
400 models include above plus
m (26.2 ft.) WP-280S8AAFD
• 8(Maxstar
400) OR WP-18S8AAFD
(Dynasty 400) TIG torch
m (16.4 ft.) work cable with clamp
• 5Universal
• Coolmate trolley
3.5 with coolant
•
800 models come with
torch connector
• Thread-lock
thread-lock weld cable connectors
• Two
• Setup video and reference guide
™
Note: Power cord is NOT included with
800 models.
Dynasty 800
Most popular accessories
Dynasty 400
Trolley 018035028 (pg 63)
• Universal
3.5 300245 (pg 64)
• Coolmate
043810 (pg 64)
• Coolant
Controls (pg 65)
• Remote
043688 RCCS-14 fingertip control
™
Allows for any input voltage hook-up
(380–575 V) with no manual linking,
providing convenience in any job
setting. Ideal solution for dirty or unreliable power.
Blue Lightning ™ high-frequency (HF) arc starter for non-contact
arc initiation. Provides more consistent arc starts and greater
reliability compared to traditional HF arc starters.
Lift-Arc™ provides AC or DC arc initiation without the use of
high frequency.
Hot Start™ adaptive control provides positive arc starts
without sticking.
Auto-postflow adjusts length of postflow time based on
amperage setting, shielding your tungsten and eliminating the
need to set postflow time.
Cooler power supply (CPS) is an integrated 120-volt
dedicated-use receptacle for the Coolmate™ 3.5.
Cooler-On-Demand™ feature operates the auxiliary cooling
system only when needed, reducing noise, energy use, and
airborne contaminants pulled through the cooler.
Program memory features nine independent program memories
that maintain/save your parameters.
High-speed DC TIG pulse controls capable of 5,000 pulses
per second.
Dynasty welders add AC TIG
capabilities and the following
AC features
194744 RFCS-14 HD foot control
Waveforms for advanced squarewave, soft
squarewave, sine wave and triangular wave.
Balance control provides adjustable oxide
removal, essential for creating the highest
quality aluminium welds.
Frequency controls the width of the arc
cone and can improve directional control
of the arc.
AC amplitude/amperage allows EP and
EN amperages to be set independently
to precisely control heat input to the work
and electrode.
Wireless Foot Control
300429 (pg 66)
*Sense voltage for low OCV stick and Lift-Arc™ TIG.
Welding
Process
Welding
Amp Range
IP
Rating
Rated Output
Amps Input at Rated Load Output, 50/60 Hz
380 V 400 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
Dimensions
Net Weight
Maxstar 400
(907716002)
(029083133)
Weld Ready pkg
TIG/stick
3–400 A
IP23
250 A at 30 V, 100% duty cycle
14
13
12
9
9.4
9.1
300 A at 32 V, 60% duty cycle
18
17
15
12
12
11.6
75 VDC
(10–15 VDC*)
H: 629 mm (24.75 in.)
W: 349 mm (13.75 in.)
D: 559 mm (22 in.)
61 kg
(134 lb.)
400 A at 36 V, 20% duty cycle
27
25
22
17
18.1 17.3
Maxstar 800
(907718002)
TIG/stick
500 A at 40 V, 100% duty cycle
36
34
30
24
24.4 23.3
600 A at 44 V, 60% duty cycle
48
45
39
31
32.4 31.1
75 VDC
(10–15 VDC*)
90 kg
(198 lb.)
800 A at 44 V, 20% duty cycle
65
61
53
42
41.8 40.1
H: 876 mm (34.5 in.)
W: 349 mm (13.75 in.)
D: 559 mm (22 in.)
Dynasty 400
(907717002)
(029083134)
Weld Ready pkg
TIG/stick
250 A at 30 V, 100% duty cycle
15
14
13
10
10.3 9.8
300 A at 32 V, 60% duty cycle
19
19
16
13
13.1 12.5
75 VDC
(10–15 VDC*)
H: 629 mm (24.75 in.)
W: 349 mm (13.75 in.)
D: 559 mm (22 in.)
61 kg
(134 lb.)
400 A at 36 V, 20% duty cycle
29
28
24
19
19.4 18.6
Dynasty 800
(907719002)
TIG/stick
500 A at 40 V, 100% duty cycle
39
37
32
25
26.3 25.2
600 A at 44 V, 60% duty cycle
51
48
42
33
34.7 33.2
75 VDC
(10–15 VDC*)
90 kg
(198 lb.)
800 A at 44 V, 20% duty cycle
69
65
57
45
46.9 45.0
H: 876 mm (34.5 in.)
W: 349 mm (13.75 in.)
D: 559 mm (22 in.)
AC/DC Dynasty
DC Maxstar
Model/Stock Number
5–800 A
3–400 A
5–800 A
IP23
IP23
IP23
45
TIG Torches
Weldcraft
Series
™
TIG Torches
Synonymous with versatility and
performance, Weldcraft TIG
torches can handle the most
intricate to the most demanding
TIG welding challenges. From
125-amp hand-held MicroTIG®
torches to 900-amp machine-held
water-cooled models, there’s a
Weldcraft torch for nearly every
TIG application.
W-250
(Water-Cooled)
W-250
(Automation)
See literature AY/37.0
for more information.
A-150
(Air-Cooled)
Contact your local sales office to
configure your specific torch.
W-125
(Specialty)
Setting the standard for performance
Extreme reliability
Super Cool™ technology provides additional surface
area to increase cooling efficiency and capacity.
Comfort and control are increased with the
lightweight well-balanced body and handle
designs, helping to reduce fatigue.
Robust performance through heavy copper
construction that delivers maximum welding
capacity for rugged fieldwork.
Simplify torch package installation with
ColorSmart™ hose and cable sets that differentiate
input water, water/power cable, and gas hoses.
Improve gas coverage and cooling capacity
through the use of a gas lens.
Reduce downtime due to overheating through
consistent water-cooled performance.
Extend parts life using the durable copper
components, maximizing current capacity.
Reduce leakage of gas and water through secure
mechanical fittings.
Works in cold weather with the Tri-flex™ hose
and cable assembly that remains flexible to ease
handling and extends cable life.
Product Naming
Current Product Name Breakdown
Former
Product Name
Product Line
Descriptor
Air/Water
and Amperage
Features
Set Label
Current
Product Name
WP-9FV
Weldcraft
A-125
Flex Valve
Weldcraft A-125 Flex Valve
WP-17F
Weldcraft
A-150
Flex
Weldcraft A-150 Flex
WP-225
Weldcraft
W-225
Modular
Weldcraft W-225 Modular
CS410
Weldcraft
W-410
—
Weldcraft W-410
Example
Weldcraft A-125 Flex Valve
Weldcraft Air-Cooled Torches
Recommended for welding amperages under 200 amps. Air-cooled torches are great for portable applications as
they do not require a water-circulator. For power sources without a built-in gas solenoid, the air-cooled two-piece
torch is the solution of choice.
Weldcraft Water-Cooled Torches
Recommended for welding amperages above 200 amps. Offering a small torch design, water-cooled torches
allow for precise control due to the efficient around-the-head cooling. This same cooling allows for extended torch
life and higher amperage capacities.
Weldcraft Specialty Torches
Specialty torches are designed to fit best in unique applications. For those hard-to-reach areas, the Micro
Series torches provide access and superior maneuverability. The Modular Series torches allow for a quick change
of many different torch styles for any joint configuration. If high amperage is your need, the W-500 torch is the
answer.
Weldcraft Automation Torches
Ideal for mechanized applications, the Weldcraft Automation Series offers air-cooled and water-cooled torches
designed for both high and low applications. See literature AY/37.0 for more information.
46
“Flex Valve” signifies additional feature
“125” signifies an amperage of 125
“A” signifies air-cooled
•
Process TIG (GTAW)
Suggested power sources
220P (pg 30)
• MPi
(A-150)
160/160 L (pg 43)
• STH
(A-150)
/Maxstar 210 DX (pg 44)
• Dynasty
(A-150, W-250)
/Maxstar 280 DX (pg 44)
• Dynasty
(A-200, W-280)
/Maxstar 400 (pg 45)
• Dynasty
(W-375)
/Maxstar 800 (pg 45)
• Dynasty
(W-400)
®
®
®
®
®
®
®
®
Fingertip controls
East/West Rotary (pg 65)
• RCC
151086 14-pin
North/South Rotary (pg 65)
• RCCS
195184 6-pin, 4 m (13.25 ft.) cord
•
•
•
195503 6-pin, 8 m (25.5 ft.) cord
043688 14-pin
RMS Momentary Push Button (pg 65)
195269 6-pin
187208 14-pin
RMLS Momentary/Maintained (pg 65)
129337 14-pin
RPBS Two-Button Start/Stop
300666 14-pin
TUNGSTEN/AIR-COOLED
Weldcraft Tungsten
™
Type
Stock Number
Diameter
mm (in.)
WC040X7
1.0 (0.040)
WC116X7
1.6 (1/16)
WC332X7
2.4 (3/32)
WC018X7
3.2 (1/8)
WC532X7
4.0 (5/32)
2% Ceriated (EWCe-2)
Performs well in DC welding
and arc starting at low-current
settings, and offers excellent
performance in AC processes.
Tungsten for the most demanding TIG welding applications!
Available in four types and industry-standard diameters, our line of Weldcraft tungsten
electrodes has undergone rigorous testing to ensure the highest quality and durability.
Color-coded packages include ten 175 mm (7 in.) tungsten electrodes.
Type
Stock Number
Diameter
mm (in.)
Pure (EWP)
2% Lanthanated (EWLa-2)
Provides excellent arc starting,
arc stability and re-ignition,
and less tip erosion in AC or
DC welding. Can substitute
for 2% Thoriated.
TIG Torches
Forms a clean, balled end
when heated and provides
good arc stability for AC
welding with a balanced
or unbalanced squarewave or
sine wave.
—
1.0 (0.040)
WP116X7
1.6 (1/16)
WP332X7
2.4 (3/32)
WP018X7
3.2 (1/8)
—
4.0 (5/32)
Rare Earth (EWG)
WL2040X7
1.0 (0.040)
WL2116X7
1.6 (1/16)
WL2332X7
2.4 (3/32)
WL2018X7
WL2532X7
—
1.0 (0.040)
WG116X7
1.6 (1/16)
WG332X7
2.4 (3/32)
3.2 (1/8)
WG018X7
3.2 (1/8)
4.0 (5/32)
—
4.0 (5/32)
Combines the best of all
alloying elements, and
provides excellent arc stability
in AC or DC welding.
Note: Refer to manufacturer SDS sheets for proper preparation
and safety. Use proper ventilation/capture during preparation.
Refer to manufacturer warning regarding ventilation.
Applications
Weldcraft A-80 Series (Air-cooled)
™
Formerly known as WP-24 Series
Innovative air-cooled torches designed for intricate
welding applications, especially in limited-access
areas and on thin-gauge materials.
Featherweight torch body is well balanced to improve
operator comfort and control.
Minimize discontinuities. Insulating gasket on torch body
minimizes gas leakage and minimizes weld discontinuities.
Combining the flexible neck and gas valve is ideal for
optimal positioning and gas flow control (A-80 Flex Valve).
A-80
(WP-24)
A-80 Flex
(WP-24F)
A-80 Flex Valve
(WP-24FV)
Model
Specs
A-80
A-80 Flex
A-80 Flex Valve
Rated Output
DC: 80 A at 60% duty cycle
AC: 50 A at 60% duty cycle
Air-cooled torches designed for optimal control
while welding thin-gauge materials, especially in
hard-to-reach places.
The lightweight body reduces fatigue and downtime, and
increases operator comfort.
The pencil-style model without a back cap allows for
superior access to confined areas (A-125 Pencil).
Combine the flexible neck and gas valve for welding
limited-access joints using power sources without gas
solenoids (A-125 Flex Valve).
For maximum versatility on multiple welding applications,
without adding expenses, use the A-125 Flex Redhead and
A-125 Flex Valve Redhead.
A-125 Pencil
(WP-9P)
Specs
A-125
A-125 Valve
A-125 Flex
A-125 Flex Valve
A-125 Pencil
Rated Output
DC: 125 A at 60% duty cycle
AC: 100 A at 60% duty cycle
Most popular accessories
Applications
Formerly known as WP-9 Series
Model
•
Electrode Range
0.5–2.4 mm
(.020–3/32 in.)
Weldcraft A-125 Series (Air-cooled)
A-125
(WP-9)
•
53N14
1.6 mm (1/16 in.)
24C332 2.4 mm (3/32 in.)
Collet Bodies
53N18
1.0 mm (.040 in.)
53N19
1.6 mm (1/16 in.)
24CB332 2.4 mm (3/32 in.)
Alumina Nozzles
A53N24 #4, 1/4 in.
A53N25 #5, 5/16 in.
A53N27 #6, 3/8 in.
• Collet Body Wrench 53N20
™
A-125 Flex Valve
(WP-9FV)
• Shipbuilding
• Motorsports
• Aerospace • Restricted areas
Most popular consumables
• Collets
53N16
1.0 mm (.040 in.)
Electrode Range
0.5–3.2 mm
(.020–1/8 in.)
and repair
• Maintenance
Home/hobby
• Metal art Fabrication
• Motorsports
•
•
Most popular consumables
• Collets
13N22 1.6 mm (1/16 in.)
•
•
13N23 2.4 mm (3/32 in.)
13N24 3.2 mm (1/8 in.)
Collet Bodies
13N27 1.6 mm (1/16 in.)
13N28 2.4 mm (3/32 in.)
13N29 3.2 mm (1/8 in.)
Alumina Nozzles
13N10 #6, 3/8 in.
13N11 #7, 7/16 in.
13N12 #8, 1/2 in.
Most popular accessories
Kit AK-1C
• Accessory
Includes one long back cap, one
of each size (#4, #5, #6) alumina
nozzle, and one of each size
(1.0, 1.6 mm) of the following:
collet, collet body, and 175 mm
2% ceriated tungsten electrode.
47
TIG Torches AIR-COOLED
Weldcraft A-150 Series (Air-cooled)
Applications
™
Formerly known as WP-17 Series
Versatile and innovative air-cooled
torches designed for maximum
comfort in a variety of applications.
A-150
(WP-17)
A-150 Flex
(WP-17F)
A-150 Flex Valve
Redhead
(WP-R17FV)
A-150 Valve PSH
(WP-17V-Positive
Stop Handle)
Diamond Grip™ head design (A-150 and
A-150 Valve) has ergonomic contact points
for thumb and fingers. Provides a more
comfortable grip and reduces operator fatigue.
Improve control and comfort with the
A-150 Flex and the flexible neck that allows
access into hard-to-reach areas.
Maximum versatility. Utilize the Redhead™
Series torches in a variety of welding
applications without adding expenses.
Model
Specs
A-150
A-150 Valve
A-150 Flex
A-150 Flex Valve
A-150 Flex Valve Redhead
A-150 PSH*
A-150 Valve PSH*
Rated Output
DC: 150 A at 60% duty cycle
AC: 115 A at 60% duty cycle
Electrode Range
0.5–3.2 mm (.020–1/8 in.)
Formerly known as WP-26 Series
Dependable, top-performing
air-cooled torches designed for
heavy-duty welding applications.
48
•
Most popular accessories
Kit
• Accessory
AK-150MFC
Allows A-150
torch customization. Converts
into 28 different
torch styles while using existing cable.
Includes collets, collet bodies, nozzles,
torch heads, handle and more.
Applications
™
A-200 Flex
Valve
(WP-26FV)
•
10N24 2.4 mm (3/32 in.)
10N25 3.2 mm (1/8 in.)
Collet Bodies
10N31 1.6 mm (1/16 in.)
10N32 2.4 mm (3/32 in.)
10N28 3.2 mm (1/8 in.)
Alumina Nozzles
10N48 #6, 3/8 in.
10N47 #7, 7/16 in.
10N46 #8, 1/2 in.
*PSH = positive stop handle (threaded handle).
Weldcraft A-200 Series (Air-cooled)
A-200
(WP-26)
Maintenance and repair
• Fabrication
•Food/beverage
industry
• Aerospace
•
art • Petro/chemical
• Metal
• Shipbuilding
Most popular consumables
• Collets
10N23 1.6 mm (1/16 in.)
Eliminate the expense of a water-cooled
system. The air-cooled capability pairs
reliability with cost-effectiveness for all
field applications.
Combining the flexible neck and gas valve
advances capabilities with greater comfort
and control (A-200 Flex Valve).
Maximum versatility. Utilize the Redhead
Series torches in a variety of welding
applications without adding expenses.
Model
Specs
A-200
A-200 Valve
A-200 Flex
A-200 Flex Valve
A-200 Flex Redhead
A-200 Flex Valve Redhead
Rated Output
DC: 200 A at 60% duty cycle
AC: 150 A at 60% duty cycle
Electrode Range
0.5–4.0 mm (.020–5/32 in.)
and repair
• Fabrication
• Maintenance
Manufacturing
Shipbuilding
• Vocational •
•
Most popular consumables
• Collets
10N23 1.6 mm (1/16 in.)
•
•
10N24 2.4 mm (3/32 in.)
10N25 3.2 mm (1/8 in.)
Collet Bodies
10N31 1.6 mm (1/16 in.)
10N32 2.4 mm (3/32 in.)
10N28 3.2 mm (1/8 in.)
Alumina Nozzles
10N47 #7, 7/16 in.
10N46 #8, 1/2 in.
10N45 #10, 5/8 in.
Most popular accessories
• Accessory Kit AK-3C
WATER-COOLED
TIG Torches
Applications
Weldcraft W-180 (Water-cooled)
™
Formerly known as WP-24W
One of the smallest water-cooled TIG torches on the
market and designed for welding in confined areas
that require high amperage.
Use high amperage in confined areas for efficient welding.
Superior maneuverability in limited-access locations with the
compact torch body.
Excellent weld capacity without increasing torch size, due to the
efficient cooling system.
Model
Specs
W-180
Rated Output
DC: 180 A at 100% duty cycle
AC: 115 A at 100% duty cycle
Weldcraft W-200 Pencil Flex (Water-cooled)
Formerly known as WP-25
Versatile water-cooled torch optimized for use in
limited-access welding situations.
Pencil-style, flexible neck designed for both high-amperage
applications and confined area access.
Decreased downtime and longer trouble-free service due to
overheating with the innovative cooling design.
Comfort and control are increased with the lightweight,
well-balanced body design.
Specs
W-200 Pencil Flex
Rated Output
DC: 200 A at 100% duty cycle
AC: 140 A at 100% duty cycle
•
•
53N14
1.6 mm (1/16 in.)
24C332 2.4 mm (3/32 in.)
Collet Bodies
53N18
1.0 mm (.040 in.)
53N19
1.6 mm (1/16 in.)
24CB332 2.4 mm (3/32 in.)
Alumina Nozzles
A53N24 #4, 1/4 in.
A53N25 #5, 5/16 in.
A53N27 #6, 3/8 in.
Electrode Range
0.5–2.4 mm
(.020–3/32 in.)
™
Model
• Aerospace
• Manufacturing
industry • Shipbuilding
• Food/beverage
and repair
• Maintenance
• Petro/chemical • Precision fabrication
Most popular consumables
• Collets
53N16
1.0 mm (.040 in.)
Electrode Range
0.5–3.2 mm
(.020–1/8 in.)
Applications
• Aerospace
• Manufacturing
industry • Shipbuilding
• Food/beverage
and repair
• Maintenance
• Petro/chemical • Precision fabrication
Most popular consumables
(non-gas lens and gas lens)
• Insulator
(required) 598882
(non-gas lens and gas lens)
• Collets
13N20 0.5 mm (.020 in.)
•
•
•
Weldcraft W-225 Pencil (Water-cooled)
™
Formerly known as WP-20P
Water-cooled torch designed for long-term, troublefree service with consistent welding performance in
general applications.
13N21 1.0 mm (.040 in.)
13N22 1.6 mm (1/16 in.)
13N23 2.4 mm (3/32 in.)
13N24 3.2 mm (1/8 in.)
Collet Bodies
13N25 0.5 mm (.020 in.)
13N26 1.0 mm (.040 in.)
13N27 1.6 mm (1/16 in.)
13N28 2.4 mm (3/32 in.)
13N29 3.2 mm (1/8 in.)
Gas Lens
45V41 0.5 mm (.020 in.)
45V42 1.0 mm (.040 in.)
45V43 1.6 mm (1/16 in.)
45V44 2.4 mm (3/32 in.)
45V45 3.2 mm (1/8 in.)
Alumina Nozzles
13N08 #4, 1/4 in.
13N09 #5, 5/16 in.
13N10 #6, 3/8 in.
13N11 #7, 7/16 in.
13N12 #8, 1/2 in.
13N13 #10, 5/8 in.
53N58 #4, 1/4 in. (gas lens)
53N59 #5, 5/16 in. (gas lens)
53N60 #6, 3/8 in. (gas lens)
53N61 #7, 7/16 in. (gas lens)
53N61S #8, 1/2 in. (gas lens)
Extend torch life and minimize downtime due to overheating with
the efficient around-the-head cooling design.
Pencil-style head allows for greater access into hard-to-reach joints.
Comfort and control are increased with the lightweight, compact
body design.
Model
Specs
W-225 Pencil
Rated Output
DC: 225 A at 100% duty cycle
AC: 160 A at 100% duty cycle
Electrode Range
0.5–3.2 mm
(.020–1/8 in.)
49
TIG Torches WATER-COOLED
Weldcraft W-250 Series (Water-cooled)
™
Formerly known as WP-20 Series
Water-cooled torch provides
consistent performance and
long-term trouble-free service with
around-the-head water cooling.
W-250
(WP-20)
W-250 Valve
(WP-20V)
Extend torch life and minimize downtime
due to overheating with the efficient
around-the-head cooling design.
Reduce leakage of gas and water through
secure mechanical fittings and connections.
Easy hose replacement with the innovative
mechanical fittings design (W-250 Valve).
Model
Specs
W-250
W-250 Valve
Rated Output
DC: 250 A at 100% duty cycle
AC: 180 A at 100% duty cycle
Electrode Range
0.5–3.2 mm (.020–1/8 in.)
Weldcraft W-280 Super Cool
fabrication
• Aerospace
• Aluminium
Manufacturing
• Automotive
•
material fabrication
• Exotic
metal fabrication
• Precision
vessel fabrication
• Pressure
• Shipbuilding
• Tool and die
• Tube and pipe • Vocational
Most popular consumables
(non-gas lens and gas lens)
• Insulator
(required) 598882
(non-gas lens and gas lens)
• Collets
13N20 0.5 mm (.020 in.)
•
•
•
™
™
Applications
(Water-cooled)
Formerly known as WP-280
Reliable water-cooled torch designed for demanding,
high-amperage applications.
Super Cool technology provides additional surface area to
increase cooling efficiency and capacity.
Reduce downtime due to overheating through consistent
water-cooled performance.
Reduce leakage of gas and water through secure mechanical
fittings and connections.
Model
Specs
W-280 Super Cool
Rated Output
DC: 280 A at 100% duty cycle
AC: 195 A at 100% duty cycle
Weldcraft W-375 Super Cool
Electrode Range
0.5–3.2 mm
(.020–1/8 in.)
™
™
(Water-cooled)
Reliable water-cooled torch designed for demanding,
high-amperage applications.
Super Cool technology provides additional surface area to
increase cooling efficiency and capacity.
Reduce downtime due to overheating through consistent
water-cooled performance.
Reduce leakage of gas and water through secure mechanical
fittings and connections.
50
Model
Specs
W-375 Super Cool
Rated Output
DC: 375 A at 100% duty cycle
AC: 265 A at 100% duty cycle
Electrode Range
0.5–3.2 mm
(.020–1/8 in.)
•
13N21 1.0 mm (.040 in.)
13N22 1.6 mm (1/16 in.)
13N23 2.4 mm (3/32 in.)
13N24 3.2 mm (1/8 in.)
Collet Bodies
13N25 0.5 mm (.020 in.)
13N26 1.0 mm (.040 in.)
13N27 1.6 mm (1/16 in.)
13N28 2.4 mm (3/32 in.)
13N29 3.2 mm (1/8 in.)
Gas Lens
45V41 0.5 mm (.020 in.)
45V42 1.0 mm (.040 in.)
45V43 1.6 mm (1/16 in.)
45V44 2.4 mm (3/32 in.)
45V45 3.2 mm (1/8 in.)
Alumina Nozzles
13N08 #4, 1/4 in.
13N09 #5, 5/16 in.
13N10 #6, 3/8 in.
13N11 #7, 7/16 in.
13N12 #8, 1/2 in.
13N13 #10, 5/8 in.
53N58 #4, 1/4 in. (gas lens)
53N59 #5, 5/16 in. (gas lens)
53N60 #6, 3/8 in. (gas lens)
53N61 #7, 7/16 in. (gas lens)
53N61S #8, 1/2 in. (gas lens)
Back Caps
41V33 Short
41V35 Medium
41V24 Long
Most popular accessories
Kit AK-4C
• Accessory
Includes one long back cap,
one of each size (#5, #6, #7)
alumina nozzle, and one of each
size (1.6, 2.4, 3.2 mm) of the
following: collet, collet body,
and 175 mm 2% ceriated tungsten
electrode.
WATER-COOLED
TIG Torches
Weldcraft W-350 Series (Water-cooled)
™
Formerly known as WP-18 Series
Rugged water-cooled torches
engineered for high-amperage and
continuous hand-held welding in
mechanized applications.
Reduce downtime and costs by minimizing
overheating with the unique cooling design
engineered for operator comfort.
Reduce discomfort and fatigue using the
comfortable handle design.
Superior gas flow control offered through the
built-in fingertip gas control (W-350 Valve).
W-350
(WP-18)
Applications
• Fabrication
• Manufacturing
and repair
• Maintenance
• Shipbuilding • Tube and pipe
Most popular consumables
• Collets
10N24 2.4 mm (3/32 in.)
•
•
10N25 3.2 mm (1/8 in.)
54N20 4.0 mm (5/32 in.)
Collet Bodies
10N32 2.4 mm (3/32 in.)
10N28 3.2 mm (1/8 in.)
406488 4.0 mm (5/32 in.)
Alumina Nozzles
10N48 #6, 3/8 in.
10N47 #7, 7/16 in.
10N46 #8, 1/2 in.
10N45 #10, 5/8 in.
10N44 #12, 3/4 in.
W-350 Valve
(WP-18V)
Model
Specs
W-350
W-350 Valve
Rated Output
DC: 350 A at 100% duty cycle
AC: 250 A at 100% duty cycle
Electrode Range
0.5–4.0 mm (.020–5/32 in.)
Weldcraft W-400 Super Cool
Applications
™
™
(Water-cooled)
Formerly known as WP-18SC
Water-cooled torch designed to endure some of the most
demanding applications while minimizing overheating.
Extend torch and consumable life with the full-flow water chamber
that provides around-the-head cooling.
Improve gas coverage and cooling capacity with gas lens usage with
heavy-duty stubby collet body.
Extend parts life using the durable copper components, maximizing
current capacity.
Model
Specs
W-400 Super Cool
Rated Output
DC: 400 A at 100% duty cycle
AC: 280 A at 100% duty cycle
Formerly known as CS410
Water-cooled torch that increases amperage output
without increasing torch size. Designed for demanding
applications.
D-Handle™ design features a self-indexing flat top that allows for
torch orientation by feel.
Work in cold weather with the Tri-Flex™ hose and cable assembly
that remains flexible to ease handling and extends cable life.
Improve high-frequency shielding and minimize gas leakages with
the double-lip back cap seal.
Specs
Rated Output
DC: 410 A at 100% duty cycle
AC: 310 A at 100% duty cycle
•
Applications
Weldcraft W-410 (Water-cooled)
W-410
•
•
54N20HD 4.0 mm (5/32 in.)
18C36
4.8 mm (3/16 in.)
Heavy-Duty Nose Collet Body
(all sizes) NCB-36
Alumina Nozzles
54N16
#6, 3/8 in.
54N15
#7, 7/16 in.
54N14
#8, 1/2 in.
Back Caps
57Y04
Short
300M
Medium
Electrode Range
0.5–4.8 mm
(.020–3/16 in.)
™
Model
fabrication • Tool and die
• Heavy
and tube fabrication
• Pipe
• Pressure vessel fabrication
Most popular consumables
Collets
• Heavy-Duty
10N25HD 3.2 mm (1/8 in.)
and pipe
• Aerospace
• Tubefabrication
Exotic
material
• Pipe and tube fabrication
•
Most popular consumables
• Collets
10N24 2.4 mm (3/32 in.)
•
•
10N25 3.2 mm (1/8 in.)
54N20 4.0 mm (5/32 in.)
Collet Bodies
10N32 2.4 mm (3/32 in.)
10N28 3.2 mm (1/8 in.)
406488 4.0 mm (5/32 in.)
Alumina Nozzles
10N46 #8, 1/2 in.
10N45 #10, 5/8 in.
10N44 #12, 3/4 in.
Electrode Range
0.5–4.0 mm
(.020–5/32 in.)
51
TIG Torches SPECIALTY
Weldcraft W-125 Micro Series (Water-cooled)
™
Formerly known as WP-125 Series
Water-cooled MicroTig® torches designed for limitedaccess joints.
W-125
Medium Micro
(89 mm)
(WP-125M)
W-125
Long Micro
(127 mm)
(WP-125L)
Low-profile nozzle fits into holes as small as 16 mm diameter.
45-degree, 90-degree, and 180-degree options improve access
in tight areas.
Lower maintenance costs incurred with the replaceable silicone
rubber insulator and head components.
Specs
W-125 Medium Micro
W-125 Long Micro
Rated Output
DC: 125 A at 100% duty cycle
AC: 80 A at 100% duty cycle
Electrode Range
1.0–2.4 mm
(.040–3/32 in.)
Dependable water-cooled torch designed for
high-capacity, demanding applications.
Comfort and reduced downtime due to the sealed water
chamber that minimizes torch overheating.
Heavy-duty components provide reliable welding performance,
even after continuous and demanding use.
100-percent-copper construction ensures maximum thermal
conductivity.
Model
Specs
W-500
Rated Output
DC: 500 A at 100% duty cycle
AC: 350 A at 100% duty cycle
Air-cooled and water-cooled torches engineered
to weld multiple joint configurations for various
applications and angles.
52
W-225
Modular
(WP-225)
90°, 90° short) glass nozzle, and
one of each size (1.0, 1.6 mm) of the
following: 180°chuck, 45°chuck,
90°chuck, and 175 mm 2% ceriated
tungsten electrode.
fabrication • Tool and die
• Heavy
Pipe
and
tube fabrication
• Pressure vessel
fabrication
•
Most popular consumables
(required) 12NG
• Insulator
• Collets
85Z17 4.0 mm (5/32 in.)
•
•
85Z18 4.8 mm (3/16 in.)
85Z19 6.4 mm (1/4 in.)
Collet Body (all sizes) 11WP65
Alumina Nozzles
14N59
#6, 3/8 in.
14N60
#7, 7/16 in.
14N61
#8, 1/2 in.
14N61-10 #10, 5/8 in.
14N61-12 #12, 3/4 in.
Applications
™
A-150
Modular Valve
(WP-150V)
Kit AK-125C
• Accessory
Includes one of each size (180°, 45°,
Electrode Range
1.6–6.4 mm
(1/16–1/4 in.)
Weldcraft Modular Series
A-200
Modular Valve
(WP-200V)
•
125C116-90 1.6 mm (1/16 in.)
125C332-90 2.4 mm (3/32 in.)
90° Glass Nozzle (all sizes) 125N90
Other nozzles are available.
Applications
™
A-150
Modular
(WP-150)
• Aerospace
• Food/beverage industry
Automotive • Petro/chemical
• HVAC
•
• Precision fabrication
Most popular consumables
Chucks
• 90°
125C40-90 1.0 mm (.040 in.)
Most popular accessories
Model
Weldcraft W-500 (Water-cooled)
Formerly known as WP-12
Applications
Built-in, efficient cooling system reduces overheating
to extend parts and consumable life.
Modular design minimizes costs and downtime for torch
changeover and parts inventory.
Easy configurable head options provide greater
flexibility and joint access, and minimize downtime for
torch changeover.
Gas valve provides greater shielding gas flow control
(A-150 Modular Valve and A-200 Modular Valve).
Model
Specs (Torch head dependent)
A-150 Modular
A-150 Modular Valve
(Air-cooled)
Rated Output
DC: 150 A at 60% duty cycle
AC: 105 A at 60% duty cycle
Electrode Range
0.5–3.2 mm
(.020–1/8 in.)
A-200 Modular Valve
(Air-cooled)
DC: 200 A at 60% duty cycle
AC: 150 A at 60% duty cycle
0.5–4.0 mm
(.020–5/32 in.)
W-225 Modular
(Water-cooled)
DC: 225 A at 100% duty cycle
AC: 160 A at 100% duty cycle
0.5–4.0 mm
(.020–5/32 in.)
and repair • Aerospace
• Maintenance
Metal
art
Food/beverage
• Petro/chemical
• Shipbuildingindustry
• Manufacturing •Vocational
• Precision fabrication
• Tube and pipe
•
•
Most popular accessories
Kit
• Accessory
AK-150MFC For A-150 torch
AK-225MFC For W-225 torch
Welding Intelligence
™
Transform data into actionable information that drives continuous improvement.
Increase productivity
Complete coverage for any application.
Improve weld quality
Manufacturing
Pipe and vessel
Automation
Submerged arc
Manage costs
Choose the Right Welding Intelligence System
Pipe and Vessel
For Use With
FactoryInstalled
FieldInstalled/
Activated
Requirements
What Capability
Do You Need?
Data Storage
•
Continuum™/Auto-Continuum™
•
14-pin compliant power source
(see MillerWelds.com/insight)
•
••
••
•
Internet connection (wired/wireless)
Productivity monitoring
Weld parameter verification
Simplicity/basic monitoring
Goal setting
Cloud based
•
Continuum™/Auto-Continuum™
—
•
Continuum™/Auto-Continuum™
•
PC and Ethernet connection
•
•
•
•
•
•
••
••
•
Prevent/detect missed welds
Minimize overwelding/underwelding
Electronic work instructions
Measure overall equipment
effectiveness (OEE)
Local server or PC
ArcAgent
••
•
ANY welding power source (old or new)
ANY brand
ANY welding process
PipeWorx 400
PC and Ethernet connection
Real time contract, spool, joint
documentation
Enterprise resource planning
system integration (ERP)
Productivity/quality metrics
Local PC
•
••
•
•
PC and Ethernet connection
With use of Centerpoint:
Prevent/detect missed welds
Minimize overwelding/underwelding
Electronic work instructions
Local server or PC
53
Welding Intelligence
™
Simplified, Internet-based welding information solution that reports operator productivity and weld parameter verification.
6
5
1
3
2
4
Visit our online Insight Core simulator at Insight-simulator.MillerWelds.com
How it works
Insight Core dashboard descriptions
1 Asset tree. A list of power sources within your fleet that are enabled
with Insight Core — organized by building, department or machine —
showing real-time activity status icons and active operators.
2 Productivity dashboard. Instant visibility of arc-on time and wire
deposition, by location, work cell, power source or operator.
3 Quality dashboard. Real-time analysis and reporting of all welds,
revealing when quality fails to meet established thresholds for amps,
volts and WFS. Includes weld trace.
Wi-Fi and wired Ethernet connectivity are built into Insight Core for
flexible integration with your company’s information network.
4 Goals dashboard. Shows progress toward continuous improvement
goals you set for improving arc-on time, deposition rates and arc starts.
Factory installed on Continuum™/Auto-Continuum,™ power sources.
5 Reports. In-depth information is available in reports that can be easily
modified and displayed in a wide variety of customizable formats.
Compatible with 14-pin compliant Miller® power sources. See
MillerWelds.com/insight for a list of 14-pin compatible power sources.
6 Multiple languages available. English, German, Spanish, French,
Italian, Dutch, Portuguese and Chinese.
*Additional stock numbers are available — visit MillerWelds.com/insight.
**SubArc Digital Series requires Insight Core to SubArc Digital Series Adapter Kit (301295).
14-pin Compliant Miller Power Sources
Continuum 350 (907645)
Continuum 500 (907648)
Auto-Continuum 350 (907660)
Auto-Continuum 350 DI (907660001)
Auto-Continuum 500 (907661)
Auto-Continuum 500 DI (907661001)
—
Field-Installed Insight Core Upgrade Modules
54
—
Accessory
Continuum Model /Stock Number*
Factory-Installed Insight Core Power Sources
MIG
Type
(301072) Insight Core 14-pin module**
Welding Intelligence
™
Advanced PC software for visualization, analysis and tracking of weld process information.
Operator interface as shown
through Insight Centerpoint.
How it works
Standard capability software (SCP)
Tracking provides real time operator feedback to ensure accurate weld sequence,
• Part
prevent missed welds and ensure proper weld parameters.
and standards captures required information relating actual welding parameters
• Codes
to the specific operator, contract, joint and weld pass to ensure productivity and quality
™
PC
Insight
Centerpoint
Manual
welding
requirements are met.
Insight
Reporter
Advanced capability software (ACP)
enables you to present electronic work instructions for pre/intra/post weld activities
• WorkFlow
(using video, pdf, and more) to ensure consistent standardized production for every operator.
™
PC
Insight
Centerpoint
Fixed
automation
Server
running
SQL
database
Optional reporting software
Insight Reporter provides preconfigured management charts and reports that provide a
• wide
range of information about weld process, productivity and business metrics, stored in an
™
PC
SQL server database.
Insight
Centerpoint
Pipe and Vessel. Powerful pipe documentation solution that provides
traceability by relating weld data to specific contract/spool/joint.
PipeWorx 400 requires Insight Module (301304).
Flexible
automation
*Additional stock numbers are available — visit MillerWelds.com/insight.
Optional
Insight Reporter
Model/Stock Number*
Capability Software
Insight Centerpoint
Factory-Installed
Insight Centerpoint
Power Sources
Continuum 350 (907645)
Continuum 500 (907648)
Auto-Continuum 350 (907660)
Auto-Continuum 350 DI (907660001)
Auto-Continuum 500 (907661)
Auto-Continuum 500 DI (907661001)
(301297) Standard (SCP)
(301257) Advanced (ACP)
(requires standard capability software)
(301322) Standard and advanced
(301255) Single seat license
(301256) Site license
(300709) Single license
(1 required per PC)
(300710) SQL database
(1 required per facility)
PipeWorx 400 Module
(301304) Only provides Pipe and Vessel
—
—
—
Pipe
Field-Installed
Insight Centerpoint
Upgrade Module
MIG
Type
Accessories
Insight LTD Gun
(Q4015JS3EML) For Continuum
M12/RJ45 Ethernet Cables
(300734) 3 m (9.8 ft.)
(300735) 5 m (16.4 ft.)
(300736) 10 m (32.8 ft.)
Field Application Support
(195480) Miller field support
(contact distributor for details)
55
Welding Intelligence
™
ArcAgent
Most popular accessories
See literature WI/1.0
Voltage monitoring
Premium Welding Intelligence solutions for any brand of welding power source, designed to
integrate with Insight Centerpoint.™
Models
ArcAgent Manual
with Part Tracking
controls
ArcAgent Manual
ArcTimer.™ Monitors very
basic weld data (displayed
on LCD): total arc time, last
weld time, current weld time
and total arc count. Battery
operated (4 C-sized).
Manual. Designed for
manual welding. Provides
process control and
monitoring that detects
and prevents missed welds.
Auto. Designed for automated welding. Real-time
monitoring of weld count,
length (duration), process
set-point parameters
(voltage, current, wire feed,
gas flow), total arc time,
total wire used and total
clamp time.
ArcAgent Auto
ArcTimer
Typical manual welding installation
Current monitoring
Current Sensors
• Standard
(for up to 4/0 lugged cables)
•
•
301353 150 A
301351 650 A
Large Diameter Current Sensors
(for Dinse- or Tweco®-style cables)
301357 600 A solid core
301356 1,000 A solid core
Current Sensor Cables
301364 7.6 m (25 ft.) standard
301367 7.6 m (25 ft.) large diameter
Wire feed speed monitoring
Speed Sensor 301350
• Wire
Speed Sensor Cable
• Wire
301368 7.6 m (25 ft.)
Gas flow monitoring
Flow Sensor 301358
• Gas
Flow Sensor Cable
• Gas
301369 7.6 m (25 ft.)
Travel speed monitoring
NOT compatible with ArcAgent Manual or
ArcAgent Manual with Part Tracking controls.
Speed Encoder 301362
• Travel
Requires Auxiliary Sensor Module and
Travel Speed Wheel.
Ethernet
Arc current
ArcAgent sensors
(wire and gas sensors available)
ArcAgent Manual
Insight Centerpoint (optional)
Arc voltage
Arc current
PLC or robot
controller
Wire feed speed
Ethernet
or USB
Gas flow
Power source
ArcAgent sensors
•
•
•
Allows for use of travel speed sensors
as well as two analog inputs.
Travel Speed Wheel
301360 152.4 mm (6 in.)
Travel Speed Encoder Mounting
Bracket 301363
Travel Speed Encoder Cable
301376 7.6 m (25 ft.)
For a complete accessory list see literature
WI/1.0.
Typical automation welding installation
ArcAgent Auto
Insight Centerpoint (optional)
Model/Stock Number
Insight Centerpoint
Optional Insight Reporter
ArcTimer (301349)
—
—
ArcAgent Manual Series
(301342) Manual
(301343) Manual with front panel Part Tracking controls
(301345) Manual with Insight torch capability
Optional: (301255) Single seat license
(301256) Site license
(300709) Single license (1 required per PC)
(300710) SQL database (1 required per facility)
ArcAgent Auto
(301346) Auto
Optional: (301255) Single seat license
(301256) Site license
(300709) Single license (1 required per PC)
(300710) SQL database (1 required per facility)
56
•
applications. Requires 7.6 m (25 ft.)
TIG filter cable (301384).
Voltage Sense Cables
301365 With lugs
Sensor Module (24 VDC)
• Auxiliary
301374
Arc voltage
Power source
Filter Sensor 301359
• TIGVoltage
sensing cable used in TIG
Big Blue®
400X Pro
57
Big Blue®
500X Pro
58
Big Blue®
500X CC
58
Product Key
Weldable
Metals
Continuous
Generator
Pwr. (watts)
Welding
Output
Ranges (DC)
Engine Brand
Special Features
Typical Applications
4.8 Lift eye, truck mount,
mm optional trailer
Steel, stainless
10,000
20–400 A
14–40 V
CAT, Kubota
Quiet, compact, fuel efficient
Construction, repair
8 Lift eye, generally
mm mounted on
optional trailer
8
mm
Steel, stainless
15,000
20–500 A
14–50 V
Perkins
Quiet, powerful, fuel efficient
Construction, repair
4,000
55–500 A
Perkins
Quiet, powerful, fuel efficient
Construction, repair
Portability
Class:
Light industrial
Industrial
Heavy industrial
*If using self-shielded wire, use CV weld output.
Big Blue 400X Pro
®
Capability:
Designed for this process
Diesel
Product
Guide
Page
Class
Stick
MIG
Flux-cored*
DC TIG
CAC-A
Engine-Driven
Capable of this process
Heavy industrial
See literature ED/5.7
Processes
(SMAW) • MIG (GMAW)
• Stick
(FCAW) • DC TIG (GTAW)
• Flux-cored
carbon arc cutting and gouging
• Air(CAC-A)
(rated 4.8 mm carbons)
Clean, quiet and reliable low-speed diesel is more efficient than ever before.
Ideal for construction, piping and fleet use.
Diesel engines
Diesel
400-amp output now available in a compact package.
Provides up to 400 amps at 100 percent duty cycle.
The vault — ultimate control board reliability.
A sealed aluminium case protects the circuit board from
dust, dirt, moisture and heat.
Low OCV stick (VRD) for improved operator safety
without compromising arc starts.
Tailored arc control (DIG) allows arc characteristics to
be changed for specific applications and electrodes.
Smooth running 7018 or stiffer, more penetrating 6010.
Quiet operation. Only 71.6 decibels (96 Lwa) under
full load. Improves jobsite communication and safety.
CE compliant.
Standard features include digital weld meters, auto
idle, 120-volt block heater and output contactor control.
Stock Number
(907630) CAT
(907631) Kubota
Welding
Mode
Process
Welding
Output Ranges
CC/DC
DC stick/TIG
20–400 A
CV/DC
MIG/FCAW
14–40 V
Rated Output at 40°C (104°F)
300 A at 32 V, 100% duty cycle
350 A at 27 V, 100% duty cycle
400 A at 24 V, 100% duty cycle
IP
Rating
Single-Phase Generator
Power at 40°C (104°F)
IP23
Peak: 12,000 watts
Continuous: 10,000 watts
CAT C1.5: 21.7 hp at 1,800 rpm
Three-cylinder, industrial, liquid-cooled
Kubota V1505: 20.2 hp at 1,800 rpm
Four-cylinder, industrial, liquid-cooled
Note: Engines are warranted separately
by engine manufacturer.
Most popular accessories
Feeders (pg 18)
• SuitCase
210 DX/280 DX (pg 44)
• Dynasty
• Protective Cover 195301 (pg 64)
®
®
Wireless Hand Control/
Wireless Antenna Kit
300430/300749 (pg 66)
Dimensions
Net Weight
H: 813 mm (32 in.)
W: 667 mm (26.25 in.)
D: 1,422 mm (56 in.)
CAT 458 kg (1,010 lb.)
Kubota 431 kg (950 lb.)
57
Engine-Driven
Big Blue® 500X Pro
Heavy industrial
See literature ED/11.0
Processes
Clean, quiet, multiprocess machines designed to give welders the output they need for
heavy-duty applications on construction and fabrication sites.
Diesel
Meter maintenance displays include coolant temperature,
oil pressure, battery voltmeter and fuel gauge/hour meter/
oil change interval/engine shutdown indicator.
Infinite arc control allows the arc characteristics to
be changed for specific applications in stick, MIG and
flux-cored welding.
Low OCV stick (VRD) for improved operator safety without
compromising arc starts.
Auto Remote Sense™ (ARS) detects if a remote control
is plugged into the 14-pin receptacle and eliminates
confusion of a remote/panel switch.
Thermal overload protection prevents machine damage if
the duty cycle is exceeded or airflow is blocked.
CE compliant.
Standard features include digital
preset weld meters, automatic idle,
and cold weather starting aids.
Deluxe models add a polarity
reversing switch and a vandalism
lockout (protects control panel and
receptacles, see photo at right).
Stock Number
(907602) Perkins
(907602001) Perkins Deluxe
Welding
Mode
Process
Welding
Output Ranges
CC/DC
DC stick/TIG
20–500 A
CV/DC
MIG/FCAW
14–50 V
Big Blue® 500X CC
Rated Output at 40°C (104°F)
400 A at 36 V, 100% duty cycle
450 A at 33 V, 60% duty cycle
500 A at 30 V, 40% duty cycle
IP
Rating
Generator Power at
40°C (104°F)
IP23
Three-phase
Peak: 21,000 watts
Continuous: 15,000 watts
Single-phase
Peak: 15,000 watts
Continuous: 12,000 watts
(SMAW) • MIG (GMAW)
• Stick
(FCAW) • DC TIG (GTAW)
• Flux-cored
carbon arc cutting and gouging
• Air(CAC-A)
(rated 8 mm carbons)
Diesel engine
Perkins 404D.22:
32.6 hp at 1,800 rpm
Four-cylinder, industrial, liquid-cooled
Note: Engine is warranted separately
by engine manufacturer.
Most popular accessories
Feeders (pg 18)
• SuitCase
210 DX/280 DX (pg 44)
• Dynasty
• Protective Cover 194683 (pg 64)
®
®
Wireless Hand Control/
Wireless Antenna Kit
300430/300749 (pg 66)
Dimensions
Net Weight
H: 1,067 mm (42 in.)
W: 724 mm (28.5 in.)
D: 1,654 mm (65.125 in.)
694 kg (1,530 lb.)
Heavy industrial
See literature EDX/10.11
Processes
Designed for fleet owners that demand the ultimate in reliability and performance. Built with
reliable, heavy-duty industrial components for operation in remote locations, without downtime.
(SMAW) • DC TIG (GTAW)
• Stick
carbon arc cutting and gouging
• Air(CAC-A)
(rated 8 mm carbons)
Diesel engine
Diesel
Meter maintenance displays include coolant temperature,
oil pressure and fuel gauge/hour meter/oil change interval/
engine shutdown indicator.
Enclosed robust case design protects internal components
from impact and allows air flow to cool and prolong the life
of the engine. Also reduces sound levels.
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.
Arc-Drive™ makes welding easy. Automatically enhances
stick welding, especially on pipe, by focusing the arc and
preventing the electrode from going out.
5,500-watt peak AC power independent of weld settings
means no interaction between tools and welding arc.
Quick and easy maintenance with single-side access to
oil level check, oil fill, oil filter, fuel filter and air cleaner.
CE compliant.
58
Stock Number
(907187) Perkins
(907187021) Perkins with
weld meters and polarity switch
Welding
Mode
Process
Welding
Amperage Range
CC/DC
DC stick/TIG
55–500 A
Rated Output at 40°C (104°F)
400 A at 36 V, 100% duty cycle
450 A at 38 V, 60% duty cycle
500 A at 30 V, 40% duty cycle
IP
Rating
Single-Phase Generator
Power at 40°C (104°F)
IP23
Peak: 5,500 watts
Continuous: 4,000 watts
Perkins 404D.22:
32.6 hp at 1,800 rpm
Four-cylinder, industrial, liquid-cooled
Note: Engine is warranted separately
by engine manufacturer.
Most popular accessories
SuitCase X-TREME 8VS/12VS
• Feeders
(pg 18)
210 DX/280 DX (pg 44)
• Dynasty
• Protective Cover 194683 (pg 64)
®
™
®
Wireless Hand Control/
Wireless Antenna Kit
300430/300749 (pg 66)
Dimensions
Net Weight
H: 1,092 mm (43 in.)
W: 724 mm (28.5 in.)
D: 1,654 mm (65.125 in.)
732 kg (1,614 lb.)
Submerged Arc
Miller offers an array of versatile submerged arc components, including power sources,
controls, wire drives, torches, tractors and a variety of other accessories.
Heavy industrial
SubArc Digital Series
SubArc DC Series
is DC only.
See literature ADM/10.0 UK
The SubArc Digital Series of power sources, interface controls and accessories include digital
control and communication electronics designed to improve weld performance and simplify the
integration of the equipment in more advanced applications.
Low-voltage accessory
operation and improved
environmental protection.
The Digital Series accessories
are powered with 24 VAC
control voltage from the
power source. All power
sources, interface controls
and wire drives are IP23
rated providing a high level
of protection for harsh
environments.
SubArc DC
1250 Digital
SubArc DC
800 Digital
Processes
arc (SAW)
• Submerged
(ESW)
• Electroslag
carbon arc cutting and gouging
• Air(CAC-A)
Most popular accessories
14-pin Insight Core Module
• 301072
(pg 54)
™
•
•
•
Requires Insight Core to SubArc
Digital Series Adapter Kit (301295).
ArcAgent™ Auto 301346 (pg 56)
4.6 m (15 ft.) SubArc Parallel Cable
260775015 (pg 62)
4.6 m (15 ft.) SubArc Tandem Cable
260878015 (pg 62)
Easy to integrate. Our
SubArc power sources are
easy to integrate by using
a standard Modbus®
connection.
SubArc AC/DC
1250 Digital
Two DC power source models and one AC/DC power source model. Power
sources have sufficient power capacity to cover applications from traditional DC
single-arc to multi-wire tandem welding. In the case of electroslag welding or
other high-current demand, two or more power sources can easily be paralleled
(both DC and AC/DC machines).
All power sources also
feature thermal overload
protection, line voltage
compensation and
Fan-On-Demand.™
*While idling.
Amperage Range
(CC Mode)
Voltage Range
(Sub Arc Mode)
SubArc DC 800 Digital
(907623) 380/400/440 V
50–815 A
20–44 V
SubArc DC 1250 Digital
(907625) 380/400/440 V
100–1,250 A
SubArc AC/DC 1250 Digital
(907621) 380/400 V
300–1,250 A
Model/Stock Number
IP
Rating
Amps Input at Rated Output, 50 Hz
380 V 400 V 440 V KVA KW
Max OpenCircuit Voltage
Dimensions (Includes lift eye,
but not strain relief)
650 A at 44 V,
100% duty cycle
IP23
95
90
83
50
34.8
1.9* 1.8* 1.6* 1.52* 0.76*
75 Vpk
269 kg
(593 lb.)
20–44 V
1,000 A at 44 V,
100% duty cycle
IP23
135 128 117 73
5.2* 5.0* 4.5* 3.2*
68 Vpk
H: 762 mm (30 in.)
W: 584 mm (23 in.)
D: 965 mm (38 in.)
20–44 V
1,000 A at 44 V,
100% duty cycle
IP23
179 176 —
3.0* 3.0* —
H: 1,092 mm (43 in.)
W: 711 mm (28 in.)
D: 1,219 mm (48 in.)
538 kg
(1,187 lb.)
Rated Output
53
0.5*
122 67
2.37* 0.95*
93 Vpk
Net Weight
309 kg
(682 lb.)
Customers count on Hobart® to provide an exceptional level of
expertise and commitment in developing unique filler metal and
flux solutions with them to meet current and future challenges.
Rely on Hobart for submerged arc applications
and all your welding needs.
Visit HobartBrothers.com or your local distributor to learn more.
Questions? Hobart is here to help.
59
Submerged Arc
SubArc Interface Controls
Most popular accessories
See literature no. ADM/10.0 UK
Control Cables (pg 62)
• SubArc
260622030 9.1 m (30 ft.)
260622050
260622060
260622080
260622100
260622120
260622200
Easier setup and operation. The SubArc Digital Series
Interface controls recognize the power source and wire drive
connected, and automatically configure the system for
proper operation.
15 m (50 ft.)
18.3 m (60 ft.)
24.4 m (80 ft.)
30.5 m (100 ft.)
36.6 m (120 ft.)
61.0 m (200 ft.)
Internal terminal strip is able to integrate with positioners,
sidebeams, turning rolls and other peripheral equipment.
Model/Stock Number
Input Power from Welding Power Source
Welding Power Source Type
IP Rating
Dimensions
Net Weight
SubArc Interface Digital (300936)
24 VAC, 1-phase, 25 A, 50/60 Hz
Constant voltage (CV), AC or DC,
with remote contactor and
output control capabilities
IP23
H: 292 mm (11.5 in.)
W: 305 mm (12 in.)
D: 178 mm (7 in.)
7.2 kg (15.8 lb.)
SubArc Remote Operator Interface
Point-of-use installation.
Remote Pendant can be handheld
or secured at point of use to
improve operation.
Remote installation. Motor
Control can be remotely installed,
resulting in reduced cables at the
operator workstation.
Most popular accessories
Motor/Control Cables
• Continuum
(pg 62)
•
Side handles on Remote Pendant
provides option for handheld
operation with full functionality
of a traditional SubArc Interface.
Motor Control Digital
263368015 4.6 m (15 ft.)
263368020 6.1 m (20 ft.)
263368025 7.6 m (25 ft.)
263368050 15 m (50 ft.)
263368080 24.4 m (80 ft.)
2633680100 30.5 m (100 ft.)
SubArc Control Cables (pg 62)
260622030 9.1 m (30 ft.)
260622050 15 m (50 ft.)
260622060 18.3 m (60 ft.)
260622080 24.4 m (80 ft.)
260622100 30.5 m (100 ft.)
260622120 36.6 m (120 ft.)
260622200 61.0 m (200 ft.)
Remote Pendant Digital
Model/Stock Number
Input Power from Welding Power Source
Welding Power Source Type
IP Rating
Dimensions
Net Weight
SubArc Motor Control Digital (301425)
(requires SubArc Remote Pendant Digital below
and Continuum control/motor cable)
24 VAC, 1-phase, 25 A, 50/60 Hz
Constant voltage (CV), AC or DC,
with remote contactor and
output control capabilities
IP23
H: 292 mm (11.5 in.)
W: 305 mm (12 in.)
D: 178 mm (7 in.)
7.2 kg (15.8 lb.)
SubArc Remote Pendant Digital (301424)
(requires SubArc Motor Control Digital above
and Continuum control/motor cable)
42 VDC, 1 A
H: 279 mm (11 in.)
W: 270 mm (10.63 in.)
D: 80 mm (3.125 in.)
1.4 kg (3 lb.)
Most popular accessories
SubArc Wire Drive Assemblies
Extension Cables (pg 62)
• Motor
254232005 1.5 m (5 ft.)
See literature no. ADM/10.0 UK
SubArc Wire Drive 400
Digital Low Voltage
SubArc Strip Drive 100
Digital Low Voltage
SubArc Strip Drive 100 Digital
Low Voltage is a heavy-duty, rightangle drive assembly designed for
automated strip clad applications.
SubArc Wire Drive 400 and 780
Digital Low Voltage are right-angle
wire drive assemblies. The 400
model is standard speed and the
780 is high speed.
•
•
•
•
254232010 3 m (10 ft.)
254232025 7.6 m (25 ft.)
254232065 19.8 m (65 ft.)
Drive Rolls (pg 62)
Manual Slide (pg 62)
Single-Wire Straightener 199733
(pg 62)
Twin-Wire Straighteners
(for twin-wire torches only) (pg 62)
301160 Single adjustment
301162 Double/separate adjustment
Model
Stock Number
Input Power
Input Power Cord
Rating
IP Rating
Wire Feed Speed
Wire Diameter Capacity
Net Weight
SubArc Strip Drive 100
Digital Low Voltage
(300940) With mounting bracket
38 VDC
1.2 m (4 ft.)
1/5 hp, 21 rpm
IP23
0.3–1.6 mpm
(10–69 ipm)
N/A (strip cladding applications)
13 kg (29 lb.)
SubArc Wire Drive 400
Digital Low Voltage
(300938) Standard speed
38 VDC
1.2 m (4 ft.)
1/5 hp, 85 rpm
IP23
0.8–10.2 mpm
(30–400 ipm)
2.4–4.8 mm (3/32–3/16 in.)
11.8 kg (26 lb.)
SubArc Wire Drive 780
Digital Low Voltage
(300941) High speed
38 VDC
1.2 m (4 ft.)
1/4 hp, 143 rpm
IP23
1.3–19.8 mpm
(50–780 ipm)
1.6–3.2 mm (1/16–1/8 in.)
11.8 kg (26 lb.)
60
Submerged Arc
SubArc Torches
Most popular accessories
600 Torch Body Extensions
• OBT
(pg 62)
See literature ADM/10.0 UK
OBT 600 is a 600-amp, 100 percent duty cycle
torch with concentric flux flow nozzle. Can be used
with 1.6–4.0 mm (1/16–5/32 in.) wire.
OBT 1200 is a 1,200-amp, 100 percent duty cycle
torch with concentric flux flow nozzle. Can be used
with 1.6–4.8 mm (1/16–3/16 in.) wire. OBT 1200
features a replaceable breakaway adapter end
to prevent costly damage should torch run into
an obstruction.
1200-Amp Twin-Wire Torch (long) is a 1,200-amp,
100 percent duty cycle torch. Can be used with
1.2–2.4 mm (3/64–3/32 in.) wires.
OBT 600
OBT 1200
•
•
043967 25.4 mm (1 in.)
043969 50.8 mm (2 in.)
043973 101.6 mm (4 in.)
043975 152.4 mm (6 in.)
OBT 1200 Torch Body Extension
043981 (pg 62)
Contact Tips (pg 62)
1200-Amp Twin-Wire
Model/Stock Number
Rated Output
Wire Diameter Capacity
Single/Twin
Torch Body Length
OBT 600 (043923)
600 A at 100% duty cycle
1.6–4.0 mm (1/16–5/32 in.)
Single
260.4 mm (10.25 in.)
OBT 1200 (043900)
1,200 A at 100% duty cycle
1.6–4.8 mm (1/16–3/16 in.)
Single
438.2 mm (17.25 in.)
1200-Amp Twin-Wire Torch (301144) Long
1,200 A at 100% duty cycle
1.2–2.4 mm (3/64–3/32 in.)
Twin
431 mm (16.97 in.)
External Cladding Head
Most popular accessories
Strip Drive 100 Digital Low
• SubArc
Voltage (pg 60) 300940
Coolmate 3 (pg 64)
• 043007
115 V
See literature AY/52.0
™
043008 230 V
Cost-efficient means of depositing stainless steel and Ni-alloy
materials to create corrosion- or wear-resistant overlays on large
non- or low-alloyed steel components.
Designed for both submerged arc and electroslag strip cladding
applications.
Flexible external cladding head accommodates strip widths from
30 to 90 mm.
Individually adjustable spring-loaded contact jaws provide optimal
current transfer, reducing risk of cladding failures.
Stock Number
External Cladding Head 30–90 mm (301167)
•
•
40V76R 3.8 m (12.5 ft.)
40V76LR 7.6 m (25 ft.)
Water Coupler 11N18
Quick-Release Water Kit QRW
Rated Output
Strip Width Range
Cooling Method
Dimensions
Net Weight
3,000 A at 100% duty cycle
30–90 mm
Coolant
H: 379 mm (14.92 in.)
W: 223 mm (8.76 in.)
D: 226 mm (8.9 in.)
17.5 kg (38.5 lb.)
SubArc Flux Hopper
Most popular accessories
Hopper Extension Cables (pg 62)
• Flux
260623010 3 m (10 ft.)
See literature ADM/10.0 UK
Improved flux delivery system. Our SubArc Flux Hopper Digital
Low Voltage utilizes a flux valve mechanism that assures continuous
delivery of flux to the arc.
Sight glass allows the weld operator to visually monitor the remaining
flux in the hopper.
Versatile opening is sized to allow hook-up of any flux-hoppermounted recovery system.
Includes slag screen to capture fused slag particles from entering
the flux hopper.
Stock Number
SubArc Flux Hopper Digital Low Voltage (300942)
Flow Switch Kit 195461
• Coolant
(pg 64)
Hose Extensions
• Water
40V76R6 1.8 m (6 ft.)
260623025 7.6 m (25 ft.)
260623065 19.8 m (65 ft.)
Input Power
Input Power Cord
Flux Capacity
Net Weight
12 VDC (PWM signal from SubArc Interface)
3.3 m (11 ft.)
11 kg (25 lb.)
5 kg (11 lb.)
61
Submerged Arc
SubArc Digital 4-Wheel Tractor
Required system components
(sold separately)
Digital 4-Wheel Tractor
• SubArc
(includes 27 kg wire reel)
Designed and built to provide maximum reliability in the
toughest conditions. Can easily connect to SubArc DC or
AC/DC Digital power supplies.
Horizontal and vertical slides with travel up to 300 mm.
Polyurethane wheels with aluminium base for optimum grip
on various materials. Wheels are equipped with v-groove for
easy track conversion.
Guide rollers for guidance alongside a guide profile or rail.
Travel speed controller integrated into the control box.
Individual adjustable speed for forward and reverse.
Tacho-feedback assures an accurate digital speed indication.
Stock Number
(058035008)
Tractor only
Input Power from
Welding Power Source
Wire Feed Speed
Wire Diameter
Capacity
Gun Positioning Slides
Drive Motor
Travel Speed
System Dimensions
24 VAC, 1-phase,
50/60 Hz, 360 watts
0.8–10.2 mpm
(30–400 ipm)
1.6–5.6 mm
(1/16–7/32 in.)
101.6 mm (4 in.)
vertical and horizontal
24 VDC permanent
magnet gear motor
0.1–1.75 mpm
(4–70 ipm)
H: 1,050 mm (40.25 in.)
W: 440 mm (17.375 in.)
D: 960 mm (37.8 in.)
Submerged Arc Accessories
System
Net Weight
78 kg (172 lb.)
without flux or wire
See literature ADM/10.0 UK
Cables
Wire Drive Assembly Accessories
SubArc Parallel Cable
260775015 4.6 m (15 ft.)
Cable between SubArc
Interface or Motor Control
and power source.
SubArc Tandem Cable
260878015 4.6 m (15 ft.)
SubArc Control Cables
260622030 9.1 m (30 ft.)
260622050 15 m (50 ft.)
260622060 18.3 m (60 ft.)
260622080 24.4 m (80 ft.)
260622100 30.5 m (100 ft.)
260622120 36.6 m (120 ft.)
260622200 61.0 m (200 ft.)
Torch Accessories
Cable between SubArc
Interface or Motor Control
and flux hopper.
Flux Hopper Extension Cables
260623010 3 m (10 ft.)
260623025 7.6 m (25 ft.)
260623065 19.8 m (65 ft.)
Cable between SubArc
Interface or Motor Control
and drive motor.
Motor Extension Cables
254232005 1.5 m (5 ft.)
254232010 3 m (10 ft.)
254232025 7.6 m (25 ft.)
254232065 19.8 m (65 ft.)
Cable between SubArc
Motor Control and
SubArc Remote Pendant.
Continuum Motor/Control Cables
263368015 4.6 m (15 ft.)
263368020 6.1 m (20 ft.)
263368025 7.6 m (25 ft.)
263368050 15 m (50 ft.)
263368080 24.4 m (80 ft.)
263368100 30.5 m (100 ft.)
62
058035008
Digital Tractor Interface
• SubArc
301423
Wire Drive 400 Digital Low
• SubArc
Voltage 300938
flux hopper with air-powered
• Manual
flux recovery 156102016
600 torch 043923
• OBT
• Wire straightener 199733
Most popular accessories
Control Cables (see below)
• SubArc
Tips (see below)
• Contact
• Drive Rolls (see below)
Drive Rolls
132955 1.6 mm (1/16 in.)
132960 2.0 mm (5/64 in.)
132961 2.4 mm (3/32 in.)
132962 2.8 mm (7/64 in.)
132963 3.2 mm (1/8 in.)
193700 4.0 mm (5/32 in.)
193701 4.8 mm (3/16 in.)
V-knurled drive rolls for use with hard-shelled cored wires.
OBT 600 Torch Body Extensions
043967 25.4 mm (1 inch)
043969 50.8 mm (2 inch)
043973 101.6 mm (4 inch)
043975 152.4 mm (6 inch)
OBT 1200 Torch Body Extension 043981
Overall length with extension is 228.6 mm (9 in.).
Actual length of extension is 215.9 mm (8.5 in).
OBT Torch Contact Tips
OBT 600
OBT 1200
192700
192141
192701
199026
192702
192142
192703
200771
192704
192143
192705
192144
—
192136
Wire Size
1.6 mm (1/16 in.)
2.0 mm (5/64 in.)
2.4 mm (3/32 in.)
2.8 mm (7/64 in.)
3.2 mm (1/8 in.)
4.0 mm (5/32 in.)
4.8 mm (3/16 in.)
1200-Amp Twin-Wire Torch Contact Tips
264595 1.2 mm (3/64 in.)
264596 1.6 mm (1/16 in.)
264597 2.0 mm (5/64 in.)
264588 2.4 mm (3/32 in.)
Manual Slide 301137
Provides smooth and accurate movement of the welding
head. Allows for 200 mm (7.87 in.) travel adjustment with
load capacity of 100 kg (220 lb.) at 500 mm (1.64 ft.).
Not recommended for tandem.
Single-Wire Straightener 199733
For use with OBT 600 and OBT 1200
single-wire torches. For 1.6–4.8 mm
(1/16–3/16 in.) wire.
Twin-Wire Straighteners
301160 Single adjustment
301162 Double/separate adjustment
For 1200-Amp Twin-Wire torch only.
Wire Reel 108008
Supports 27 kg (60 lb.)
coil of wire. Requires Spool
Support Assembly (119438).
Accessories
Contents
Carts, Cylinder Racks and Running Gear
Cable Connectors and Adapters 63
Carts, Cylinder Racks and Running Gear 63
Coolant Systems 64
Engine Drive Accessories 64
TIG Accessories 65–66
XPS Cylinder/Water Cooler Rack
058066065
For XPS 350/450. Two-compartment
rack accommodates one HydraCool® 1
coolant system and one gas cylinder up
to 1,650 millimeters (65 in.) high and
250 millimeters (9.8 in.) in diameter.
Wire Feeder Accessories 66
Cable Connectors and Adapters
For XPS 350/450, AlumaFeed System, XMS 425 MPa,
Invision 352 MPa, XMT 350, Maxstar, and Dynasty. These
power sources are equipped with Dinse- or Tweco-style
connectors for secondary connections and are shipped
with two male plugs for use with 25 to 50 mm cable.
XPS Single Cylinder Rack
058066064
For XPS 350/450. Single-compartment
rack accommodates one gas cylinder up
to 1,650 millimeters (65 in.) high and
250 millimeters (9.8 in.) in diameter.
Continuum Running
Gear/Cylinder Rack
301264
For Continuum
350/500. Small
footprint and easily
maneuverable, with
cylinder rack low
enough that you do
not have to lift bottles.
Dinse-Style Connector Kits
042418 Accepts 25 mm to 50 mm cable
042533 Accepts 50 mm to 70 mm cable
Kits include one male Dinse-style plug which attaches to
the work and/or weld cables and plugs into the Dinse-style
receptacles on the power source.
Extension Kit for Dinse-Style Cable Connectors
042419 Accepts 25 mm to 50 mm cable
Used to adapt or extend weld and/or work cables.
Kit includes one male Dinse-style plug and one in-line
female Dinse-style receptacle.
Extensions for Dinse-Style Cable Connectors
134460 Male Dinse-style plug
136600 Female Dinse-style receptacle
Used to adapt or extend weld and/or work cables.
Accepts 50 mm to 70 mm cable.
Standard
Running Gear and
Cylinder Rack
042886
Running gear
042887
Cylinder rack
For Deltaweld,
Dimension 562/812
and Gold Star.
Shown with optional
Running gear has
cylinder rack (042887).
254 mm (10 in.)
rear wheels and 127 mm (5 in.) front casters for excellent
mobility on the shop floor. Very easy to install. Handles
double as a cable holder. Cylinder rack only installs on
Standard Running Gear.
Dimension 650
Running Gear
301307
For Dimension 650.
Large 254 mm
(10 in.) rear wheels
and 127 mm (5 in.)
front casters provide
excellent mobility.
Easy to install.
Compatible with single and dual 70 Series feeders.
Handles double as a cable holder.
Note: Does not accommodate gas cylinders. Use Universal Trolley
(018035028) when gas cylinders are required.
MH Trolley 018035026
For Maxstar 210 DX/280 DX and
Dynasty 210 DX/280 DX with or
without Coolmate 1.3. Easy-tomaneuver two-wheel cart features
single-cylinder rack, chain for cylinder,
straps (quick and easy to detach and
carry machine), cable holders, torch
holder, storage area, and filler rod
storage area.
Small Runner™ Cart 301318
For Maxstar 210 DX/280 DX and
Dynasty 210 DX/280 DX with or
without Coolmate 1.3. Cart features
single-cylinder rack, foot pedal holder,
two cable/torch holders and two TIG
filler holders.
Runner™ Cart 300244
For Maxstar 400/800 and
Dynasty 400/800 with or without
Coolmate 3.5. Cart features
single-cylinder rack, foot pedal
holder, three cable/torch holders
and two TIG filler holders.
Universal Trolley
Universal Trolley (base) 018035028
For AlumaFeed System, XMS 425 MPa, Invision 352 MPa, Continuum,
Dimension 650, XMT, Maxstar, Dynasty and a coolant system.
Part of a flexible modular system that can be customized for your
particular needs. Includes easy-access cylinder rack in a small and easily
maneuverable footprint.
Universal Trolley TIG
Order base 018035028 and Shelf Kit 1 058066127 for a cart that can
hold a power source and coolant system.
Universal Trolley MIG
Order base 018035028, Shelf Kit 1 058066127, Shelf Kit 2 058066129
and Handle Kit 058066130 (not shown) for a cart that can hold a power
source, coolant system and wire feeder.
Universal Trolley (base)
Universal Trolley TIG
Universal Trolley MIG
Also available: Wire Feeder Support Swivel 028066300 and Coolmate 3
Mounting Brackets 028066301.
63
Accessories
Coolant Systems
Coolant
See literature AY/7.2
HydraCool 1
Coolmate 1.3
Coolmate™ 1.3
300972 120 V
For Maxstar 210 DX/280 DX and Dynasty
210 DX/280 DX. Light industrial, 4.9 L
cooler designed for water-cooled torches on
power sources rated up to 280 amps*.
Coolmate™ 3
043007 120 V 043008 240 V
Economical, 11.4 L cooler designed for
water-cooled torches rated up to 500 amps*.
Coolmate™ 3.5
300245 120 V
For Maxstar 400/800 and Dynasty 400/800.
Industrial, 13.2 L cooler designed for watercooled torches rated up to 600 amps*.
Coolmate 3.5
Coolmate 3
Coolmate 4
HydraCool 2
HydraCool® 1
028042103 120 V 028042104 240 V
Economical, 8 L cooler designed for watercooled torches rated up to 600 amps*.
HydraCool® 2
028042105 120 V 028042106 240 V
Economical, 8 L cooler designed for watercooled torches rated up to 600 amps*.
Coolmate™ 4
042288 120 V
Best performer in its class — industrial,
15 L cooler designed for water-cooled
torches rated up to 600 amps*.
Low-Conductivity Coolant
043810
Clear, pre-mixed coolant for TIG and MIG
applications. NOT for use in push-pull
systems or systems where aluminium is
in coolant path/circuit. Sold in multiples
of four, in 3.78-liter recyclable plastic
bottles. Coolant contains a base of
ethylene glycol and deionized water to
protect against freezing to -38° Celsius
(-37° F) or boiling to 108° Celsius
(227° F).
Coolant Flow Switch 195461
For external cladding head and water-cooled
torches. To ensure coolant is flowing in the
system. Lack of coolant flow may cause
damage to water-cooled torches. Module
allows wiring into the peripheral connector
port. 15.2 m (50 ft.) cable with connector
and separate shell connector for simple
modification to desired length in the field.
Quarter-turn quick connection.
*May vary with torch design and cable length. Miller coolant systems are backed by the best warranty in the industry — one full year.
Model
Motor Input Voltage
Maximum Current Draw
Maximum Cooling Capacity
IEC Cooling Capacity
Tank Capacity
Dimensions
Net Weight
Coolmate 1.3
115 V, 60 Hz
4.7 A (60 Hz)
3,400 W (11,600 Btu/hr.)
3.6 L/min. (3.8 qt./min.)
1,330 W (4,540 Btu/hr.)
1 L/min. (1.1 qt./min.)
4.9 L (1.3 gal.)
H: 286 mm (11.25 in.)
W: 264 mm (10.38 in.)
D: 610 mm (24 in.)
20 kg (43 lb.)
Coolmate 3
115 V, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
1,420 W (4,840 Btu/hr.)
1 L/min. (1.1 qt./min.)
H: 337 mm (13.25 in.)
W: 311 mm (12.25 in.)
D: 584 mm (23.25 in.)
18 kg (40 lb.)
2.5 A (50 Hz), 3.0 A (60 Hz)
3,820 W (13,000 Btu/hr.)
4.0 L/min. (4.2 qt./min.)
11.4 L (3 gal.)
230 V, 50/60 Hz
Coolmate 3.5
115 V, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
4,140 W (14,000 Btu/hr.)
4.7 L/min. (5.0 qt./min.)
1,660 W (5,660 Btu/hr.)
1 L/min. (1.1 qt./min.)
13.2 L (3.5 gal.)
H: 298 mm (11.75 in.)
W: 400 mm (15.75 in.)
D: 660 mm (26 in.)
29 kg (64 lb.)
HydraCool 1
115 V, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
H: 674 mm (26.5 in.)
W: 263 mm (10.4 in.)
D: 305 mm (12 in.)
20.7 kg (45.6 lb.)
2.5 A (50 Hz), 3.0 A (60 Hz)
1,670 W (5,698 Btu/hr.)
1 L/min. (1.1 qt./min.)
8 L (2.1 gal.)
230 V, 50/60 Hz
3,820 W (13,000 Btu/hr.)
4.0 L/min. (4.2 qt./min.)
115 V, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
H: 286 mm (11.3 in.)
W: 324 mm (12.8 in.)
D: 585 mm (23 in.)
20.8 kg (45.9 lb.)
2.5 A (50 Hz), 3.0 A (60 Hz)
1,760 W (6,005 Btu/hr.)
1 L/min. (1.1 qt./min.)
8 L (2.1 gal.)
230 V, 50/60 Hz
3,820 W (13,000 Btu/hr.)
4.0 L/min. (4.2 qt./min.)
115 V, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
5,500 W (18,000 Btu/hr.)
5.6 L/min. (5.9 qt./min.)
1,780 W (6,070 Btu/hr.)
1 L/min. (1.1 qt./min.)
15 L (4 gal.)
H: 413 mm (16.25 in.)
W: 387 mm (15.25 in.)
D: 476 mm (18.75 in.)
17 kg (38 lb.)
HydraCool 2
Coolmate 4
Polarity Reversing Switch Kit
301112 For Big Blue 500X Pro.
043942 DC polarity switch. For Big Blue 500X Pro.
195095 AC/DC polarity switch. For Big Blue 500X Pro.
Engine Drive Accessories
Cable Holder 043946
For Big Blue 500X Pro/500X CC.
Vandalism Lockout Kit
399802 Field
For Big Blue 500X Pro. Lockable
hinged steel panels cover and
protect name plate gauges and
ignition switch (padlock included).
Also includes engine compartment
door lock and key.
64
Engine Filter Kits
246987 CAT. For Big Blue 400X Pro.
253901 Kubota. For Big Blue 400X Pro.
246985 Perkins. For Big Blue 500X Pro/500X CC.
Protective Covers
195301 For Big Blue 400X Pro.
194683 For Big Blue 500X Pro/500X CC.
Heavy-duty, water- and mildew-resistant covers protect and
maintain the finish of the welder.
Spark Arrestor Muffler Kit
300585 For Big Blue 400X Pro.
195012 For Big Blue 500X Pro/500X CC.
International Plugs
255419 1-phase, 120 V, 16 A plug
255416 1-phase, 240 V, 16 A plug
255421 3-phase, 400 V, 32 A plug
Accessories
TIG Accessories
Protective Covers
301381 For Maxstar 210 DX.
301382 For Maxstar 280 DX
and Dynasty
210 DX/280 DX.
195478 For XMT 350/425.
Remote Controls
RMLS-14 (14-pin plug) 129337
Momentary- and maintained-contact rocker switch for
contactor control. Push forward for maintained contact and
backward for momentary contact. Includes 8 m (26.5 ft.)
cord with plug.
RFCS-6M (6-pin plug)
195183 4 m (13.25 ft.) cord with plug
195504 6 m (20 ft.) cord with plug
For STi and STH 160.
RFCS-14 (14-pin plug)
043554 6 m (20 ft.) cord with plug
Foot pedal current/contactor control.
RMS-6M (6-pin plug) 195269
For STi and STH 160.
RMS-14 (14-pin plug) 187208
Momentary-contact switch for contactor control. Rubbercovered pushbutton dome switch ideal for repetitive on-off
applications. Includes 8 m (26.5 ft.) cord with plug.
14-Pin to 6-Pin Adapter Cord
300507
For STi and STH 160. 305 mm
(12 in.) cord adapts Miller® 14-pin
foot control or fingertip control to a
6-pin plug.
RCC-6M (6-pin plug)
301118 4 m (13.25 ft.) cord with plug
For STi and STH 160.
RCC-14 (14-pin plug)
151086 8 m (26.5 ft.) cord with plug
East/west rotary-motion fingertip current/contactor control
attaches to TIG torch using two hook-and-loop fasteners.
Great for production or contractors that need quick ramp-up.
RCCS-6M (6-pin plug)
195184 4 m (13.25 ft.) cord with plug
195503 8 m (26.5 ft.) cord with plug
For STi and STH 160.
RCCS-14 (14-pin plug)
043688 8 m (26.5 ft.) cord with plug
North/south rotary-motion fingertip current/contactor control
attaches to TIG torch using two hook-and-loop fasteners.
Great for applications that require a finer amperage control.
HF 5000
RFCS-14 HD (14-pin plug) 194744
Heavy-duty foot pedal current/contactor control provides
increased stability and durability from larger base and
heavier cord. Cord can exit front, back or either side of the
pedal for flexibility. Includes 6 m (20 ft.) cord with plug.
RPBS-14 (14-pin plug) 300666
Attaches to the TIG torch to remotely start and stop the TIG
welding process. Includes 7.6 m (25 ft.) cord with plug.
SHRC-14 Remote Control
058040019 5 m (16.4 ft.)
058040020 10 m (32.8 ft.)
058040021 20 m (65.6 ft.)
Single-hand control for current only.
RHC-14* (14-pin plug)
242211020 6 m (20 ft. ) cord with plug
242211100 30.5 m (100 ft.) cord with plug
Miniature hand current/contactor control.
Dimensions: 102 x 102 x 82 mm (4 x 4 x 3.25 in.).
Torch Connector
273483
For STi and STH 160. 25 mm (small)
Dinse-style gas thru for one-piece
air-cooled torches.
See literature AYM/5.1
High-frequency arc starter provides excellent arc starting for DC TIG welding.
Excellent arc starting on thin stainless steel, brass,
copper, and a range of ferrous and non-ferrous alloys
Lightweight, portable design can be easily moved around
the workplace.
Compatible with Miller constant-current DC power
sources and others that feature a 14-socket receptacle.
Thermally protected secondary terminals automatically
shut off the unit if duty cycle is exceeded.
Easy-to-read front panel includes ammeter display and a
push-button interface with amperage and set-up controls.
Fan-cooled design protects the unit from overheating.
115 V (50/60 Hz) input meets most single-phase power
configurations, and is rated at 100 percent duty cycle.
Gas solenoid valve offers exact control over pre-flow
ranges and built-in post-flow eliminates contamination.
Stock Number
V29012345
14-pin receptacle on the front panel allows for easy
remote control connection.
Quick-connect fittings allow for quick installation of
water-cooled TIG welding torch.
Circuit breaker protects unit from primary power overload.
Input Power
Welding Amperage Range
Welding Voltage Range
Rated Output
IP Rating
Dimensions
Net Weight
115 V, single-phase,
500 mA, 50/60 Hz
5–450 A
10–95 V
400 A at 34 VDC,
100% duty cycle
IP23
H: 265 mm (10.4 in.)
W: 250 mm (9.8 in.)
D: 420 mm (16.5 in.)
13 kg
(28.7 lb.)
65
Accessories
Wireless Remote Foot and Hand Controls
Industrial
Processes
(GTAW) • Pulsed TIG (GTAW-P)
•TheTIGfollowing
processes are with
See literature AY/6.5 (Foot) and AY/6.6 (Hand)
Increases productivity, saves money, improves safety and easy to use.
Wireless
foot control
Wireless 14-pin receiver
(included with both systems)
Wireless hand control
hand control only
Improves productivity and maneuverability by eliminating cord
tangles. Reduces clean up time and work area cord clutter.
Improves safety by eliminating control cord and reducing potential
trip hazard.
Improves reliability by eliminating control cord failure.
Multiple frequency sharing allows up to 20 systems to operate in
a 27.4 m (90 ft.) radius with accuracy and precision — and without
delay, system interference, or crosstalk.
Easy-to-install receiver plugs directly into the 14-pin receptacle of
Miller® machines.
Easily programmable. Control can be quickly and easily paired with
any other Miller 14-pin wireless receiver. (Control is preprogrammed
when purchased with the receiver.)
Foot control
Hand control
Foot control is designed specifically for TIG welding
in manufacturing, fabrication and plant applications,
allowing operator to adjust amperage at point of use
without the limitations of remote cord.
Auto on feature extends the battery life up to 250 hours
of welding without turning the pedal on and off.
Easy-Glide Wear Pads™ glide across concrete, making it
easy to reposition the pedal for comfort and speed.
Hand control is designed for stick, TIG, MIG and flux-cored
welding, allowing operator to adjust parameters for different joint
configurations, electrodes and wire types/sizes at the point of use
instead of walking back to the machine.
Allows parameter adjustments up to 91 m away from welder
without returning to machine.
Improves weld quality. Operators can adjust their machines to
optimize the parameters for different joint configurations, electrodes,
and wire types and sizes.
Smart Touch™ buttons allow quick and accurate machine
parameter adjustments.
Digital meter display allows presetting percentage of machine output
before welding, and viewing amperage and voltage while welding.
*Some applications are not suitable for wireless communication.
Keep in mind that the rated range is subjective, and depends on
factors such as obstructions, frequency interference, transmission
technology, and weather. The figures listed assume ideal conditions
are present.
Stick (SMAW) • MIG (GMAW)*
• Flux-cored
(FCAW)
•
Model/Stock Number
Wireless Foot Control System
(300429)
Component
Foot control
(transmitter)
Power Supply
Three AA batteries
Battery Life
250 hours
Rated Range*
27.4 m (90 ft.)
Wireless Hand Control System
(300430)
Hand control
(transmitter)
Three AA batteries
250 hours
91 m (300 ft.)
Temperature
-25° to +70°C
(-13° to +158°F)
Radio Frequency
2.4 GHz (ISM band)
RF Power
<3 mW
*Only with voltage-sensing feeder.
Comes complete with
foot control (300429) or
• Wireless
hand control (300430) transmitter
14-pin receiver (300722)
• Wireless
box (249297)
• Battery
AA batteries
• Three
Easy-Glide Wear Pads
• Four
(for foot control only)
™
(sold individually, 248274)
clip (for hand control only)
• Belt
(249233)
Suggested power sources
Look throughout this catalog for the
icon above signifying compatibility
with a wireless remote.
Antenna
Internal
Dimensions
H: 152 mm (6 in.)
W: 146 mm (5.75 in.)
D: 292 mm (11.5 in.)
H: 127 mm (5 in.)
W: 70 mm (2.75 in.)
D: 35 mm (1.375 in.)
Weight
1.4 kg
(3 lb.)
w/batteries
0.27 kg
(0.6 lb.)
w/batteries
Wire Feeder Accessories
Interconnecting Cables
Spool Adapter
Extension Cables (14-Pin)
Air-Cooled Interconnecting Cable Assembly
058019242 1.5 m (4.9 ft.)
058019243 2.5 m (8.2 ft.)
058019244 5 m (16.4 ft.)
058019245 10 m (32.8 ft.)
058019246 15 m (50 ft.)
058019247 20 m (65.6 ft.)
047141
For use with 6.4 kg (14 lb.) spool of Hobart or Lincoln
self-shielding wire.
8-Conductor Cables
242208025 7.6 m (25 ft.)
242208050 15 m (50 ft.)
242208080 24.4 m (80 ft.)
For SuitCase 12RC and 70 Series (except MPa Plus)
feeders, and XR-Control. For 14-pin remote controls/
24 VAC wire feeders. 14-pin plug to a 14-pin socket.
(Not for 115-volt XR or 50 Series feeders.)
11-Conductor Cables
247831025 7.6 m (25 ft.)
247831050 15 m (50 ft.)
247831080 24.4 m (80 ft.)
For XR-AlumaFeed and MPa Plus feeders. Eleven conductors
to support contactor control and remote voltage control on
all Miller® electronic CV 14-pin power sources. Additional
functions supported when using the Invision MPa or XMT
MPa power sources include synergic pulsed MIG, remote
process select and side select capabilities.
66
Water-Cooled Interconnecting Cable Assembly
027112337 1.5 m (4.9 ft.)
058019237 2.5 m (8.2 ft.)
058019236 5 m (16.4 ft.)
058019239 10 m (32.8 ft.)
058019240 15 m (50 ft.)
058019241 20 m (65.6 ft.)
For XMS 425 MPa. 70 mmq weld cable, control cable and
gas hose. Water-cooled assemblies adds water hose.
Turntable Assembly
146236
Allows feeder to rotate as operator changes work position.
Reduces strain and bending of gun cable.
Wire Straightener
For 20 Series and 70 Series.
141580 For 0.9–1.1 mm (.035–.045 in.) wire.
141581 For 1.6–3.2 mm (1/16–1/8 in.) wire.
WE BUILD
connections
™
Contents
New From Blue 3
Help Me Choose 4
MIG (GMAW) 6
Wire Feeders 17
MIG Guns 23
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and high-performance products for all of your projects.
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Multiprocess 29
Stick (SMAW) 39
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TIG (GTAW) 43
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Index New! or Improved! products appear in blue type.
Welding System . . . . . 11
A AlumaFeed
Auto-Continuum Systems . . . . . . . 16
BTB MIG Guns. . . . . . . . . 23
B Bernard
Bernard Dura-Flux Guns . . . . . . . . 24
Bernard Fume Extraction Guns . . . 24
Big Blue 400X Pro . . . . . . . . . . . . 57
Big Blue 500X Pro . . . . . . . . . . . . 58
Big Blue 500X CC. . . . . . . . . . . . . 58
Blue Thunder Series . . . . . . . . . . . 42
G Gold Star Series . . . . . . . . . . . . . . 42
H HF 5000 . . . . . . . . . . . . . . . . . . . . 65
. . . . . . . . . . . . . . . . . . . . . . 20
I I-24A
Insight ArcAgent . . . . . . . . . . . . . . 56
Insight Centerpoint . . . . . . . . . . . . 55
Insight Core . . . . . . . . . . . . . . . . . 54
Invision MPa Plus System . . . . . . . 14
210 DX . . . . . . . . . . . . . . 44
Systems . . . . . . . . . . . 15
M Maxstar
C Continuum
Maxstar 280 DX . . . . . . . . . . . . . . 44
Coolant Systems . . . . . . . . . . . . . . 64
Series . . . . . . . . . . . . . . 13
D Deltaweld
Dimension 562/812 . . . . . . . . . . 31
Dimension 650 . . . . . . . . . . . . . . 31
Dynasty 210 DX . . . . . . . . . . . . . . 44
Dynasty 280 DX . . . . . . . . . . . . . . 44
Dynasty 400/800 . . . . . . . . . . . . 45
Maxstar 400/800 . . . . . . . . . . . . 45
MigMatic 175 . . . . . . . . . . . . . . . . 7
MigMatic 220/220 DX. . . . . . . . . . 7
MigMatic 250/250 DX. . . . . . . . . . 7
MigMatic 300/300 DX. . . . . . . . . . 8
MigMatic 380/380 DX. . . . . . . . . . 8
MPi 220P . . . . . . . . . . . . . . . . . . . 30
350 FieldPro System . . . 34
P PipeWorx
PipeWorx XC Welding System . . . . 36
PipeWorx 400 Welding System . . . 37
Series . . . . . . . . . . . . . . . . . . . 20
S 70
70 Series Remote Configurations . 22
Si 160/160 PFC. . . . . . . . . . . . . . 39
STH 160/160 L . . . . . . . . . . . . . . 43
STi 160. . . . . . . . . . . . . . . . . . . . . 40
STi 203. . . . . . . . . . . . . . . . . . . . . 40
STR 400/500 Series . . . . . . . . . . 41
ST Series . . . . . . . . . . . . . . . . . . . 20
SubArc Accessories. . . . . . . . . . . . 62
SubArc Digital Series . . . . . . . . . . 59
SubArc Components. . . . . . . . 60/61
SubArc Digital 4-Wheel Tractor . . . 62
SuitCase Series. . . . . . . . . . . . . . . 18
T Tregaskiss Robotic MIG Guns . . . . 25
TIG Torches . . . . . . . . . . 46
W Weldcraft
Wireless Remote Controls . . . . . . . 66
425 MPa Welding System . . 13
X XMS
XMT 350 FieldPro System. . . . . . . 34
XMT Series . . . . . . . . . . . . . . . . . . 32
XPS Series . . . . . . . . . . . . . . . . . . . 9
XR Push-Pull Guns . . . . . . . . . . . . 26
XR Control. . . . . . . . . . . . . . . . . . . 27
Contact us
Austria
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© 2017 Miller Electric Mfg. Co.
Middle East and Caspian Region
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Algeria, Morocco, Tunisia
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Egypt, Libya, Sudan
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Sub-Saharan Africa
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