Full-line Catalog MillerWelds.com 2016

Full-line Catalog MillerWelds.com 2016
™
with you
Full-line Catalog
MillerWelds.com
2016
™
with you
From left to right:
Todd Engel
Seagrave Fire Apparatus
Stacy Tucker
Detroit Speed
Clay Adkins II
Textron Systems
Louis Graham
Avalon & Tahoe Mfg., Inc.
Your talent. Miller® products.
Together, we can build anything.
Hard-working people who have the drive to achieve — and the desire to create. Hard-working
products that have the durability to serve — and the design to inspire.
People like you. Products from Miller. Together, what we do is nothing short of amazing.
Because together, we build skills. We build confidence. We build careers. We build our world.
Miller and you. Together, we build.
MillerWelds.com/webuild
For list prices or to find your local distributor,
visit us on the Web or give us a call.
MillerWelds.com
1-800-4-A-Miller (1-800-426-4553)
New from Blue
7
Millermatic®125 Hobby
23
Continuum 350
74
Big Blue®600 Pro
™
9
Millermatic®211
33
Dimension 650
ArcReach
80
SubArc Portable
Welding System
™
™
18
Spoolmate 150
Spool Gun
54
Maxstar®210 Series
Dynasty®210 Series
™
95/96
Digital Infinity Series
Welding Helmets and
Safety Glasses
Shop with Expert
Advice and Attention
Shop with Speed
and Convenience
Visit your local Miller distributor for
in-depth knowledge and one-on-one
assistance in product selection.
MillerWelds.com/wheretobuy
Visit MillerWelds.com for a fast
and easy way to buy welding
products for your home or shop.
™
Help me choose.
Finding the welding or cutting 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 or cut.
Process skill level Low Moderate High
Metal type
S Steel
SS Stainless Steel
Ni Nickel Alloys
AL Aluminum
CI Cast Iron
CB Copper/Brass
Ti Titanium
Mg Magnesium Alloys
EC All Electrically Conductive
Welding processes
MIG (GMAW) Resistance Spot S SS Ni
S SS Ni AL CB
•
•
•
•
•
Easiest process to learn
High welding speeds possible
Provides better control on thinner metals
Cleaner welds possible with no slag
Same equipment can be used for flux-cored welding
Pulsed MIG (GMAW-P) S SS Ni AL CB
and productivity — nearly all metals can
• Flexibility
be welded in all positions
diameter electrode wires for higher
• Larger
deposition rates
no spatter
• Virtually
Welds
thin
to thick metals
•
Flux-cored (FCAW) S SS
work as well as stick on dirty or rusty material
• Can
welding
• Out-of-position
penetration for welding thick sections
• Deep
• 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
•
Simple, easy-to-operate welder for light industrial
• applications
Submerged Arc (SAW) S SS
deposition rates can enhance weld speed
• High
and production
Excellent mechanical properties for high-quality
• code
and X-ray requirements
• Improves welding operator comfort and appeal
Cutting processes
Plasma Arc Cutting and Gouging (PAC) S SS Ni AL CI CB Ti Mg EC
with any electrically conductive metals
• Use
and precise cut
• Small
heat-affected zone which helps prevent
• Small
warping or paint damage
Oxy-fuel Cutting S
ferrous (containing iron) steels
• Cuts
Requires
no electricity
• Highly portable
•Note: Oxy-fuel equipment can also be used for welding, heating,
brazing and soldering
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
•
•
4
Air Carbon Arc Cutting and Gouging (CAC-A) AC CB DC S SS AL CI
Wide variety of metals
Removes discontinuities or inferior welds
•
•
Input power
Does your machine need to be self-powered, or will AC power
be available at the location where it’s primarily used?
For locations where an electrical hookup is not practical,
• consider
a gas- or diesel-powered engine-driven
welder/generator to supply welding and generator power.
For locations where AC power is available, you need to
• know
its type — and whether it’s a match for the machine
you’re considering:
Single-phase power is found in most homes and garages.
Check to see if the machine you’re considering requires
single-phase power, and whether its voltage requirements
(120 or 240 volts) are met by the electrical service at the
intended location.
Three-phase power is common in industrial settings.
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.
Output power
Light industrial products are suitable for the home hobbyist
or occasional user. They are designed to be easy to operate,
are affordably priced and typically have a 20 percent duty
cycle and rated output of 230 amps or lower.
Industrial products are suitable for applications that do
not require high-volume production. They typically have a
40 to 60 percent duty cycle and/or rated output of 300 amps
or lower. 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.
Power icons
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
Generator power
Out in the field, you may need an engine-driven welder/
generator to supply 120- or 240-volt 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.
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.
Many engine-driven welding generators fit in the back of a
• pickup
truck, 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
Page
Class
MIG
Pulsed MIG*
Flux-cored**
CAC-A
2
Evaluate your needs: input power, output
power, generator power and portability.
Millermatic®
125 Hobby
7
Millermatic® 141
8
Millermatic® 190
8
Millermatic® 211
9
Millermatic®
212 Auto-Set™
9
Millermatic® 252
10
Portability
Welding
Weldable Output
Metals Range
Handle, optional
running gear
Steel,
stainless
30–130 A
All-in-one, 115 V input, Auto-Set™ for .030 solid wire
Up to 3/16 in.*** using self-shielded wire, hobb
Steel,
stainless,
aluminum
30–140 A
All-in-one, 120 V input, Auto-Set,™ Smooth-Start™
Up to 3/16 in.*** using self-shielded wir
maintenance/repair, auto body, hobby
Installed running gear
Steel,
stainless,
aluminum
Special Features
Typical Applications
All-in-one, 240 V input, Auto-Set,™ Smooth-Start™
Up to 5/16 in.*** maintenance/repair, a
30–230 A
All-in-one, 120 or 240 V input, Auto-Set,™ Smooth-Start™
Up to 3/8 in.*** maintenance/repair,
30–210 A
All-in-one, 230 V input, Fan-On-Demand,™
Gun-On-Demand™
Up to 3/8 in.*** fabrication, farm
30–300 A
All i o e t d d
30–190 A
Note: Units listed in more than one classification share attributes of both.
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 similarsized 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
POWER SOURCES/PACKAGES
GMAW
Millermatic® 252
Industrial
See literature no. DC/12.49
Processes
Welding Capability
Max. 1/2 in. (13 mm)
Max. 3/8 in. (9.5 mm)
Mild Steel
Aluminum
Min. 22 ga. (0.8 mm)
Min. 14 ga. (1.9 mm)
Aluminum welding uses
optional Spoolmatic 15A
or 30A spool gun.
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
m), 250-amp M-25 gun
• 1510 ft.ft. (4.5
cable with clamp
• 10 ft. (3(3 m)m) work
power cord
• (and plug onindustrial
200/230 V model)
gas solenoid
• Factory-installed
gauge regulator and gas hose
• Flow
for argon or AR/CO mix
Factory-installed
lowered
• gear/cylinder rack running
in. reversible dual-groove
• .030/.035
drive rolls
• Extra contact tips
Most popular accessories
Spoolmate
200 and Spoolmatic
• Spool Guns (pg
18/19)
Push-Pull Guns (pg 20)
• XRDualAir-Cooled
Low Cylinder Rack
• #300EZ-Change
337 (pg 106)
Elevated
Gun
and
• #300 335 (pg 106)Cable Rack
• Protective Cover #195 142 (pg 109)
2
For more product
specifications, give
the product name and
literature number to
your distributor, visit
us on the Web at
MillerWelds.com or
call 1-800-4-A-MILLER.
Recommended
aluminum solution
Spoolmatic 15A (#195 156)
or 30A (#130 831).
*With Spoolmatic 30A, regulator, gas hose and
dual cylinder rack.
Model/Stock Number
(#907 321) 200(208)/230 V
(#951 066*) 200(208)/230 V
(#907 322) 230/460/575 V
(#951 065*) 230/460/575 V
Amperage
Range
30–300
Infinite voltage control with self-calibrating digital meters that permit
presetting of voltage and wire feed speed. Ensures precise parameters
and accuracy.
EXCLUSIVE! Auto-Gun Detect™ automatically adjusts voltage, wire speed
and timers for faster switching between MIG, push-pull and spool guns.
Integrated digital timers come complete with presettable preflow/postflow,
burnback, spot and delay (stitch) timers. Independent timers for MIG and
spool gun.
Heavy-duty aluminum, two-drive-roll system.
Fan-On-Demand™ cooling system only operates when needed reducing
power consumption and keeping internal components cleaner.
Superior aluminum MIG welding with direct connection of optional
XR™ push-pull guns, Spoolmatic®/Spoolmatic Pro and Spoolmate™ 200
spool guns. No extra module to buy or install.
Rated Output
200 A at 28 VDC,
60% duty cycle
250 A at 28 VDC,
40% duty cycle
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V 575 V KVA KW
48
42
—
—
9.5 7.5
(at 60% duty cycle)
—
46
23
18
9.5 7.5
(at 60% duty cycle)
®
™
™
™
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Wire Feed Speed
Wire Type and Diameter Capacity
Dimensions
50–700 ipm
(1.3–17.8 m/min.)
Solid steel .023–.045 in. (0.6–1.2 mm)
Stainless .023–.045 in. (0.6–1.2 mm)
Flux-cored .030–.045 in. (0.8–1.2 mm)
H: 30 in. (762 mm)
W: 19 in. (483 mm)
D: 40 in. (1,016 mm)
Net
Weight
205 lb.
(94 kg)
Brief listing of most popular accessories. Refer to pages listed for more details.
5
MIG
For more detailed
information, visit
GMAW
MillerWelds.com/mig
Guns and Controls
Power Sources
Product
Guide
Page
Class
MIG
Pulsed MIG*
Flux-cored**
CAC-A
Also see Multiprocess section for machines that can MIG weld.
Millermatic®
125 Hobby
7
Millermatic® 141
8
Millermatic® 190
8
Millermatic® 211
9
Millermatic®
212 Auto-Set™
9
Millermatic® 252
10
Millermatic® 350P
10
CP-302
12
Deltaweld® 302
12
Deltaweld® 452
12
Deltaweld® 652
12
Invision™ 352 MPa
Plus System
Portability
Welding
Weldable Output
Metals Range
Special Features
Typical Applications
Handle, optional
running gear
Steel,
stainless
30–130 A
All-in-one, 115 V input, Auto-Set™ for .030 solid wire
Up to 3/16 in.*** using self-shielded wire, hobby
Steel,
stainless,
aluminum
30–140 A
All-in-one, 120 V input, Auto-Set,™ Smooth-Start™
Up to 3/16 in.*** using self-shielded wire
maintenance/repair, auto body, hobby
30–190 A
All-in-one, 240 V input, Auto-Set,™ Smooth-Start™
Up to 5/16 in.*** maintenance/repair, auto body, hobby
30–230 A
All-in-one, 120 or 240 V input, Auto-Set,™ Smooth-Start™
Up to 3/8 in.*** maintenance/repair, auto body, hobby
30–210 A
All-in-one, 230 V input, Fan-On-Demand,™
Gun-On-Demand™
Up to 3/8 in.*** fabrication, farm, garage/body shops
30–300 A
All-in-one, standard timers menu, Fan-On-Demand,™
can connect MIG gun, push-pull gun or spool gun
Up to 1/2 in.*** industrial production/fabrication, farm
25–400 A
All-in-one, can connect standard MIG gun, push-pull
gun or spool gun — auto body aluminum repair system
available (see page 15)
Up to 1/2 in.*** industrial production/fabrication,
pulsed MIG ideal for thin gauge aluminum
14–44 V
Hi/lo stabilizer, power efficient
Equip/auto mfg, metal fab, construction, agri equipment
10–32 V
Power efficient, material-specific output terminals
Equip/auto mfg, metal fab, construction, agri equipment
10–38 V
Power efficient, material-specific output terminals
Equip/auto mfg, metal fab, construction, agri equipment
Installed running gear
Steel,
stainless,
aluminum
1⁄ 4"
13
Invision™ 450 MPa
Plus System
13
5⁄ 16"
Millermatic® 350P
Aluminum
16
Installed running gear
AlumaFeed™ 350
Aluminum System
17
Handles, optional cart,
MIGRunner ™
AlumaFeed™ 450
Aluminum System
17
Spoolmate™
Spool Guns
18
12 ft. (100) or 20 ft.
(150/200/3035) cable
Spoolmatic®
Spool Guns
19
15 or 30 ft. cable
XR™-Pistol
Push-Pull Guns
20
15 or 30 ft. (Pistol) or
15, 25 or 35 ft.
(Pistol-Pro) cable
XR-Aluma-Pro™ Lite
Push-Pull Gun
20
XR-Aluma-Pro™
Push-Pull Guns
20
XR™-Controls
Handles, optional cart
.030–1/16 in. (0.8–1.6 mm) wire capacity, push-pull
Heavy industrial aluminum fabrication
Class: Light Industrial Industrial Heavy Industrial
Capability: Designed for this process Capable of this process
New! or Improved! products appear in blue type. *Guns and controls require pulse capable power source. **If using self-shielded wire on a CC/CV machine, use CV weld output. ***In a single pass.
Product Key
Lift eye,
optional running gear,
MIGRunner ™
Most
metals
3⁄ 8"
1⁄ 4"
Handles, optional cart,
MIGRunner ™
10–44 V
Power efficient, material-specific output terminals
Equip/auto mfg, metal fab, construction, agri equipment
5–425 A
10–38 V
Alumination™ allows push/pull gun,
optimized with 74 MPa Plus wire feeder
Manufacturing and production
15–600 A
10–38 V
Alumination™ allows push/pull gun,
optimized with 74 MPa Plus wire feeder
Manufacturing and production
Aluminum
25–400 A
All-in-one, optimized for feeding aluminum
wire only using a push-pull gun or spool gun
Up to 1/2 in.*** industrial aluminum production/fab,
pulsed MIG ideal for thin gauge aluminum
Aluminum
5–425 A
10–38 V
Profile Pulse,™ lightweight feeder can be up to
100 feet from power source
Heavy industrial aluminum production/fabrication,
truck trailer, shipbuilding
15–600 A
10–38 V
Profile Pulse,™ lightweight feeder can be up to
100 feet from power source
Heavy industrial aluminum production/fabrication,
truck trailer, shipbuilding
Steel,
stainless,
aluminum
—
.023–.035 in. (0.6–0.9 mm) wire capacity, economical, Light industrial aluminum fabrication
135 A (100), 150 A (150/3035), 160 A (200)
Aluminum
—
Most
metals
.030–1/16 in. (0.8–1.6 mm) wire capacity;
easy-to-rotate, self-seating head tube on Pro model
Industrial aluminum fabrication
.030–1/16 in. (0.8–1.6 mm) wire capacity,
air- and water-cooled models; easy-to-rotate,
self-seating head tube on Pro model
Heavy industrial aluminum fabrication
25 ft. cable
.030–3/64 in. (0.8–1.2 mm) wire capacity,
lightweight, air-cooled
Industrial aluminum fabrication
15, 25 or 35 ft. cable
.030–1/16 in. (0.8–1.6 mm) wire capacity,
high-amperage, air- and water-cooled models
Heavy industrial aluminum fabrication
21
See MIG packages chart (page 11) and aluminum solutions chart (page 14) for additional information.
6
ALL-IN-ONE
MIG
GMAW
Millermatic 125 Hobby
®
Light industrial
See literature no. DC/12.3
Processes
Auto-Set™ for .030-inch solid wire selects the correct
parameters for the material you are welding.
Turn the wire speed knob to Auto-Set
Dial in the thickness of material you are welding
Start welding!
•
•
•
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
ft. (2.4 m) M-80 MIG gun and
• 8cable
assembly
ft. (2.4 m) work cable with clamp
• 8Power
cord with plug
• Quick Select
drive roll for
• .024 in. (0.6 mm)
or .030/.035 in.
™
Manual mode allows you to set your own parameters.
Tapped voltage control allows you to easily adjust
the voltage when changing material thicknesses.
Cast-aluminum drive system with calibrated tension
knob creates consistent feeding and easy setup.
Factory-installed gas solenoid makes it easy to
change from MIG welding to flux-cored wire welding.
Quick Select™ drive roll makes setup quicker by
offering three grooves — two for different size solid
wire and a third for flux-cored wire.
Welding Capability
Max. 3/16 in. (4.8 mm)
Mild Steel
•
(0.8/0.9 mm) solid wire, and
.030/.035 in. (0.8/0.9 mm)
flux-cored wire
Fixed flow regulator and gas hose,
two .030 in. contact tips, Hobart®
spool of .030 in. solid wire and
material thickness gauge (#229 895)
Most popular accessories
Gear/Cylinder Rack
• Running
#301 239 (pg 106)
• Protective Cover #301 333 (pg 109)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Thermal overload protection shuts down unit and
activates the over temperature light if airflow is
blocked or duty cycle is exceeded. Automatically
resets when unit cools.
Min. 24 ga. (0.6 mm)
Uses 4- or 8-inch (102 or 203 mm) spools.
Stock Number
(#907 692)
(#951 678) with running
gear/cylinder rack
Input
Power
Amperage
Range
115 V
30–130
Rated Output
85 A at 18.25 VDC,
20% duty cycle
Amps Input at Rated Output, 60 Hz
115 V
KVA
KW
20
2.79
2.65
Wire Feed Speed
Wire Type and Diameter Capacity
Machine Only
Dimensions
Machine Only
Net Weight
0–415 ipm
(0–11 m/min.)
Solid steel .023–.030 in. (0.6–0.8 mm)
Stainless .023 in. (0.6 mm)
Flux-cored .030–.035 in. (0.8–0.9 mm)
H: 16.875 in. (429 mm)
W: 9.875 in. (251 mm)
D: 12.125 in. (308 mm)
49.7 lb.
(22.5 kg)
The Miller Owners Club
®
Created for welders who are passionate
about what they do, the Miller Owners
Club provides a personalized experience
at Owners.MillerWelds.com. Since
membership is limited to Miller equipment
owners, members have exclusive access to
product previews,
welding tips and
project ideas
that support a
welder’s ability to
do great work.
Sign up now at Owners.MillerWelds.com
7
ALL-IN-ONE
MIG
GMAW
Millermatic 141 and 190
®
See literature no.
DC/12.42 (141) and DC/12.44 (190)
Light industrial
Processes
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
(3 m) M-100 MIG gun and
• 10cableft. assembly
(#248 282)
cable with clamp
• 106.5ft.ft.(3(2m)m)work
cord with plug
• Quick Select power
drive
roll
for
• .024 in. (0.6 mm) or .030/.035
in.
™
(0.8/0.9 mm) solid wire, and
.030/.035 in. (0.8/0.9 mm)
flux-cored wire
Millermatic 190
gauge regulator and gas hose
• Flow
for argon or AR/CO mix, two .030 in.
Millermatic 141
2
Mild Steel Welding Capability
Max.
5/16 in. (7.9 mm)
3/16 in. (4.8 mm)
Model
141
190
Min.
24 ga. (0.6 mm)
24 ga. (0.6 mm)
Aluminum Welding Capability
Max.
1/4 in. (6.4 mm)
Model
14 ga. (1.9 mm)
141
190
Min.
18 ga. (1.2 mm)
18 ga. (1.2 mm)
Aluminum welding uses optional Spoolmate 100
spool gun and 4043 series aluminum wire.
Recommended
aluminum solution
Spoolmate 100 (#300 371).
Auto-Set™ automatically provides the right settings to weld mild steel
while infinite voltage control allows the flexibility to manually set your
own parameters.
Set the wire diameter
(.024- or .030-inch diameter
solid steel wire), a blue light
shows Auto-Set is activated
Dial in the thickness of
material you are welding
Start welding with the exact parameters you need!
Angled cast-aluminum drive system with calibrated tension knob creates
consistent feeding and easy setup with included 10-foot (3 m) MIG gun or
optional 15-foot (4.6 m) M-150 MIG gun (pg 11).
Quick Select™ drive roll makes setup quicker by offering three grooves —
two for different size solid wire and a third for flux-cored wire.
Auto Spool Gun Detect™ automatically detects when a MIG gun or spool
gun is connected eliminating the need for a switch.
Smooth-Start ™ provides a smooth, spatter-free start.
Thermal overload protection shuts down unit and activates the
over temperature light if airflow is blocked or duty cycle is exceeded.
Automatically resets when unit cools.
Uses 4- or 8-inch (102 or 203 mm) spools.
•
contact tips, Hobart® spool of
.030 in. solid wire, hook-and-loop
cord wraps and material thickness
gauge (#229 895)
Most popular accessories
• Spoolmate 100 #300 371 (pg 18)
™
•
•
Gear/Cylinder Rack
• Running
#301 239 (pg 106)
• Protective Cover #301 262 (pg 109)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Millermatic 190 model additional features
Inverter technology combines best-in-class arc characteristics with the
portability of a 35-pound machine. The arc is extremely forgiving to
variations in arc length and travel speeds.
Fan-On-Demand™ power source cooling system operates only when
needed, reducing noise, energy use and the amount of contaminants
pulled though the machine.
Amps Input at Rated Output, 60 Hz
240 V
KVA
KW
120 V
Input
Power
Amperage
Range
Millermatic 141
(#907 612)
(#951 601) with running
gear/cylinder rack
120 V
30–140
90 A at 18.5 VDC,
20% duty cycle
20
—
3.0
Millermatic 190
(#907 613)
(#951 602) with running
gear/cylinder rack
240 V
30–190
140 A at 21 VDC,
40% duty cycle
—
21
5.0
Model/Stock Number
8
Rated Output
Wire Feed Speed
Wire Type and Diameter Capacity
2.45
15–360 ipm
(0.4–9.1 m/min.)
Solid steel .023–.030 in. (0.6–0.8 mm)
Stainless .023–.030 in. (0.6–0.8 mm)
Flux-cored .030–.035 in. (0.8–0.9 mm)
3.8
60–600 ipm
(1.5–15.2 m/min.)
Solid steel .023–.035 in. (0.6–0.9 mm)
Stainless .023–.035 in. (0.6–0.9 mm)
Flux-cored .030–.035 in. (0.8–0.9 mm)
Machine Only
Dimensions
Machine Only
Net Weight
H: 12.5 in.
(318 mm)
W: 11.25 in.
(286 mm)
D: 20.5 in.
(521 mm)
51 lb.
(23.1 kg)
35 lb.
(15.9 kg)
ALL-IN-ONE
MIG
GMAW
Millermatic 211
®
Light Industrial
See literature no. DC/12.58
Processes
Welding Capability
Max. 3/8 in. (9.5 mm)
Max. 3/8 in. (9.5 mm)
Mild Steel
Aluminum
Min. 24 ga. (0.6 mm)
Min. 18 ga. (1.2 mm)
Aluminum welding uses
optional Spoolmate 100 or
Spoolmate 150 spool guns.
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
(3 m) M-100 MIG gun and
• 10cableft. assembly
(#248 282)
cable with clamp
• 106.5ft.ft.(3(2m)m)work
cord with MVP
• plugs for 120power
V and 240 V
Select drive roll for
• Quick
.024 in. (0.6 mm) or .030/.035 in.
™
Multi-voltage plug (MVP ™) allows connection to common
120- and 240-volt power receptacles without the use of
any tools — simply choose the plug that fits the
receptacle and connect to the power cord.
Recommended
aluminum solutions
Spoolmate 100 (#300 371)
or 150 (#301 272).
Stock Number
(#907 614)
(#951 603)
with running
gear/cylinder
rack
Advanced Auto-Set ™ now includes five different wire/gas
combinations and .024-, .030- and .035-inch wires. The easiest
welder to use just became more versatile. Manual mode allows you
to set your own parameters while welding.
Inverter technology combines best-in-class arc characteristics
with the portability of a 38-pound machine. The arc is extremely
forgiving to variations in arc length and travel speeds.
Angled cast-aluminum drive system with calibrated tension knob for
consistent feeding and easy setup for up to 15-foot (4.6 m) MIG guns.
Quick Select™ drive roll makes setup quicker by offering three grooves
— two for different size solid wire and a third for flux-cored wire.
Auto Spool Gun Detect™ automatically detects when a MIG gun or
spool gun is connected eliminating the need for a switch.
Fan-On-Demand™ and thermal overload protection protect your
investment (see page 8 for more information).
Smooth-Start™ provides a smooth, spatter-free start. It’s the
best-starting machine in the small MIG machine category.
Uses 4- or 8-inch (102 or 203 mm) spools.
Input
Power
Amperage
Range
120 V
30–130
115 A at 19.8 VDC,
20% duty cycle
24.3
—
2.9
2.9
240 V
30–230
150 A at 21.5 VDC,
40% duty cycle
—
16.6
4.0
4.0
Rated Output
Amps Input at Rated Output, 60 Hz
120 V
240 V
KVA
KW
30–210
160 A at 24.5 VDC,
60% duty cycle
Solid steel .023–.035 in. (0.6–0.9 mm)
Stainless .023–.035 in. (0.6–0.9 mm)
Flux-cored .030–.045 in. (0.8–1.2 mm)
H: 12.5 in. (318 mm)
W: 11.25 in. (286 mm)
D: 20.5 in. (521 mm)
38 lb.
(17.2 kg)
Light Industrial
See literature no. DC/12.46
Max. 3/8 in. (9.5 mm)
Max. 3/8 in. (9.5 mm)
Mild Steel
Aluminum
Min. 22 ga. (0.8 mm)
Min. 14 ga. (1.9 mm)
Amps Input at Rated Output, 60 Hz
200 V
230 V
KVA
KW
31
28
6.2
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
60–600 ipm
(1.5–15.2 m/min.)
Aluminum welding uses
optional Spoolmate 200
spool gun.
5.2
Processes
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
m), 250-amp M-25 gun
• 1510 ft.ft. (4.5
cable with clamp
• 7 ft. (2.1(3 m)m)work
power
• Flow gauge regulatorcordandandgas plug
• for argon or AR/CO mix hose
lowered running
• Factory-installed
gear/cylinder rack
in. reversible dual-groove
• .030/.035
drive rolls
contact tips and material
• Extra
thickness gauge (#229 895)
2
Auto-Set makes setup quick and easy. On the Millermatic 212, it
works with .030- and .035-inch wire (see page 8 for more information).
Infinite voltage control. When used in manual mode provides
broader operating range with finer control than a tap machine.
Gun-On-Demand.™ Simply pull the trigger for either gun and you’re ready
to weld. No wasted time installing modules and using gas valve kits.
Heavy-duty aluminum, two-drive-roll system.
Fan-On-Demand™ cooling system only operates when needed reducing
power consumption and keeping internal components cleaner.
Aluminum MIG welding with optional Spoolmate™ 200 spool gun.
Wire feed speed control on the gun saves time by reducing trips
back to the machine. Also compatible with the more industrial
Spoolmatic® spool guns.
Rated Output
™
Machine Only
Net Weight
™
Amperage
Range
™
Machine Only
Dimensions
Welding Capability
Stock Number
(#907 405) 200(208)/230 V
(#951 177) 200(208)/230 V
with Spoolmate 200, regulator,
gas hose and dual cylinder rack
100 #300 371 (pg 18)
• Spoolmate
150 #301 272 (pg 18)
• Spoolmate
Gear/Cylinder Rack
• Running
#301 239 (pg 106)
Cover #301 262 (pg 109)
• Protective
• V-Knurled Drive Roll #202 926
Wire Type and Diameter Capacity
™
Spoolmate 200 (#300 497).
Most popular accessories
Wire Feed Speed
Millermatic® 212 Auto-Set
Recommended
aluminum solution
•
(0.8/0.9 mm) solid wire, and
.030/.035 in. (0.8/0.9 mm)
flux-cored wire
Flow gauge regulator and gas hose
for argon or AR/CO2 mix, two .030 in.
contact tips, Hobart® spool of
.030 in. solid wire, hook-and-loop
cord wraps and material thickness
gauge (#229 895)
Most popular accessories
200 #300 497 (pg 18)
• Spoolmate
Dual
EZ-Change
• #300 337 (pg 106)Low Cylinder Rack
Gun and Cable Rack
• Elevated
#300 335 (pg 106)
Cover #195 142 (pg 109)
• Protective
• Full KVA Adapter Cord #300 517
™
™
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Wire Feed Speed
Wire Type and Diameter Capacity
Dimensions
50–700 ipm
(1.3–17.8 m/min.)
Solid steel .023–.035 in. (0.6–0.9 mm)
Stainless .023–.035 in. (0.6–0.9 mm)
Flux-cored .030–.045 in. (0.8–1.2 mm)
H: 30 in. (762 mm)
W: 19 in. (483 mm)
D: 40 in. (1,016 mm)
Net
Weight
183 lb.
(83 kg)
9
ALL-IN-ONE
MIG
GMAW
Millermatic 252
®
Industrial
See literature no. DC/12.49
Processes
Welding Capability
Max. 1/2 in. (13 mm)
Max. 3/8 in. (9.5 mm)
Mild Steel
Aluminum
Min. 22 ga. (0.8 mm)
Min. 14 ga. (1.9 mm)
Aluminum welding uses
optional Spoolmatic 15A
or 30A spool gun.
• MIG (GMAW) • Flux-cored (FCAW)
Comes complete with
m), 250-amp M-25 gun
• 1510 ft.ft. (4.5
(3
m)
cable with clamp
• 10 ft. (3 m) work
power cord
• (and plug onindustrial
200/230 V model)
gas solenoid
• Factory-installed
gauge regulator and gas hose
• Flow
for argon or AR/CO mix
lowered running
• Factory-installed
gear/cylinder rack
in. reversible dual-groove
• .030/.035
drive rolls
• Extra contact tips
Most popular accessories
200 and Spoolmatic
• Spoolmate
Spool Guns (pg 18/19)
Push-Pull Guns (pg 20)
• XRDualAir-Cooled
Low Cylinder Rack
• #300EZ-Change
337 (pg 106)
Gun and Cable Rack
• Elevated
#300 335 (pg 106)
• Protective Cover #195 142 (pg 109)
2
Infinite voltage control with self-calibrating digital meters that permit
presetting of voltage and wire feed speed. Ensures precise parameters
and accuracy.
EXCLUSIVE! Auto-Gun Detect™ automatically adjusts voltage, wire speed
and timers for faster switching between MIG, push-pull and spool guns.
Integrated digital timers come complete with presettable preflow/postflow,
burnback, spot and delay (stitch) timers. Independent timers for MIG and
spool gun.
Heavy-duty aluminum, two-drive-roll system.
Fan-On-Demand™ cooling system only operates when needed reducing
power consumption and keeping internal components cleaner.
Superior aluminum MIG welding with direct connection of optional
Spoolmate™ 200 and Spoolmatic®/Spoolmatic Pro spool guns or
XR™ push-pull guns. No extra module to buy or install.
Recommended
aluminum solution
Spoolmatic 15A (#195 156)
or 30A (#130 831).
*With Spoolmatic 30A, regulator, gas hose and
dual cylinder rack.
Model/Stock Number
(#907 321) 200(208)/230 V
(#951 066*) 200(208)/230 V
Amperage
Range
30–300
(#907 322) 230/460/575 V
(#951 065*) 230/460/575 V
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V 575 V KVA KW
Rated Output
200 A at 28 VDC,
60% duty cycle
250 A at 28 VDC,
40% duty cycle
48
42
—
—
9.5 7.5
(at 60% duty cycle)
—
46
23
18
9.5 7.5
(at 60% duty cycle)
Millermatic 350P
®
®
™
™
™
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Net
Weight
Wire Feed Speed
Wire Type and Diameter Capacity
Dimensions
50–700 ipm
(1.3–17.8 m/min.)
Solid steel .023–.045 in. (0.6–1.2 mm)
Stainless .023–.045 in. (0.6–1.2 mm)
Flux-cored .030–.045 in. (0.8–1.2 mm)
H: 30 in. (762 mm)
W: 19 in. (483 mm)
D: 40 in. (1,016 mm)
205 lb.
(94 kg)
Industrial
See literature no. DC/12.51
Processes
Welding Capability
Max. 1/2 in. (13 mm)
Max. 1/2 in. (13 mm)
(GMAW) • Flux-cored (FCAW)
• MIG
• Pulsed MIG (GMAW-P)
Comes complete with
m) Bernard BTB Gun
• 15300ft.A(4.5
with Centerfire consumables
cable with clamp
• 1010 ft.ft. (3(3 m)m) work
industrial
cord
• (without plug) for single-power
or three-phase
gas solenoid
• Factory-installed
gauge regulator and gas hose
• Flow
for argon or AR/CO mix
Factory-installed,
low-mounted
• running gear/cylinder
rack
in. reversible V-groove
• .035/.045
drive rolls (order U-groove drive rolls
™
XR-Aluma-Pro push-pull
gun (see page 20).
Input
Power
Amperage
Range
Threephase
25–400
Singlephase
10
Aluminum
Min. 24 ga. (0.6 mm)
Min. 18 ga. (1.2 mm)
™
Built-in pulsed MIG programs. All programmed information is restored
after each power up — aluminum/steel/stainless steel/metal-cored.
Infinite voltage control with self-calibrating digital meters that permit
presetting of voltage and wire feed speed. Ensures precise parameters
and accuracy.
EXCLUSIVE! Auto-Gun Detect™ automatically adjusts voltage, wire speed
and timers for faster switching between MIG, push-pull and spool guns.
Integrated digital timers come complete with presettable preflow/postflow
and spot timers. Independent timers for MIG and push-pull guns.
Heavy-duty aluminum, four-drive-roll system.
Fan-On-Demand™ cooling system only operates when needed reducing
power consumption and keeping internal components cleaner.
Recommended
aluminum solution
Stock Number
(#907 300)
200/230/460 V
Mild Steel
Aluminum welding uses
optional Aluma-Pro
push-pull gun.
Rated Output
300 A at 32 VDC,
60% duty cycle
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V KVA KW
34
30
15
11.6 11.5
69
61
30
13.1 11.2
2
for aluminum welding)
• Extra contact tips
Most popular accessories
Spool Guns (pg 19)
• Spoolmatic
Push-Pull Guns (pg 20)
• XRDualAir-Cooled
Cylinder Rack #195 299
• (pg 106)
• Protective Cover #195 142 (pg 109)
®
™
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Wire Feed Speed
Wire Type and Diameter Capacity
Dimensions
MIG gun
50–700 ipm (1.3–17.8 m/min.)
Optional spool gun/push-pull gun
50–800 ipm (1.3–20 m/min.)
Solid steel
Stainless
Aluminum
Metal-cored
Flux-cored
H: 34 in. (863 mm)
W: 19 in. (483 mm)
D: 41 in. (1,041 mm)
.023–.045 in. (0.6–1.2 mm)
.030–.045 in. (0.8–1.2 mm)
.035–.047 in. (0.9–1.2 mm)
.035–.052 in. (0.9–1.3 mm)
.030–.052 in. (0.8–1.3 mm)
Net
Weight
181 lb.
(82 kg)
GUNS/POWER SOURCES/PACKAGES
MIG
GMAW
MIGmatic M-Series MIG Guns
™
See literature no. AY/15.0
M-150
Three-piece nozzle construction extends nozzle life by
reducing wear and helps prevent rocking of nozzle on
contact tip adapter.
Interchangeable contact tips and monocoil liners help
reduce parts inventory.
Brass contact tip adapter helps prevent galling, sticking
and stripping of threads.
Single-piece high-impact handle is almost indestructible
with ergonomic design.
Steel spring strain relief protects power cable from
wear and helps prevent liner from kinking, allowing better
wire feedability.
360-degree rotatable gooseneck permits trigger
activation with either the finger or thumb.
M-25
M-100/M-150
Processes
An ideal match for Miller® all-in-one MIG machines or other Miller wire feeders.
M-100
Light industrial
Industrial
M-25
MIG (GMAW) • Flux-cored (FCAW)
•Suggested
power sources
141/190/211
• Millermatic
(M-100/M-150) (pg 8/9)
212 Auto-Set /252
• Millermatic
(M-25) (pg 9/10)
Multimatic 200 (M-150) (pg 31)
•Most
popular accessories
M-Series Consumable Kits
• MIGmatic
(pg 109)
®
™
®
•
For M-100/M-150
#234 607 .023 in. (0.6 mm)
#234 608 .030 in. (0.8 mm)
#234 609 .035 in. (0.9 mm)
For M-25
#234 610 .030 in. (0.8 mm)
#234 611 .035 in. (0.9 mm)
#234 612 .045 in. (1.2 mm)
Aluminum Conversion Kit #172 136
(pg 109)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Stock Number
Cable Length
Rated Output
Rated Duty Cycle
Standard Wire Size
Max. Wire Size
Gun Only Net Weight
M-100
#248 282
10 ft. (3 m)
100 A
100% with CO2 gas, 60% with mixed gas
.030–.035 in. (0.8–0.9 mm)
.045 in. (1.2 mm)
3.2 lb. (1.5 kg)
M-150
#249 039
10 ft. (3 m)
150 A
100% with CO2 gas, 60% with mixed gas
.030–.035 in. (0.8–0.9 mm)
.045 in. (1.2 mm)
4.4 lb. (2.0 kg)
#249 040
12 ft. (3.7 m)
#249 041
15 ft. (4.6 m)
#169 594
10 ft. (3 m)
#169 596
12 ft. (3.7 m)
#169 598
15 ft. (4.6 m)
#169 599
15 ft. (4.6 m)
M-25
4.7 lb. (2.1 kg)
6.0 lb. (2.7 kg)
250 A
.030–.035 in. (0.8–0.9 mm)
100% with CO2 gas, 60% with mixed gas
3/64 in. (1.2 mm)
5.4 lb. (2.5 kg)
6.0 lb. (2.7 kg)
7.2 lb. (3.3 kg)
.035–.045 in. (0.9–1.2 mm)
3/64 in. (1.2 mm)
7.2 lb. (3.3 kg)
MIG Packages for Demanding Industrial Applications
Power Source
Welding
Performance
450 Amp
300 Amp
Invision™
Invision™
650 Amp
352 MPa
Axcess®
300
350
Deltaweld®
452
450 MPa
Axcess®
450
Continuum™
CP-302
Deltaweld®
302
Continuum™
500
Deltaweld®
652
Axcess®
675
with 22A
(pg 12)
with S-74D
(pg 12)
w/S-74 MPa Plus
(pg 13)
w/Feeder
(pg 22)
w/Feeder
(pg 23)
with S-74D
(pg 12)
w/S-74 MPa Plus
(pg 13)
w/Feeder
(pg 22)
w/Feeder
(pg 23)
with S-74D
(pg 12)
w/Feeder
(pg 22)
Mild Steel
Material
Stainless Steel
Aluminum
Gauge (.020–.125 in.)
Material
Thickness
Sheet (.125–.375 in.)
Plate (.375–1 in.)
Plate (1+ in.)
.030 in.
.035 in.
Wire Size
.045 and .052 in.
1/16 in.
5/64 in.
3/32 in.
Process
All machines
designed for
MIG spray
transfer and
flux-cored.
Short Circuit
Pulsed Spray
Accu-Pulse®
RMD®
CAC-A
Icon Key
Optional 1/4 in.
Capability:
Designed for
Capable of
1/4 in.
Process Quality:
1/4 in.
Optional 5/16 in.
1/4 in.
5/16 in.
Optional
3/8 in.
3/8 in.
Good Better Best Optimized
11
MIG
CP-302
POWER SOURCES/PACKAGES
GMAW
Industrial
302 models
Heavy industrial
452/652 models
See literature no. DC/13.0
Cost-effective, simple MIG power source designed for manufacturing.
Processes
(GMAW) • Flux-cored (FCAW)
• MIG
Air
carbon
(CAC-A)
• (Deltaweld arc452:gouging
1/4 in. carbons)
Large analog meters are easy to read and
display preset and actual voltage and amperage.
Build your own system at
MillerWelds.com/equiptoweld
or see packages below.
(Deltaweld 652: 3/8 in. carbons)
Stationary package includes
source
• Power
(CP-302) or S-74D (Deltaweld)
• 22A
feeder with .035/.045 in. drive rolls
BTB Gun 300 A (CP-302) or
• Bernard
BTB Gun 400 A (Deltaweld)
MIG 4/0 kit consisting of
• Industrial
flowmeter regulator with 10 ft. (3 m)
14-pin receptacle provides a quick, direct
connection to Miller® wire feeders.
115-volt power for tools and coolant systems.
™
gas hose, 10 ft. (3 m) 4/0 feeder
weld cable with lugs, and 15 ft.
(4.6 m) work cable with 600-amp
C-clamp.
CP-302 MIGRunner package (#951 230) shown.
Deltaweld® Series
MIGRunner™ package includes
above plus
See literature no. DC/16.2
standard running
• Factory-installed
gear and standard cylinder rack
Industry standard for heavy-industrial MIG welding. Designed for manufacturing operations,
with 100 percent duty cycle for extended arc-on time.
Most popular accessories
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.
14-pin receptacle provides a quick, direct connection to Miller®
wire feeders. Capable of remote voltage control.
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.
Deltaweld 452
MIGRunner package
(#951 302) shown.
Feeders (pg 44)
• 2070 Series
Series Feeders (pg 44)
• Bernard
Guns (pg 47)
• Standard MIG
• (pg 106) Running Gear #042 886
Cylinder Rack #042 887
• Standard
(pg 106)
MIG 4/0 Kit (with lug
• Industrial
connectors) #300 390 (pg 109)
Cables (pg 114)
• Extension
#242 208 025 25 ft. (7.6 m)
#242 208 050 50 ft. (15 m)
#242 208 080 80 ft. (24.4 m)
When purchasing components separately,
visit MillerWelds.com/equiptoweld or
your distributor for other Miller® options
and accessories.
Build your own system at
MillerWelds.com/equiptoweld
or see packages below.
Models/Packages
*Additional packages are
available — visit MillerWelds.com
or your distributor.
Models
Power Source Only Stock Number
Stationary Package Stock Number*
MIGRunner Package Stock Number*
CP-302
(#903 786) 200/230/460 V
(#951 231)
(#951 230)
Deltaweld 302
(#903 376) 200(208)/230/460 V
(#951 235)
(#951 234)
(#903 392) 230/460/575 V
—
(#951 300)
(#903 377) 200(208)/230/460 V
(#951 237)
(#951 236)
(#903 394) 230/460/575 V
(#951 301)
(#951 302)
Deltaweld 652
(#903 396) 230/460/575 V
(#951 239)
(#951 238)
Model
Voltage
Range
Rated Output
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V 575 V KVA KW
Open-Circuit
Voltage
Dimensions
(Includes lift eye and strain relief)
CP-302
14–44
300 A at 32 VDC, 100% duty cycle
38
33
16.5
—
13.1 12.3
14–44 VDC
Deltaweld 302
10–32
300 A at 32 VDC, 100% duty cycle
48
42
21
17
16.9 12.9
42 VDC max.
Deltaweld 452
10–38
450 A at 38 VDC, 100% duty cycle
72
63
32
25
25.1 21.1
48 VDC max.
H: 30 in. (762 mm)
W: 23 in. (585 mm)
302 D: 30.5 in. (775 mm)
452/652 D: 38 in. (966 mm)
Deltaweld 652
10–44
650 A at 44 VDC, 100% duty cycle
—
96
48
38
38.2 34.2
54 VDC max.
Deltaweld 452
12
Net Weight
332 lb. (151 kg)
323 lb. (147 kg)
384 lb. (174 kg)
472 lb. (214 kg)
POWER SOURCES/PACKAGES
MIG
GMAW
Invision MPa Plus System
Heavy industrial
™
Invision 450
is 3-phase only.
See literature no. DC/23.6
MIG and synergic pulsed MIG system with optimized weld programs for both steel and aluminum.
Invision 352 MPa with S-74 MPa Plus feeder shown.
Build your own system at
MillerWelds.com/equiptoweld
or see packages below.
Recommended Aluminum Solution
Dedicated XR Plus guns work with MPa Plus
feeders to coordinate wire feed speed of the
gun and the feeder. This provides optimized
aluminum feeding and welding performance.
See page 45 for stock numbers.
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.
Invision 352 model allows
for any input voltage hookup
(208–575 V, single- or three-phase) with no
manual linking, providing convenience in any job
setting. Ideal solution for dirty or unreliable power.
450 model is 230/460 V manual link or 575 V,
three-phase only.
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.
Processes
(GMAW) • Flux-cored (FCAW)
• MIG
MIG (GMAW-P)
• Pulsed
Air
carbon
gouging (CAC-A)
• (Invision 352:arc 1/4
in. carbons)
(Invision 450: 5/16 in. carbons)
Optimized wire feeding options
Series MPa Plus feeders (pg 44)
• 70XR-Aluma-Pro
Plus and XR -Pistol
• Plus push-pull guns
(pg 45)
Series Swingarc with MPa Plus
• 70control
box (pg 46)
and dual-remote configurations
• Single(pg 46, for more information
™
™
™
see literature no. DC/23.6)
Most popular accessories
Cart (single feeders only)
• MIGRunner
#195 445 (pg 107)
Gear Cylinder Rack
• Running
#300 408 (pg 107)
3 #043 007 (pg 107)
• Coolmate
MIG 4/0 Kits (pg 109)
• Industrial
#300 405 With Dinse connectors
™
™
•
(352 MPa only)
#300 390 With lug connectors
(450 MPa only)
Consists of flowmeter regulator with
10 ft. (3 m) gas hose, 10 ft. (3 m)
4/0 feeder weld cable, and 15 ft.
(4.6 m) work cable with 600-amp
C-clamp.
Extension Cables (pg 114)
#247 831 025 25 ft. (7.6 m)
#247 831 050 50 ft. (15 m)
#247 831 080 80 ft. (24.4 m)
When purchasing components separately,
visit MillerWelds.com/equiptoweld or
your distributor for other Miller® options
and accessories.
Models/Packages
*Additional packages are
available — visit MillerWelds.com
or your distributor.
Invision 352 MPa
(#907 431) 208–575 V
(#907 431 001)
208–575 V
with auxiliary power
Alum
Invision 450 MPa
(#907 485) 230/460 V
with auxiliary power
(#907 486) 575 V
with auxiliary power
Steel
Power Source Only
Stock Number
Package Stock Number*
70 Series MPa Plus Feeder with Push-Only Bernard™
BTB Gun 400 A and .035/.045 in. Drive Rolls
XR-Aluma-Pro™ Plus
Push-Pull MIG Gun
Industrial MIG 4/0 Kit
Cart
(#951 287) w/352 model (#907 431)
S-74 (single-wire feeder with one gun)
25 ft. air-cooled
With Dinse connectors
MIGRunner cart
(#951 501) w/352 model (#907 431)
D-74 (dual-wire feeder with two guns)
25 ft. air-cooled
With Dinse connectors
Running gear cylinder rack
(#951 411) w/352 model (#907 431)
S-74 (single-wire feeder with one gun)
—
With Dinse connectors
MIGRunner cart
(#951 500) w/352 model (#907 431)
D-74 (dual-wire feeder with two guns)
—
With Dinse connectors
Running gear cylinder rack
(#951 499) w/450 model (#907 485)
S-74 (single-wire feeder with one gun)
—
With lug connectors
MIGRunner cart
(#951 457) w/450 model (#907 485)
D-74 (dual-wire feeder with two guns)
—
With lug connectors
Running gear cylinder rack
Note: See aluminum solutions comparison chart on page 14.
KVA
KW
Max. OpenCircuit Voltage
350 A at 34 VDC,
60% duty cycle
40.4
36.1
20.6
17.8
14.1
14.2
13.6
75 VDC
80 lb.
(36.3 kg)
5–425 A
10–38 V
300 A at 32 VDC,
60% duty cycle
60.8
54.6
29.7
24.5
19.9
11.7
11.2
H: 17 in. (432 mm)
W: 12.5 in. (318 mm)
D: 24 in. (610 mm)
15–600 A
10–38 V
450 A at 36.5 VDC,
100% duty cycle
—
49.4
—
27.2
23.6
21.6
(23.5 on
575 V)
18.3
90 VDC
H: 17.25 in. (438 mm)
W: 14.5 in. (368 mm)
D: 27.125 in. (689 mm)
122 lb.
(55.3 kg)
Rated Output
Three-phase
5–425 A
10–38 V
Single-phase
Three-phase
Input Power
Invision 352 MPa
Invision 450 MPa
Amps Input at Rated Load Output, 60 Hz
208 V 230 V 400 V 460 V 575 V
Amp/Volt
Ranges
Model
Dimensions
Net
Weight
13
MIG
ALUMINUM
GMAW
Choose the Right Industrial Aluminum MIG Solution
For additional aluminum MIG solutions, see spool guns, push-pull guns and controls on pages 18–21.
Millermatic® 350P Aluminum
Push-Pull Gun System (page 16)
AlumaFeed® Synergic Aluminum
Welding System (page 17)
Invision™ MPa Plus System
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 aluminum welding, with advanced
features that can handle larger weldments.
Its lightweight push-pull feeder can easily be
carried up to 100 feet from the power source.
Versatile, heavy-industrial advanced system
for large, high-duty-cycle aluminum and
steel weldments. Features push and/or
push-pull bench feeder for easy switchover
between solid, aluminum and tubular wires.
(page 13)
Millermatic 350P
Aluminum with
XR-Aluma-Pro
gun shown.
Cost-effective industrial all-in-one
MIG/pulsed MIG solution with easy-to-use
interface for aluminum welding on material
up to 1/2-inch thick. Features built-in
running gear for mobility.
Power Source
Millermatic 350P Aluminum (all-in-one)
AlumaPower™ 350 MPa or 450 MPa
Invision 352 MPa or 450 MPa
Feeder
All-in-one — built-in running gear with cylinder rack
is easily maneuverable from area to area
Single-wire XR-AlumaFeed — portable feeder can
be carried up to 100 feet from power source
Single- or dual-wire 74 MPa Plus — stationary feeders
can be mounted up to 100 feet from power source
Input Voltage
Single- or three-phase
Single- or three-phase (450 MPa is three-phase only)
Single- or three-phase (450 MPa is three-phase only)
Rated Output
300 A at 60% duty cycle
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
Auto-Link® — Automatically links the power source
to primary voltage being applied. Auto-link is used
to link to 208 or 230 V and manually moving a link
board is required to link to 460 V.
350 MPa: Auto-Line™ — Allows for any primary
input voltage (208–575 V, single- or three-phase,
50 or 60 Hz) with no manual linking. Also
adjusts for voltage spikes within the entire range.
450 MPa: 230/460 V manual linking or 575 V
352 MPa: Auto-Line™ — Allows for any primary
input voltage (208–575 V, single- or three-phase,
50 or 60 Hz) with no manual linking. Also
adjusts for voltage spikes within the entire range.
450 MPa: 230/460 V manual linking or 575 V
Aluminum Wire
Diameters
.035–.047 in. (0.9–1.2 mm)
.035–1/16 in. (0.9–1.6 mm)
.035–1/16 in. (0.9–1.6 mm)
Gun Capability
XR-Aluma-Pro™, XR-Aluma-Pro™ Lite, or XR™-Pistol
XR-Aluma-Pro™, XR-Aluma-Pro™ Lite, 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
Yes — “one-knob” control, only need to change wire
feed speed to weld different material thicknesses
MIG
Spray transfer MIG — for aluminum wires
Spray transfer MIG — for aluminum wires
Conventional MIG — modes for aluminum, steel
and other wires
Built-In Pulsed
Programs
Aluminum
Aluminum
Aluminum, steel, stainless and others
Portability
Built-in running gear with cylinder rack —
easily maneuverable from area to area
Lightweight, portable feeder with handle —
can be carried up to 100 feet from power source
Stationary feeder — can be mounted up to
100 feet from power source
Trigger Hold
Yes — reduces operator fatigue from holding trigger
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
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
14
ALUMINUM
MIG
GMAW
Industrial
Millermatic 350P
®
Processes
Auto Body Aluminum Repair System
See literature no. DC/12.51
The ideal auto body welding package for aluminum and steel repair.
™
Welding Capability
Max. 1/2 in. (13 mm)
Max. 1/2 in. (13 mm)
Mild Steel
Aluminum
Min. 24 ga. (0.6 mm)
Min. 22 ga. (0.8 mm)
Aluminum welding uses
Bernard BTB Gun 200 A
aluminum MIG gun.
Complies with 2015 Ford F-150 body shop welding
machine certification for aluminum body vehicles.
Optimized low-end aluminum pulse program. Reduces heat
input to prevent warping and burn-through on thin 18-gauge
aluminum auto body panels
Customized Bernard™ aluminum MIG gun. 12-foot (3.7 m)
Bernard BTB Gun 200 A with Teflon liner and 30-degree head
tube for superior aluminum wire delivery.
Hobart® 5554 aluminum wire specified by Ford. Includes
one eight-inch, five-pound spool of .047-inch aluminum wire.
See page 10 for Millermatic 350P power source features.
Stock Number
(#907 300 002)
200/230/460 V
Input
Power
Amperage
Range
Threephase
25–400
Singlephase
Rated Output
300 A at 32 VDC,
60% duty cycle
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V KVA KW
34
30
15
11.6 11.5
69
61
30
13.1 11.2
(GMAW) • Flux-cored (FCAW)
• MIG
• Pulsed MIG (GMAW-P)
Comes complete with
m) Bernard BTB Gun
• 12200ft.A(3.7
aluminum MIG gun
cable with clamp
• 1010 ft.ft. (3(3 m)m) work
industrial
cord
• (without plug) for single-power
or three-phase
gas solenoid
• Factory-installed
gauge regulator and gas hose
• Flow
for argon or AR/CO mix
Factory-installed,
low-mounted
• running gear/cylinder
rack
in. (1.2 mm) U-groove drive rolls
• .047
in. (1.2 mm) aluminum
• .047
Centerfire contact tips (#T-047AL)
(203 mm), 6 lb. (2.7 kg) spool
• 8ofin.Hobart
.047 in (1.2 mm) 5554
2
™
aluminum wire
Most popular accessories
Spool Guns (pg 19)
• Spoolmatic
Push-Pull Guns (pg 20)
• XRDualAir-Cooled
Cylinder
Rack
#195 299
• (pg 106)
• Protective Cover #195 142 (pg 109)
®
™
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Net
Weight
Wire Feed Speed
Wire Type and Diameter Capacity
Dimensions
MIG gun
50–700 ipm (1.3–17.8 m/min.)
Optional spool gun/push-pull gun
50–800 ipm (1.3–20 m/min.)
Solid steel
Stainless
Aluminum
Metal-cored
Flux-cored
H: 34 in. (863 mm)
181 lb.
W: 19 in. (483 mm)
(82 kg)
D: 41 in. (1,041 mm)
.023–.045 in. (0.6–1.2 mm)
.030–.045 in. (0.8–1.2 mm)
.035–.047 in. (0.9–1.2 mm)
.035–.052 in. (0.9–1.3 mm)
.030–.052 in. (0.8–1.3 mm)
Bernard semi-automatic MIG guns and consumables
have been used and trusted for decades by top companies in
agriculture, shipbuilding and fabrication. This is why Miller not only
recommends Bernard MIG guns but also pairs these guns with
many of their industrial wire feeders and power sources.
To learn more about Bernard MIG guns and the Miller equipment
that they are offered with, please see page 47 in this catalog.
For information on additional Bernard MIG gun options and
for detailed technical support information, please visit
BernardWelds.com or your local distributor to learn more.
Questions? Call 1-855-MIGWELD (644-9353)
15
MIG
ALUMINUM
GMAW
Millermatic 350P Aluminum
®
Welding Capability
Max. 1/2 in. (13 mm)
Aluminum
Min. 18 ga. (1.2 mm)
Aluminum welding uses
optional Aluma-Pro
push-pull gun.
Not compatible with
standard MIG gun.
Millermatic 350P Aluminum with
XR-Aluma-Pro Lite gun shown.
Industrial
See literature no. DC/12.56
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.
Electronic wire spool brake allows wire spool to free
spool while welding resulting in smooth wire delivery.
Built-in aluminum pulsed MIG programs for
simplicity and improved puddle control. Pulsed
welding virtually eliminates burn-through and
warping issues on thinner materials.
Synergic MIG and synergic pulsed MIG provide
communication between power source, feeder and
gun. As wire speed increases/decreases, the pulse or
MIG parameters also increase/decrease to match the
right amount of power needed.
Trigger schedule select allows operator to change
between two sets of weld parameters.
Trigger hold reduces operator fatigue on extended welds.
Standard jog and purge.
Processes
MIG (GMAW)
• Aluminum
• Aluminum pulsed MIG (GMAW-P)
Comes complete with
cable with clamp
• 1010 ft.ft. (3(3 m)m) work
power cord
• (without plug)industrial
for single- or three-phase
gas solenoid
• Factory-installed
gauge regulator and gas hose
• Flow
for argon
low-mounted
• Factory-installed,
running gear/cylinder rack
and .047 in. (0.9 and 1.2 mm)
• .035
U-groove drive rolls for aluminum
welding
Push-pull gun system includes
above plus
push-pull gun
• XR(seeair-cooled
choices far left in chart below)
™
Most popular accessories
Push-Pull Guns (pg 20)
• XRDualAir-Cooled
Cylinder
Rack
#195 299
• (pg 106)
• Protective Cover #195 142 (pg 109)
™
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Note: See aluminum solutions comparison chart on page 14.
Model/Stock Number
Millermatic 350P Aluminum Push-Pull Gun System
(#951 451) w/15 ft. XR-Aluma-Pro™ air-cooled gun
(#951 452) w/25 ft. XR-Aluma-Pro™ air-cooled gun
(#951 453) w/25 ft. XR™-Pistol Pro air-cooled gun
(#951 454) w/25 ft. XR-Aluma-Pro™ Lite air-cooled gun
Millermatic 350P Aluminum (gun NOT included)
(#907 474) 200/230/460 V, standard unit
Input
Power
Amperage
Range
Threephase
25–400
Singlephase
Rated Output
300 A at 32 VDC,
60% duty cycle
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V KVA KW
34
30
15
11.6 11.5
69
61
30
13.1 11.2
Wire Feed Speed
Optional spool gun/
push-pull gun
50–800 ipm
(1.3–20 m/min.)
Wire Type and
Diameter Capacity
Aluminum
.035–.047 in.
(0.9–1.2 mm)
Dimensions
H: 34 in.
(863 mm)
W: 19 in.
(483 mm)
D: 41 in.
(1,041 mm)
Net
Weight
181 lb.
(82 kg)
Feeding Aluminum
Choose the Right Gun Solution
Push-only guns (pg 11/47)
UPGRADE
Spool guns (pg 18/19)
UPGRADE
Push-pull guns (pg 20)
Also known as standard MIG guns,
these guns are only used for
occasional aluminum work.
Integrated wire spools
and better feedability make spool
guns great for repair and small jobs.
Preferred guns for
production work with the best overall
aluminum wire feedability.
used with hard wire or flux• Typically
cored wires in general manufacturing
aluminum, guns should be limited
• For
to 12-foot lengths and configured with
initial cost versus push-pull guns
• Low
Works
many power sources
• Light andwithsimple
use
• Usually lower dutytocycles
• Limited deposition because of wire size
•
for longevity
• Built
Can
feed
wire sizes
• Great arc various
and performance
• Higher dutystarts
cycles and amp ratings
• Air- and water-cooled
models
•
correct aluminum liner and consumables
Learn more at MillerWelds.com/aluminum
16
ALUMINUM
MIG
GMAW
®
AlumaFeed
Heavy industrial
Synergic Aluminum Welding System
AlumaPower 450
is 3-phase only.
See literature no. DC/34.0
Processes
Dedicated aluminum system for the most advanced MIG and synergic pulsed MIG performance.
AlumaPower ™ 350 model allows for any
input voltage hookup (208–575 V, singleor three-phase) with no manual linking, providing convenience
in any job setting. Ideal solution for dirty or unreliable power.
450 model is 230/460 V manual link or 575 V, three-phase only.
Synchronized, true push-pull wire feed system for precise wire
feeding and arc performance.
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.
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.
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.
Parameter and system locks enhance quality assurance and
protect weld consistency.
Trigger schedule select allows operator to change between two
sets of weld parameters.
AlumaPower 350 MPa and XR-AlumaFeed with
XR-Aluma-Pro gun air-cooled package (#951 147) shown.
Build your own system at
MillerWelds.com/equiptoweld
or see packages below.
Aluminum MIG (GMAW)
• Aluminum
pulsed MIG (GMAW-P)
•
Most popular accessories
Push-Pull Guns (pg 20)
• XRMIGRunner
• Coolmate 3Cart#043#195007445(pg (pg107)107)
• Coolant #043 810 (pg 107)
• Industrial MIG 4/0 Kits (pg 109)
• #300 405 With Dinse connectors
™
™
™
•
•
•
•
(350 MPa only)
#300 390 With lug connectors
(450 MPa only)
Consists of flowmeter regulator with
10 ft. (3 m) gas hose, 10 ft. (3 m)
4/0 feeder weld cable, and 15 ft.
(4.6 m) work cable with 600-amp
C-clamp.
Extension Cables (pg 114)
#247 831 025 25 ft. (7.6 m)
#247 831 050 50 ft. (15 m)
#247 831 080 80 ft. (24.4 m)
1/16-Inch (1.6 mm) Liner and
Wire Kit for Gun #230 708
1/16-Inch (1.6 mm) Drive Roll Kit for
Control Box #195 591
For gun and feeder remote options,
please refer to spec sheet or visit
MillerWelds.com.
When purchasing components separately,
visit MillerWelds.com/equiptoweld or
your distributor for other Miller® options
and accessories.
Models/Packages
*Additional packages are
available — visit MillerWelds.com
or your distributor.
Package Stock Number*
XR-AlumaFeed
Feeder
XR-Aluma-Pro™
Push-Pull MIG Gun
XR™-Pistol Grip
Push-Pull MIG Gun
Industrial MIG 4/0 Kit
Coolmate™
with Coolant
Cart
AlumaPower 350 MPa
(#907 420) 208–575 V
(#907 420 001) 208–575 V
with auxiliary power
(#951 147) w/350 model (#907 420)
(#300 509)
25 ft. air-cooled
—
—
—
—
(#951 149) w/350 model (#907 420)
(#300 509)
—
30 ft. air-cooled
—
—
—
(#951 151) w/350 model (#907 420)
(#300 509)
25 ft. air-cooled
—
With Dinse connectors
—
MIGRunner cart
AlumaPower 450 MPa
(#907 483) 230/460 V
with auxiliary power
(#907 484) 575 V
with auxiliary power
(#951 460) w/450 model (#907 483)
(#300 509)
25 ft. air-cooled
—
—
—
—
(#951 459) w/450 model (#907 483)
(#300 509)
25 ft. air-cooled
—
With lug connectors
—
MIGRunner cart
(#951 558) w/450 model (#907 483)
(#300 509)
—
30 ft. water-cooled
—
Coolmate 3
—
(#951 559) w/450 model (#907 483)
(#300 509)
25 ft. water-cooled
—
With lug connectors
Coolmate 3
MIGRunner cart
Power Source Only
Stock Number
Note: All packages listed include gun drive rolls, feeder drive rolls and consumables for .035- and 3/64-inch (0.9 and 1.2 mm) wire.
All systems come set up out of the box to run 3/64-inch wire. 1/16-inch consumables not included — order separately above.
See aluminum solutions comparison chart on page 14.
Amp/Volt
Ranges
Rated Output
Three-phase
5–425 A
10–38 V
Single-phase
AlumaPower 450 MPa
Three-phase
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
50–900 ipm
(1.3–22.9 m/min.)
.035–1/16 in. (0.9–1.6 mm)
Requires wire kit #230 708 for gun and drive roll kit
#195 591 for control box to run 1/16 in. (1.6 mm) wire
12 in. (305 mm)
H: 16 in. (406 mm)
W: 9.5 in. (241 mm)
D: 21.25 in. (540 mm)
42.5 lb.
(19.2 kg)
Model
Input Power
AlumaPower 350 MPa
Amps Input at Rated Load Output, 60 Hz
208 V 230 V 400 V 460 V 575 V
KVA
KW
Max. OpenCircuit Voltage
350 A at 34 VDC,
60% duty cycle
40.4
36.1
20.6
17.8
14.1
14.2
13.6
75 VDC
80 lb.
(36.3 kg)
5–425 A
10–38 V
300 A at 32 VDC,
60% duty cycle
60.8
54.6
29.7
24.5
19.9
11.7
11.2
H: 17 in. (432 mm)
W: 12.5 in. (318 mm)
D: 24 in. (610 mm)
15–600 A
10–38 V
450 A at 36.5 VDC,
100% duty cycle
—
49.4
—
27.2
23.6
21.6
(23.5 on
575 V)
18.3
90 VDC
H: 17.25 in. (438 mm)
W: 14.5 in. (368 mm)
D: 27.125 in. (689 mm)
122 lb.
(55.3 kg)
Dimensions
Net
Weight
17
ALUMINUM
MIG
GMAW
Spoolmate Spool Guns
™
See literature no. M/1.45 (100), M/1.46 (150),
M/1.47 (200) and M/1.5 (3035)
(GMAW) with aluminum and
• MIG
other soft alloy wires
• MIG (GMAW) with hard wires
Spoolmate 100
Suggested power sources
Light industrial gun for 4043 series aluminum wire rated at 135 amps
at 30 percent duty cycle.
12-foot direct-connect cable with heavy-duty strain relief provides
extended reach and accessibility to your work.
Dual V-knurled drive rolls with adjustable tension control for
consistent feeding of different types of wire.
Clear spool canister protects the wire and allows easy view of spool.
Includes carrying case, extra contact tips and nozzle.
Spoolmate 100 includes
carrying case that holds
gun and cable, extra
contact tips, nozzle and
wire (wire sold separately).
Spoolmate 150
Light industrial gun for 4000 or 5000 series aluminum wire rated at
150 amps at 60 percent duty cycle.
20-foot direct-connect cable with heavy-duty strain relief provides
extended reach and accessibility to your work.
Heavy-duty head tube.
Dual V-knurled drive rolls with adjustable tension control for
consistent feeding of different types of wire.
Clear spool canister protects the wire and allows easy view of spool.
Spoolmate 150
Spoolmate 200
Light industrial gun for 4000 or 5000 series aluminum wire rated at
160 amps at 60 percent duty cycle.
20-foot weld/control cables with strain relief and sheath provide
extended reach and accessibility to your work.
Wire feed speed adjustment on the gun — not machine — for easy setup.
Easy access to drive assembly and drive rolls.
Two-stage trigger with built-in gas valve allows for gas preflow/postflow.
Toolless head tube removal allows easy replacement. Three optional
head tubes.
Spoolmate 200
now comes
standard with
heavy-duty
head tube.
Use with CV, DC power sources.
Processes
Reliable and economical spool guns designed for home hobbyists and light fabricators.
Spoolmate 100
Light industrial
For Spoolmate 100
Millermatic® 141 (pg 8)
Millermatic® 190 (pg 8)
Millermatic® 211 (pg 9)
Multimatic™ 200 (pg 31)
Syncrowave™ 210 TIG/MIG Complete
(pg 53)
For Spoolmate 150
Millermatic® 211 (pg 9)
Multimatic™ 200 (pg 31) effective
with serial number MF364047N
For Spoolmate 200
Millermatic® 212 Auto-Set ™ (pg 9)
Millermatic® 252 (pg 10)
For Spoolmate 3035
Direct connect to vintage Millermatic
210/212 tapped-voltage models
Millermatic® 141/190/211/212
(pg 8/9) with SGA 100 control
Bobcat™ 225 (pg 68)
with SGA 100C control
•
•
•
•
•
•
•
•
•
•
•
•
Most popular accessories
For Spoolmate 200
45-Degree Head Tube #300 591
9-Inch Extension Head Tube
#300 592
5-Inch Head Tube #243 385
Spoolmatic Adapter Cable #195 287
Allows connection to older Millermatic
210 and 212 (non-Auto-Set).
For Spoolmatic 3035
SGA 100 #043 856 (pg 114)
SGA 100C #043 857 (pg 114)
Heavy-Duty Head Tube #195 375
•
•
•
•
•
•
•
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Spoolmate 3035
Spoolmate 3035
Model/
Stock Number
Light industrial gun for 4000 or 5000 series aluminum wire rated at
150 amps at 60 percent duty cycle.
20-foot weld/control cables with strain relief and sheath provide
extended reach and accessibility to your work.
Light weight and well balanced for operator comfort.
Clear spool canister protects the wire and allows easy view of spool.
Easy-to-remove head tube assembly.
Maximum Spool
Size Capacity
Net Weight with
Cable Assembly
Welding Current Rating
Wire Feed Speed
Wire Type and Diameter Capacity
Spoolmate 100
(#300 371)
135 A at 30% duty cycle
5–625 ipm (1.7–15.9 m/min.)
Wire speed dependent on power source used
Aluminum .030–.035 in. (0.8–0.9 mm)
Solid steel .023–.035 in. (0.6–0.9 mm)
Stainless .023–.035 in. (0.6–0.9 mm)
4 in. (102 mm)
H: 11.5 in. (291 mm)
W: 3 in. (76 mm)
L: 13 in. (330 mm)
6 lb. (2.7 kg)
9 lb. (4.1 kg) with case
Spoolmate 150
(#301 272)
150 A at 60% duty cycle
115–715 ipm (2.9–18.1 m/min.)
Wire speed dependent on power source used
Aluminum .030–.035 in. (0.8–0.9 mm)
Solid steel .030–.035 in. (0.8–0.9 mm)
Stainless .030–.035 in. (0.8–0.9 mm)
4 in. (102 mm)
H: 11.5 in. (291 mm)
W: 3 in. (76 mm)
L: 12.5 in. (318 mm)
7.3 lb. (3.2 kg)
Spoolmate 200
(#300 497)
160 A at 60% duty cycle,
70–875 ipm (1.8–22.2 m/min.)
Aluminum .030–.035 in. (0.8–0.9 mm)
Solid steel .023–.035 in. (0.6–0.9 mm)
Stainless .023–.035 in. (0.6–0.9 mm)
4 in. (102 mm)
H: 9 in. (229 mm)
W: 2.5 in. (64 mm)
L: 14.5 in. (368 mm)
11 lb. (5 kg)
Spoolmate 3035
(#195 016)
150 A at 60% duty cycle,
200 A at 60% duty cycle with
optional heavy-duty head tube
115–715 ipm (2.9–18.1 m/min.)
Aluminum .030–.035 in. (0.8–0.9 mm)
Solid steel .023–.035 in. (0.6–0.9 mm)
Stainless .023–.035 in. (0.6–0.9 mm)
4 in. (102 mm)
H: 11.5 in. (291 mm)
W: 2.25 in. (57 mm)
L: 8 in. (203 mm)
9.1 lb. (4.1 kg)
18
Dimensions
ALUMINUM
MIG
GMAW
Spoolmatic Spool Guns
®
See literature no. M/1.73 (Spoolmatic)
and M/1.76 (Spoolmatic Pro)
Spoolmatic
(GMAW) with aluminum and
• MIG
other soft alloy wires
(GMAW) with hard wires
• MIG
MIG (GMAW-P) with
• Pulsed
optional pulsing power source
Cost-effective, industrial aluminum spool gun.
Suggested power sources
Integrated spool canister rotates 180 degrees for
operator flexibility and comfort.
Available in 15- or 30-foot cable lengths, providing
flexibility to be used in the shop and in the field.
Two-stage trigger with built-in gas valve allows for
gas preflow, and eliminates the need to purge long
gas lines.
Wire feed speed adjustment on the gun handle and
reversible drive rolls save time and money.
Quick-change, single-turn contact tip provides
excellent performance and is easy to replace.
Spoolmatic Pro additional features
The most reliable, easy-to-use spool gun in
the industry for the professional welder.
Wire tension settings.
4000- or 5000-specific tension
settings ensure the very best
wire feeding performance and
arc consistency.
Spoolmatic Pro
Use with CC/CV, DC power sources.
Processes
Portable, aluminum wire feeder for industrial applications.
Spoolmatic
Industrial
212 Auto-Set (pg 9)
• Millermatic
252 (pg 10)
• Millermatic
Millermatic
350P/350P Aluminum
• (except Spoolmatic
Pro)
®
®
®
™
(pg 10/15/16)
Shopmate™ 300 DX (pg 31)
Bobcat™ Series (pg 68) —
with SGA 100C control
These power sources require
WC-24 control (#137 549)
CP-302 (pg 12)
Deltaweld® Series (pg 12)
Invision™ MPa (pg 13)
AlumaPower ™ MPa (pg 17)
Dimension™ Series (pg 32/33)
XMT® Series (except VS model)
(pg 34/36)
Trailblazer® Series (pg 70)
•
•
•
•
•
•
•
•
•
Most popular accessories
#137 546 (pg 114)
• WC-115A
WC-115A
(with
• #137 546-01-1contactor)
(pg 114)
• WC-24 #137 549 (pg 114)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
More 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.
Easy-to-rotate, self-seating head tube allows for better
access into tight spots, preventing leaks and providing
excellent current transfer. Head tubes are common with
the XR-Aluma-Pro gooseneck-style guns.
Head tube options in several different lengths and
bend configurations are available for use when a
standard head tube doesn’t fit the application.
*Spoolmatic Pro requires wire kit #230 708 to run 1/16 in. (1.6 mm) wire.
Model/Stock Number
Welding Current Rating
Wire Feed Speed
Spoolmatic
(#195 156) 15 ft. (4.5 m) cable
(#130 831) 30 ft. (9 m) cable
200 A at 100% duty cycle
70–875 ipm (1.8–22.2 m/min.)
Wire speed dependent on control
or Millermatic used
Spoolmatic Pro
(#301 147) 15 ft. (4.5 m) cable
(#301 148) 30 ft. (9 m) cable
200 A at 100% duty cycle
70–900 ipm (1.8–23 m/min.)
Wire speed dependent on control
or Millermatic used
Wire Type and
Diameter Capacity
Maximum Spool
Size Capacity
Aluminum*
.030–1/16 in.
(0.8–1.6 mm)
Hard wire
.030–.045 in.
(0.8–1.1 mm)
4 in. (102 mm)
Dimensions
Gun Only
Net Weight
H: 10.25 in. (260 mm)
W: 2.5 in. (64 mm)
L: 15.125 in. (384 mm)
2.9 lb.
(1.3 kg)
H: 10.75 in. (273 mm)
W: 2.5 in. (64 mm)
L: 15.375 in. (390 mm)
3.0 lb.
(1.4 kg)
19
ALUMINUM
MIG
GMAW
XR Push-Pull Guns
™
See literature no. M/1.75 (Aluma-Pro Lite), M/1.71 (Aluma-Pro),
M/1.73 (Pistol) and M/1.74 (Pistol-Pro)
XR-Aluma-Pro and XR-Pistol guns work in conjunction with XR Controls, XR-AlumaFeed or
select Millermatic machines to provide the best solution for push-pull applications.
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 5000specific 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 Lite
XR-Aluma-Pro Lite
™
Lightest weight gooseneck-style gun features rear
trigger that allows access to hard-to-reach welds.
XR-Aluma-Pro
XR-Aluma-Pro
™
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.
Industrial
XR-Aluma-Pro Lite
Heavy industrial
XR-Aluma-Pro and
all Pistol models
Use with CC/CV,
DC power sources.
Processes
(GMAW) with aluminum wire
• MIG
(capable of other wires with optional
hardwire kits)
MIG (GMAW-P) with optional
• Pulsed
pulsing power source
Suggested feeders/controls
(pg 17)
• XR-AlumaFeed
(pg 21)
• XRXR -S-D Control
• Control (pg 21)
Suggested power sources
252 (pg 10)
• Millermatic
Millermatic
• (pg 10/15/16)350P/350P Aluminum
®
™
™
®
®
These power sources require
XR-AlumaFeed (pg 17) or XR-Control
(pg 21)
Deltaweld® Series (pg 12)
Invision™ MPa (pg 13)
AlumaPower™ MPa (pg 17)
XMT® Series (except VS model)
(pg 34/36)
Trailblazer® Series (pg 70)
•
•
•
•
•
Most popular accessories
• Hardwire Liner Kit #198 377
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
XR -Pistol
™
Reliable, cost-effective gun for light- to mediumindustrial applications.
XR-Pistol
XR -Pistol-Pro
™
Exceptional aluminum welding results for
heavy-industrial applications.
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.
XR-Pistol-Pro
*Dependent on control box or Millermatic used. **Wire kit #230 708 required to run 1/16 in. (1.6 mm) wire.
Model
15 ft. (4.6 m)
Cable Length
25 ft. (7.6 m) 30 ft. (9 m)
XR-Aluma-Pro Lite
(Air-cooled)
—
(#300 948)
XR-Aluma-Pro (Air-cooled)
(#300 000)
XR-Aluma-Pro (Water-cooled)
(#300 003)
XR-Pistol (Air-cooled)
XR-Pistol (Water-cooled)
35 ft. (10.6 m)
Welding Current Rating
Wire Feed Speed*
Wire Type and
Diameter Capacity
—
—
175 A at 60% duty cycle
70–900 ipm
(1.8–23 m/min.)
Aluminum
.030–.047 in. (0.8–1.2 mm)
H: 4 in. (102 mm)
W: 1.9 in. (48 mm)
L: 15 in. (381 mm)
2.0 lb. (0.9 kg)
(#300 001)
—
(#300 264)
300 A at 100% duty cycle
—
(#300 265)
400 A at 100% duty cycle
70–900 ipm
(1.8–23 m/min.)
Aluminum**
.030–1/16 in. (0.8–1.6 mm)
H: 5 in. (127 mm)
W: 2.5 in. (64 mm)
L: 17 in. (432 mm)
2.5 lb. (1.1 kg)
(#300 004)
(#198 127)
—
(#198 128)
—
200 A at 100% duty cycle
—
(#198 130)
—
400 A at 100% duty cycle
70–875 ipm
(1.8–22.2 m/min.)
Aluminum
.030–1/16 in. (0.8–1.6 mm)
XR-Pistol-Pro (Air-cooled)
(#300 782)
(#300 783)
—
(#300 784)
200 A at 100% duty cycle
XR-Pistol-Pro (Water-cooled)
(#300 786)
(#300 787)
—
(#300 788)
400 A at 100% duty cycle
70–900 ipm
(1.8–23 m/min.)
Aluminum**
.030–1/16 in. (0.8–1.6 mm)
H: 7.375 in. (187 mm)
W: 1.875 in. (48 mm)
L: 10.625 in. (270 mm)
2.2 lb. (1 kg)
(#198 129)
20
Dimensions
Gun Only
Net Weight
2.9 lb. (1.3 kg)
2.4 lb. (1.1 kg)
2.2 lb. (1 kg)
2.4 lb. (1.1 kg)
ALUMINUM
GMAW
XR Controls
MIG
Heavy industrial
™
Use with CC/CV, DC power sources.
See literature no. M/1.7
Standard aluminum 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-D
Includes both .035 and factory-installed 3/64 in. drive rolls.
Order 1/16 in. control box drive roll kit (#195 591) separately.
(GMAW) with aluminum 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-S
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 20)
Suggested power sources
Series (pg 12)
• Deltaweld
MPa (pg 13)
• Invision
MPa (pg 17)
• AlumaPower
Series (except VS model) (pg 34)
• XMT
• Trailblazer Series (pg 70)
Most popular accessories
Cables (pg 114)
• Extension
PSA-2
Control
• Gas Flowmeter(pgKit 114)
#246 127
•
®
™
™
®
®
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 (#300 601)
XR-D (#300 687)
Input Power
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool Size Capacity
Dimensions
Net Weight
24 VAC, 50/60
or 100 Hz
50–900 ipm
(1.3–23 m/min.)
Aluminum .030–1/16 in. (0.8–1.6 mm)
Requires drive roll kit #195 591 to run 1/16 in. (1.6 mm) wire
12 in. (305 mm)
H: 16 in. (406 mm)
W: 9.25 in. (235 mm)
D: 21.25 in. (540 mm)
42.5 lb.
(19.2 kg)
Hobart®aluminum filler metals — wire and
cut lengths — have been designed to provide
the best performance for the best welds.
These products are backed by the deep industry
knowledge of Hobart welding specialists
who can help customers find the right
aluminum filler metal solution. Every time.
No matter how challenging the application.
Visit HobartBrothers.com
or your local distributor to learn more.
Questions? Hobart is here to help.
21
MIG
ADVANCED/
AUTOMATED
For more detailed
information, visit
MillerWelds.com/advanced
Industrial
300 models
Heavy industrial
450/675 models
Axcess® and Auto-Axcess Systems
™
Auto-Axcess
is CV only.
See literature no. DC/8.0 (Axcess) and AU/8.0 (Auto-Axcess)
Advanced industrial MIG systems for both hand-held and robotic applications, which improve
arc performance and productivity.
Build your own system at
MillerWelds.com/equiptoweld
or see packages below.
Auto-Axcess 450 shown
with required AA-40GB
motor (ordered separately).
Axcess 450 MIGRunner
package (#951 228) shown.
Automated MIG applications may require additional support to ensure
the system and components needed are properly selected and installed.
Contact Miller at 1-920-954-3813.
Allows for any input voltage
hookup (208–575 V, singleor three-phase) with no manual linking, providing
convenience in any job setting. Ideal solution for
dirty or unreliable input power.
Accu-Pulse® provides shorter arc lengths, along
with a more focused arc column, which provides
significantly improved puddle control and arc
stability. Accu-Pulse also improves welding in
tight corners without arc wandering as well as
greatly reduced spatter.
SureStart® technology provides consistent arc
starts by precisely controlling power levels for
specific wire and gas combinations.
AA-40GB wire drive motor assembly with
OCP (over current protection) to protect
against current surges. Direct-panel-mounted
to eliminate motion stress on the motor’s
power and tachometer feedback wires.
(Required for Auto-Axcess and used for Axcess
remote configurations.)
Welding Intelligence.™ Increase productivity,
improve quality and manage costs with Insight
Core™ and Insight Centerpoint™ welding information
management systems (see pages 24 and 25).
Various wire feeding options for Axcess available.
See literature no. DC/8.0 for more information.
Multi-MIG® Welding Process Capabilities
Standard
Spray
Process
Weld Puddle Control
Pulsed
Spray
Standard
Short Circuit
Accu-Pulse,® Accu-Curve™
Accu-Speed ™ (Optional)
Flat/Horizontal
RMD® Regulated
Metal Deposition (Optional)
All Position Performance
Processes
Multi-MIG
Accu-Pulse MIG (GMAW-P)
- Accu-Curve
- Accu-Speed (optional)
- Accu-Pulse tandem (factory option
available on Auto-Axcess only)
Pulsed MIG (GMAW-P) MIG (GMAW)
Metal-cored RMD (optional)
Air carbon arc gouging (CAC-A) can
also be activated
•
•
•
•
•
•
Stationary package includes
power source
• Axcess
feeder with Bernard BTB Gun
• Axcess
and drive rolls
interconnecting feeder
• DeviceNet
control cable
MIG 4/0 kit consisting of
• Industrial
flowmeter regulator with 10 ft. (3 m)
™
gas hose, 10 ft. (3 m) 4/0 feeder
weld cable with lugs, and 15 ft.
(4.6 m) work cable with 600-amp
C-clamp.
MIGRunner™ package includes
above plus
• Running gear cylinder rack (pg 107)
Wire feeding options
(see lit. no. DC/8.0 and AU/8.0 for
more information and required cables)
Axcess Feeders
#951 311 Single-wire
#951 431 Dual-wire
Axcess ROI Swingarc™ Boom-Mounted
Feeders
Single- and Dual-Remote Configurations
AA-40GB Wire Drive Motor
(includes 50 ft. volt-sense lead)
#195 426 Left-hand drive
#195 515 Right-hand drive
•
•
•
•
Note: AA-40GB wire drive motor is required
for Auto-Axcess and used for Axcess remote
configurations.
Thin Materials/Gap Filling
Note: Look for high-speed video clips of Accu-Pulse, Accu-Curve, Accu-Speed and front panel simulator at MillerWelds.com/advanced.
Most popular accessories
Models/Packages
*Additional packages are available —
visit MillerWelds.com
or your distributor.
**Order wire drive motor
assembly and required
motor control cable
length separately.
Axcess 450
MIGRunner package
(#951 228) shown.
Axcess 450
stationary package
(#951 229) shown.
Axcess 300
(#907 150)
shown.
The following are for Auto-Axcess only
Flow Switch (pg 106)
• Coolant
Kits (one required
• Receptacle/Adapter
per machine) #194 793 (ABB ),
®
Power Source Only Stock Number
Stationary Package Stock Number*
MIGRunner Package Stock Number*
Axcess 300 (#907 150)
Auto-Axcess 300 (#907 151)**
(#951 227) with Axcess 300 (#907 150)
(#951 226) with Axcess 300 (#907 150)
Axcess 450 (#907 152)
Auto-Axcess 450 (#907 153)**
(#951 229) with Axcess 450 (#907 152)
(#951 228) with Axcess 450 (#907 152)
Axcess 675 (#907 154)
Auto-Axcess 675 (#907 155)**
—
—
Max. OpenCircuit Voltage
Model
Amp/Volt Ranges
Rated Output
Amps Input at Rated Output, 50/60 Hz, 3-Phase
208 V 230 V 400 V 460 V 575 V KVA KW
Axcess 300 and Auto-Axcess 300
5–400 A, 10–44 V
300 A at 29 VDC, 60% duty cycle
33
29.7 16.9 14.6 11.6 11.7 11.2
80 VDC
Axcess 450 and Auto-Axcess 450
5–600 A, 10–44 V
450 A at 36.5 VDC, 100% duty cycle
—
60
80 VDC
Axcess 675 and Auto-Axcess 675
5–900 A, 10–44 V
675 A at 38 VDC, 100% duty cycle
—
89.7 —
22
File Management
• Axcess
Software for PC #300 529
MIG 4/0 Kit (with lug
• Industrial
connectors) #300 390 (pg 109)
33.7 28.8 22.8 23.8 22.9
43.7 34.8 35.7 34.4
80 VDC
•
•
#194 791 (FANUC®), #194 790
(Motoman®), #300 056 (Panasonic®)
and #195 002 (Universal)
Smart Adapter #300 012
(enables semi-automatic function)
FANUC/Motoman Motor Bracket
#300 013
Dimensions
Net Weight
300 H: 23 in. (584 mm)
450 H: 31 in. (787 mm)
675 H: 39 in. (991 mm)
W: 17 in. (432 mm)
D: 22.5 in. (572 mm)
112 lb. (50.8 kg)
163 lb. (73.9 kg)
215 lb. (97.5 kg)
MIG
ADVANCED/AUTOMATED
Continuum Systems
Heavy industrial
™
See literature no. DC/36.0
Processes
New generation of advanced industrial welding solutions improves productivity through weld
quality, ease of use and system flexibility.
Improved processes
™
Accu-Pulse,® RMD®
New Versa-Pulse and improvements to
and MIG processes allow you to take the performance of
each process to the highest level.
™
Continuum 350
model shown with
MIGRunner package.
Filler metal sold
separately.
MIG (GMAW-P)
• Accu-Pulse
Versa-Pulse • RMD • MIG (GMAW)
• High-deposition
MIG (GMAW)
• Air carbon arc gouging
(CAC-A)
•
MIGRunner package includes
power source
• Continuum
single feeder with
• Continuum
Bernard BTB Gun 400 A and
All-new 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 24 and 25).
™
•
•
•
Wire feeding options
Feeders
• Continuum
#951 631 Single-wire
All-new feeder design
Tru-Feed™ technology provides precise feeding operation for
stable arc performance.
New 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.
.035/.045 in. V-groove drive rolls
Continuum running gear/cylinder rack
3 ft. (0.9 m) control/motor cable
Industrial MIG 4/0 kit consisting of
flowmeter regulator with 10 ft. (3 m)
gas hose, 10 ft. (3 m) 4/0 feeder
weld cable with lugs, and 15 ft.
(4.6 m) work cable with 600-amp
C-clamp.
•
•
•
•
#951 673 Dual-wire
Includes Bernard BTB Gun 400 A
(two with dual-wire models) and
.035/.045 in. V-groove drive rolls.
Continuum Swingarc™
Boom-Mounted Feeders
#951 633 8 ft. (2.4 m) single-wire
#951 634 12 ft. (3.7 m) single-wire
#951 635 16 ft. (4.9 m) single-wire
Includes Bernard BTB Gun 400 A and
.035/.045 in. V-groove drive rolls.
See literature no. DC/36.0 for
additional options
Most popular accessories
Centerpoint Software (pg 25)
• Insight
MIG Guns (pg 47)
• Bernard
Running Gear/Cylinder
• Continuum
Rack #301 264 (pg 107)
Coolant Systems (pg 107)
• Coolmate
MIG 4/0 Kit (with lug
• Industrial
connectors) #300 390 (pg 109)
Control/Motor Cables
• Continuum
#263 368 003 3 ft. (0.9 m)
™
™
Continuum Processes
Standard
Spray
Best For
High-Deposition
MIG
Accu-Pulse
Versa-Pulse Short Circuit
RMD
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
Out-of-Position Welds
Low Spatter
A
A
A
B
C
B
Thick Metals
A
A
A
C
D
D
B
A
A
A
A
A
A
A
B
C
Thin Metals
Increased Travel Speed
HOT
COLD
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.
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.
™
#263 368 015
#263 368 020
#263 368 025
#263 368 050
#263 368 080
15 ft. (4.6 m)
20 ft. (6.1 m)
25 ft. (7.6 m)
50 ft. (15 m)
80 ft. (24.4 m)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
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.
Model
Continuum
350
Continuum
500
Stock Number
(#907 636) 230–575 V Machine only
(#907 636 001) 230–575 V w/running gear
(#951 671) 230–575 V MIGRunner package
(#907 640) 230–575 V Machine only
(#907 640 001) 230–575 V w/running gear
(#951 672) 230–575 V MIGRunner package
Model/Stock Number
Continuum Feeder only
(#951 631) Single-wire model
(#951 673) Dual-wire model
Input
Power
50 VDC
Amp/Volt
Ranges
20–400 A,
10–44 V
Rated Output
350 A at 34 VDC,
100% duty cycle
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
20–600 A,
10–44 V
500 A at 40 VDC,
100% duty cycle
34.9 —
0–1 * —
75 VDC
Input Welding
Circuit Rating
500 A at
100% duty cycle
Wire Feed Speed
Standard:
50–1000 ipm
(1.3–25.4 m/min.)
33.2
0–1*
28.9
0–1*
Wire Diameter Capacity
.035–5/64 in.
(0.9–2.0 mm)
23.3
0–1*
23.1 21.9
0.8* 0.17*
Maximum Spool
Size Capacity
18 in. (457 mm),
60 lb. (27 kg)
Machine Only Dimensions
(Includes lift eye)
H: 27.187 in. (691 mm)
W: 17.5 in. (444 mm)
D: 28.125 in. (714 mm)
Dimensions
H: 13.812 in. (351 mm)
Single W: 16.312 in. (414 mm)
Dual W: 17 in. (432 mm)
D: 29.687 in. (754 mm)
Machine Only
Net Weight
127 lb.
(57.6 kg)
148 lb.
(67.1 kg)
Net Weight
Single 43 lb. (19.5 kg)
Dual 61.5 lb. (27.9 kg)
23
Welding Intelligence
™
For more detailed
information, visit
Insight Welding Intelligence helps your operation be more competitive and profitable
by delivering accurate, decision-ready information about your welding processes.
MillerWelds.com/insight
Knowledge to Drive Your Business Forward
Increase Productivity
Evaluate key indicators of operator productivity
Improve Weld Quality
Measure important indicators of weld quality
Manage Costs
Monitor and analyze welding costs
Submerged arc
MIG
Advanced
MIG
TIG
A simplified, Internet-based weld data solution that collects, transmits and presents
actionable information to any Web-connected device in the world.
Basic monitoring
14-pin provides arc-on time and weld parameters (volts/amps) and
deposition (MPa feeder required)
Axcess®/Auto-Axcess™ and Continuum™ provide arc-on time,
deposition, wire feed speed, process, wire type/diameter, gas type
and machine error codes
Wi-Fi and wired Ethernet connectivity are built into Insight Core for
flexible integration with your company’s information network.
No special software or applications required, for easier installation
and more accessible reports.
Factory installed on Axcess®/Auto-Axcess,™ Continuum™ and Dynasty®
280 DX with Insight power sources.
Compatible with 14-pin compliant Miller® power sources. See
MillerWelds.com/insight for a list of 14-pin compatible power sources.
•
•
Factory-installed Insight Core Power Sources
#907 150 002
#907 152 002
#907 154 002
#907 151 004
#907 153 004
#907 155 006
#907 151 005
#907 153 005
#907 155 005
#907 636
#907 640
#907 514 003
Axcess 300 with Insight Core
For more information regarding
Axcess 450 with Insight Core
Axcess/Auto-Axcess power sources
Axcess 675 with Insight Core
and DeviceNet see literature no.
Auto-Axcess 300 with Insight Core
DC/8.0 or AU/8.0 respectively.
Auto-Axcess 450 with Insight Core
Auto-Axcess 675 with Insight Core
Auto-Axcess 300 DeviceNet with Insight Core
Auto-Axcess 450 DeviceNet with Insight Core
Auto-Axcess 675 DeviceNet with Insight Core
Continuum 350
Continuum 500
Dynasty 280 DX with Insight
Field-installed Insight Core Upgrade Modules
#301 072*
#951 617
#301 081
14-pin compliant Miller power source module
14-pin compliant Miller power source module w/S-74 MPa Plus wire feeder
Axcess/Auto-Axcess module
*SubArc Digital Series requires Insight Core to SubArc Digital Series Adapter Kit (#301 295).
24
Visit our online Insight Core simulator at
Insight-simulator.MillerWelds.com
Welding Intelligence
™
Focused on monitoring welding outputs
14-pin products
(Deltaweld,®
Dimension,™
Invision,™
XMT® and
SubArc Digital)
Brings advanced process control into weld cell
Axcess®/Auto-Axcess,™
Continuum™ and Dynasty®
280 DX with Insight
Axcess® E/Auto-Axcess™ E,
Continuum™ and Dynasty®
280 DX with Insight
SOPHISTICATION OF INFORMATION AVAILABLE
For more information regarding Insight Core, Insight Centerpoint and software options visit MillerWelds.com/insight
Advanced, real-time operator feedback to provide process control —
to maximize quality and efficiency in welding and fabrication.
Monitor and control
Part Tracking ™ — human machine interface (HMI) in the cell for real-time
feedback; sequence and weld quality control; reports by part, arc time,
welds, deposition, cell downtime and more
Work Flow ™ — welding and non-welding work instructions to govern the
entire fabrication process
Codes and Standards — captures required information relating actual
welding parameters to the specific operator, contract, joint and weld
pass to ensure productivity and quality requirements are met
Optional Insight Reporter ™ — Preconfigured management charts and
reports that provide a wide range of information about weld process,
productivity, and business metrics, stored in an SQL server database
•
•
•
•
Axcess® E/Auto-Axcess™ E, Continuum™ and Dynasty® 280 DX with Insight
deliver complete software functionality.
Insight Pipe and Vessel
Tailored to the unique needs of pipe and vessel fabricators.
PipeWorx 400 requires Insight Module (#301 304).
Advanced MIG Factory-installed Insight Centerpoint Power Sources
TIG Factory-installed Insight Centerpoint Power Sources
#907 440
#907 439
#907 441
#907 442
#907 443
#907 444
#907 497
#907 496
#907 495
#301 255
#301 256
#301 257
#300 709
#300 710
Axcess E 300
Axcess E 450
Axcess E 675
For more information regarding
Auto-Axcess E 300 Analog
Axcess E/Auto-Axcess E power
Auto-Axcess E 450 Analog
sources see literature no.
DC/8.05 or AU/9.5 respectively.
Auto-Axcess E 675 Analog
Auto-Axcess E 300 Digital
Auto-Axcess E 450 Digital
Auto-Axcess E 675 Digital
Insight Centerpoint single seat license
Insight Centerpoint site license
Advanced capability software (standard capability included)
Insight Reporter single license (1 required per PC)
Insight Reporter SQL database (1 required per facility)
#907 514 003 Dynasty 280 DX with Insight
#301 316 Insight Centerpoint single seat license
#301 256 Insight Centerpoint site license
#301 314 Standard capability software
#301 323 Advanced capability upgrade (requires standard capability to use)
#301 315 Standard and advanced capability software
#300 709 Insight Reporter single license (1 required per PC)
#300 710 Insight Reporter SQL database (1 required per facility)
#907 636
#907 640
#301 255
#301 256
#301 297
#301 257
#301 322
#300 709
#300 710
Continuum 350
Continuum 500
Insight Centerpoint single seat license
Insight Centerpoint site license
Standard capability software
Advanced capability upgrade (requires standard capability to use)
Standard and advanced capability software
Insight Reporter single license (1 required per PC)
Insight Reporter SQL database (1 required per facility)
Field-installed Insight Centerpoint Upgrade Modules
#300 641
#300 852
#300 648
#301 304
Axcess E module
Auto-Axcess E Analog module
Auto-Axcess E Digital module
PipeWorx 400 module (only provides codes and standards)
Accessories
#3DM4015-45Q Insight LTD gun for Axcess E or Continuum
#300 677 Axcess E semi-automatic wire feeder
#300 726 Axcess E remote operator interface (ROI)
#300 734 9.8 ft. (3 m) M12/RJ45 ethernet cable
#300 735 16.4 ft. (5 m) M12/RJ45 ethernet cable
#300 736 32.8 ft. (10 m) M12/RJ45 ethernet cable
#195 480 Field application support
25
Automation
To order automation solutions:
Contact local Miller district manager or email [email protected]
For more detailed
information, visit
MillerWelds.com/automation
For automation service/parts:
Call 1-630-653-6819 or email [email protected]
A family of pre-engineered solutions integrating Miller®
welding technology to solve your manufacturing challenges.
Fast installation. Pre-wired and pre-assembled making set up fast and
easy. Most systems are up and running in under two hours from delivery
(connect power/wire/gas and mounting tooling).
Integrated controls. Control station and full-color teach pendant keep the
operator informed, maximizing production uptime.
Flexibility. Fully welded frame allows for easy relocation and reconnection
as production plans or layouts change.
Single-station load and unload
A/B-style turntable configurations
Side-by-side configurations —
operator walks around system
PA250M 250 lb./side
60 in. manually indexed table
PA350S 350 lb./side
66 in. servo indexing table
PA750S/PA750SW 750 lb./side
92 or 108 in. servo indexing table
Robot between dual head
and tailstock/single- or
dual-robot configuration
PA1100SS 1,100 lb./side
120 in. long x 44 in. turning
diameter
PA2200SS 2,200 lb./side
120 in. long x 66 in. turning
diameter
Ferris wheel configurations —
high-volume production
Single-station load and unload
H-frame configurations
Dual head and tailstock/single- or
dual-robot configuration
PA550H 550 lb./side
48 in. long x 34 in. turning diameter
on 92 in. servo indexer
PA550HW 550 lb./side
PA1100HW 1,100 lb./side
60 in. long x 40 in. turning diameter
on 108 in. servo indexer
Dual head and tailstock/
single-, dual- or triple-robot
configuration
PA1100FW 1,100 lb./side
118 in. long x 43 in. turning
diameter
Automation components
Auto-Axcess™/Auto-Axcess™ E power sources
26
Panasonic® robots
Tregaskiss™ MIG guns
FILTAIR® system with low profile hood
Miller recommends Hobart® filler metals
Automation
To order automation solutions:
Contact local Miller district manager or email [email protected]
For automation service/parts:
Call 1-630-653-6819 or email [email protected]
Active Wire Process (AWP)
Active wire is an advanced short arc welding process combining the robot motion path,
welder waveform and servo wire feed control simultaneously reversing the wire at the
short circuit to control the weld deposition precisely.
Spatter control. Spatter is virtually eliminated in all phases of the weld using mixed
argon 90/10 or 100 percent CO2 gas.
Fast and clean arc striking. At the moment the wire touches the base the wire is
reversed, reducing arc strike spatter by up to 90 percent.
Flexibility. Large variations in torch angle are possible allowing push-pull in and out
of corners without increasing spatter.
Appearance. The precise nature of the process allows many customers an alternative
to TIG welding.
Wide range of materials. Mild steels, stainless steels and aluminum from thin to
medium gauge benefit from AWP.
Thick Plate Welding
Fast and easy programming even on the most complex multi-pass weldments.
All required commands and sensor setup in a single menu screen. Welding
procedures can be developed quickly and transported easily from part to part.
Graphical, menu-driven interface. Pop-up graphical windows allow for fast
programming of any welding joint in a single location.
Multi-layer path control. Easy-to-use interface to sequence the location of
starts/stops and create multi-layer weld paths with appropriate offsets.
Advanced sensors. High-voltage touch sensing with menu-driven touch macros, a
specialized high-amperage arc sensor system, and adaptive fill capability allow the
weld process to adapt to incoming/varying production parts.
DeskTop Programming and
Simulation (DTPS)
Software allows the development of programs offline, minimizing
robot downtime and maximizing throughput and productivity.
Specialized software generates programs and simulates the actual
taught paths from your desktop.
Cutting edge technology and innovation to manage the challenges
of manufacturing and create customer success in metal fabrication.
Native language programming. Same language and functions that
the technician will see on the teaching pendent, making program
generation off-line easier than competitive code-based systems.
File transfer (from old to new). DTPS has the ability to transfer robot
programs between robot types, sizes and controller generations with
no additional formatting requirements.
27
Automation
To order automation solutions:
Contact local Miller district manager or email [email protected]
TM/TL Series Welding Robots
For automation service/parts:
Call 1-630-653-6819 or email [email protected]
Thru-arm
Conventional arm
Best-in-class robot speed and greatly improved
trajectory control — now 20 percent faster with
16 times better trajectory control than TA/TB Series
robots. For thermal process applications including
MIG, TIG or laser welding and plasma or laser cutting.
TM Series. Versatile design accepting conventional or thru-arm
torch configurations.
TL Series. Dedicated design accepting conventional torch
configurations (long arm, niche application support).
TM/TL Series features include
Dedicated welding robot design (application specific)
Collision detection software (reduced downtime)
Password protection software (increased security)
Automated program backup (program recovery)
Advanced error recovery (better uptime)
Axis mastering pins (improved maintenance)
Optional wire conduit through the base axis
(reduced maintenance)
•
•
•
•
•
•
•
TM1400G3
robots
Model
TM1100
TM1400
TM1600
TM1800
TL1800
TL2000
Reach
45.7 in. (1,163 mm)
56.5 in. (1,437 mm)
64.7 in. (1,645 mm)
71.2 in. (1,809 mm)
70.9 in. (1,801 mm)
78.7 in. (1,999 mm)
Fixed Automation
Fixed automation systems integrate MIG,
submerged arc and TIG weld process solutions
based on your application requirements.
Longitudinal seamers (LS) for straight line welding.
Circumferential seamers (CS) for circular welding.
Weld head locators (WHL) for customized welding.
Circumferential seamer
Longitudinal seamer
28
Weld head locator
Payload
12.2 lb. (6 kg)
12.2 lb. (6 kg)
8.8 lb. (4 kg)
12.2 lb. (6 kg)
17.6 lb. (8 kg)
12.2 lb. (6 kg)
Automation
Tregaskiss Robotic Guns
Industrial
™
•
Process MIG (GMAW)
Suggested robots
Air-Cooled MIG Guns
All Panasonic TM/TL Series welding
• robots
(pg 28)
Also
compatible
with robots by
• ABB , COMAU , FANUC
, Kawasaki ,
®
PerformArc® robotic
Available with all
welding systems, fully configurable TOUGH GUN robotic
MIG guns are engineered for precision, durability, accuracy, repeatability, minimal downtime
and fast and easy maintenance.
™
TOUGH GUN CA3 MIG Guns
See Tregaskiss literature no. SP-CA3
Designed for high-volume production environments.
®
See Tregaskiss literature no. SP-TA3
Designed for precise, repeatable performance on today’s
through-arm style robots.
Re-engineered neck clamp improves durability and consistency of
clamping force.
Available as a complete package from the power pin to the contact tip.
Easy maintenance with minimal downtime.
®
®
Packages
Robotic Welding Systems
• PerformArc
(pg 26)
Most popular accessories
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.
TOUGH GUN TA3 MIG Guns
®
KUKA™, Motoman®, OTC Daihen® and
Reis™ (CA3 only)
TOUGH GUN
TT3 Reamer
equipped with
optional wire
cutter and
lubricator.
GUN TT3 Reamer
• TOUGH
The perfect addition to your Miller
®
•
automation solution, this robotic
nozzle cleaning station is tough on
spatter and operates reliably in even
the harshest welding environments.
See Tregaskiss literature no. M086
for more information.
TOUGH GARD™ Anti-Spatter Liquid
Visit Tregaskiss.com or your distributor for
other Tregaskiss options and accessories.
For more information or to configure your
Tregaskiss robotic gun online, visit
Tregaskiss.com/ConfigureMyGun
Robust. Resilient. Repeatable.
The robotic MIG welding guns and peripherals that you can rely on.
Tregaskiss understands that automated welding applications require reliable products
that maximize production uptime and throughput. This is why industrial manufacturers
repeatedly turn to Tregaskiss and its proven track record in providing resilient, easy to
maintain, robotic MIG welding guns, consumables and peripherals.
Visit Tregaskiss.com to configure a robotic gun for your welding application today.
Or call 1-855-MIGWELD (644-9353) for more information.
29
Multiprocess
Power Source
Welding
Performance
150 A
250 A
300 Amp
Multimatic™ Shopmate™
200 (1-Phase) 300 DX (1-Phase)
For more detailed
information, visit
MillerWelds.com/multiprocess
450 Amp
350 Amp
650 Amp
Dimension™
302
XMT®
304 CC/CV
XMT®
350 VS
XMT®
350 CC/CV
XMT®
350 MPa
Dimension™
452
XMT®
450 CC/CV
XMT®
450 MPa
Dimension™
650
(pg 34)
(pg 32)
(pg 34)
(pg 34)
(pg 33)
(pg 31)
(pg 31)
(pg 32)
(pg 34)
(pg 34)
(pg 34)
5/16 in.
5/16 in.
5/16 in.
3/8 in.
Mild Steel
Material
Stainless Steel
Aluminum*
Gauge
(.020–.125 in.)
Material
Thickness
Sheet
(.125–.375 in.)
Plate
(.375–1 in.)
Plate
(1+ in.)
.023 in.
.030 in.
.035 in.
Wire Size
.045 in.
.052 in.
1/16 in.
5/64 in.
3/32 in.
Short Circuit
3/16 in.
1/4 in.
1/4 in.
1/4 in.
1/4 in.
1/4 in.
Pulsed Spray
Process
Stick
TIG
CAC-A
Icon Key
30
Capability:
Designed for
Capable of
*XR push-pull system recommended for best results.
Process Quality:
Good Better Best Optimized
Multiprocess
Multimatic 200
Light industrial
™
See literature no. DC/12.57
Processes
Welding Capability
Max. 3/8 in. (9.5 mm)
Max. 1/4 in. (6.4 mm)
Max. 3/16 in. (4.8 mm)
MIG Mild Steel
MIG Aluminum
TIG Mild Steel
Min. 24 ga. (0.6 mm)
Min. 18 ga. (1.2 mm)
Min. 0.020 in. (0.5 mm)
Aluminum welding uses optional Spoolmate 100 and 4000 series aluminum wire
or Spoolmate 150 (effective with Multimatic serial number MF364047N) and either
4000 or 5000 series aluminum wire. TIG welding uses optional TIG contractor kit.
See page 113
(GMAW) • Flux-cored (FCAW)
• MIG
• DC stick (SMAW) • DC TIG (DC GTAW)
Comes complete with
Bernard Q150 MIG gun
• 1013 ft.ft. (4(3 m)m)cable
with electrode holder
• and 25 mm Dinse-style
connector
10
ft.
(3
m)
work
cable
with
clamp
• and 25 mm Dinse-style connector
cord with MVP plugs for
• Power
120 V and 240 V
Select drive roll for
• Quick
.024 in. (0.6 mm) or .030/.035 in.
™
™
The only all-in-one, portable, multiprocess power source
from Miller is our most versatile machine to date.
Weighing only 29 pounds (13.2 kg) and running on either
120 or 230 volts, the Multimatic 200 can go anywhere you
need to MIG, TIG or stick weld.
Auto-Set™ Elite can be used on multiple materials and
multiple processes with the ability to fine-tune your settings.
Simple to set up and use!
(MVP ™)
Multi-voltage plug
allows connection to common
120- and 240-volt power receptacles without the use of
any tools — simply choose the plug that fits the
receptacle and connect to the power cord.
Impact-resistant case provides strength and durability while
protecting the internal components and welding wire.
Spoolmate 100 (#300 371)
or 150 (#301 272).
Amps Input at Rated Output, 50/60 Hz
120 V
230 V
KVA
KW
Welding
Mode/Process
Input
Power
Amperage
Range
Rated Output
CV: MIG/
flux-cored
120 V
30–140
90 A at 18.5 V, 60% duty cycle
18
—
2.2
2
110 A at 19.5 V, 20% duty cycle
20
—
2.7
2.6
3.8
CC: TIG
CC: Stick
230 V
30–200
150 A at 21.5 V, 20% duty cycle
—
17.5
4.0
120 V
5–150
150 A at 16 V, 30% duty cycle
27
—
3.3
3.2
230 V
5–150
150 A at 16 V, 30% duty cycle
—
13.8
3.2
3.0
120 V
20–150
100 A at 24 V, 35% duty cycle
24
—
2.9
2.8
230 V
20–150
150 A at 26 V, 30% duty cycle
—
20.8
4.8
4.5
Shopmate 300 DX
Voltage
Range
5–400
10–35
Max. OpenCircuit Voltage
90 VDC
—
90 VDC
(22–25 VDC,
sense voltage
for stick and
Lift-Arc™ TIG)
Net
Weight
Dimensions
H: 14.5 in.
(368 mm)
W: 9.75 in.
(248 mm)
D: 17 in.
(432 mm)
29 lb.
(13.2 kg)
Light industrial
See literature no. DC/12.7
Processes
(GMAW) • Flux-cored (FCAW)
• MIG
stick (SMAW) • DC TIG (DC GTAW)
• DCAir carbon
arc cutting and gouging
• (CAC-A) (3/16
in. carbons)
Process selector switch is an “operator-friendly” single process
switch that eliminates the confusion of several switch combinations.
Digital meters for presetting or monitoring voltage and amperage.
Built-in 10-pin connector for direct hookup of Spoolmatic® spool
guns and built-in 14-pin connector for direct hookup of 14-pin,
Miller® wire feeders and accessories.
Fan-On-Demand™ cooling system operates only when needed.
Line voltage compensation keeps welding parameters constant.
Arc control adjusts inductance in MIG mode and DIG in stick mode
to optimize weld performance.
Lift-Arc™ start provides DC TIG arc starting without the use of high
frequency. Starts the arc without contaminating the weld with tungsten.
Amperage
Range
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
70–425 ipm
(1.8–10.8 m/min.)
An economical single-phase DC multiprocess power source that provides versatility and
outstanding arc performance in CV mode (MIG) and CC mode (stick and TIG).
Stock Number
(#907 315) 200(208)/230 V
(#907 316) 230/460/575 V
(#951 076) 200(208)/230 V w/MIG package
(#951 077) 230/460/575 V w/MIG package
Spool Guns (pg 18)
• Spoolmate
Kit #301 287 (pg 112)
• TIG14-PinContractor
to
6-Pin
Adapter Cord
• #300 507 (pg 112)
Remote Fingertip Control
• RCCS-6M
#195 184 (pg 112)
Wire Feed Speed
™
Shopmate
300 DX with
MIG package
shown.
Most popular accessories
™
Excellent arc characteristics! Unit offers positive arc starts
and an extremely stable arc with minimal spatter on both
mixed gases and straight CO2.
Recommended
aluminum solution
Stock Number
(#907 518) 120/230 V
(#951 649) 120/230 V
with TIG contractor kit
(see page 112 for
kit contents)
•
(0.8/0.9 mm) solid wire, and
.030/.035 in. (0.8/0.9 mm)
flux-cored wire
Flow gauge regulator and gas hose
for argon or AR/CO2 mix, extra contact
tips, information/settings chart and
material thickness gauge (#229 895)
Rated Output
250 A at 30 VDC,
60% duty cycle
MIG package comes
complete with
wire feeder with Bernard BTB
• 22A
Gun 300 A
300 MIG kit consisting of
• Shopmate
flow gauge regulator and 10 ft. (3 m)
™
gas hose for argon or AR/CO2 mix,
10 ft. (3 m) 1/0 interconnecting cable,
15 ft. (4.6 m) 1/0 work cable with
clamp and consumable storage box.
Most popular accessories
Running Gear/Dual
• Shopmate
Cylinder Rack #300 145 (pg 107)
300 MIG Kit #300 150
• Shopmate
(pg 109)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Amps Input at Rated Load Output, 60 Hz
208 V 230 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
Dimensions
(Includes lift eye)
Net
Weight
66
80 VDC
H: 24.5 in. (622 mm)
W: 19 in. (483 mm)
D: 25.5 in. (648 mm)
177 lb.
(80.3 kg)
57
29
23
13
11.2
31
Multiprocess
Dimension 302 and 452
Heavy industrial
™
See literature no. DC/19.2
Processes
(GMAW) • Flux-cored (FCAW)
• MIG
(SMAW) • TIG (GTAW)
• Stick
carbon arc cutting and gouging
• Air(CAC-A)
(carbons — 302: 1/4 in.,
Multiprocess performance in a reliable package. Designed for heavy-industrial applications,
with 100 percent duty cycle for extended arc-on time.
452: 5/16 in.)
Stationary package includes
Built-in arc control for stick welding allows operators
more flexibility when welding in tight areas where
sticking electrodes is a problem.
source
• Power
feeder with Bernard BTB Gun
• S-74D
400 A and .035/.045 in. drive rolls
MIG 4/0 kit consisting of
• Industrial
flowmeter regulator with 10 ft. (3 m)
™
Line voltage compensation ensures consistent weld
performance even when primary power varies.
gas hose, 10 ft. (3 m) 4/0 feeder
weld cable with lugs, and 15 ft. (4.6 m)
work cable with 600-amp C-clamp.
Fan-On-Demand™ cooling system operates only when
needed. Reduces contaminants drawn into the
machine and excess noise in work areas.
MIGRunner™ package includes
above plus
running gear with
• Factory-installed
cylinder rack
Digital meters are easy to read and display preset
and actual voltage and amperage.
Most popular accessories
115-volt power for tools and coolant systems.
Dimension 452
Stationary package
(#951 273) shown.
X-TREME Feeders (pg 42)
• SuitCase
Series Feeders (pg 44)
• 70Standard
Running Gear/Cylinder Rack
• #042 886/#042
887 (pg 106)
MIG 4/0 Kit (with lug
• Industrial
connectors) #300 390 (pg 109)
Extension
Cables (pg 114)
•
®
Build your own system at
MillerWelds.com/equiptoweld
or see packages below.
When purchasing components separately,
visit MillerWelds.com/equiptoweld or
your distributor for other Miller® options
and accessories.
Note: Dimension 652 still available for a limited time; see page 33 for Dimension 650.
Amperage/
Voltage Ranges
Model
Stock Number
Dimension
302
(#903 216) 230/460/575 V, Machine only
(#951 272) 230/460/575 V, Stationary pkg
(#951 276) 230/460/575 V, MIGRunner pkg
CC mode: 15–375 A
Dimension
452
(#903 254) 200(208)/230/460 V, Machine only
(#903 255) 230/460/575 V, Machine only
(#951 273) 230/460/575 V, Stationary pkg
CC mode: 20–565 A
CV mode: 10–32 V
CV mode: 10–38 V
™
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
Machine Only Dimensions
(Includes lift eye and strain relief)
Machine Only
Net Weight
300 A at 32 VDC,
100% duty cycle
57.5 50
25
20
20
12.9
60 VDC
69
60
30
24
23.7 13.4
36 VDC
H: 30 in. (762 mm)
W: 23 in. (585 mm)
D: 30.5 in. (775 mm)
361 lb.
(164 kg)
450 A at 38 VDC,
100% duty cycle
91
79
39
31
31.4 22
65 VDC
424 lb.
(192 kg)
104
90
45
36
35.3 22.3
43 VDC
H: 30 in. (762 mm)
W: 23 in. (585 mm)
D: 38 in. (966 mm)
Rated Output
Innovation
Focused on optimizing quality,
ease-of-use and cost
Collaboration
Partnering to meet customer needs
Trusted source
Deep product and application
expertise to deliver success
Visit HobartBrothers.com for more information.
More than just filler metal… SOLUTIONS for your business.
32
Multiprocess
Dimension 650
Heavy industrial
™
See literature no. DC/19.3
Processes
(GMAW) • Flux-cored (FCAW)
• MIG
(SMAW) • TIG (GTAW)
• Stick
arc (SAW)
• Submerged
Air
carbon
arc
and gouging
• (CAC-A) (ratedcutting
3/8 in. carbons)
Developed for harsh environmental conditions and output requirements
that range from power-intensive to precise.
All aluminum construction helps the
machine resist corrosion for long life.
Exclusive protection input inductor protects
machine’s performance and reliability from
“dirty” input power.
Wind Tunnel Technology™ protects internal
components, greatly improving reliability.
Fan-On-Demand™ reduces power consumption
and improves reliability.
BUILT
TO
LAST
source
• Power
MPa Plus feeder with
• S-74
Bernard BTB Gun 400 A and
™
•
High-quality performance in all welding
processes, from thick to thin metals.
Arc control available in the stick and wire
modes for easier fine tuning of tough-to-weld
materials and out-of-position applications.
Build your own system at
MillerWelds.com/equiptoweld
or see packages below.
Stationary package includes
POWER
FOR
THICK
METALS
PRECISION
FOR
.035/.045 in. drive rolls
Industrial MIG 4/0 kit consisting of
flowmeter regulator with 10 ft. (3 m)
gas hose, 10 ft. (3 m) 4/0 feeder
weld cable with lugs, and 15 ft.
(4.6 m) work cable with 600-amp
C-clamp.
MIGRunner™ package includes
above plus
• Running gear cylinder rack
Most popular accessories
THIN METALS
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 652 and also
uses 40 percent less floor space.
4-pack
rack
shown.
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 652.
93%
EFFICIENT
650 Rack
• Dimension
#907 687 2-pack rack
•
Dimension 650 ArcReach
™
Remote control of the power source
without a cord. An ArcReach system
allows you to change weld settings from your SuitCase
wire feeder or Stick/TIG Remote, saving a trip to the
power supply. No extra control cable to purchase,
maintain, string or unstring — saving time and money.
See page 43 for ArcReach wire feeders.
•
•
•
•
•
•
•
#907 688 4-pack rack
Rack comes assembled with two or
four Dimension 650 power sources
fused for 460 V.
Dimension 650 ArcReach Rack
#907 702 2-pack rack
#907 701 4-pack rack
Rack comes assembled with two or
four Dimension 650 ArcReach power
sources fused for 460 V.
SuitCase® X-TREME™ Feeders (pg 42)
70 Series Feeders (pg 44)
Bernard™ MIG Guns (pg 47)
Running Gear Cylinder Rack
#300 408 (pg 107)
Dimension 650 Running Gear
#301 307 (pg 107)
Industrial MIG 4/0 Kit (with
lug connectors) #300 390 (pg 109)
Extension Cables (pg 114)
#242 208 025 25 ft. (7.6 m)
#242 208 050 50 ft. (15 m)
#242 208 080 80 ft. (24.4 m)
When purchasing components separately,
visit MillerWelds.com/equiptoweld or
your distributor for other Miller® options
and accessories.
Model/Stock Number
Dimension 650
(#907 617) 380/460 V Machine only
(#951 638) 380/460 V Stationary package
(#951 637) 380/460 V MIGRunner package
Dimension 650 ArcReach
(#907 617 001) 380/460 V Machine only
Amperage/
Voltage Ranges
CC mode: 10–815 A
CV mode: 10–44 V
SAW mode: 10–65 V
Rated Output
650 A at 44 VDC,
100% duty cycle
Amps Input at Rated Output, 50/60 Hz
380 V
460 V
KVA
KW
Max. OpenCircuit Voltage
Machine Only Dimensions
(Includes lift eye)
Machine Only
Net Weight
53.2
87 VDC
H: 28.187 in. (716 mm)
W: 16.687 in. (424 mm)
D: 31.625 in. (803 mm)
158 lb.
(71.7 kg)
42.8
34
30.7
33
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
XMT 304
Input power choices
Reliability
Auto-Link® (304 model) automatically links the power source to
primary voltage being applied (230/460 V, single- or three-phase).
(350 models) allows for any input voltage hookup
(208–575 V, single- or three-phase) with no
manual linking, providing convenience in any job setting. Ideal solution
for dirty or unreliable input power.
Standard hookup (450 models). Available as 230/460 V manual link
or 575 V models, three-phase only.
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.
Welder friendly control panel
Process selector switch reduces the number of control setup combinations
without reducing any features.
Ultra-tough, polycarbonate-blended cover protects front controls from damage.
Large, dual digital meters are easy to view and presettable to ease setting
weld output.
Advanced features for the professional welder
Adaptive Hot Start™ makes starting stick electrodes easy without
creating an inclusion.
Infinite arc control available in the stick and wire modes for easier
fine tuning of tough-to-weld materials and out-of-position applications.
Lift-Arc™ provides arc starting that minimizes contamination of the
electrode and without the use of high frequency.
Welding Intelligence™ system. XMT 14-pin
models are Insight Core capable to monitor
weld voltage, amperage, and arc-time and percentage.
Output connector choices
Dinse- or Tweco®-style weld disconnects (304/350 models) provide high-quality
weld cable connections.
Note: Two Dinse connectors are supplied with Dinse machines. Tweco connectors must be ordered separately.
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
300 Amp
XMT 304 CC/CV
Input Power
Primary Operating Range
Weld Output
Carbon Arc Gouging
Net Weight
350 Amp
XMT 350 VS
3- or 1-phase power
Auto-Link (230/460 V)
XMT 450 CC/CV
XMT 450 MPa
3- or 1-phase power
3-phase
Manual link (230/460 V) or 575 V
UPGRADE
Auto-Line (208–575 V)
UPGRADE
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: 1/4 in. (6.4 mm)
UPGRADE
Rated: 1/4 in. (6.4 mm)
UPGRADE
Rated: 5/16 in. (7.9 mm)
79.5 lb. (36.1 kg)
80 lb. (36.3 kg)
Tweco
Pulsed MIG
—
14-pin Compliant
Yes
Insight Core Capable
(requires Insight Core
14-pin module)
34
450 Amp
XMT 350 MPa
300 A at 32 VDC
(3-phase input power at 60% duty cycle)
Dinse
Output Connector
XMT 350 CC/CV
122 lb. (55.3 kg)
Dinse or Tweco
Dinse or Tweco
—
—
Yes
—
—
Yes
Yes
Yes
Yes
Yes
—
Yes
(pg 24)
Yes
(pg 24)
Yes
(pg 24)
Yes
(pg 24)
—
Factory option
(pg 36)
Factory option
(pg 36)
—
Factory option
(pg 36)
—
UPGRADE
1/2 in. stud
UPGRADE
Yes
Multiprocess
XMT® 304 CC/CV
Heavy industrial
XMT 450
is 3-phase only.
See literature no. DC/18.8
Cost-effective multiprocess machine featuring Auto-Link®.
XMT® 350 VS
Processes
(GMAW) • Pulsed MIG (GMAW-P)*
• MIG
(SMAW) • TIG (GTAW)
• Stick
Flux-cored
• Air carbon (FCAW)
arc cutting and gouging
• (CAC-A) (carbons
— 304: 1/4 in.,
See literature no. DC/18.93
For applications in which 14-pin receptacle is not needed for remote control or 14-pin feeders.
350: 1/4 in., 450: 5/16 in.)
*Only XMT MPa models.
XMT® 350 CC/CV and 450 CC/CV
See literature no. DC/18.93 (350)
and DC/18.94 (450)
Most popular accessories
for non-VS models
(pg 17)
• XR-AlumaFeed
Spoolmatic
/WC-24
• XR Controls (pg 21) (pg 19)
• 20 and 70 Series Feeders (pg 44)
•
®
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.
®
™
Most popular accessories
for all models
Stronger weld output for increased capabilities. XMT 350 provides
24 percent more output than the 304 model for larger wires and stick
electrodes. XMT 450 provides 43 percent more output for carbon arc gouging.
XMT® 350 MPa and 450 MPa
Rack
• XMT
Available in
See literature no. DC/18.93 (350) and DC/18.94 (450)
Built-in pulse programs for manufacturing and fabrication applications that have benefits for
standard steels, high-strength steels and aluminum.
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.
four- or sixpack models
for XMT 304
and 350,
or four-pack
models for
XMT 450. See literature no.
DC/18.81 for more information and
stock numbers.
SuitCase® X-TREME™ Feeders (pg 42)
Cylinder Cart #042 537 (pg 106)
MIGRunner™ Cart #195 445 (pg 107)
Running Gear Cylinder Rack
#300 408 (pg 107)
Coolmate™ Coolant System (pg 107)
Industrial MIG 4/0 Kits (pg 109)
#300 405 XMT 304/350
#300 390 XMT 450
Protective Cover (XMT 304/350 only)
#195 478 (pg 112)
Gas Valve Kit
#195 286 XMT 350
#300 928 XMT 450
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*Feeders include gun and drive rolls. MIGRunners add 2/0 weld cable and 2/0 work cable with clamp, flowmeter regulator with gas hose and MIGRunner cart.
**Duty cycle rating below achieved with 6-gauge input power cord (8-gauge cord supplied with unit).
Max.OpenCircuit
Dimensions
Voltage
XMT 304 CC/CV (Dinse)
(#903 471) 208–230/460 V
(#951 343) 208–230/460 V MIGRunner w/22A*
3-phase 5–400 A
10–35 V
1-phase
300 A at 32 VDC, 60% duty cycle
33.7
30.5
—
18.9
—
12.2 11.6 90 VDC
225 A at 29 VDC, 60% duty cycle
52.4
47.4
—
24.5
—
11.3 7.6
XMT 350 VS (no remote control) (Tweco®)
(#907 224) 208–575 V
XMT 350 CC/CV (Dinse)
(#907 161) 208–575 V
(#907 161 011) 208–575 V w/auxiliary power
(#951 549) 208–575 V w/SuitCase X-TREME 12VS*
(#951 327) 208–575 V MIGRunner w/22A*
(#951 314) 208–575 V MIGRunner w/S-74D*
XMT 350 MPa (Dinse except where noted)
(#907 366) 208–575 V
(#907 366 011) 208–575 V w/auxiliary power
(#907 366 014) 208–575 V w/Tweco®
3-phase 5–425 A
10–38 V
350 A at 34 VDC, 60% duty cycle
40.4
36.1
20.6
17.8
14.1
14.2 13.6 75 VDC
1-phase 5–425 A
10–38 V
300 A at 32 VDC, 60% duty cycle**
60.8
54.6
29.7
24.5
19.9
11.7 11.2
XMT 450 CC/CV (1/2 in. stud)
(#907 481) 230/460 V
(#907 482) 575 V
3-phase 15–600 A
10–38 V
450 A at 38 VDC, 100% duty cycle
—
51
—
27.6
24.4
22
—
51
450 A
Power Source Model/Stock Number
300 A
Amps Input at Rated Load Output, 60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
350 A
Amperage/
Voltage
Ranges
Rated Output
Input
Power
XMT 450 MPa (1/2 in. stud)
(#907 479) 230/460 V
(#907 479 001) 230/460 V w/auxiliary power
(#907 480) 575 V
(#907 480 001) 575 V w/auxiliary power
18.9 90 VDC
Net
Weight
H: 17 in. (432 mm)
W: 12.5 in. (318 mm)
D: 24 in. (610 mm)
79.5 lb.
(36.1 kg)
H: 17 in. (432 mm)
W: 12.5 in. (318 mm)
D: 24 in. (610 mm)
80 lb.
(36.3 kg)
H: 17.25 in. (438 mm) 122 lb.
W: 14.5 in. (368 mm)
(55.3 kg)
D: 27.125 in. (689 mm)
—
27.6 23.6 21.6 18.3
(KVA is 23.5 on 575 V)
35
Multiprocess
XMT® 350 and 450 ArcReach Systems
™
See literature no. DC/18.93 (350) and DC/18.94 (450)
Remote control of the power source without
a cord. An ArcReach system allows you to
change weld settings from your SuitCase wire feeder or
Stick/TIG Remote, saving a trip to the power supply. No extra
control cable to purchase, maintain, string or unstring — saving
time and money. See page 43 for ArcReach wire feeders.
XMT 350 CC/CV ArcReach shown with SuitCase X-TREME 12VS ArcReach feeder (sold separately).
Feeders include Bernard S-Gun or BTB Gun 300 A with reversible dual size (.045 and 1/16 in.)
VK drive rolls.
More arc-on time and reduced exposure to
MORE
workplace hazards for operators can be realized
WELDS
using ArcReach because less time is spent going
IN LESS
back to the XMT to set process and arc voltage.
TIME
Auto-Process Select.™ System automatically changes
to MIG/FCAW (with gas) if electrode positive polarity is detected or
FCAW (no gas) if electrode negative polarity is detected, when ArcReach
communication is established between the feeder and the XMT — reducing
the need to access the power supply.
Automatic return to panel settings. System automatically returns to XMT
setting when ArcReach communication is terminated. For example, if the
XMT is set to gouging at 350 amps and an ArcReach feeder is connected,
the XMT will go to a MIG/FCAW process. If the feeder is disconnected, the
XMT will go back to its previous setting (gouging at 350 amps).
Auto-Bind™ automatically establishes exclusive communication between the
power source and the wire feeder, using the existing weld cables upon
system power up.
Operator can precisely set arc voltage at the feeder
BETTER
and monitor the actual arc voltage and current
WELDS
delivered to the weld using the digital meters on
WITH LESS
the feeder. This removes guesswork when it comes
REWORK
to adhering to weld procedures.
Less operator fatigue by not needing to move or reposition both heavy
secondary weld leads bundled with control cords on the jobsite. Control
cables are not used.
Save time by no longer needing to troubleshoot
welding system problems that result from damaged
FEWER
control cords.
CABLES
TO MAINTAIN
Eliminate costly control cord repairs because
control cords are not used.
36
Remote override of XMT. When an ArcReach feeder is connected to an
XMT the feeder has full control and the XMT controls are disabled. While
under ArcReach control, process and voltage/amperage adjustments are
locked out, preventing accidental changes by personnel other than the
welding operator.
Remote in use indicator provides convenient feedback indicating an
ArcReach wire feeder is controlling the power source.
LED process indicator.
Front panel process selections
are illuminated with an LED
that identifies the active
process. This enables the
selected weld process to be
seen at a distance from the
power source. Includes new
carbon arc gouging mode for
enhanced arc stability and control, and two new stick modes (EXX10 and
EXX18) designed to reduce spatter and enhance arc starts.
Fleet compatibility. ArcReach-equipped power sources and wire feeders
work with non-ArcReach equipment; however the complete ArcReach
benefit is only realized with the ArcReach system. This allows you to start
investing in ArcReach one power source, one wire feeder at a time.
Multiprocess
Heavy industrial
How ArcReach Works
XMT 450
is 3-phase only.
Processes
(GMAW) • Stick (SMAW)
• TIGMIG(GTAW)
(FCAW)
• Air carbon arc• Flux-cored
cutting
and
gouging
• (CAC-A) (carbons — 304: 1/4
in.,
ArcReach
SuitCase feeder
or Stick/TIG
Remote
350: 1/4 in., 450: 5/16 in.)
Most popular accessories
for non-VS models
#300 509 (pg 17)
• XR-AlumaFeed
Spoolmatic
/WC-24
• XR Controls (pg 21) (pg 19)
• 20 and 70 Series Feeders (pg 44)
•
®
®
™
Most popular accessories
for all models
ArcReach
power source
ArcReach technology uses the existing weld cable to communicate welding control information between the feeder
and power source. This technology eliminates the need for control cords, and their associated problems and costs.
350 CC/CV ArcReach Rack
• XMT
#907 699 4-pack rack
ArcReach™ Accessories
For MIG or flux-cored welding —
SuitCase X-TREME 8VS/12VS
ArcReach feeders
voltage control
• Remote
indication
• Polarity
• Auto-Process Select
•
•
•
™
For stick or TIG welding —
ArcReach Stick/TIG Remote
(available first quarter 2016)
amperage control
• Remote
Arc
control
for stick
• Polarity indication
• Auto-Process Select
•
•
™
#907 698 6-pack rack
Rack comes assembled with four or
six XMT 350 CC/CV ArcReach power
sources fused for 460/575 V. See
literature no. DC/18.81 for more
information.
XMT 450 CC/CV ArcReach Rack
#907 700 4-pack rack
Rack comes assembled with four XMT
450 CC/CV ArcReach power sources
fused for 460 V. See literature no.
DC/18.81 for more information.
ArcReach™ Stick/TIG Remote
(see at left) #301 325
SuitCase® X-TREME™ 8VS ArcReach™
Feeders (see at left and pg 42)
#951 588 w/Bernard™ S-Gun™
#951 584 w/Bernard BTB Gun 300 A
SuitCase® X-TREME™ 12VS ArcReach™
Feeders (see at left and pg 42)
#951 589 w/Bernard™ S-Gun™
#951 581 w/Bernard BTB Gun 300 A
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Input
Power
Amperage/
Voltage Ranges
Rated Output
3-phase
350 A
XMT 350 VS ArcReach (Tweco®)
(#907 224 002) 208–575 V
XMT 350 CC/CV ArcReach (Tweco®)
(#907 161 032) 208–575 V
(#907 161 033) 208–575 V w/auxiliary power
5–425 A
10–38 V
1-phase
450 A
*Duty cycle rating below achieved with 6-gauge input power cord (8-gauge cord supplied with unit).
XMT 450 CC/CV ArcReach (1/2 in. stud)
(#907 481 003) 230/460 V
(#907 481 004) 230/460 V w/auxiliary power
(#907 482 002) 575 V
3-phase
Power Source Model/Stock Number
Amps Input at Rated Load Output, 60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
350 A at 34 VDC,
60% duty cycle
40.4 36.1 20.6 17.8 14.1 14.2 13.6
75 VDC
H: 17 in. (432 mm)
W: 12.5 in. (318 mm)
D: 24 in. (610 mm)
80 lb.
(36.3 kg)
5–425 A
10–38 V
300 A at 32 VDC,
60% duty cycle*
60.8 54.6 29.7 24.5 19.9 11.7 11.2
15–600 A
10–38 V
450 A at 38 VDC,
100% duty cycle
—
90 VDC
H: 17.25 in. (438 mm)
W: 14.5 in. (368 mm)
D: 27.125 in. (689 mm)
122 lb.
(55.3 kg)
51
—
27.6 24.4 22
18.9
Dimensions
Net
Weight
37
Multiprocess
PIPE WELDING
PipeWorx 350 FieldPro System
™
Simplicity-driven performance for your pipe construction site.
See literature no. PWS/6.0
Simplified cable management
Save time by eliminating the need to trace cables back to
change welding parameters and processes
No control cables to string and manage on the jobsite
Complete control at the weld joint
FieldPro remote reduces weld defects by automatically
setting correct polarity for each welding process — without
the need to manually swap cables
Eliminates the need to “get by” with less than optimal
settings without 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
Arc performance optimized for critical pipe welding
Industry-leading arc performance like the PipeWorx 400
welding system, but in a field-ready package
True multiprocess system provides conventional stick,
TIG, flux-cored and MIG welding, as well as the advanced
technologies of RMD® and pulsed MIG
Smart feeder delivers excellent RMD and pulsed MIG
welding 200 feet from 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
•
•
•
PipeWorx 350 FieldPro
shown with optional
FieldPro Remote,
FieldPro Smart Feeder,
and FieldPro Feeder.
•
•
See page 113
FREE! PipeWorx 350 FieldPro
system DVD showcases the
features and benefits of PipeWorx
350 FieldPro system and new
pipe welding techniques. Visit
MillerWelds.com to order your
DVD today.
Stick/TIG system includes
350 FieldPro power source (#907 533)
• PipeWorx
Remote with work sense lead and clamp
• FieldPro
(#300 934)
MIG/flux-cored system includes
350 FieldPro power source (#907 533)
• PipeWorx
Feeder with drive rolls, work sense lead
• FieldPro
and clamp (#301 228)
• 15 ft. (4.6 m) PipeWorx 300 MIG gun (#195 400)
RMD/pulse system includes
350 FieldPro power source (#907 533)
• PipeWorx
Smart Feeder with drive rolls (#300 935)
• FieldPro
• 15 ft. (4.6 m) PipeWorx 300 MIG gun (#195 400)
PipeWorx 400 Welding System
Optimized for pipe fabrication shops.
•
•
•
•
See literature no. PWS/2.0
Simple process setup
The front panel was designed by welders for welders
Requires just a few basic steps to set up a new weld
process, resulting in less training time and minimizing
errors from incorrect setups
Memory feature stores 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
(#951 381) shown with accessory kit
(#300 568). Filler metal and shielding
gas sold separately.
PipeWorx welding system
comes complete with
400 power source with cable
• PipeWorx
hangers (#907 382) or (#907 384)
feeder with drive rolls (#300 366)
• Dual
15 ft. (4.6 m) PipeWorx 300 guns
• Two
(#195 400)
gear with gas cylinder rack and
• Running
handles (#300 368)
kit with 25 ft. (7.6 m) work sense
• Cable
lead (#300 367)
•
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
•
•
Quick process changeover
push a process selection button to choose a
• Simply
welding process
set-up time and reduces the risk of weld
• Eliminates
reworks due to incorrect cable connections
“Quick Select” technology automatically selects
• PipeWorx
the welding process, the correct polarity, cable outputs,
gas solenoid, and user-programmed welding parameters
See page 113
38
FREE! PipeWorx 400 welding system CD
showcases the features and benefits of
PipeWorx welding system and new pipe
welding techniques. Visit MillerWelds.com
to order your CD today.
Single-system design
One machine designed to perform all of your pipe
welding needs
Simplified and optimized specifically for pipe welding
•
•
PIPE WELDING
Multiprocess
Advanced Technologies of PipeWorx Systems
Heavy industrial
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
Processes
•
•
•
•
•
•
•
•
PipeWorx Memory Card, Accu-Power #300 667
Displays instantaneous power during welding to meet the new
ASME requirement for calculating heat input on complex
waveform processes (RMD and pulsed MIG).
PipeWorx 400
is 3-phase only.
Pulsed MIG
heat input than traditional
• Less
spray pulse transfer
arc length
• Shorter
arc cone
• Narrower
fusion and fill at the
• Improved
toes of the weld resulting in:
•
•
(SMAW) • DC TIG (GTAW)
• Stick
(GMAW) • Flux-cored (FCAW)
• MIG
• RMD
• Pulsed MIG (GMAW-P)
carbon arc cutting and gouging
• Air(CAC-A)
Most popular accessories for
both PipeWorx Systems
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
PipeWorx Guns
• Bernard
#195 399 15 ft. (4.6 m) 250-15
™
#195 400 15 ft. (4.6 m) 300-15
Most popular accessories for
PipeWorx 400 Welding System
PipeWorx 350 FieldPro Racks
NEW! PipeWorx 400 Insight Module
• #301
304
Accessories Kit for
• PipeWorx
Dual Feeder #300 568
All the benefits of the individual PipeWorx 350 FieldPro in an easy to transport package for
multiple arcs in the field.
Flexible solution. The flexibility of the PipeWorx 350 FieldPro makes it ideal for multiple
system racks. Every system in a rack can be used for different tasks on-site, increasing
fleet utilization and making the best use of equipment budgets.
Easy installation. The power distribution system on the rack allows the entire rack to be
wired into a single power drop, isolating high-voltage power in the field.
Model/Stock Number
Rack Capacity Input Power to Rack
4-Pack Rack (#907 588)
4 units
6-Pack Rack (#907 589)
6 units
Empty Rack (#195 466)
6 units
Dimensions
•
•
•
•
•
•
Net Weight
230–575 V, three-phase, 50/60 Hz. H: 59 in. (1,500 mm)
W: 43 in. (1,092 mm)
(Fuses included for 460 or 575 V
operation. Only empty racks require D: 34.375 in. (873 mm)
ordering appropriate fuse kit.)
679 lb. (308 kg)
879 lb. (399 kg)
279 lb. (127 kg)
PipeWorx 350 FieldPro System
PipeWorx 400 Welding System
Rated Output at
60% Duty Cycle
Amps Input at Rated Output, 60 Hz
230 V 460 V 575 V
KVA
KW
Max. OpenCircuit Voltage
CC mode: 10–350 A
CV mode: 10–44 V
350 A at 34 VDC
36.1
17.8
14.1
15.0
14.4
75 VDC
CC mode: 10–350 A
CV mode: 10–44 V
300 A at 32 VDC
54.6
25.4
19.9
11.7
11.2
Input Power
Amperage/Voltage Ranges
PipeWorx 350 FieldPro System
(#951 547) Stick/TIG
(#951 572) MIG/flux-cored
(#951 573) RMD/pulse
PipeWorx 350 FieldPro
Power Source only
(#907 533) 230–575 V
Three-phase
Single-phase*
Model/Stock Number
Input Power
FieldPro Feeder only
(#301 228) For use with
CC or CV, DC power sources
Operates on open-circuit
voltage and arc voltage:
14–110 VDC
FieldPro Smart Feeder only
(#300 935) For use with
PipeWorx 350 FieldPro or
Big Blue 800 Duo Pro SF only
Operates on open-circuit
voltage and arc voltage:
14–110 VDC*
Model/Stock Number
PipeWorx 400 Welding System
(#951 381) 230/460 V
(#951 382) 575 V
PipeWorx 400
Power Source only
(#907 382) 230/460 V
(#907 384) 575 V
Model/Stock Number
PipeWorx Feeder only
(#300 365) Single-wire model
(#300 366) Dual-wire model
Includes 25 ft. work cable,
EG500 work clamp, two flowmeter
regulators and two 4 ft. gas hoses.
Composite Cable Kit
#300 454 25 ft. (7.6 m)
#300 456 50 ft. (15.2 m)
PipeWorx Cooler #300 370
Foot Control Bracket #300 676
DSS-9 Dual Schedule Switch
#071 833
RFCS-14 HD #194 744 (pg 112)
RPBS-14 #300 666 (pg 112)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*Welding with the smart feeder requires the PipeWorx 350 FieldPro to be hooked up to three-phase power. **Dimensions and weight are for power source only.
Model/Stock Number
™
Dimensions**
H: 17 in.
(432 mm)
W: 12 in.
(305 mm)
D: 22 in.
(559 mm)
Net
Weight**
95 lb.
(43.1 kg)
Net
Weight
Wire Feed Speed
Wire Diameter Type and Capacity
Maximum Spool
Size Capacity
425 A at
60% duty cycle
50–800 ipm
(1.3–20.3 m/min.)
dependent on arc voltage
Solid wire .023–5/64 in. (0.6–2.0 mm)
Flux-cored .030–5/64 in. (0.8–2.0 mm)
12 in. (305 mm),
45 lb. (20 kg)
H: 15.5 in. (394 mm)
W: 9 in. (229 mm)
D: 21 in. (533 mm)
35 lb.
(15.9 kg)
275 A at
60% duty cycle
50–500 ipm
(1.3–12.7 m/min.)
dependent on arc voltage
.035–.045 in. (0.9–1.1 mm)
12 in. (305 mm),
33 lb. (15 kg)
H: 13 in. (330 mm)
W: 18 in. (457 mm)
D: 21.5 in. (546 mm)
50 lb.
(23 kg)
Input Welding
Circuit Rating
Dimensions
Welding Mode/
Process
Amperage/
Voltage Ranges
Rated Output at
100% Duty Cycle
Amps Input at Rated
Output, 60 Hz, 3-Phase
230 V 460 V 575 V
KVA
230 V 460 V 575 V
KW
230 V 460 V 575 V
Max. OpenCircuit
Voltage
CC: Stick
40–400 A
400 A at 36 VDC
43.9
26.6
22.4
17.5
21.2
22.3
16.1
16.3
16.4
90 VDC
CC/DC: TIG
10–350 A
350 A at 24 VDC
29.3
18.2
13.5
11.8
14.5
13.4
10.7
10.6
10
CV: MIG/flux-cored
10–44 V
400 A at 34 VDC
42.9
24
20.5
17.3
19.2
20.5
16
15.8
16.2
Input
Power
Input Welding
Circuit Rating
Wire Feed Speed
Wire Diameter Capacity
Maximum Spool
Size Capacity
24 VAC,
11 A
100 V, 750 A at
100% duty cycle
50–780 ipm
(1.3–19.8 m/min.)
.035–.062 in. (0.9–1.6 mm)
60 lb. (27 kg)
Dimensions**
H: 28.5 in.
(724 mm)
W: 19.5 in.
(495 mm)
D: 31.75 in.
(806 mm)
Net
Weight**
225 lb.
(102 kg)
Dimensions
Net Weight
H: 14 in. (356 mm)
W: 19 in. (483 mm)
D: 29 in. (737 mm)
Single 65 lb. (29.5 kg)
Dual 90 lb. (41 kg)
39
Professional Welding Made Friendly
Bernard appreciates that no two welders and
no two welding applications are exactly alike.
That’s why we make it easy to get a
made-to-order, hand-held MIG gun that
meets the needs of your welding application
and your highest expectations.
Drop by online anytime to build your
industrial-duty MIG gun with our
user-friendly configurator. Or give us
a call and we’ll lend a hand in helping
you select the ideal mix of MIG gun
options and consumables to maximize
the success of your welding operation.
Visit BernardWelds.com
or your local distributor,
or call 1-855-MIGWELD (644-9353)
to learn more.
Configure your MIG gun today at BernardWelds.com/ConfigureMyGun
It’s the tie that binds
Finding the right filler metal solution for your welding needs is
critical in an industry that is about getting the job done right.
Filler metals are more than just a component of welding —
they are the tie that binds science and people. The right
solutions. Solutions to make our world more secure.
More dynamic. More of what you need.
Every day, every project, every weld is another opportunity
for Hobart to earn and secure your trust by helping you find
the right filler metal solution.
That kind of help and finding your welding solutions
is our passion.
Visit HobartBrothers.com for more information.
Find Your Solution. Today.
Wire Feeders
For more detailed
information, visit
MillerWelds.com/wirefeeders
Wire Types
Special Features
Typical Applications
8 in. (8VS) or 12 in. (12VS) diameter spool
capacity, lightweight, powered by arc voltage
Construction, site fabrication,
field maintenance
CV** .023–5/64 in. (0.6–2.0 mm)
8 in. (8VS) or 12 in. (12VS) diameter spool
capacity, powered by arc voltage, remote voltage
control without a control cord
Construction, site fabrication
field maintenance
CV
.023–5/64 in. (0.6–2.0 mm)
Standard remote voltage control, 12 in. diameter
spool capacity, powered by 14-pin control cord
Field maintenance,
site fabrication
CV
Two quick-change drive rolls
Manufacturing, fabrication
.023–3/32 in. (0.6–2.4 mm)
Four quick-change drive rolls
Manufacturing, fabrication
CV
.023–5/64 in. (0.6–2.0 mm)
44
.023–1/8 in. (0.6–3.2 mm)
Low-speed option
recommended for 1/8 in. wires
Four drive roll, adjustable weld control
Heavy and light manufacturing,
fabrication
70 Series MPa Plus —
Singles and Duals
44
CV
.023–5/64 in. (0.6–2.0 mm)
Aluma-Pro Plus or Pistol Plus guns for feeding
soft wires
Manufacturing requiring
multiple wire types
70 Series Swingarc™ —
Singles and Duals
46
CV
***
.023–5/64 in. (0.6–2.0 mm)
8, 12 and 16 ft. booms, four drive rolls,
adjustable weld control
Heavy and light manufacturing,
fabrication
70 Series
46
Remote Configurations —
Singles and Duals
CV
***
.023–5/64 in. (0.6–2.0 mm)
Control box, cables and wire drive motor
assemblies for generic booms or fixed automation
Heavy and light manufacturing,
fabrication
CC/CV
42
CC/CV
SuitCase® 12RC
42
22A
44
24A
44
70 Series S/D/DX —
Singles and Duals
SuitCase® X-TREME ™
8VS/12VS
42
SuitCase® X-TREME ™
8VS/12VS ArcReach
Product Key
CV
CV**
Class:
Light Industrial
Industrial
Heavy Industrial
Capability:
Designed for this process
*Requires MPa inverter power source.
**Certain self-shielded wires require CV output. Miller recommends a CV power source whenever possible.
***MPa models are designed for aluminum welding.
Bench
Wire Diameters
.023–5/64 in. (0.6–2.0 mm)
Flux-cored Flux-cored
Dual-shld Self-shld
Portable
Alum.
Page
Class
MIG
Pulsed MIG*
Flux-cored**
Portable
Power Source
Required
Hard
Product
Guide
Also see Advanced/Automated MIG and Multiprocess sections for wire feeding options.
Capable of this process
41
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
X-TREME ArcReach
8VS 12VS 8VS 12VS 12RC
Feature
Available with BTB Gun 300 A
Available w/Dura-Flux gun
Available with S-Gun
Remote voltage control
(control cord required)
Remote voltage control
without a cord
Digital meters
Impact-resistant case
Gas purge
Wire jog
Standard
SuitCase 12RC
SuitCase X-TREME
12VS ArcReach
SuitCase X-TREME 12VS
SuitCase X-TREME 8VS
Bernard BTB Gun
300 A shown.
Optional
Models include male Tweco® connector installed on weld cable and Bernard™ BTB Gun 300 A with reversible dual
size (.045 and 1/16 in.) VK drive rolls. 12VS model is also available with Dura-Flux™ flux-cored gun with reversible
dual size (.068/.072 and 5/64 in.) VK drive rolls. ArcReach™ models are also available with Bernard S-Gun™ with
reversible dual size (.045 and 1/16 in.) VK drive rolls. For more options, visit MillerWelds.com/equiptoweld.
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. (X-TREME™ feeders only.)
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. (Meters are optional on 8VS.)
42
Built-in slide rails allow you to drag the feeder into position for welding.
Innovative feeder door design allows you can change wire while feeder is
standing upright or laying down.
Case is available in two sizes. (X-TREME™ feeders only.)
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 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
™
SuitCase® X-TREME 8VS and 12VS See literature no. M/6.42
Voltage-sensing feeders designed to run off of arc voltage from almost any welding power source.
8VS model is sized for an 8-inch spool of wire, can be carried to remote welding sites and fits through
a 14-inch manhole/manway. 12VS model is sized for an 8- or 12-inch spool of wire. 12-inch spools
are the most common in structural steel and fabrication.
Heavy industrial
Use with CC (except 12RC model) and CV,
DC power sources.
Processes
• MIG (GMAW) • Flux-cored (FCAW)
Suggested power sources
Series (pg 32/33)
• Dimension
XMT
Series
not
• compatible with(VSRCmodel
feeder) (pg 34/36)
Series (pg 68)
• Bobcat
Series (pg 70)
• Trailblazer
• Big Blue Series (pg 72–76)
™
®
™
™
™
SuitCase® X-TREME 8VS and 12VS ArcReach
See literature no. M/6.42
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. See page 33 and 36 for ArcReach power sources.
SuitCase® 12RC See literature no. M/6.5
Standard remote voltage control with a control cord. For applications where the feeder is within
100 feet of the power source and control cords are acceptable.
®
®
Note: Full functionality of ArcReach is only
available with ArcReach power sources.
RC feeder requires power source with
14-pin connector.
Suggested guns
• Bernard Guns (pg 47)
Most popular accessories
Cables
• Extension
(12RC only, 1 required) (pg 114)
Kit #300 343
• Flowmeter
Shielding
Gas
Filter #195 189
•
™
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*Additional packages are available — visit MillerWelds.com or your distributor.
Input Welding
Circuit Rating
Stock Number*
Input Power
SuitCase
X-TREME 8VS
(#951 583) w/Bernard BTB Gun 300 A
(without meters)
(#951 582) w/Bernard BTB Gun 300 A
330 A at
60% duty cycle
SuitCase
X-TREME 12VS
(#951 543) w/Bernard BTB Gun 300 A
(#951 544) w/Bernard Dura-Flux gun
Operates on
open-circuit
voltage and
arc voltage:
14–48 VDC/
110 max. OCV
Operates on
open-circuit
voltage and
arc voltage:
14–48 VDC/
110 max. OCV
330 A at
60% duty cycle
24 VAC, 10 A,
50/60 Hz
425 A at
60% duty cycle
ArcReach
Model
SuitCase
X-TREME 8VS
ArcReach
(#951 588) w/Bernard S-Gun
(#951 584) w/Bernard BTB Gun 300 A
SuitCase
X-TREME 12VS
ArcReach
(#951 589) w/Bernard S-Gun
(#951 581) w/Bernard BTB Gun 300 A
SuitCase
12RC
(#951 580) w/Bernard BTB Gun 300 A
(#951 599) w/Bernard BTB Gun 300 A,
lift eye, and flowmeter
425 A at
60% duty cycle
425 A at
60% duty cycle
Wire Feed Speed
Wire Type and Diameter Capacity
Maximum Spool
Size Capacity
50–780 ipm
(1.3–19.8 m/min.)
Actual range in
CC mode is
dependent on arc
voltage applied
Solid wire .023–.052 in. (0.6–1.4 mm)
Flux-cored .030–5/64 in. (0.8–2.0 mm)
8 in. (203 mm),
14 lb. (6.4 kg)
H: 12.75 in. (324 mm) 28 lb.
W: 7.25 in. (184 mm) (13 kg)
D: 18 in. (457 mm)
Solid wire .023–.052 in. (0.6–1.4 mm)
Flux-cored .030–5/64 in. (0.8–2.0 mm)
12 in. (305 mm),
45 lb. (20 kg)
H: 15.5 in. (394 mm)
W: 9 in. (229 mm)
D: 21 in. (533 mm)
Solid wire .023–.052 in. (0.6–1.4 mm)
Flux-cored .030–5/64 in. (0.8–2.0 mm)
8 in. (203 mm),
14 lb. (6.4 kg)
H: 12.75 in. (324 mm) 28 lb.
W: 7.25 in. (184 mm) (13 kg)
D: 18 in. (457 mm)
Solid wire .023–.052 in. (0.6–1.4 mm)
Flux-cored .030–5/64 in. (0.8–2.0 mm)
12 in. (305 mm),
45 lb. (20 kg)
H: 15.5 in. (394 mm)
W: 9 in. (229 mm)
D: 21 in. (533 mm)
35 lb.
(15.9 kg)
Solid wire .023–.052 in. (0.6–1.4 mm)
Flux-cored .030–5/64 in. (0.8–2.0 mm)
12 in. (305 mm),
45 lb. (20 kg)
H: 15.5 in. (394 mm)
W: 9 in. (229 mm)
D: 21 in. (533 mm)
31 lb.
(14.1 kg)
50–780 ipm
(1.3–19.8 m/min.)
Actual range in
CC mode is
dependent on arc
voltage applied
50–700 ipm
(1.3–17.8 m/min.)
Dimensions
Net
Weight
35 lb.
(15.9 kg)
Increase, Improve and Maximize
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.
Increase productivity — No time-consuming trips to the power source.
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.
43
Wire Feeders
BENCH
20 Series
Industrial Bench Feeders
70 Series
Heavy-Industrial
Bench Feeders
Designed for manufacturing,
our popular bench feeders
are available in two series with
multiple models to fit your needs.
D-74 MPa Plus
S-74DX
S-74D
Bernard BTB Gun
300 A shown.
22A
Models include Bernard ™ BTB Gun 300 A (20 Series) or BTB Gun 400 A (70 Series, two with dual-wire models),
.035/.045 in. drive rolls and Centerfire™ contact tips. For more options, visit MillerWelds.com/equiptoweld.
20 and 70 Series Features
20 Series
70 Series
22A 24A 74S 74D 74DX 74MPA
Feature
Includes BTB Gun 300 A
Includes BTB Gun 400 A
Trigger hold
Adjustable run-in control
Automatic run-in control
Digital meters
Remote voltage control
Preflow/postflow
Spot control
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
Alumination™
Synergic Pulsed MIG
Profile Pulse™
Standard
Optional
1
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.
Quick-release drive-roll pressure arm allows drive roll change without losing spring preload setting.
Easy loading and threading of welding wire without having to release the drive roll pressure arm.
Each feeder includes a 15-foot Bernard BTB Gun 300 A (20 Series) or BTB Gun 400 A
(70 Series, two with dual-wire models), plus a 10-foot 14-pin interconnecting cord.
1
Additional features for 70 Series feeders
4
2
1
Field option.
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.
High-torque permanent-magnet motor, sealed ball bearing gear drive and solid-state speed
and brake control are maintenance free for long life.
Trigger dual schedule for easily changing weld parameters while welding. Achieves the best weld
settings for different joint configurations. (DX and MPa models only.)
22A and 24A See literature no. M/11.0
Simple and cost-effective feeders for industrial manufacturing and fabricating.
Ideal for most high-duty-cycle applications requiring day-in/day-out
trouble-free operation.
On-board burnback and motor ramp control for excellent starting and
stopping performance.
Two gear-driven drive rolls on 22A and four gear-driven drive rolls on
24A provide smooth, positive wire feed.
44
Additional features for 24A feeder
Remote voltage control at feeder for easier adjustments in the weld cell.
Adjustable run-in control for better arc-starting performance on a variety
of wires.
Four gear-driven drive rolls provide more consistent feeding on larger
wire diameters.
BENCH
Wire Feeders
Industrial
20 Series
Heavy Industrial 70 Series
74S and 74D See literature no. M/3.0
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.
Digital meters (74D models only) ensure accuracy
when presetting and reading actual voltage, amperage
and wire feed speed.
Processes
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
Suggested power sources
(22A and S-74S) (pg 12)
• CP-302
Series (pg 12)
• Deltaweld
MPa Series (pg 13)
• Invision
Series (pg 32/33)
• Dimension
• XMT Series (except VS model) (pg 34)
Suggested guns
Guns (pg 47)
• Bernard
Plus and XR -Pistol
• XR-Aluma-Pro
Plus (see chart below)
®
™
74DX See literature no. M/3.0
™
®
Adds features for weld control and programs.
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 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.
74 MPa Plus See literature no. M/3.0
Adds push-pull aluminum capabilities. Optimized with Invision™ MPa or XMT® MPa power sources.
Recommended aluminum
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 aluminum feeding and welding performance.
See chart below for gun models and stock numbers.
Trigger schedule select saves time when switching
between two weld settings by simply tapping gun trigger.
Accu-Mate™ properly seats the MIG gun power pin for
best feeding performance.
Alumination™ gives you the ability to use the extended
reach of a push-pull system for consistent, versatile and
dependable aluminum wire feeding.
™
™
Most popular accessories
Cart #142 382 (pg 106)
• Feeder
Extension
Cables (pg 114)
• Spool Adapter
#047 141 (pg 114)
• Turntable Assembly
#146 236
• (pg 114)
Straightener (pg 114)
• Wire
Hanging
#058 435
• Wire ReelBailAssembly
• Spool Covers #108 008
• #057 607 For 20 and 70 Series
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.
™
•
single-wire models
and left side of
dual-wire models
#090 389 For right side of
dual-wire models
Single- and dual-remote configurations
are available for 70 Series. For more
information see page 46 and literature
no. M/3.0.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*Additional packages are available — visit MillerWelds.com or your distributor. **Wire kit #230 708 required to run 1/16 in. (1.6 mm) wire.
Input
Power
Model
Stock Number*
20 Series
22A (#951 190)
22A (#951 191) w/run-in control
22A (#951 192) w/digital display and voltage control
24A (#951 193)
24A (#951 194) w/digital display
70 Series
(Single-wire
models)
S-74S (#951 196)
S-74D (#951 198)
S-74DX (#951 200)
S-74 MPa Plus (#951 291)
70 Series
(Dual-wire
models)
D-74S (#951 203)
D-74D (#951 204)
D-74DX (#951 206)
D-74 MPa Plus (#951 292)
Maximum Spool
Size Capacity
Dimensions
Net Weight
22A
.023–5/64 in. (0.6–2.0 mm)
24A
.023–3/32 in. (0.6–2.4 mm)
60 lb. (27 kg) coil
with optional wire reel
assembly #108 008
H: 11 in. (279 mm)
W: 10.75 in. (273 mm)
D: 23.5 in. (597 mm)
22A
36 lb. (15.4 kg)
24A
40 lb. (18 kg)
.023–1/8 in. (0.6–3.2 mm)
Low speed motor required for 1/8 in.
(3.2 mm) diameter wire (factory option)
60 lb. (27 kg) coil
with optional wire reel
assembly #108 008
H: 14 in. (356 mm)
W: 12.5 in. (318 mm)
D: 28 in. (711 mm)
58 lb. (26 kg)
H: 14 in. (356 mm)
W: 21 in. (533 mm)
D: 35 in. (889 mm)
87 lb. (39.5 kg)
Wire Feed Speed
Wire Type and Diameter Capacity
24 VAC,
7 A,
50/60 Hz
75–750 ipm
(1.9–19 m/min.)
24 VAC,
10 A,
50/60 Hz
50–780 ipm
(1.3–19.8 m/min.)
MPa Plus model
Hard wire
.023–5/64 in. (0.6–2.0 mm)
Aluminum**
.035–1/16 in. (0.9–1.6 mm)
Optional Push-Pull Gun
(For MPa Plus feeders only)
15 ft. (4.6 m)
Cable Length
25 ft. (7.6 m)
35 ft. (10.6 m)
Welding Current Rating
Wire Feed Speed
Wire Type and
Diameter Capacity
Dimensions
Net Weight
XR-Aluma-Pro Plus (Air-cooled)
(#300 000 001)
(#300 001 001)
—
300 A at 100% duty cycle
(#300 003 001)
(#300 004 001)
—
400 A at 100% duty cycle
Aluminum**
.030–1/16 in. (0.8–1.6 mm)
H: 5 in. (127 mm)
W: 2.5 in. (64 mm)
L: 17 in. (432 mm)
2.5 lb. (1.1 kg)
XR-Aluma-Pro Plus (Water-cooled)
70–900 ipm
(1.8–23 m/min.)
XR-Pistol Plus (Air-cooled)
(#300 753)
(#300 754)
(#300 755)
200 A at 100% duty cycle
—
(#300 757)
(#300 758)
400 A at 100% duty cycle
Aluminum**
.030–1/16 in. (0.8–1.6 mm)
H: 7.375 in. (187 mm)
W: 1.875 in. (48 mm)
L: 10.625 in. (270 mm)
2.2 lb. (1 kg)
XR-Pistol Plus (Water-cooled)
70–900 ipm
(1.8–23 m/min.)
2.9 lb. (1.3 kg)
2.4 lb. (1.1 kg)
45
Wire Feeders
70 Series Swingarc
Heavy industrial
™
Use with CV, DC power sources.
See literature no. M/13.11
Processes
Swingarc boom-mounted wire feeders bring an extra dimension of flexibility and efficiency to
weld stations dealing with large weldments, or wherever operator mobility is required.
Single- and dual-wire models with 8-, 12- or 16-foot
booms are sized to accommodate a variety of weld cell
layouts (16-, 24- or 32-foot diameter work area).
Counterbalance design makes it easy to position
boom and 360-degree rotation and 60-degree lift
angle maximizes work area.
In-boom cable routing organizes hoses and cables for
a cleaner work environment.
Each feeder includes a 15-foot Bernard BTB Gun
400 A (two with dual-wire models), plus a 10-foot
14-pin interconnecting cord to connect power source
to boom control.
MPa Plus Swingarcs. Optimized for the Invision™ MPa
and XMT® MPa power sources and available with
single- or dual-wire feeders and three boom lengths.
Includes same gun, drive rolls and tips
as 70 Series. For more options, visit
MillerWelds.com/equiptoweld.
Swingarc
Pipe post
(required,
order separately)
Bernard ™ BTB Gun
is included
Optional
Swingpak base
Power source
(required, order
separately)
Model
Stock Number with Single-Wire Feeders
Stock Number with Dual-Wire Feeders
SS-74S8 (#951 522) w/S-74S
8 ft.
(2.4 m) SS-74D8 (#951 525) w/S-74D
SS-74DX8 (#951 528) w/S-74DX
Boom
SS-74MPa Plus-8 (#951 437) w/S-74 MPa Plus
SS-74S12 (#951 523) w/S-74S
12 ft.
(3.7 m) SS-74D12 (#951 526) w/S-74D
SS-74DX12 (#951 529) w/S-74DX
Boom
SS-74MPa Plus-12 (#951 438) w/S-74 MPa Plus
SS-74S16 (#951 524) w/S-74S
16 ft.
(4.9 m) SS-74D16 (#951 527) w/S-74D
SS-74DX16 (#951 530) w/S-74DX
Boom
SS-74MPa Plus-16 (#951 439) w/S-74 MPa Plus
(GMAW) • Flux-cored (FCAW)
• MIG
MIG (GMAW-P) with MPa Plus
• Pulsed
feeder and optional MPa power source
DS-74S8 (#951 531) w/D-74S
DS-74D8 (#951 534) w/D-74D
DS-74DX8 (#951 537) w/D-74DX
DS-74MPa Plus-8 (#951 440) w/D-74 MPa Plus
DS-74S12 (#951 532) w/D-74S
DS-74D12 (#951 535) w/D-74D
DS-74DX12 (#951 538) w/D-74DX
DS-74MPa Plus-12 (#951 441) w/D-74 MPa Plus
DS-74S16 (#951 533) w/D-74S
DS-74D16 (#951 536) w/D-74D
DS-74DX16 (#951 539) w/D-74DX
DS-74MPa Plus-16 (#951 442) w/D-74 MPa Plus
Input
Power
Wire Feed Speed
Suggested power sources/guns
• Same as 70 Series
Most popular accessories
Base #183 997
• Swingpak
Post with 18 in. Base
• Pipe
4 ft. #149 838 / 6 ft. #149 839
Spool Carrier
• Single/Dual
(pipe post not included)
™
#300 353 For 4 ft. post
#300 352 For 6 ft. post
Designed to put
spool hub assembly
at 36 inches from
base for easier wire
spool installation.
Visit MillerWelds.com or your distributor for
other Miller® options and accessories.
Wire Diameter Maximum Spool
Capacity
Size Capacity
24 VAC,
.023–5/64 in.
50–780 ipm
10 A,
(1.3–19.8 m/min.) (0.6–2.0 mm)
50/60 Hz Consult factory for
low- and high-speed
motor options on
non-MPa feeders
Net Weight with Feeder
60 lb. (27 kg) coil Single-wire feeder
with optional wire Dual-wire feeder
reel assembly
#108 008
Single-wire feeder
Dual-wire feeder
110 lb. (50 kg)
134 lb. (61 kg)
160 lb. (73 kg)
207 lb. (94 kg)
Single-wire feeder 210 lb. (95 kg)
Dual-wire feeder 280 lb. (127 kg)
70 Series Remote Configurations
Heavy industrial
See literature no. M/3.0
Remote wire feeder control box and wire drive assembly for non-Miller boom applications.
Note: MPa Plus wire drive motor assemblies and control
cables are only for use with MPa Plus control boxes.
Use with CV, DC power sources.
Processes
(GMAW) • Flux-cored (FCAW)
• MIG
Pulsed
(GMAW-P) with MPa Plus
• control MIG
box and optional MPa power
source
Suggested power sources/guns
S-74 MPa
Plus shown.
Single-wire control box
#300 881 S-74S
#300 882 S-74D
#300 883 S-74DX
#300 738 S-74 MPa Plus
Gun NOT included.
Must be ordered separately.
Wire drive motor assembly
#300 904 Standard left-hand drive
#300 740 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-AlumaPro™ Plus and Pistol Plus push-pull guns.
Motor Control Cable
11 conductor
Motor control cable
Standard: 11 conductor
MPa Plus: 14 conductor
• Same as 70 Series
Most popular accessories
Control Cable (11 conductor)*
• Motor
#254 935 010 10 ft. (3 m)
•
#254 935 025 25 ft. (7.6 m)
For push-only gun configurations.
MPa Plus Motor Control Cable
(14 conductor)*
#254 864 010 10 ft. (3 m)
#254 864 025 25 ft. (7.6 m)
For MPa Plus configurations only —
single-wire or left side of dual-wire.
*For additional lengths visit
MillerWelds.com/equiptoweld.
Gun NOT included.
Must be ordered separately.
Push-only wire drive motor assembly
#300 741 001 Standard right-hand drive
#300 741 MPa Plus right-hand drive
46
D-74D
shown.
Dual-wire control box
#300 886 D-74S
#300 887 D-74D
#300 888 D-74DX
#300 739 D-74 MPa Plus
Gun NOT included.
Must be ordered separately.
Wire drive motor assembly
#300 904 Standard left-hand drive
#300 740 MPa Plus left-hand drive
MPa Plus drive can be used with push-only guns,
or XR-AlumaPro™ Plus and Pistol Plus push-pull guns.
Base #195 369
• Feeder
For use with spooled wire.
Visit MillerWelds.com or your distributor for
other Miller® options and accessories.
Wire Feeders
™
Bernard Semi-Automatic Guns
Air-Cooled MIG and Flux-Cored Guns
Miller integrates industrial-duty Bernard semi-automatic MIG guns on various Miller® industrial
wire feeders to bring customers one complete system for their welding applications.
Industrial
Processes
• MIG (GMAW) • Flux-cored (FCAW)
Suggested equipment
350P/350P Auto Body
• Millermatic
Aluminum Repair System (pg 10/15)
(pg 12)
• CP-302
Series (pg 12)
• Deltaweld
Invision
MPa
• Axcess (pg 22)Series (pg 13)
• Continuum (pg 23)
• Multimatic 200 (pg 31)
• Shopmate 300 DX (pg 31)
• Dimension 302/452 (pg 32)
• Dimension 650 (pg 33)
• XMT Series (pg 34)
• XMT ArcReach (pg 36)
• PipeWorx 350 FieldPro (pg 38)
• PipeWorx 400 (pg 38)
• SuitCase Series (pg 42)
• 20 and 70 Series (pg 44)
• 70 Series Swingarc (pg 46)
• Big Blue 350 PipePro (pg 73)
• FILTAIR 130/400 (pg 100)
•
®
®
BTB MIG Guns
™
See Bernard literature no. 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 lineup.
From front to back, Bernard BTB guns are designed to withstand the rigors
of industrial welding applications
Compatible with three high-performance consumable lines — Centerfire,™
Quik Tip™ and TOUGH LOCK™
Compatible with Universal Conventional or front-loading QUICK LOAD™ liners
which are ideal for boom-mounted equipment or where uptime is critical
Fixed or rotatable aluminum armored necks in various lengths and angles
Choice of six different handles ensures a comfortable, ergonomic fit
Front and rear 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
One year manufacturer’s warranty with lifetime warranty on rear strain relief
•
•
•
•
•
•
•
Fume Extraction MIG Guns
See Bernard literature no. SP-CLA (Clean Air) and SP-FFE (FILTAIR)
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 either of our two models.
™
™
®
®
®
®
™
™
®
™
®
®
®
Most popular consumables
Centerfire Consumable Series
Diffusers (amps)
DS-1
200, 300
D-1
400, 500, 600
Brass Nozzles (inches)
NS-1218B 1/2 ID, 1/8 Rec., Sm.
Copper Nozzles (inches)
NS-5818C 5/8 ID, 1/8 Rec., Sm.
N-5818C 5/8 ID, 1/8 Rec., Lg.
N-5814C 5/8 ID, 1/4 Rec., Lg.
N-3414C 3/4 ID, 1/4 Rec., Lg.
Bernard Clean Air ™ fume extraction MIG gun
Available in 400-, 500- and 600-amp models
Choice between Centerfire, Quik Tip or TOUGH LOCK consumables
Ergonomic, lightweight straight handle improves operator comfort
Bernard FILTAIR™ fume extraction MIG gun
Available in 300- and 400-amp models
Choice between Centerfire or Quik Tip consumables
Small lightweight curved handle for maximum maneuverability and comfort
Contact Tips (inches)
T-035
.035
T-045
.045
Quik Tip Consumable Series
Diffusers (amps)
D118Q
200, 300, 400
D114Q
500, 600
Dura-Flux Self-Shielded Flux-Cored Guns
Contact Tips (inches)
T1035
.035
T1045
.045
TOUGH LOCK Consumable Series
Diffusers (amps)
404-18
200, 300, 400 SD
404-26
300, 400, 500, 600 HD
•
•
•
•
•
•
™
See Bernard literature no. SP-DF
For structural steel applications, bridge construction and
heavy equipment repair, Bernard offers two lines of 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
•
•
•
•
For more detailed information, visit
BernardWelds.com
Plated Copper Nozzles (inches)
N1C58Q
5/8 ID
N1C34HQ 3/4 ID, 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
Brass Nozzles (inches)
401-5-75 3/4 ID, 1/8 Rec., HD
Contact Tips (inches)
403-14-35 .035 SD
403-20-35 .035 HD
403-14-45 .045 SD
403-20-45 .045 HD
Visit BernardWelds.com or your distributor
for other Bernard consumable options.
47
Stick
For more detailed
information, visit
SMAW
MillerWelds.com/stick
3-Phase
Thunderbolt® XL 225 AC
48
Thunderbolt® XL
225 AC/150 DC
48
Dialarc® 250 AC/DC
48
Maxstar® 150 S
49
Maxstar® 210 STR
CAC-A
Product
Guide
Page
Class
Stick
DC TIG
Flux-cored*
1- & 3-Ph
1-Phase
Also see TIG and Multiprocess sections for machines that can stick weld.
Weldable
Metals
Welding
Amperage Range
Special Features
Typical Applications
Steel,
stainless
30–235 AC
Infinite current control
Education, maintenance/repair, farm
30–235 AC
30–160 DC
Infinite current control
Education, maintenance/repair, farm
Lift eye, optional
running gear
35–300 AC
35–265 DC
One control knob with
high/low range
Education, maintenance/repair, fabrication
Shoulder strap,
optional case
20–150 DC
120–240 V Auto-Line,™
MVP™ plugs
MRO, ship installation/repair, farm/ranch
49
Shoulder strap, handles,
optional carts
5–210 DC
120–480 V Auto-Line,™
stick/TIG machine
Construction, fabrication, pipe, steel erection,
shipbuilding
CST ™ 280
50
Handle, optional cart
5–280 DC
Portable at 41 lb., optional meter,
also available in multi-unit rack
Construction, fabrication, pipe, steel erection,
shipbuilding
CST ™ 280 Rack
eye, optional
Steel,
5–280 DC
Up to 4 or 8 operators, lightweight
Construction, maintenance/repair, shipbuilding
⁄ ** Lift
running gear
stainless
⁄
20–590
DC
Built-in
arc
control
Steel
erection, pipe, fab, shipbuilding, foundries
49 ⁄
50–850 DC
Built-in arc control
Steel erection, pipe, fab, shipbuilding, foundries
Class: Light Industrial Industrial Heavy Industrial
Capability: Designed for this process Capable of this process
New! or Improved! products appear in blue type. *Constant-current (stick) machines can utilize voltage-sensing wire feeders for some flux-cored applications. **Two machines paralleled.
Gold Star® 452
Gold Star® 652
Product Key
Portability
Optional running gear
3⁄ 16"
Steel,
stainless
5 16"
50
5 16"
49
3 8"
Thunderbolt XL 225 AC and 225 AC/150 DC
Light industrial
See literature no. AC/2.0 (AC model) and AD/8.0 (AC/DC model)
Process Stick (SMAW)
Comes complete with
®
225 AC model
is AC only.
•
Economical stick machines with precise, dependable control.
Accu-Set™ amperage indicator provides
precise heat control.
Unit allows higher duty cycle when
amperage decreases.
Infinite current control allows the
operator to adjust output by as little
as one-amp increments.
(4.5 m) No. 4 electrode cable
• 15withft.heavy-duty
electrode holder
10
ft.
(3
m)
work
• Power cord with plugcable with clamp
•
Most popular accessories
XL Running Gear
• Thunderbolt
#043 927 (pg 107)
Output selector switch on AC/DC units
allows you to quickly select AC, DCEP or
DCEN without adjusting the output leads.
Certified by Canadian Standards
Association to both the Canadian and
U.S. Standards.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Thunderbolt XL 225 AC shown.
Welding
Mode
Welding
Amperage Range
Rated Output at 20% Duty Cycle, 60 Hz
(15% Duty Cycle, 50 Hz)
Rated Output at
100% Duty Cycle
Amps Input at
Rated Output
Max. OpenCircuit Voltage
(#903 641)
230 V, 50/60 Hz
AC
30–235
225 A at 25 V
100 A
47.5
80 VAC
(#903 642)
230 V, 50/60 Hz
AC
30–235
225 A at 25 V
100 A
47.5
80 VAC
DC
30–160
150 A at 25 V
65 A
47.5
80 VDC
Model
Stock Number
Thunderbolt XL
225 AC (CSA)
Thunderbolt XL
225 AC/150 DC (CSA)
Dialarc® 250 AC/DC
H: 18.75 in. (476 mm)
W: 12.75 in. (323 mm)
D: 17.5 in. (445 mm)
Net
Weight
85 lb.
(39 kg)
104 lb.
(47 kg)
Light industrial
See literature no. AD/2.1
Processes
Superb performance and versatility in a flexible stick machine.
Single-dial infinite current control
simplifies and allows precise weld
output adjustment.
High and low ranges for both AC and DC
allow greater control of weld performance.
Forced-draft cooling fan ensures
cooler running product, extending life
of power source.
Superior 6010 and 7018 stick welding
performance offers wide range of
electrode versatility.
High output and duty cycle allow unit to
handle nearly all stick welding needs.
Optional remote weld output control
provides current control without going back
to power source saving time and effort.
(SMAW)
• Stick
carbon arc cutting and gouging
• Air(CAC-A)
(3/16 in. carbons)
Most popular accessories
• No. 19 Running Gear #041 580
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Amps Input at Rated Output, 60 Hz
200 V 208 V 230 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
225 A at 29 V
84
—
73
36
29
16.8 9.8
70 VAC
225 A at 29 V
92
—
80
40
32
18.6 11.8
79 VDC
22
12.5 9.9
70 VAC
24
13.7 10.8
79 VDC
Model
Stock Number
Welding
Mode
Welding
Amperage Range
Rated Output at
30% Duty Cycle
Dialarc without Power
Factor Correction
(#907 017) 200(208)/230/460 V
AC
35–300
DC
35–265
Dialarc with Power
Factor Correction
(#907 015) 208/230/460/575 V
AC
35–300
225 A at 29 V
—
60
55
27
DC
35–265
225 A at 29 V
—
66
60
30
48
Dimensions
Dimensions
H: 24.25 in. (616 mm)
W: 19 in. (483 mm)
D: 28 in. (711 mm)
Net
Weight
360 lb.
(163 kg)
365 lb.
(166 kg)
SMAW
Maxstar 150 S
®
Stick
Light industrial
•
See literature no. DC/27.0
Process Stick (SMAW)
Comes complete with
Best in class — provides maximum portability and performance
in the most compact stick package in the industry.
Packs dependability and performance all in one machine.
Multi-voltage plug (MVP™) allows
for connection to 120- or 240-volt
receptacles without tools. Choose
the plug that fits the receptacle
and connect it to the power cord.
Portable with adjustable shoulder
strap. Easy to transport at only
13.2 pounds.
Allows for any
input voltage
hook-up (120–240 V) with no manual
linking, providing convenience in any
job setting.
Adaptive Hot Start™ for stick arc
starts reduces electrode sticking.
Single amperage range allows
operator to accurately set amperage on
both 120- or 240-volt primary power.
Maxstar 150 S with X-CASE
(#907 134 012) shown.
cord with MVP plugs for
• 10120ft.Vpower
and 240 V
13 ft. (4 m) electrode cable with holder
• and
25 mm Dinse-style connector
work cable with clamp
• 10andft.25(3mmm) Dinse-style
connector
#907 134 012 includes
above plus
• Protective X-CASE
Most popular accessories
Plugs (pg 110)
• MVP
Protective
• (pg 110) X-CASE #300 184
™
™
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Note: See page 52 in the TIG section for Maxstar 150 STL and STH.
*Sense voltage for stick.
Stock Number
(#907 134)
(#907 134 012) with X-CASE
Input
Power
Welding Amperage
Range
Rated Output
Amps Input at Rated
Output, 50/60 Hz
KVA at
Duty Cycle
KW
115 V
20–100
100 A at 24 V, 35% duty cycle
26.4
3.0
3.0
230 V
20–150
150 A at 26 V, 30% duty cycle
21.6
4.9
4.7
Maxstar 210 STR
®
Max. OpenCircuit Voltage
90 VDC
(12–16 VDC*)
H: 9 in. (229 mm)
W: 5.5 in. (140 mm)
D: 13.25 in. (337 mm)
13.2 lb.
(6.0 kg)
Industrial
See literature no. DC/32.1
Processes
Maximum flexibility with automatic connection to any input power while
maintaining the best DC stick/TIG welding performance in its product class.
Note: See page 54 in the TIG
section for Maxstar 210 Series.
Net
Weight
Dimensions
Allows for any input
voltage hook-up
(120–480 V) with no manual linking,
providing convenience in any job setting.
Lift-Arc™ provides TIG arc initiation without
the use of high frequency.
Dual schedule allows operators to switch
between welding parameters for specific
electrodes without readjusting the machine.
Adaptive Hot Start™ for stick arc starts.
Remote amperage control and digital meter.
Portable with adjustable shoulder strap.
• Stick (SMAW) • TIG (GTAW)
Comes complete with
power cord (no plug)
• 8Twoft. 50(2.4mmm)Dinse-style
connectors
•
Most popular accessories
ft. (3.8 m) Weldcraft A-150
• 12.5
Valve TIG torch #WP-17V-25-2 (pg 59)
Controls (pg 112)
• Remote
TIG Torch Connector
• Air-Cooled
(pg 113)
™
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*Sense voltage for stick and Lift-Arc TIG.
Stock
Number
(#907 682)
Welding
Process
Input Power
Welding
Amperage Range
Rated Output
Phase
Amps Input at Rated Load Output, 50/60 Hz
120 V 208 V 240 V 400 V 480 V KVA KW
Max. OpenCircuit Voltage
Stick
208–480 V
5–210
160 A at 26.4 V, 60% duty cycle
Three-phase
—
15
13
8
6
5.5 5.2
Single-phase
—
26
22
13
11
5.3 5.3
80 VDC
(11 VDC*)
TIG
120 V
5–100
90 A at 23.6 V, 60% duty cycle
Single-phase
23
—
—
—
—
2.8 2.8
208–480 V
1–210
210 A at 18.4 V, 60% duty cycle
Three-phase
—
14
12
7
6
5.2 4.9
Single-phase
—
24
20
12
10
4.9 4.9
Single-phase
22
—
—
—
—
2.6 2.6
120 V
125 A at 15 V, 60% duty cycle
1–210
Gold Star® Series
Start and built-in arc control • Power efficient
• Hot
circuit board
control capability
• Enclosed
• Remote
Thermal
overload
protection
Optional
digital volt and amp
• with light
• meters (#300
359 Field).
Easy to install, front-panel mount.
• Fan-On-Demand
• 15 A, 115 V duplex receptacle
™
Note: For models AFTER serial number KG283595.
Amperage Range
in CC Mode
Model
Stock Number
Gold Star
452
(#903 374) 200(208)/230/460 V
(#903 400) 230/460/575 V
20–590
Gold Star
652
(#903 402) 230/460/575 V
50–850
36 lb.
(16.3 kg)
Processes
™
Gold Star 452 shown.
H: 13.6 in.
(346 mm)
W: 8.6 in.
(219 mm)
D: 19.5 in.
(495 mm)
Heavy industrial
See literature no. DC/8.1
Rugged, reliable performance and superior arc characteristics.
See page 113
Net
Weight
Dimensions
(SMAW) • TIG (GTAW)
• Stick
carbon arc cutting and
• Airgouging
(CAC-A) (carbons —
452: 5/16 in., 652: 3/8 in.)
(FCAW)
• Flux-cored
MIG
spray
transfer
(GMAW) with
• voltage-sensing feeder
Visit MillerWelds.com or your distributor
for Miller® options and accessories.
Amps Input at Rated Output, 60 Hz
200 V 230 V 460 V
575 V
KVA
KW
Max. OpenCircuit Voltage
Dimensions (Includes
lift eye and strain relief)
450 A at 38 VDC,
60% duty cycle
102
89
45
36
35.5
23.3
72 VDC
650 A at 44 VDC,
60% duty cycle
—
124
62
50
49.4
36
72 VDC
H: 30 in. (762 mm)
W: 23 in. (585 mm)
D: 38 in. (966 mm)
Rated Output
Net Weight
404 lb.
(183 kg)
505 lb.
(229 kg)
49
Stick
SMAW
Industrial
™
CST 280
See literature no. DC/29.55
Processes
Durable power source designed for the construction industry. Ideal for stick electrodes up to
3/16-inch and TIG welding of pipe and plate.
See page 113
CST 280
CST 280 with meter
Superior stick arc performance even on the difficult-to-run
electrodes like E6010.
Simple voltage-changeover switch saves time when changing
primary voltage. Input voltage can be changed without removal
from inverter rack or removal of machine case.
NEW! Optional digital meter for more precise control when
presetting or monitoring welding amperage.
Portable in the shop or at the jobsite — at 41 pounds (18.6 kg)
the CST 280 is easily moved from location to location.
Lift-Arc™ start provides TIG arc starting without the use of
high frequency.
Rack mountable for protection, storage and transportation of
multiple power sources while using a single primary power cable.
(SMAW)
• TIGStick(GTAW)
•
Comes with
cord
• 6Oneft. set(1.8ofm)malepowerconnectors
• (Dinse-style model only)
Most popular accessories
280 Rack (see below)
• CST
Controls (pg 112/113)
• Remote
For
TIG
torches
• DC/29.55 see literature no.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*Output on single-phase reduced to comply with
current limitation on input cable.
Stock Number
(#907 244) Dinse
(#907 244 011) Tweco®
(#907 696) Tweco® with meter
220–230/460–575 V
Welding
Process
Input
Power
Welding
Amperage Range
Rated Output
Amps Input at Rated Load Output, 50/60 Hz
208 V 220 V 230 V 400 V 440 V 460 V 575 V KVA KW
Max. OpenCircuit Voltage
Stick/TIG
Threephase
5–280
280 A at 31.2 V, 35% duty cycle
—
35.0 34.2 —
—
17.8 14.7 14.6 10.2
77 VDC
200 A at 28 V, 100% duty cycle
—
23.3 22.5 —
—
11.7 9.7
9.6 6.4
Singlephase
5–200
200 A at 28 V, 50% duty cycle*
—
43.9 43.0 —
—
—
—
10.1 6.6
150 A at 26 V, 100% duty cycle*
—
32.7 32.0 —
—
—
—
Threephase
5–280
280 A at 31.2 V, 35% duty cycle
36.0 —
34.0 19.8 18.0 17.5 —
14.0 10.2
200 A at 28 V, 100% duty cycle
23.5 —
22.8 13.5 12.0 12.7 —
10.2 6.9
Singlephase
5–200
Stick/TIG
(#907 251) Dinse
(#907 251 011) Tweco®
(#907 563) Dinse with meter
208–230/400–460 V
7.3 4.6
200 A at 28 V, 50% duty cycle*
43.9 —
43.0 —
—
—
—
9.9 6.5
150 A at 26 V, 100% duty cycle*
35.0 —
32.9 —
—
—
—
7.6 4.8
H: 13.5 in.
(343 mm)
W: 7.5 in.
(191 mm)
D: 18 in.
(457 mm)
Net
Weight
41 lb.
(18.6 kg)
Heavy industrial
™
CST 280 Racks
67 VDC
Dimensions
See literature no. DC/18.82
Processes
Rugged enclosure provides simple means for protecting and transporting multiple welding power
sources for construction, maintenance/repair and shipbuilding applications.
(SMAW)
• Stick
(GTAW)
• TIGAir carbon
arc cutting and gouging
• (CAC-A) (5/16
in. carbons with
paralleled CST 280 units)
Light weight and small footprint for easy transportation.
The low weight enables the use of elevators to move the rack.
Most popular accessories
All controls including power switch are located on front of
machine for easy access.
Top cover protects machines from falling debris.
Lift eye simplifies crane or overhead lifting device transport.
Lift truck fork pockets.
One main disconnect box with branched fusing for each machine.
Common output ground connection (for same polarity use only).
Rack Running Gear
• 4-Pack
#195 114
Rack Running Gear
• 8-Pack
#195 436
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Optional rack running gear available for moving the rack.
CST 280 8-pack rack shown.
See page 113
Note: For additional rack systems see Dimension™ 650 (pg 33),
XMT® (pg 35/37) and PipeWorx FieldPro™ (pg 39).
Rack
Capacity
Model
Stock Number
4-Pack
Rack
(#907 245) Dinse
(#907 247) Tweco®
4 units
8-Pack
Rack
(#907 365) Tweco®
8 units
(#195 051)
4 units
(#300 580)
8 units
Empty
Rack
50
Amps Input at Rated Output, 50/60 Hz
220 V 230 V 400 V 440 V 460 V 575 V
KVA
KW
Dimensions
Net Weight
220–230/460–575 V, three-phase, 50/60 Hz.
Note: CST 280 machines are factory-linked for 460–575 V.
Dinse units include one set of male connectors; Tweco
units do not. See above for information on CST 280.
137
134
79
72
70
57
58.4
40.8
355 lb. (161 kg)
274
268
158
145
140
114
116.8
81.6
H: 50.75 in. (1,289 mm)
4-pack W: 25.5 in. (648 mm)
8-pack W: 46 in. (1,168 mm)
D: 26.5 in. (673 mm)
—
—
—
—
Same as 4-pack rack
166 lb. (75 kg)
Same as 8-pack rack
280lb. (127 kg)
Input Power to Rack
640 lb. (290 kg)
For more detailed
information, visit
GTAW
MillerWelds.com/tig
TIG
Product
Guide
Page
TIG
Pulsed TIG
Stick
CAC-A
MIG/Flux-cored
Also see Multiprocess section for machines that can TIG weld.
Maxstar® 150
52
Maxstar® 210
Welding
Amperage
Range
Pulse Capability
Weight
—
1/8 in.
.020–3/16 in.
5–150 A
0.5, 1, 2.5, 60 PPS
(STH model)
13.7 lb.
(6.2 kg)
5 kW
54
3/16 in.
3/16 in. 5/32 in. 5/32 in. —
.002–1/4 in.
1–210 A
0.1–250 PPS (base model)
0.1–500 PPS (DX model)
38 lb.
(17.2 kg)
9 kW
Maxstar® 280
54
7/32 in.
3/16 in. 3/16 in. 3/16 in. 3/16 in. .004–3/8 in.
1–280 A
0.1–250 PPS (base model)
0.1–500 PPS (DX model)
47 lb.
(21.3 kg)
11 kW
Maxstar® 350
56
5/16 in.
5/16 in. 1/4 in.
.012–5/8 in.
3–350 A
0.1–5,000 PPS
135 lb.
(61 kg)
12 kW
Maxstar® 700
56
5/16 in.
5/16 in. 5/16 in. 5/16 in. 3/8 in.
.020–1 in.
5–700 A
0.1–5,000 PPS
198 lb.
(90 kg)
32 kW
Diversion™ 165/180
52
—
—
—
—
.030–3/16 in. (alum.)
.025–3/16 in. (steel)
10–165 A (165)
10–180 A (180)
—
50 lb.
(23 kg)
5.5 kW
Syncrowave® 210
53
5/32 in.
1/8 in.
1/8 in.
3/32 in. —
.020–1/4 in.
(aluminum/steel)
5–210 A
0.1–50 PPS (expandable)
133.5 lb.
(61 kg)
6 kW
Dynasty® 210
54
3/16 in.
3/16 in. 5/32 in. 5/32 in. —
.012–1/4 in. (alum.)
.002–1/4 in. (steel)
2–210 A (AC)
1–210 A (DC)
0.1–250 PPS (base model)
0.1–500 PPS (DX model)
47 lb.
(21.3 kg)
9 kW
Dynasty® 280
54
7/32 in.
3/16 in. 3/16 in. 3/16 in. 3/16 in. .012–3/8 in. (alum.)
.004–3/8 in. (steel)
2–280 A (AC)
1–280 A (DC)
0.1–250 PPS (base, DC)
0.1–500 PPS (DX model)
52 lb.
(23.6 kg)
12.5 kW
Dynasty® 350
56
5/16 in.
5/16 in. 1/4 in.
.015–5/8 in. (alum.)
.012–5/8 in. (steel)
3–350 A
0.1–500 PPS (AC)
0.1–5,000 PPS (DC)
135 lb.
(61 kg)
13 kW
Dynasty® 700
56
5/16 in.
5/16 in. 5/16 in. 5/16 in. 3/8 in.
.020–1 in.
(aluminum/steel)
5–700 A
0.1–500 PPS (AC)
0.1–5,000 PPS (DC)
198 lb.
(90 kg)
35 kW
Syncrowave® 250 DX
57
1/4 in.
1/4 in.
3–310 A
0.25–10 PPS (optional)
378 lb.
(172 kg)
22 kW
Syncrowave® 350 LX
57
5/16 in.
5/16 in. 1/4 in.
3–400 A
0.25–10 PPS
496 lb.
(225 kg)
30 kW
Product Key
Capability:
All models Some models
1/8 in.
3/32 in. —
1/4 in.
1/4 in.
1/4 in.
—
1/4 in.
7/32 in. 3/16 in. 3/16 in. .015–3/8 in. (alum.)
.012–1/2 in. (steel)
1/4 in.
1/4 in.
.015–1/2 in. (alum.)
.012–5/8 in. (steel)
Generator
Power
Requirement
AC/DC (Aluminum/Steel)
Material
Thickness
Range (TIG)
DC (Steel)
Max. Electrode Diameter
E6010/11 E6013 E7018 E7024 CAC-A
New! or Improved! products appear in blue type.
51
TIG
GTAW
Diversion 165 and 180 AC/DC TIG
Light industrial
™
See literature no. AD/1.5
Professional-grade arc in a package designed specifically for personal users. Contains all of
the features you need — simplicity combined with superior performance and value.
cord with 50 A, 240 V plug
• Power
(165 model) or MVP plugs for
120 V and 240 V (180 model)
TIG Welding Capability
Max. 3/16 in. (4.8 mm)
Diversion
165
Diversion
180
Easy-to-understand operator interface. Power up,
select material type, set material thickness range
and start welding!
Inverter-based, AC/DC power source provides a
more consistent welding arc while using less power.
HF arc starting for non-contact arc initiation that
reduces tungsten and material contamination.
Portable. Easy to transport at 50 pounds.
Steel
Aluminum
Min. 0.030 in. (0.75 mm)
ft. (3.8 m) Weldcraft A-150
• 12.5
TIG torch
ft. (3.7 m) work cable with clamp
• 12RFCS-RJ45
foot control
• Flow gauge remote
regulator with hose
•
Most popular accessories
Gear/Cylinder Rack
• Running
#301 239 (pg 106)
Cover #300 579 (pg 112)
• Protective
Remote Fingertip Control
• RCCS-RJ45
#301 146 (pg 112)
to 14-Pin Adapter Cord
• RJ45
#300 688
Flexible Torch Body Kits
• Weldcraft
(requires handle #105Z55R)
™
Max. 3/16 in. (4.8 mm)
Min. 0.025 in. (0.6 mm)
•
Process TIG (GTAW)
Comes with
Fan-On-Demand™ power source cooling system operates only
when needed, reducing noise, energy use and the amount of
contaminates pulled through the machine.
Auto-postflow adjusts the length of postflow time based on
the amperage setting, shielding your tungsten and eliminating
the need to set the postflow time.
Advanced squarewave AC provides a fast freezing weld
puddle and deeper penetration.
Weldcraft™ A-150 torch with Diamond Grip™ provides more
comfortable grip and reduces operator fatigue.
Diversion 180 includes multi-voltage plug
(MVP™) which allows for connection to 120- or
240-volt receptacles without tools. Choose the
plug that fits the receptacle and connect it to the power cord.
™
•
A-125F (#WP-9F)
A-150F (#WP-17F)
TIG Torch Accessory Kit #AK2C
(see pg 53 for contents list)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
AC/DC
*While idling.
Model/
Stock Number
Input
Power
Welding
Amp Range
Rated Output
Amps Input at
Rated Output
KVA
KW
Max. OpenCircuit Voltage
Diversion 165
(#907 626)
230 V
10–165
150 A at 16 V, 20% duty cycle
23 (.20*)
5.3 (.04*)
3.7 (.02*)
80 VDC
165 A at 16.6 V, 15% duty cycle
25.5 (.20*)
5.9 (.04*)
4.2 (.02*)
Diversion 180
(#907 627)
115 V
10–125
125 A at 15 V, 35% duty cycle
26.5 (.88*)
3.1 (.1*)
3.0 (.03*)
230 V
10–180
150 A at 16 V, 20% duty cycle
16 (.44*)
3.7 (.1*)
3.6 (.03*)
180 A at 17.2 V, 10% duty cycle
20.5 (.44*)
4.7 (.1*)
4.6 (.03*)
Maxstar 150 STL and STH DC TIG and Stick
Maximum portability and performance provided in one compact TIG/stick package.
Steel
Min. 0.020 in.
(0.5 mm)
Maxstar 150 STH
TIG/stick package with
remote fingertip control and X-CASE (#907 136 017) shown.
Two models available. See page 49 in the Stick section for Maxstar 150 S.
STL: DC TIG/stick with Lift-Arc™ starting without the use of
high frequency.
STH: DC TIG/stick with high frequency and Lift-Arc™ starting, plus
built-in pulsing with a selection of four fixed-pulse frequencies.
Allows for any input voltage hook-up
(120–240 V) with no manual linking.
Multi-voltage plug (MVP™) allows for connection to 120- or
240-volt receptacles without tools. Choose the plug that fits the
receptacle and connect it to the power cord. See photo above.
Portable with adjustable shoulder strap. Easy to transport at
13.7 pounds.
Built-in gas solenoid eliminates need for bulky torch with a
gas valve.
DC
*Sense voltage for stick and Lift-Arc™ TIG.
52
Model/Stock Number
Model/Stock Number
Maxstar 150 STL
(#907 135) Machine only
(#907 135 016) TIG/stick package
(#907 135 017) TIG/stick package
with remote fingertip control
Maxstar 150 STH
(#907 136) Machine only
(#907 136 017) TIG/stick package
with remote fingertip control
Welding
Process
Input
Power
Welding
Amp
Range
TIG
115 V
230 V
Stick
50 lb.
(23 kg)
Processes
See literature no. DC/27.1 (STL) and DC/27.2 (STH)
Max. 3/16 in.
(4.8 mm)
H: 17 in. (433 mm)
W: 9.875 in. (251 mm)
D: 23.875 in. (608 mm)
Light industrial
®
TIG Welding
Capability
Net
Weight
Dimensions
• TIGPulsed(GTAW)
• Stick (SMAW)
• TIG (GTAW-P) w/STH model
Comes with
cord with MVP plugs for
• 10120ft.Vpower
and 240 V
13 ft. (4 m) electrode cable with holder
• and
25 mm Dinse-style connector
work cable with clamp
• 10andft.25(3mmm) Dinse-style
connector
TIG/Stick package includes
above plus
ft. (3.8 m) Weldcraft A-150
• 12.5
TIG torch (#WP1712RDI25)
X-CASE
• Protective
Flow
gauge
regulator with hose
• RCCS-6M remote
fingertip control
• (packages #907 135
017 and
™
™
#907 136 017 only)
• AK2C TIG torch accessory kit
Visit MillerWelds.com or your distributor
for Miller® options and accessories.
Rated Output
Amps Input at KVA at
Rated Output, Duty
50/60 Hz
Cycle
KW
5–150
150 A at 16 V, 30% duty cycle
28.0
3.4
3.1
5–150
150 A at 16 V, 30% duty cycle
14.2
3.2
3.1
115 V
20–100
100 A at 24 V, 35% duty cycle
26.4
3.0
3.0
230 V
20–150
150 A at 26 V, 30% duty cycle
21.6
4.9
4.7
Max. OpenCircuit Voltage Dimensions
90 VDC
(12–16 VDC*)
Net
Weight
H: 9 in.
13.7 lb.
(229 mm) (6.2 kg)
W: 5.5 in.
(140 mm)
D: 13.25 in.
(337 mm)
GTAW
Light Industrial
Syncrowave 210 Series
®
AC/DC TIG and Stick
TIG
Processes
TIG (GTAW) • DC stick (SMAW)
• AC/DC
TIG (GTAW-P) • MIG (GMAW)*
• Pulsed
• Flux-cored (FCAW)*
See literature no. AD/4.6
Continuing the tradition of innovation through advanced inverter technology
for light-industrial and personal users.
*TIG/MIG Complete package only.
Comes with
cord with MVP plugs for
• 10120ft.Vpower
and 240 V
ft. (3.8 m) Weldcraft A-150 TIG
• 12.5
torch (#WP1712MFDI50)
(3.7 m) work cable with clamp
• 12andft.Dinse-style
connector
Electrode
holder
• connector with Dinse-style
remote foot control
• RFCS-14
gauge regulator with hose
• Flow
running gear with
• Factory-installed
EZ-Change low cylinder rack
™
Syncrowave 210 Runner
TIG/MIG Complete package
(#951 616) shown.
See page 113
Easy to use.
1) Turn power on.
2) Select the process.
3) Set amperage or voltage
based on material thickness.
Then weld! It’s easy as 1,2,3.
TIG Welding Capability
Max. 1/4 in. (6.4 mm)
Steel
Aluminum
Min. 0.020 in. (0.5 mm)
Allows for any input voltage
hook-up (120–240 V)
with no manual linking, providing convenience in any
job setting. Ideal solution for dirty or unreliable power.
Multi-voltage plug (MVP™)
allows for connection to
120- or 240-volt receptacles
without tools. Choose the plug
that fits the receptacle and
connect it to the power cord.
Update and expand. Front panel memory card data
port provides the ability to easily update software and
expand product features.
AC/DC
Low power draw. Inverter-based power source provides
full welding output from 240 volts while drawing less
than 30 amps.
Stock Number
(#907 596) Runner
(#951 616) Runner TIG/MIG Complete
Pro-Set™ (TIG/stick) eliminates the guesswork when
setting weld parameters. Use Pro-Set when you want the
speed, convenience and confidence of preset controls.
AC balance (TIG) control provides adjustable oxide
removal which is essential for creating the highest
quality aluminum welds.
TIG/MIG Complete package
comes with above plus
100 spool gun
• Spoolmate
(#300 371)
pin connector
• 4-14
Dinse-style connector
• Flow-thru
• Memory card
Most popular accessories
m) Weldcraft A-150
• 25TIG ft.Torch(7.6#WP-17-25-R
(pg 59)
Protective
Cover
#195
142
112)
• RCC-14 Remote Control #151(pg086
• (pg 112)
Remote Foot Control
• Wireless
#300 429 (pg 113)
Card Expansion
• Memory
#301 128 DC pulse expansion
™
™
•
•
Pulse (TIG). Pulsing can increase puddle agitation, arc
stability and travel speeds while reducing heat input
and distortion. Expandable feature.
DIG (stick) 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.
#301 127 AC frequency expansion
TIG Torch Accessory Kit #AK2C
Includes one short back cap, one
of each size (#4, #5, #6) alumina
nozzle, and one of each size (.040,
1/16, 3/32 in.) of the following:
collet, collet body, and 7-inch
2% ceriated tungsten electrode.
TIG Torch Accessory Kit #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.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Auto-Set™ (MIG) automatically sets your welder to the
proper parameters. Simply set the wire size, material
thickness, and shielding gas and you’re ready to weld.
(TIG/MIG complete package only.)
Input
Power
Welding
Process
Welding
Amperage Range
Rated Output (R.M.S.)
Amps Input at
Rated Output
Max. OpenCircuit Voltage
115 V
DC TIG
5–125 A
95 A at 13.8 V, 60% duty cycle
17.4 (.58 while idling)
47 VDC
AC TIG
5–125 A
90 A at 13.6 V, 60% duty cycle
12.4 (.58 while idling)
DC stick
20–90 A
70 A at 22.8 V, 60% duty cycle
20.5 (.58 while idling)
DC TIG
5–210 A
125 A at 15 V, 60% duty cycle
11.9 (.35 while idling)
AC TIG
5–210 A
114 A at 14.6 V, 60% duty cycle
8.62 (.35 while idling)
DC stick
20–150 A
90 A at 23.6 V, 60% duty cycle
11.9 (.35 while idling)
230 V
™
Dimensions
Net Weight
H: 31.5 in. (800 mm)
W: 18.5 in. (470 mm)
D: 43 in. (1092 mm)
Runner package:
133.5 lb. (61 kg)
Runner TIG/MIG
Complete package:
139.5 lb. (63 kg)
53
TIG
GTAW
Maxstar®
210/280 Series
DC TIG and Stick
See literature no. DC/32.1 (210) and DC/35.0 (280)
Dynasty®
210/280 Series
See page 113
AC/DC TIG and Stick
See literature no. AD/4.81 (210) and AD/4.9 (280)
Dynasty 280 DX
Maxstar and Dynasty
210 Series (Maxstar 210 shown).
Base and DX models available. Base model provides essential TIG and stick functions. DX model
adds extended ranges to sequencer, full trigger options, and full preflow and pulser functions.
210 Series TIG Welding Capability
Steel
Max. 1/4 in. (6.4 mm)
Aluminum
(Dynasty only)
Min. 0.002 in. (0.05 mm)
Min. 0.012 in. (0.3 mm)
Max. 1/4 in. (6.4 mm)
Note: See page 49 in the Stick section for Maxstar 210 STR.
Allows for any input voltage hook-up (210 models: 120–480 V,
280 models: 208–575 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 the length of postflow time based on the amperage setting, shielding your
tungsten and eliminating the need to set the 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. Simply select the feature and adjust until
Pro-Set appears on the 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.
Optional cooler power supply (CPS) is an integrated 120-volt dedicated-use receptacle for the
Coolmate™ 1.3. Not available on Maxstar 210 Series.
Optional Cooler-On-Demand™ feature operates the auxiliary cooling system only when
needed, reducing noise, energy use, and airborne contaminants pulled through the cooler.
Only available on CPS models.
280 Series TIG Welding Capability
Max. 3/8 in. (9.5 mm)
Max. 3/8 in. (9.5 mm)
Steel
Aluminum
(Dynasty only)
Min. 0.004 in. (0.1 mm)
Min. 0.012 in. (0.3 mm)
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.
Model/
Stock Number
Welding
Process
Input Power
Welding
Amp Range
Rated Output at
60% Duty Cycle
Amps Input at Rated Load Output, 50/60 Hz
120 V 208 V 230 V 240 V 400 V 460 V 480 V 575 V KVA KW
Max. OpenCircuit Voltage
Maxstar 210
(#907 683)
Maxstar 210 DX
(#907 684)
TIG
3-phase
1–210
210 A at 18.4 V
—
14
—
12
7
—
6
—
5.2 4.9
1-phase
1–210
210 A at 18.4 V
—
24
—
20
12
—
10
—
4.9 4.9
80 VDC
(11 VDC**)
38 lb.
(17.2 kg)
1-phase (120 V)
1–150
125 A at 15 V
22
—
—
—
—
—
—
—
2.6 2.6
3-phase
5–210
160 A at 26.4 V
—
15
—
13
8
—
6
—
5.5 5.2
1-phase
5–210
160 A at 26.4 V
—
26
—
22
13
—
11
—
5.3 5.3
H: 13.6 in.
(346 mm)
W: 8.6 in.
(219 mm)
D: 19.5 in.
(495 mm)
1-phase (120 V)
5–100
90 A at 23.6 V
23
—
—
—
—
—
—
—
2.8 2.8
3-phase
1–280
235 A at 19.4 V
—
17
15
—
9
7
—
6
6.2 6.0
1-phase
1–280
235 A at 19.4 V*
—
28
26
—
15
13
—
10
6.0 6.0
60 VDC
(11 VDC**)
3-phase
5–280
200 A at 28 V
—
20
18
—
10
9
—
7
7.2 7.0
1-phase
5–280
180 A at 27.2 V*
—
30
27
—
15
13
—
10
6.2 6.2
H: 13.6 in.
(346 mm)
W: 8.6 in.
(219 mm)
D: 22.5 in.
(569 mm)
47 lb.
(21.3 kg)
50 lb.
(22.7 kg)
with CPS
Stick
Maxstar 280
(#907 552)
(#907 538) with CPS
Maxstar 280 DX
(#907 553)
(#907 539) with CPS
54
TIG
Stick
Dimensions
Net
Weight
GTAW
TIG
Industrial
Maxstar is DC only
Processes
• TIGPulsed(GTAW)
• Stick (SMAW)
• Air carbonTIG arc(GTAW-P)
(CAC-A) w/280 models
•
Comes with
power cord (no plug)
• 8Twoft. 50(2.4mmm)Dinse-style
• Quick reference guide connectors
• (Dynasty models only)
Complete packages come with
ft. (2.4 m) power cord (no plug)
• 8Quick
guide
• (Dynastyreference
models only)
Runner cart
• Small
Coolmate
• Coolant (4 1.3
one-gallon bottles)
• Remote control
(foot or wireless foot)
• Weldcraft water-cooled
torch kit
• Dynasty 210: W-250 (WP-20)
™
™
™
Dynasty 280: W-280 (WP-280)
Most popular accessories
Dynasty welders add AC TIG capabilities and the following AC features (limited on base model)
Waveforms for advanced squarewave, soft squarewave, sine wave and triangular wave.
Balance control provides adjustable oxide removal which is essential for creating the highest quality aluminum
welds. DX models provide extended ranges.
Frequency controls the width of the arc cone and can improve directional control of the arc.
Trolley Cart #300 971
• 2-Wheel
(pg 107)
Runner Cart #301 318
• Small
(pg 107)
1.3 #300 972 (pg 107)
• Coolmate
• Coolant #043 810 (pg 107)
™
™
Dynasty 280 DX with Insight
Designed to deliver Welding Intelligence.™ The Dynasty 280 DX with Insight incorporates Insight Core™ (standard)
and Insight Centerpoint™ welding information management systems into its capabilities. These systems help welding
operations improve quality, retain weld records, increase productivity and manage costs. See pages 24 and 25 for
more information.
Kits (pg 112)
• Contractor
#301 311 w/RCCS-14 finger control
#301 309 w/RFCS-14 HD foot control
Water-Cooled Torch Kits
• Weldcraft
(pg 112)
™
Dynasty 280 DX
water-cooled complete
package (#951 469) shown.
Dynasty Water-Cooled Complete Packages
(Additional packages are available — visit MillerWelds.com or your distributor)
Packages with
Foot Control and CPS
Packages with
Wireless Foot Control and CPS
Dynasty 210
(#951 666)
(#951 667)
Dynasty 210 DX
(#951 668)
(#951 669)
Dynasty 280
(#951 466)
—
Dynasty 280 DX
(#951 468)
(#951 469)
Model
•
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*Refer to owner’s manual for 208-volt output ratings and duty cycle.
**Sense voltage for low OCV stick and Lift-Arc™ TIG.
AC/DC Dynasty
Model/Stock Number
Dynasty 210
(#907 685)
(#907 685 002) with CPS
Dynasty 210 DX
(#907 686)
(#907 686 002) with CPS
Dynasty 280
(#907 550)
(#907 537) with CPS
Dynasty 280 DX
(#907 551)
(#907 514) with CPS
(#907 514 003) w/Insight and CPS
#300 185 W-250 (WP-20)
#300 990 W-280 (WP-280)
#301 268 W-375
Remote Controls (pg 112/113)
#043 688 RCCS-14 fingertip control
#194 744 RFCS-14 HD foot control
#300 429 Wireless foot control
Welding
Process
Input Power
Welding
Rated Output at
Amp Range 60% Duty Cycle
Amps Input at Rated Load Output, 50/60 Hz
120 V 208 V 230 V 240 V 400 V 460 V 480 V 575 V KVA KW
Max. OpenCircuit Voltage Dimensions
TIG
3-phase
1–210
210 A at 18.4 V
—
14
—
12
7
—
6
—
5.2 4.9
1-phase
1–210
210 A at 18.4 V
—
24
—
20
12
—
10
—
4.9 4.9
80 VDC
(11 VDC**)
1-phase (120 V)
1–150
125 A at 15 V
22
—
—
—
—
—
—
—
2.6 2.6
3-phase
5–210
160 A at 26.4 V
—
15
—
13
8
—
6
—
5.5 5.2
47 lb.
(21.3 kg)
50 lb.
(22.7 kg)
with CPS
1-phase
5–210
160 A at 26.4 V
—
26
—
22
13
—
11
—
5.3 5.3
H: 13.6 in.
(346 mm)
W: 8.6 in.
(219 mm)
D: 22.5 in.
(569 mm)
1-phase (120 V)
5–100
90 A at 23.6 V
23
—
—
—
—
—
—
—
2.8 2.8
3-phase
—
19
17
10
9
7
7.0
6.7
60 VDC
(11 VDC**)
1-phase
1–280 (DC) 235 A at 19.4 V
2–280 (AC)
235 A at 19.4 V*
—
33
30
17
15
12
6.9
6.8
3-phase
5–280
200 A at 28 V
—
22
20
11
10
8
8.2
7.9
52 lb.
(23.6 kg)
55 lb.
(25 kg)
with CPS
180 A at 27.2 V*
—
34
31
17
15
12
7.1
7.0
H: 13.6 in.
(346 mm)
W: 8.6 in.
(219 mm)
D: 22.5 in.
(569 mm)
Stick
TIG
Stick
1-phase
Net
Weight
55
TIG
GTAW
Maxstar and Dynasty 350 and 700
Heavy Industrial
DC (Maxstar) and AC/DC (Dynasty) TIG and Stick
Processes
®
®
Maxstar is DC only
• TIGPulsed(GTAW)
• Stick (SMAW)
• Air carbonTIG arc(GTAW-P)
(CAC-A)
•
350 models come with
power cord (no plug)
• 8Twoft. 50(2.4mmm)Dinse-style
connectors
• (350)
• Setup video and reference guide
700 models come with
torch connector
• Thread-lock
Two
thread-lock
cable connectors
• Setup video andweld
reference guide
•
See literature no. DC/24.0 (Maxstar) and AD/5.0 (Dynasty)
TIG Welding Capability
700 Max.
1 in. (25.4 mm)
700 Max.
1 in. (25.4 mm)
350 Max.
5/8 in. (15.9 mm)
350 Max.
5/8 in. (15.9 mm)
Steel
Aluminum
(Dynasty only)
350 Min.
0.012 in. (0.3 mm)
350 Min.
0.015 in. (0.4 mm)
700 Min.
0.020 in. (0.5 mm)
700 Min.
0.020 in. (0.5 mm)
See page 113
Note: Power cord is NOT included with
700 models.
Complete packages come with
above plus
cart
• Runner
3.5
• Coolmate
(4 one-gallon bottles)
• Coolant
control (foot or wireless foot)
• Remote
water-cooled torch kit
• Weldcraft
(350: W-375, 700: W-400)
™
™
Dynasty welders add AC TIG capabilities
and the following AC features
Dynasty 700
Dynasty 350
Allows for any input voltage hook-up
(208–575 V) with no manual linking,
providing convenience in any job setting. Ideal solution for
dirty or unreliable 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 the length of postflow time based on the
amperage setting, shielding your tungsten and eliminating the
need to set the postflow time.
120-volt auxiliary power receptacle for cooling system or
small tools.
Program memory features nine independent program memories
that maintain/save your parameters.
High-speed DC TIG pulse controls capable of 5000 pulses
per second.
Waveforms for advanced squarewave, soft
squarewave, sine wave and triangular wave.
Balance control provides adjustable oxide
removal which is essential for creating the
highest quality aluminum 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.
Dynasty 350
package
(#951 627)
shown.
™
Most popular accessories
Cart #300 244 (pg 107)
• Runner
3.5 #300 245 (pg 107)
• Coolmate
• Coolant #043 810 (pg 107)
™
™
Water-Cooled Torch Kits
• Weldcraft
(pg 112)
™
•
#300 185 W-250 (WP-20)
#300 990 W-280 (WP-280)
#301 268 W-375
#300 186 W-400 (WP-18SC)
Remote Controls (pg 112/113)
#043 688 RCCS-14 fingertip control
#194 744 RFCS-14 HD foot control
#300 429 Wireless foot control
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*Sense voltage for low OCV stick and Lift-Arc™ TIG.
**See literature no. DC/24.0 and AD/5.0 for Complete package dimensions and weight.
Model/Stock Number
Welding
Process
Input
Power
Welding
Amp Range
Rated Output
Amps Input at Rated Load Output, 50/60 Hz
208 V 230 V 400 V 460 V 575 V KVA KW
AC/DC Dynasty
DC Maxstar
Maxstar 350
300 A at 32 V,
3-phase 3–350
33
30
17
15
12
12.0 11.5
TIG/
(#907 334) Machine only
60% duty cycle
stick
(#951 624) Complete w/foot
225 A at 29 V,
—
19
15
8.6 8.2
1-phase 3–350
41
37
(#951 625) Complete w/wireless foot
duty(wall).
cycle *Sense voltage for Low OCV Stick and Lift-Arc™ TIG.
Note: Coolmate 1 used with the Maxstar/Dynasty 200 must be plugged into a 115 V 60%
source
Maxstar 700
600 A at 44 V,
89
80
46
40
32
32 31
3-phase 5–700
TIG/
(#907 103) Machine only
60% duty cycle
stick
56
Dynasty 350
(#907 204) Machine only
(#951 626) Complete w/foot
(#951 627) Complete w/wireless foot
TIG/
stick
Dynasty 700
(#907 101) Machine only
(#951 403) Complete w/foot
(#951 404) Complete w/wireless foot
TIG/
stick
1-phase
5–700
450 A at 38 V,
60% duty cycle
106
96
—
48
38
22 21
3-phase
3–350
300 A at 32 V,
60% duty cycle
35
32
16
16
13
12.7 12.1
1-phase
3–350
225 A at 29 V,
60% duty cycle
47
43
—
21
17
9.8 9.1
3-phase
5–700
600 A at 44 V,
60% duty cycle
97
88
51
44
35
35 34
1-phase
5–700
450 A at 38 V,
60% duty cycle
115
104
—
52
42
24 22
Max. OpenCircuit Voltage
Dimensions**
Net Weight**
75 VDC
(10–15 VDC*)
H: 24.75 in. (629 mm)
W: 13.75 in. (349 mm)
D: 22 in. (559 mm)
135 lb.
(61 kg)
75 VDC
(10–15 VDC*)
H: 34.5 in. (876 mm)
W: 13.75 in. (349 mm)
D: 22 in. (559 mm)
198 lb.
(90 kg)
60 VDC
(11 VDC*)
H: 24.75 in. (629 mm)
W: 13.75 in. (349 mm)
D: 22 in. (559 mm)
135 lb.
(61 kg)
75 VDC
(10–15 VDC*)
H: 34.5 in. (876 mm)
W: 13.75 in. (349 mm)
D: 22 in. (559 mm)
198 lb.
(90 kg)
GTAW
Heavy industrial
Syncrowave 250 DX and 350 LX
®
AC/DC TIG and Stick
TIG
Processes
• TIGPulsed(GTAW)
• Stick (SMAW)
• (optionalTIGon(GTAW-P)
250 DX)
Air
carbon
arc
(CAC-A)
•
Comes with
• Two 50 mm Dinse-style connectors
See literature no. AD/4.2
The world’s first conventional squarewave TIG power source with decades of proven performance.
Note: Power cord is NOT included.
TIG Welding Capability
350 Max.
5/8 in. (15.9 mm)
250 Max.
1/2 in. (12.7 mm)
Steel
Complete packages come with
37 running gear
• No.
Coolmate
cooler
• Coolant (four3CSgallons)
• 25 ft. (7.6 m) water-cooled torch
• with Dinse-style connector
™
350 Max.
1/2 in. (12.7 mm)
250 Max.
3/8 in. (9.5 mm)
Aluminum
•
•
•
•
•
Min. 0.012 in. (0.3 mm) Min. 0.015 in. (0.4 mm)
(Syncrowave 250: Weldcraft™ W-250)
(Syncrowave 350: Weldcraft™ W-375)
15 ft. (4.6 m) work cable with clamp
and Dinse-style connector
RFCS-14 remote foot control
Flowmeter regulator with hose
Torch accessory kit with tungsten
Cable cover
Note: Power cord is NOT included.
Most popular accessories
Remote Foot Control
• Wireless
#300 429 (pg 113)
Module #300 548
• Pulser
(250 DX ONLY, standard on 350 LX)
See page 113
Syncrowave 350
Complete package
Syncrowave 250
machine only
Squarewave output with AC balance control
features adjustable cleaning action while increasing
arc stability on various aluminum alloys, and helps
eliminate tungsten spitting and arc rectification.
120-volt auxiliary power receptacle for cooling system
or small tools.
Syncro Start™ allows the choice of soft, medium, or hot
TIG starts based on the tungsten size and application.
HF arc starting for non-contact arc initiation that
reduces tungsten and material contamination.
Dual digital meters allow for quick and easy viewing of
actual and preset values of amperage and voltage.
•
Adjustable postflow of 0 to 50 seconds protects the
electrode and area near the termination of the weld.
Coolmate™ 3CS cooler (shown in Complete package).
Three-gallon cooling system features a flow indicator
to visually indicate system is working and an external
filter to stop objects from entering the water-cooled
torch cable.
For welding thin materials. Provides
a heating and cooling effect of
the weld puddle to reduce heat
input and control distortion of the
material. Provides 0.25 to 10 pulses
per second.
Sequencer Module #300 547
(250 DX/350 LX)
Provides a starting current higher
or lower than the welding current.
Provides final slope and final current
for trailing the weld. Provides a spot
timer for TIG spot application.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Last procedure recall automatically recalls the last
procedure setup when switching polarity.
Line voltage compensation keeps power source
constant regardless of fluctuations in input power
(±10 percent).
Lift-Arc™ provides DC arc initiation without the use
of high frequency.
*See literature no. AD/4.2 for Complete package dimensions and weight.
Welding
Amperage
Range
Syncrowave 250 DX
(#907 194) 200/230/460 V, 50/60 Hz, Machine only
(#907 195) 230/460/575 V, 50/60 Hz, Machine only
(#951 117) 200/230/460 V, 50/60 Hz, Complete
(#951 118) 230/460/575 V, 50/60 Hz, Complete
3–310
Syncrowave 350 LX
(#907 198) 200/230/460 V, 50/60 Hz, Machine only
(#907 199) 230/460/575 V, 50/60 Hz, Machine only
(#951 622) 200/230/460 V, 50/60 Hz, Complete
(#951 623) 230/460/575 V, 50/60 Hz, Complete
3–400
AC/DC
Model/Stock Number (Additional packages are
available — visit MillerWelds.com or your distributor)
Rated Output
Amps Input at Rated Output, 50/60 Hz
200 V 230 V 460 V 575 V KVA KW
Max. OpenCircuit
Voltage
200 A at 28 V, 60% duty cycle
—
77
38
31
17.6 8.6
80 VDC
H: 36.25 in. (921 mm)
W: 22.5 in. (572 mm)
D: 25 in. (635 mm)
378 lb.
(172 kg)
250 A at 30 V, 40% duty cycle
110
96
48
38
22
11.8
300 A at 32 V, 60% duty cycle
—
110
55
42
25
10.6
80 VDC
H: 36.25 in. (921 mm)
W: 22.5 in. (572 mm)
D: 25 in. (635 mm)
496 lb.
(225 kg)
350 A at 34 V, 40% duty cycle
146
128
65
50
29.5 13.7
Dimensions*
Net
Weight*
57
TIG Torches
AIR-COOLED
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.
For more detailed
information, visit
MillerWelds.com/tigtorches
Most popular consumables
Weldcraft A-80 Series
™
Formerly known as WP-24 Series
See literature no. AY/21.0
Innovative air-cooled torches designed for intricate
welding applications, especially in limited-access areas
and on thin-gauge materials.
A-80
(WP-24)
A-80 Flex
(WP-24F)
A-80 Flex Valve
(WP-24FV)
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.
Easy gas-flow adjustment using the fingertip gas valve (A-80 Flex Valve).
Flexible neck can be adjusted in any direction to facilitate welding in
difficult joints (A-80 Flex).
Combining the flexible neck and gas valve is ideal for optimal
positioning and gas flow control (A-80 Flex Valve).
Collets
53N16
.040 in. (1.0 mm)
53N14
1/16 in. (1.6 mm)
24C332
3/32 in. (2.4 mm)
Collet Bodies
53N18
.040 in. (1.0 mm)
53N19
1/16 in. (1.6 mm)
24CB332
3/32 in. (2.4 mm)
Alumina Nozzles
A53N24
#4, 1/4 in.
A53N25
#5, 5/16 in.
A53N27
#6, 3/8 in.
Most popular accessories
• Collet Body Wrench 53N20
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
A-80
WP-24-12-R
WP-24-25-R
Air-cooled
.020–3/32 in. (0.5–2.4 mm)
A-80 Flex
WP-24F-12-R
WP-24F-25-R
DC: 80 A at 60% duty cycle
AC: 50 A at 60% duty cycle
A-80 Flex Valve
WP-24FV-12-R
WP-24FV-25-R
Most popular consumables
Weldcraft A-125 Series
™
Formerly known as WP-9 Series
See literature no. AY/22.0
Air-cooled torches designed for optimal control while welding
thin-gauge materials, especially in hard-to-reach places.
A-125
(WP-9)
A-125
Pencil
(WP-9P)
A-125
Flex Valve
(WP-9FV)
The lightweight body reduces fatigue and downtime, and increases
operator comfort.
Perfected control. The gas valve in the A-125 Valve offers improved
shielding gas control.
Flexibility. Using the A-125 Flex, the flexible neck easily adjusts to any
angle for improved torch control.
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.
Collets
13N22
1/16 in. (1.6 mm)
13N23
3/32 in. (2.4 mm)
13N24
1/8 in. (3.2 mm)
Collet Bodies
13N27
1/16 in. (1.6 mm)
13N28
3/32 in. (2.4 mm)
13N29
1/8 in. (3.2 mm)
Alumina Nozzles
13N10
#6, 3/8 in.
13N11
#7, 7/16 in.
13N12
#8, 1/2 in.
Most popular accessories
Kit #AK1C
• Accessory
Includes one long back cap, one
of each size (#4, #5, #6) alumina
nozzle, and one of each size
(.040, 1/16 in.) of the following:
collet, collet body, and 7-inch
2% ceriated tungsten electrode.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
2-Piece Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
A-125
WP-9-12-R
WP-9-25-R
—
—
Air-cooled
.020–1/8 in. (0.5–3.2 mm)
A-125 Valve
WP-9V-12-R
WP-9V-25-R
WP-9V-12-2
WP-9V-25-2
DC: 125 A at 60% duty cycle
AC: 100 A at 60% duty cycle
A-125 Flex
WP-9F-12-R
WP-9F-25-R
—
—
A-125 Flex Valve
WP-9FV-12-R
WP-9FV-25-R
WP-9FV-12-2
WP-9FV-25-2
A-125 Pencil
WP-9P-12-R
WP-9P-25-R
—
—
58
AIR-COOLED
TIG Torches
Most popular consumables
Weldcraft A-150 Series
™
Formerly known as WP-17 Series
Collets
10N23
1/16 in. (1.6 mm)
10N24
3/32 in. (2.4 mm)
10N25
1/8 in. (3.2 mm)
Collet Bodies
10N31
1/16 in. (1.6 mm)
10N32
3/32 in. (2.4 mm)
10N28
1/8 in. (3.2 mm)
Alumina Nozzles
10N48
#6, 3/8 in.
10N47
#7, 7/16 in.
10N46
#8, 1/2 in.
See literature no. AY/23.0
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.
Ribbed handle and torch design provide cool operation and maximum
operator comfort while reducing downtime caused by operator fatigue.
Available with 12.5- or 25-foot, single- or heavy-duty two-piece
cable assembly determined by the compatibility of the power source.
Heavy-duty cable assembly allows use of a larger conductor for the
power cable which simplifies repair and replacement making it
ideal for field applications.
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.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*PSH = positive stop handle (threaded handle).
Model
Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Mono-Flex™
12.5 ft. (3.8 m)
25 ft. (7.6 m)
2-Piece Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
A-150
WP-17-12-R
WP-17-25-R
WP-17-12-MF
WP-17-25-MF
WP-17-12-2
WP-17-25-2
Air-cooled
A-150 Valve
WP-17V-12-R
WP-17V-25-R
WP-17V-12-MF
WP-17V-25-MF
WP-17V-12-2
WP-17V-25-2
DC: 150 A at 60% duty cycle
AC: 115 A at 60% duty cycle
.020–1/8 in.
(0.5–3.2 mm)
A-150 Flex
WP-17F-12-R
WP-17F-25-R
—
—
WP-17F-12-2
WP-17F-25-2
A-150 Flex Valve
WP-17FV-12-R
WP-17FV-25-R
—
—
WP-17FV-12-2
WP-17FV-25-2
A-150 Flex Valve Redhead
WP-R17FV-12-R
WP-R17FV-25-R
—
—
—
—
A-150 PSH*
—
WP-17-25-R-PSH
—
—
WP-17-12-2-PSH
WP-17-25-2-PSH
A-150 Valve PSH*
WP-17V-12-R-PSH
WP-17V-25-R-PSH
—
—
—
WP-17V-25-2-PSH
Most popular consumables
Weldcraft A-200 Series
™
Formerly known as WP-26 Series
See literature no. AY/24.0
Dependable, top-performing air-cooled torches designed
for heavy-duty welding applications.
A-200
(WP-26)
Eliminate the expense of a water-cooled system. The air-cooled
capability pairs reliability with cost-effectiveness for all field applications.
Robust performance. The heavy copper construction delivers
maximum welding capacity for rugged fieldwork.
Effortless adjustments. The A-200 Valve provides a gas control valve
to ensure a quick, easy adjustment of shielding gas flow.
Flexibility. Using the A-200 Flex, the flexible neck easily adjusts to
any angle for better torch control in limited-access joints.
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.
A-200 Flex
Valve
(WP-26FV)
Collets
10N23
1/16 in. (1.6 mm)
10N24
3/32 in. (2.4 mm)
10N25
1/8 in. (3.2 mm)
Collet Bodies
10N31
1/16 in. (1.6 mm)
10N32
3/32 in. (2.4 mm)
10N28
1/8 in. (3.2 mm)
Alumina Nozzles
10N47
#7, 7/16 in.
10N46
#8, 1/2 in.
10N45
#10, 5/8 in.
Most popular accessories
Kit
• Accessory
#AK3C
Includes one
short back cap, one of each size
(#5, #6, #8) alumina nozzle, and one
of each size (1/16, 3/32, 1/8 in.) of
the following: collet, collet body, and
7-inch 2% ceriated tungsten electrode.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
2-Piece Rubber
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
A-200
WP-26-12-R
WP-26-25-R
WP-26-25-2
Air-cooled
.020–5/32 in. (0.5–4.0 mm)
A-200 Valve
WP-26V-12-R
WP-26V-25-R
WP-26V-25-2
DC: 200 A at 60% duty cycle
AC: 150 A at 60% duty cycle
A-200 Flex
—
WP-26F-25-R
WP-26F-25-2
A-200 Flex Valve
WP-26FV-12-R
WP-26FV-25-R
WP-26FV-25-2
A-200 Flex Redhead
WP-R26F-12-R
—
WP-R26F-25-2
A-200 Flex Valve Redhead
—
WP-R26FV-25-R
—
59
TIG Torches
WATER-COOLED
Most popular consumables
Weldcraft W-125 Micro Series
™
Formerly known as WP-125 Series
See literature no. AY/25.0
Water-cooled MicroTig® torches designed for
limited-access joints.
W-125
Medium (3.5 in.)
Micro
(WP-125M)
Low-profile nozzle fits into holes as small as 5/8-inch 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.
W-125
Long (5 in.)
Micro
(WP-125L)
90° Chucks
125C40-90
.040 in. (1.0 mm)
125C116-90 1/16 in. (1.6 mm)
125C332-90 3/32 in. (2.4 mm)
90° Glass Nozzles
125N90
All sizes
Other nozzles are available.
Most popular accessories
• Chuck Wrench 53N20
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Braided Rubber
25 ft. (7.6 m)
Vinyl
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-125 Medium Micro
WP-125M-25-R
WP-125M-25
Water-cooled
.040–3/32 in. (1.0–2.4 mm)
W-125 Long Micro
WP-125L-25-R
WP-125L-25
DC: 125 A at 100% duty cycle
AC: 80 A at 100% duty cycle
Most popular consumables
Weldcraft W-180
™
Formerly known as WP-24W
See literature no. AY/26.0
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.
Comfort and control are increased with the light, well-balanced body design.
Collets
53N16
.040 in. (1.0 mm)
53N14
1/16 in. (1.6 mm)
24C332
3/32 in. (2.4 mm)
Collet Bodies
53N18
.040 in. (1.0 mm)
53N19
1/16 in. (1.6 mm)
24CB332
3/32 in. (2.4 mm)
Alumina Nozzles
A53N24
#4, 1/4 in.
A53N25
#5, 5/16 in.
A53N27
#6, 3/8 in.
Most popular accessories
• Collet Body Wrench 53N20
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Braided Rubber
25 ft. (7.6 m)
Vinyl
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-180
WP-24W-25-R
WP-24W-25
Water-cooled
DC: 180 A at 100% duty cycle, AC: 115 A at 100% duty cycle
.020–3/32 in. (0.5–2.4 mm)
Weldcraft W-200 Pencil Flex
™
Formerly known as WP-25
See literature no. AY/27.0
Versatile water-cooled torch optimized for use in limitedaccess 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 light, well-balanced body design.
Most popular consumables
Collets
13N21
.040 in. (1.0 mm)
13N22
1/16 in. (1.6 mm)
13N23
3/32 in. (2.4 mm)
Collet Bodies
13N26
.040 in. (1.0 mm)
13N27
1/16 in. (1.6 mm)
13N28
3/32 in. (2.4 mm)
Alumina Nozzles
13N09
#5, 5/16 in.
13N10
#6, 3/8 in.
13N11
#7, 7/16 in.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Braided Rubber
25 ft. (7.6 m)
Vinyl
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-200 Pencil Flex
WP-25-25-R
WP-25-25
Water-cooled
DC: 200 A at 100% duty cycle, AC: 140 A at 100% duty cycle
.020–1/8 in. (0.5–3.2 mm)
60
WATER-COOLED
TIG Torches
Most popular consumables
Weldcraft W-225 Pencil
™
Formerly known as WP-20P
See literature no. AY/28.0
Water-cooled torch designed for long-term, trouble-free service
with consistent welding performance in general applications.
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
Vinyl – 25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-225 Pencil
WP-20P-25
Water-cooled
DC: 225 A at 100% duty cycle, AC: 160 A at 100% duty cycle
.020–1/8 in. (0.5–3.2 mm)
Weldcraft W-250 Series
™
Formerly known as WP-20 Series
See literature no. AY/29.0
Insulator (non-gas lens and gas lens)
598882
Required
Collets (non-gas lens and gas lens)
13N20
.020 (0.5 mm)
13N21
.040 in. (1.0 mm)
13N22
1/16 in. (1.6 mm)
13N23
3/32 in. (2.4 mm)
13N24
1/8 in. (3.2 mm)
Collet Bodies
13N25
.020 in. (0.5 mm)
13N26
.040 in. (1.0 mm)
13N27
1/16 in. (1.6 mm)
13N28
3/32 in. (2.4 mm)
13N29
1/8 in. (3.2 mm)
Gas Lens
45V41
.020 in. (0.5 mm)
45V42
.040 in. (1.0 mm)
45V43
1/16 in. (1.6 mm)
45V44
3/32 in. (2.4 mm)
45V45
1/8 in. (3.2 mm)
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)
W-250 Series Back Caps
41V33
Short
41V35
Medium
41V24
Long
Most popular accessories
Water-cooled torch provides
consistent performance and
long-term trouble-free service with
around-the-head water cooling.
W-250
(WP-20)
Extend torch life and minimize downtime
due to overheating with the efficient aroundthe-head cooling design.
Comfort and control are increased with the
lightweight, compact body 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).
W-250 Valve
(WP-20V)
Covers
• Cable
#WC-3-10 10 ft. (3 m)
#WC-3-22 22 ft. (6.7 m)
Kit #AK4C
• Accessory
Includes one long back cap,
one of each size (#5, #6, #7)
alumina nozzle, and one of each
size (1/16, 3/32, 1/8 in.) of the
following: collet, collet body, and
7-inch 2% ceriated tungsten electrode.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Braided Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Vinyl
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-250
WP-20-12-R
WP-20-25-R
WP-20-25
Water-cooled
.020–1/8 in. (0.5–3.2 mm)
W-250 Valve
—
—
WP-20V-25
DC: 250 A at 100% duty cycle
AC: 180 A at 100% duty cycle
61
TIG Torches
WATER-COOLED
Most popular consumables
Weldcraft W-280 Super Cool
™
™
Formerly known as WP-280
See literature no. AY/30.0
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.
Extend torch life with dependable water-cooled technology.
Reduce leakage of gas and water through secure mechanical
fittings and connections.
Model
Braided Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
W-280 Super Cool
#301 251 012
#301 251 025
50 ft. (15.2 m)
Braided Rubber
with 50 mm Dinse
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
#301 251 050
#301 251 001
Water-cooled
DC: 280 A at 100% duty cycle
AC: 195 A at 100% duty cycle
.020–1/8 in.
(0.5–3.2 mm)
Weldcraft W-375 Super Cool
™
™
See literature no. AY/32.5
Insulator (non-gas lens and gas lens)
598882
Required
Collets (non-gas lens and gas lens)
13N20
.020 (0.5 mm)
13N21
.040 in. (1.0 mm)
13N22
1/16 in. (1.6 mm)
13N23
3/32 in. (2.4 mm)
13N24
1/8 in. (3.2 mm)
Collet Bodies
13N25
.020 in. (0.5 mm)
13N26
.040 in. (1.0 mm)
13N27
1/16 in. (1.6 mm)
13N28
3/32 in. (2.4 mm)
13N29
1/8 in. (3.2 mm)
Gas Lens
45V41
.020 in. (0.5 mm)
45V42
.040 in. (1.0 mm)
45V43
1/16 in. (1.6 mm)
45V44
3/32 in. (2.4 mm)
45V45
1/8 in. (3.2 mm)
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
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.
Extend torch life with dependable water-cooled technology.
Reduce leakage of gas and water through secure mechanical
fittings and connections.
Covers
• Cable
#WC0183 11.75 ft. (3.6 m)
#WC0182 24.25 ft. (7.4 m)
Kit #AK4C
• Accessory
Includes one long back cap,
one of each size (#5, #6, #7)
alumina nozzle, and one of each
size (1/16, 3/32, 1/8 in.) of the
following: collet, collet body, and
7-inch 2% ceriated tungsten electrode.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Braided Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Braided Rubber with 50 mm Dinse
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-375 Super Cool
#301 253 012
#301 253 025
#301 253 001
Water-cooled
DC: 375 A at 100% duty cycle
AC: 265 A at 100% duty cycle
.020–1/8 in.
(0.5–3.2 mm)
62
WATER-COOLED
TIG Torches
Most popular consumables
Weldcraft W-350 Series
™
Formerly known as WP-18 Series
See literature no. AY/32.0
Rugged water-cooled torches engineered for
high-amperage and continuous hand-held
welding in mechanized applications.
W-350
(WP-18)
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 Valve
(WP-18V)
Collets
10N24
3/32 in. (2.4 mm)
10N25
1/8 in. (3.2 mm)
54N20
5/32 in. (4.0 mm)
Collet Bodies
10N32
3/32 in. (2.4 mm)
10N28
1/8 in. (3.2 mm)
406488
5/32 in. (4.0 mm)
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.
Most popular accessories
• Accessory Kit #MAK-2S
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Vinyl
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-350
WP-18-12-R
WP-18-25-R
WP-18-12
WP-18-25
Water-cooled
.020–5/32 in. (0.5–4.0 mm)
W-350 Valve
—
WP-18V-25-R
—
WP-18V-25
DC: 350 A at 100% duty cycle
AC: 250 A at 100% duty cycle
Weldcraft W-400 Super Cool
™
™
Formerly known as WP-18SC
See literature no. AY/33.0
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.
Comfort and maximum torch control with the textured handle.
Most popular consumables
Heavy-Duty Collets
10N25HD
1/8 in. (3.2 mm)
54N20HD
5/32 in. (4.0 mm)
18C36
3/16 in. (4.8 mm)
Heavy-Duty Nose Collet Body
NCB-36
All sizes
Alumina Nozzles
54N16
#6, 3/8 in.
54N15
#7, 7/16 in.
54N14
#8, 1/2 in.
Back Caps
57Y04
Short
300M
Medium
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Vinyl
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-400 Super Cool
WP-18SC-12-R
WP-18SC-25-R
WP-18SC-25
Water-cooled
DC: 400 A at 100% duty cycle, AC: 280 A at 100% duty cycle
.020–3/16 in. (0.5–4.8 mm)
Most popular consumables
Weldcraft W-410
™
Formerly known as CS410
See literature no. AY/34.0
Water-cooled torch that increases amperage output without
increasing torch size. Designed for demanding applications.
Simplify torch package installation with ColorSmart™ hose and cable sets
that differentiate input water, water/power cable, and gas hoses.
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.
Collets
10N24
3/32 in. (2.4 mm)
10N25
1/8 in. (3.2 mm)
54N20
5/32 in. (4.0 mm)
Collet Bodies
10N32
3/32 in. (2.4 mm)
10N28
1/8 in. (3.2 mm)
406488
5/32 in. (4.0 mm)
Alumina Nozzles
10N46
#8, 1/2 in.
10N45
#10, 5/8 in.
10N44
#12, 3/4 in.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Braided Rubber – 25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-410
CS410-25
Water-cooled
DC: 410 A at 100% duty cycle, AC: 310 A at 100% duty cycle
.020–5/32 in. (0.5–4.0 mm)
63
TIG Torches
WATER-COOLED AND MODULAR
Most popular consumables
Weldcraft W-500
™
Formerly known as WP-12
Insulator
12NG
Required
Collets
85Z17
5/32 in. (4.0 mm)
85Z18
3/16 in. (4.8 mm)
85Z19
1/4 in. (6.4 mm)
Collet Body
11WP65
All sizes
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.
Back Caps
56Y45
Short
56Y44
Long
See literature no. AY/35.0
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.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Rubber – 25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-500
WP-12-25
Water-cooled
DC: 500 A at 100% duty cycle, AC: 350 A at 100% duty cycle
1/16–1/4 in. (1.6–6.4 mm)
Weldcraft Modular Series
Most popular accessories
™
See literature no. AY/36.0
Air-cooled and water-cooled
torches engineered to weld
multiple joint configurations for
various applications and angles.
A-150
Modular Valve
(WP-150V)
A-150
Modular
(WP-150)
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).
Converts into 28 different torch styles
while using existing cable. Includes
collets, collet bodies, nozzles, torch
heads, handle and more.
Kit #AK-225MFC
• Accessory
Supplements W-225 torch packages.
Includes five additional torch heads,
collets, collet bodies, nozzles, handle
and more.
W-225
Modular
(WP-225)
A-200
Modular Valve
(WP-200V)
Kit #AK-150MFC
• Accessory
Allows A-150 torch customization.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*Ratings are torch head dependent.
Model
Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
2-Piece Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Type
Rated Output*
Electrode Range*
A-150 Modular
WP-150-12-R
WP-150-25-R
WP-150-12-2
WP-150-25-2
Air-cooled
A-150 Modular Valve
WP-150V-12-R
WP-150V-25-R
WP-150V-12-2
—
DC: 150 A at 60% duty cycle
AC: 105 A at 60% duty cycle
.020–1/8 in.
(0.5–3.2 mm)
A-200 Modular Valve
WP-200V-12-R
WP-200V-25-R
—
—
Air-cooled
DC: 200 A at 60% duty cycle
AC: 150 A at 60% duty cycle
.020–5/32 in.
(0.5–4.0 mm)
Model
Braided Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Vinyl
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Type
Rated Output*
Electrode Range*
W-225 Modular
WP-225-12-R
WP-225-25-R
—
WP-225-25
Water-cooled
DC: 225 A at 100% duty cycle
AC: 160 A at 100% duty cycle
.020–5/32 in.
(0.5–4.0 mm)
64
TIG Torches
AUTOMATION AND TUNGSTEN
Weldcraft Automation Series
Most popular accessories
™
See literature no. AY/37.0
Air-cooled and water-cooled torches
designed for high- and low-amperage
mechanized applications.
A-150
Automation
(WP-23A)
W-250
Automation
(WP-22A)
Minimize downtime associated with
tungsten changeover by using the front or
back tungsten loading areas.
Pencil-style model offers outstanding
durability on mechanized applications
(W-500 Pencil Automation).
Built-in gas lens improves gas coverage
to minimize shielding gas turbulence and
improve weld quality (W-500A Automation,
W-500B Automation).
Handle the most demanding high-amperage
applications with the W-900 Automation torch.
W-500
Pencil
Automation
(WP-18P)
W-500A
Automation
(WP-27A)
W-500B
Automation
(WP-27B)
W-900
Automation
(WP-27BHD)
Covers
• Cable
#WC-3-10 10 ft. (3 m)
#WC-3-22 22 ft. (6.7 m)
#WC-4-10 10 ft. (3 m)
#WC-4-22 22 ft. (6.7 m)
Torch 1-Piece Power
• Air-Cooled
Cable Connector (pg 113)
#195 378 50 mm Dinse-style
#195 377
•
#225 028
Water-Cooled Torch 1-Piece Power
Cable Connectors (pg 113)
#195 377 50 mm Dinse-style
#225 028 50 mm thread-lock
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Model
Rubber
12.5 ft. (3.8 m)
25 ft. (7.6 m)
2-Piece Rubber
12.5 ft. (3.8 m)
Type
Rated Output
Electrode Range
A-150 Automation
WP-23A-12-R
WP-23A-25-R
WP-23A-12-2
Air-cooled
DC: 150 A at 60% duty cycle
AC: 120 A at 60% duty cycle
.040–3/32 in.
(1.0–2.4 mm)
Model
3 ft. (0.9 m)
6 ft. (1.8 m)
12.5 ft. (3.8 m)
25 ft. (7.6 m)
Type
Rated Output
Electrode Range
W-250 Automation
WP-22A-3 (Vinyl)
WP-22A-6 (Vinyl)
WP-22A-12 (Vinyl)
WP-22A-25-R (Rubber)
WP-22A-25 (Vinyl)
Water-cooled
DC: 250 A at 100% duty cycle
AC: 180 A at 100% duty cycle
.040–1/8 in.
(1.0–3.2 mm)
W-500 Pencil Automation
—
—
WP-18P-12 (Vinyl)
WP-18P-25 (Vinyl)
Water-cooled
DC: 500 A at 100% duty cycle
AC: 350 A at 100% duty cycle
.020–5/32 in.
(0.5–4.0 mm)
W-500A Automation
WP-27A-3 (Rubber)
—
WP-27A-12 (Rubber)
WP-27A-25 (Rubber)
Water-cooled
DC: 500 A at 100% duty cycle
AC: 350 A at 100% duty cycle
.040–1/4 in.
(1.0–6.4 mm)
W-500B Automation
WP-27B-3 (Rubber)
—
WP-27B-12 (Rubber)
WP-27B-25 (Rubber)
Water-cooled
DC: 500 A at 100% duty cycle
AC: 350 A at 100% duty cycle
.040–1/4 in.
(1.0–6.4 mm)
W-900 Automation
WP-27BHD-3 (Rubber)
(Power cable not included)
—
—
—
Water-cooled
DC: 900 A at 100% duty cycle
AC: 630 A at 100% duty cycle
.040–1/4 in.
(1.0–6.4 mm)
Weldcraft Tungsten
™
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 10 seven-inch (175 mm) tungsten electrodes.
Type
Diameter
in. (mm)
Part Number
2% Ceriated (EWCe-2)
Performs well in DC welding
and arc starting at low-current
settings, and offers excellent
performance in AC processes.
Note: Refer to manufacturer MSDS sheets for proper preparation
and safety. Use proper ventilation/capture during preparation.
Refer to manufacturer warning regarding ventilation.
Diameter
in. (mm)
Part Number
Pure (EWP)
0.040 (1.0)
WC040X7
1/16 (1.6)
WC116X7
3/32 (2.4)
WC332X7
1/8 (3.2)
WC018X7
5/32 (4.0)
WC532X7
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.
Type
Forms a clean, balled end
when heated and provides
good arc stability for AC
welding with a balanced
or unbalanced squarewave or
sine wave.
0.040 (1.0)
—
1/16 (1.6)
WP116X7
3/32 (2.4)
WP332X7
1/8 (3.2)
WP018X7
5/32 (4.0)
—
Rare Earth (EWG)
0.040 (1.0)
WL2040X7
1/16 (1.6)
WL2116X7
3/32 (2.4)
WL2332X7
1/8 (3.2)
WL2018X7
5/32 (4.0)
WL2532X7
Combines the best of all
alloying elements, and
provides excellent arc stability
in AC or DC welding.
0.040 (1.0)
—
1/16 (1.6)
WG116X7
3/32 (2.4)
WG332X7
1/8 (3.2)
WG018X7
5/32 (4.0)
—
65
Product
Guide
Page
Class
Stick
MIG
Flux-cored*
AC TIG
DC TIG
PAC**
CAC-A
Gas or LP
Gasoline
Engine-Driven
Blue Star® 185
67
Bobcat™ 225
68
Bobcat™ 3 Phase
68
Trailblazer® 325
70
3⁄ 16"
Trailblazer® 302
Air Pak™
72
3⁄ 16"
Bobcat™ 250
68
3⁄ 16"
Trailblazer® 275
70
3⁄ 16"
Bobcat™ 250 Diesel
68
3⁄ 16"
73 3⁄ 16"
74 75 5⁄ 16"
3⁄ 16"
Big Blue® 800 Duo Pro SF 76 Big Blue® 800 Duo
76 Air Pak
3⁄ 8"
Trailblazer® 325 Diesel 70
Big Blue® 350 PipePro® 73
Diesel
Big Blue® 400 Pro
Big Blue® 500 Pro
74
Big Blue® 600 Pro
Big Blue® 450 Duo CST ™
Big Blue® 700 Duo Pro
75
Big Blue® 800 Duo Pro
76
MillerWelds.com/enginedriven
Std.
Welding
Weldable Generator
Amperage
Metals
Pwr. (watts) Range
Engine
Brand
Steel
Special Features
Typical Applications
6,500
60–185 DC
Kohler
Compact, portable
Maintenance, service trucks
11,000
70–150 AC
50–225 DC
Kohler
Cost-effective AC/DC stick
Maintenance, farm/ranch,
construction
11,000
50–200 AC
50–210 DC
Kohler
Backup power for pivot
irrigation
Farm/ranch
12,000
10–325 DC
Kohler
Auto-Speed,™ optional EFI,
Excel™ power and
battery charge/jump start
Fab, structural, maintenance,
repair, pipe
13,000
10–225 AC
10–350 DC
Kohler
AC/DC, CC/CV, 31 cfm air,
battery charge/jump start
Service/maintenance,
construction
11,000
12,000 w/EFI
40–250 DC
Kohler
40–275 DC w/EFI
Most popular engine drive,
AC/DC, optional EFI
Fab, maintenance,
farm/ranch, construction
Steel,
stainless
12,000
11,000 w/LP
10–275 DC
Kohler
Auto-Speed™
Fab, structural, maintenance,
repair, pipe
Steel,
aluminum,
stainless
11,000
40–275 DC
Kubota
Contractor’s choice,
AC/DC stick, strong FCAW
Fab, maintenance,
farm/ranch, construction
3⁄ 16"
Steel,
stainless
12,000
10–325 DC
Kubota
Auto-Speed,™
optional Excel™ power
Fab, structural, maintenance,
repair, pipe
1⁄ 4"
Lift eye, pickup mount, Steel,
optional trailer
stainless
Portability
For more detailed
information, visit
Optional lift eye or
running gear
Lift eye, pickup mount, Steel,
optional running gear aluminum,
or trailer
stainless
Steel,
stainless
Lift eye, pickup mount, Steel,
optional running gear aluminum,
or trailer
stainless
Lift eye, optional
running gear or trailer
12,000
20–400 DC
CAT, Mitsubishi
Premium pipe arc, LINE-X® cover Pipeline
12,000
20–400 DC
Kubota,
Mitsubishi
Quiet, compact, fuel efficient
Construction, rental, repair
21,000
20–500 DC
Deutz, Perkins
Quiet, powerful, fuel efficient
Construction, rental, repair
27,000
20–600 DC
Kubota
Quiet, powerful, fuel efficient
Construction, rental, repair
Lift eye, pickup mount, Steel,
optional trailer
stainless
10,000
5–450 DC
Mitsubishi
Dual operator in a
compact package
Construction, fabrication,
pipe
Lift eye, generally
mounted on
optional trailer
20,000
20–800 DC
Deutz
Premium pipe arc, dual operator
Pipeline, construction, mining
27,000
20–800 DC
Deutz
Heavy duty, dual operator
Mining, construction, pipeline
1⁄ 2"
27,000
20–800 DC
Deutz
Smart feeder compatible
Mining, construction, pipeline
1⁄ 2"
27,000
20–800 DC
Deutz
Heavy duty, dual operator,
air compressor
Mining, construction, railroad,
repair
3⁄ 8"
1⁄ 2"
Lift eye, generally
mounted on
optional trailer
Steel,
stainless
Steel,
stainless
™
EFI advantages (vs. carburetor models)
Gasoline advantages (vs. diesel)
Diesel advantages (vs. gas)
to 42 percent more fuel efficient
• Up
• Faster, more reliable starts in any weather —
no choke adjustment needed
refueling time
• Less
• Fewer emissions
product cost (by 50 to 70 percent)
• Lower
size and less weight
• Smaller
expensive repairs
• Less
• Easier cold weather starting
to 2.5 times the engine life
• 1.5
on some jobsites for safety
• Required
have longer maintenance intervals
• Typically
• Convenient if other equipment is diesel
Product Key
66
Class:
Light industrial
Industrial
Heavy industrial
Capability:
Designed for this process
Capable of this process
New! or Improved! products appear in blue type. *If using self-shielded wire, use CV weld output. **With appropriate Spectrum plasma cutter.
Engine-Driven
Blue Star 185
®
Light industrial
See literature no. ED/2.5
Processes
Stick (SMAW) • TIG (GTAW)
•Gasoline
engine
Reliable outdoor portable power! Great for farm, ranch, maintenance, construction and hobbyist.
Kohler CH440: 13.4 hp at 3,600 rpm
One-cylinder, four-cycle, OHV, air-cooled
Compact and portable, its small footprint uses little truck space.
Optional running gear also makes the Blue Star one-man portable.
Note: Engine is warranted separately
by engine manufacturer.
All engine controls are on front panel.
Most popular accessories
Stick and TIG capable.
Eye #195 353 (pg 108)
• Lifting
Gear #301 246 (pg 108)
• Running
• Protective Cover #301 245 (pg 108)
Accu-Rated™ peak generator power is usable for maximum generator
loads such as plasma cutting, Millermatic® MIG welders and motor starting.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Gasoline
Includes electric start, 120-volt GFCI and 240-volt receptacles,
6.25-gallon fuel capacity, auto-idle and engine hour meter.
Stock Number
(#907 664)
Kohler
Welding Mode
Welding Process
Amperage Range
Rated Output at 104°F (40°C)
Single-Phase Generator Power at 104°F (40°C)
Dimensions
Net Weight
CC/DC
DC stick/TIG
60 –185
185 A at 25 V, 20% duty cycle
150 A at 25 V, 100% duty cycle
Peak: 6,500 watts
Continuous: 6,200 watts
H: 24.75 in. (629 mm)
W: 20.625 in. (524 mm)
D: 31.25 in. (794 mm)
296 lb.
(134 kg)
Bobcat /Trailblazer®: Which is Right for You?
™
Gas Model
Comparison
Bobcat (page 68)
The most popular welder/generator:
The best performer in the industry:
*Based on typical usage —
150 amps welding 40% of the time;
20 amps generator power 30% of
the time; and idling without load
30% of the time.
power and weld output
• Dependable
multiprocess welder/generator
• Cost-effective
to maintain
• Easy
• Quietest in its class
arc performance
• Unbeatable
Independent welder and generator power system
• Exclusive
— Auto-Speed and Excel power
• Most fueltechnologies
efficient and quietest in its class
•
Trailblazer (page 70)
™
Sound Levels (at 23 feet)
Bobcat 225
At Maximum Load/At 150 Amps
73 dB/72 dB
73 dB/72 dB
74 dB/65 dB
74 dB/65 dB
Good
Very good
Excellent
Excellent
Sound Quality
UPGRADE
Bobcat 250
UPGRADE
Trailblazer 275
™
UPGRADE
Trailblazer 325
Fuel System
Typical Runtime per 12-Gallon Tank*
Efficiency
Type
Delivery
13 hours
13/15.5 hours with EFI
15 hours
Up to 21 hours with options
Good
Good/Very good with EFI
Excellent
Excellent
Gasoline
Gasoline or LP
Gasoline or LP
Gasoline
Carburetor
Carburetor or EFI available
Carburetor
Carburetor or EFI available
Generator
11,000
11,000/12,000 with EFI
12,000/11,000 with LP
12,000
Clean Power Quality
Very good/Excellent
Very good/Excellent
Excellent
Excellent
Power While Welding
Fair/Good
With voltage control
set near maximum
Good
Easier to fine-tune with arc
voltage control near maximum
Independent weld and generator power
with no interaction between
tools and welding arc
Independent weld and generator power
with no interaction between
tools and welding arc
N/A
N/A
N/A
Excel power available
Watts
Excel™ Power Generator
(120 V, 60 Hz at all engine speeds)
Weld Performance
Good/Very good
Very good
Excellent
Excellent
Fair (.035 in.)
Good (.035–1/16 in.)
Excellent (.023–1/16 in.)
Excellent (.023–1/16 in.)
Fair/Good
(add WC-115A with contactor)
Very good
(add WC-115A with contactor)
Excellent
(add WC-24)
Excellent
(add WC-24)
DC TIG (steel)
Good
Very good
Excellent
Excellent
Pulsed DC TIG
(thin metal, out of position)
N/A
N/A
Yes
Yes
70–150 amps (TIG: add
HF-251D-1 and contactor kit)
40–250 amps (TIG: add
HF-251D-1 and contactor kit)
Add Dynasty®
Add Dynasty®
N/A
Good/Very good
Carbons: Rated 3/16 in.
Very good
Carbons: Rated 3/16 in.
Very good
Carbons: Rated 3/16 in., Capable 1/4 in.
Stick
MIG — Wire (solid/FCAW), Steel
MIG — Wire, Aluminum w/Spool Gun
AC Weld
Carbon Arc Gouging
Key Features
N/A
N/A
Yes
Yes
Hours/Oil change
Hours/Oil change/Fuel
Hours/Oil change/Fuel/RPMs
Hours/Oil change/Fuel/RPMs
Battery Charge/Jump Start
N/A
N/A
N/A
12/24-volt available
14-pin Receptacle
N/A
N/A
Yes
Yes
Digital Meters with SunVision™
Maintenance Displays
67
Engine-Driven
Bobcat Series
™
Gas, LP and Diesel
Bobcat engine-driven
welder/generators
are the top selling
in their class because
they are engineered to
be reliable, powerful
and durable. Their
multiprocess capabilities
make them ideal for maintenance trucks where reduced size
and weight are essential.
Bobcat 250 EFI shown.
Cleaner and stronger generator power
11,000 watts (12,000 on Bobcat 250 with EFI)
of clean, truly usable generator power that is
Accu-Rated™, not inflated — tested to deliver
uninterrupted peak output for a minimum of
30 seconds for big loads, so you can get more
jobs done.
Advanced generator technology virtually
eliminates power spikes and other electrical
imperfections so welds are cleaner and jobsite
tools can run without interruption, maximizing
quality, productivity and profit.
More portable, uses less truck space
Bobcat
Competitor
Waveform Comparison
Fewer refueling trips
Large 12-gallon fuel capacity means extended runtimes and less refueling.
Versatile AC and DC welding
Provides AC and DC welding output for greater versatility and quality welds
on all types of metals. DC is smooth and easy to run while AC stick is used
when arc blow occurs.
68
Smaller and lighter — 17 percent less
cubic space and weighing up to 100 pounds
less than the competition — means moving
Bobcat welder/generators is faster and
easier, for maximum productivity. And
because they take up less space, they let
work trucks carry more equipment and gear
so your work crews can meet weight limits
and be ready for anything.
Easier maintenance
Easy-to-read front panel maintenance displays show engine hours and
hours left before an oil change is due. This intuitive design makes
maintenance fast and easy.
Oil checks from the top by the front panel
Toolless panels that allow for quick access
Single-side fuel fill and oil drain/filter
•
•
•
Engine-Driven
Industrial
Bobcat 225 (Gas) See literature no. ED/4.4
™
Processes
Cost-effective, multiprocess welder/generator primarily used for stick welding. Great for farm,
ranch, maintenance/repair and as a stand-alone generator.
stick (SMAW)
• AC/DC
(GMAW) • Flux-cored (FCAW)
• MIG
/DC TIG (GTAW)
• ACAir carbon
arc cutting and gouging
• (CAC-A) (rated
3/16 in. carbons)
1
1
2
3
1 With
voltage-sensing feeder only.
Dynasty® 210 Series or
HF-251 (non-critical).
3 Bobcat 250 models only.
Features three DC stick/TIG controls, one AC stick/TIG control
and one wire range for output control. Stick ranges designed for
3/32, 1/8 and 5/32 inch. Very easy to set.
2 With
Engines
Bobcat 3 Phase (Gas) See literature no. ED/4.33
™
Designed for farm and ranch owners in need of single- and three-phase power to run 480-volt
three-phase pivot irrigation systems or to provide backup power for home, farm and/or ranch.
Bobcat 250 (Gas, LP or Diesel) See literature no. ED/4.4 (Gas/LP) and ED/4.34 (Diesel)
™
Multiprocess engine-driven welder/generator capable of carbon arc gouging
features a larger stabilizer for less spatter and smoother arc. Ideal welder/
generator for maintenance/repair, construction, farm/ranch or as a stand-alone generator.
Convenient front panel fuel gauge.
More precise amperage settings with wider range for optimal
stick/flux-cored welding.
Features four AC/DC stick/TIG controls and two wire ranges
for output control. Stick ranges designed for 3/32, 1/8, 5/32
and 3/16 inch. Very easy to set.
Add optional electronic fuel injection (EFI) —
improved fuel efficiency for maximum productivity and profitability
Adding EFI to your Bobcat 250 welder/generator provides multiple benefits. With EFI you’ll get faster, more
reliable starts in any weather — no choke adjustments needed. EFI-equipped Bobcat 250 machines are also up
to 42 percent more fuel efficient than standard carbureted models, improving profitability. Plus, refueling less
frequently means you’ll spend more of your time welding, improving productivity.
Gas: Kohler CH730
23.5 hp at 3,600 rpm
EFI gas: Kohler ECH730
23 hp at 3,600 rpm
LP: Kohler CH730
Liquid withdrawal LP system
21.5 hp at 3,600 rpm
V-twin-cylinder, four-cycle, overhead
valve, industrial, air-cooled
EPA Tier 4 Final Diesel: Kubota D722
19 hp at 3,600 rpm
Three-cylinder, industrial, liquid-cooled
Note: Engines are warranted separately
by engine manufacturer.
Most popular accessories
X-TREME Feeders (pg 42)
• SuitCase
210 Series (pg 54)
• Dynasty
625 X-TREME (pg 82)
• Spectrum
Multi-Terrain
Running Gear (pg 108)
• Off-Road Running
108)
• Protective Cage withGearCable(pg Holders
• (pg 108)
and LP Tank Mounting Assembly
• Hose
(pg 108)
Oil Drain/Filter Kit (pg 108)
• Remote
Running Gear (pg 108)
• All-Purpose
Full
KVA
Adapter
• (pg 108) Cord #300 517
Cover (pg 108)
• Protective
HWY-1000
#195 013 (pg 109)
• GFCI Panel Trailer
Mount 120 VAC
• Duplex Kit #300
975
Fuel Pump Kit*
• Electric
(gas models only) #300 976
Spark
Arrestor Kit (gas models only)
• #300 924
®
®
®
™
™
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Diesel
Gas or LP
Gasoline
*Recommended for operation at altitudes above 5,000 feet.
Model
Stock Number
Bobcat
225
(#907 498 001) Kohler
(#907 498) Kohler with GFCI
Bobcat
3 Phase
(#907 505) Kohler with GFCI
Bobcat
250
(#907 500 001) Kohler
(#907 500) Kohler with GFCI
(#907 500 002) Kohler with electric fuel pump*
(#907 502) EFI Kohler
(#907 504) LP Kohler with GFCI
(order hose and LP tank mounting assembly
#300 917 separately)
(#907 565) Kubota with GFCI
Bobcat
250
Diesel
Welding
Mode
Process
CC/AC
CC/DC
Amp/Volt
Ranges
Rated Output at 104°F (40°C)
Stick/TIG
70–150 A
150 A at 25 V, 100% duty cycle
Stick/TIG
50–225 A
225 A at 25 V, 100% duty cycle
CV/DC
MIG/FCAW
19–28 V
200 A at 20 V, 100% duty cycle
CC/AC
Stick/TIG
50–200 A
200 A at 25 V, 100% duty cycle
CC/DC
Stick/TIG
50–210 A
210 A at 25 V, 100% duty cycle
CV/DC
MIG/FCAW
19–28 V
200 A at 20 V, 100% duty cycle
CC/AC
Stick/TIG
40–250 A
40–275 A w/EFI
250 A at 25 V, 60% duty cycle
225 A at 25 V, 100% duty cycle
CC/DC
Stick/TIG
40–250 A
40–275 A w/EFI
250 A at 25 V, 100% duty cycle
CV/DC
MIG/FCAW
17–28 V
275 A at 25 V, 60% duty cycle
250 A at 25 V, 100% duty cycle
CC/AC
CC/DC
Stick/TIG
40–275 A
250 A at 25 V, 100% duty cycle
CV/DC
MIG/FCAW
17–28 V
275 A at 25 V, 60% duty cycle
250 A at 28 V, 100% duty cycle
Generator Power
at 104°F (40°C)
Single-phase
Peak: 11,000 watts
Continuous: 9,500 watts
Dimensions
Net
Weight
H: 28 in. (711 mm)
H: 32.75 in. (832 mm)
to top of exhaust
W: 20 in. (508 mm)
D: 40.5 in. (1,029 mm)
485 lb.
(220 kg)
Single-phase
Peak: 11,000 watts
Continuous: 9,500 watts
EFI model
Peak: 12,000 watts
Continuous: 10,500 watts
H: 28 in. (711 mm)
H: 32.75 in. (832 mm)
to top of exhaust
W: 20 in. (508 mm)
D: 40.5 in. (1,029 mm)
501 lb.
(227 kg)
Single-phase
Peak: 11,000 watts
Continuous: 9,500 watts
H: 28 in. (711 mm)
H: 34.5 in. (876 mm)
to top of exhaust
W: 20 in. (508 mm)
D: 45.5 in. (1,156 mm)
638 lb.
(289 kg)
Single-phase/three-phase
Peak: 11,000 watts
Continuous:
9,500 watts/10,000 watts
495 lb.
(225 kg)
69
Engine-Driven
Trailblazer Series
®
Gas, LP and Diesel
See lit. no. ED/4.75 (Gas/LP) and ED/4.8 (Diesel)
Trailblazer welder/generators deliver unbeatable arc
performance providing the smoothest, most stable arc
in the industry. The Trailblazer exclusive Auto-Speed™
technology delivers superior runtimes, increased fuel
efficiency, and improved welder/generator performance.
See page 113
Trailblazer 325 EFI shown.
Unbeatable arc performance
Auto-Speed technology
Wide amperage output with better welding deposition rates means
you can get jobs done faster, saving time and money. The Trailblazer
also has precise arc control, which allows you to fine-tune the arc to
match your personal preferences and quickly dial in the perfect
parameters to optimize weld quality and maximize productivity across
a variety of applications and welding processes.
Get the welding power you need — plus reduced fuel consumption and lower
noise levels for a more-profitable, safer jobsite. Unlike competitive machines
that operate at 3,600 rpm (max) under any load, Miller-exclusive Auto-Speed
technology responds to weld requirements by automatically adjusting engine
speed to one of four rpm levels so the engine never works harder than
necessary. Refueling time and operating costs are reduced, which means more
productivity and profitability. Auto-Speed technology — available only from Miller.
Cleaner and stronger generator power
Combines a 25 hp engine and 12,000 watts of clean, truly usable
generator power that is Accu-Rated™, not inflated — tested to deliver
uninterrupted peak output for a minimum of 30 seconds for big loads,
so you can get more jobs done.
Maximum cost savings
Less money spent on fuel means more profit for you. Every Trailblazer
welder/generator has fuel-saving Auto-Speed technology — add optional
Excel™ power and EFI to save even more on fuel costs and enjoy a
combination of advanced, profit-enhancing features that are only
available on a Trailblazer welder/generator.
Safer, more productive jobsites
Quieter jobsites are safer and more
productive because work crews can
communicate easier, and work can
start earlier and end later — even in
noise-sensitive areas.
70
Welding at idle speed
Welding below
150 A
Welding between
151–210 A
Welding between
211–250 A
Welding above
250 A
2,400
2,800
3,200
3,600
RPM
RPM
RPM
RPM
Auto-Speed™ in XX18 mode
Fewer refueling trips
Spend more time working and less time refueling. Only Trailblazer welder/
generators provide Auto-Speed technology, plus Excel power and electronic
fuel injection (EFI) options, to deliver maximum runtime.
More portable, uses less truck space
Smaller and lighter — 17 percent less cubic
space and 10 percent less machine weight
than the competition — means moving
Trailblazer welder/generators is faster and
easier, for maximum productivity.
Engine-Driven
Heavy industrial
Options to Maximize Your Trailblazer 325 Performance
Processes
(SMAW)
• Stick
(GMAW)
• MIG
(FCAW)
• Flux-cored
DC
TIG/pulsed
TIG (GTAW/GTAW-P)
• Air carbon arc cutting
gouging
• (CAC-A) (rated 3/16 in.andcarbons,
1
1
Excel™ power
2
Unlike competitive machines that provide auxiliary power only at 3,600 rpm
(max), Excel power delivers a full 2,400 watts (20 A) of 120-volt inverter-based,
pure sine wave power at all speeds, including idle. With Excel power you can
operate jobsite tools like grinders at quiet, fuel-saving speeds.
Refueling time and operating costs are reduced with Excel power, which means
more productivity and profitability. Plus everyone on the jobsite gets a better
working environment because noise levels and exhaust emissions are lowered.
Excel power — available only from Miller.
capable 1/4 in. carbons)
1 With
Engines
Based on generator-only use for total runtime.
EFI (gas models)
Adding EFI to your Trailblazer welder/generator
adds multiple benefits. With EFI, you’ll get
faster, more-reliable starts in any weather —
no choke adjustments needed. EFI-equipped
Trailblazer machines are also up to 40 percent
more fuel efficient than standard carbureted
models, improving profitability. Plus, refueling
less frequently means you’ll spend more of your
time welding, improving productivity.
Add Excel power to your Trailblazer with EFI,
and you’ll have the most fuel-efficient
compact welder/generator available.
Carbureted
models
Trailblazer 325
with EFI & Excel power
+6
15
HOURS
HOURS
wire feeder.
TIG torch recommended.
2 Two-piece
OF RUNTIME
21
HOURS
OF RUNTIME
Gas: Kohler CH730
23.5 hp at 3,600 rpm
EFI gas: Kohler ECH730
23 hp at 3,600 rpm
LP: Kohler CH730
Liquid withdrawal LP system
21.5 hp at 3,600 rpm
V-twin-cylinder, four-cycle, overhead
valve, industrial, air-cooled
EPA Tier 4 Final Diesel: Kubota D902
24.8 hp at 3,600 rpm
Three-cylinder, industrial, liquid-cooled
Note: Engines are warranted separately
by engine manufacturer.
Most popular accessories
30A / WC-24 Control
• Spoolmatic
#130 831 / #137 549 (pg 19)
X-TREME 12VS (pg 42)
• SuitCase
Series (pg 54/56)
• Dynasty
625 X-TREME (pg 82)
• Spectrum
Running Gear (pg 108)
• Multi-Terrain
Running Gear (pg 108)
• Off-Road
Cage with Cable Holders
• Protective
(pg 108)
and LP Tank Mounting Assembly
• Hose
(pg 108)
Running Gear (pg 108)
• All-Purpose
Full
KVA
Adapter
• (pg 108) Cord #300 517
Cover (pg 108)
• Protective
Trailer #195 013 (pg 109)
• HWY-1000
Fuel Pump Kit
• Electric
(gas models only) #300 976
®
Auto-Speed technology
Auto-Speed technology
Electronic Fuel Injection (EFI)
Electronic Fuel Injection (EFI)
Excel power
Excel power
Based on typical usage — 150 amps welding 40% of the time; 20 amps generator power
30% of the time; and idling without load 30% of the time.
Battery charge/jump start (gas models)
Reduce downtime with battery charge/jump start capability. Designed and recommended for mechanics or anyone
else responsible for a fleet of trucks or equipment. By using your Trailblazer to charge dead batteries or jump a
stubborn engine, you’ll keep your crew working and the fleet up and running.
Note: Battery charge/jump cables (#300 422) must be ordered separately.
®
®
®
•
™
™
Recommended for operation at
altitudes above 5,000 feet.
25 ft. Battery Charge/Jump Cables
with plug (for Trailblazer 325 EFI
#907 512 002 only) #300 422
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Gas or LP
*Recommended for operation at altitudes above 5,000 feet.
Process
Amp/Volt
Ranges
Rated Output at
104°F (40°C)
Single-Phase Generator
Power at 104°F (40°C)
(#907 506) Kohler with GFCI
(#907 691) LP Kohler with Excel power and GFCI
(order hose and LP tank mounting assembly
#300 917 separately)
CC/DC
Stick/TIG
10–275 A
275 A at 28 V,
100% duty cycle
CV/DC
MIG/FCAW
10–35 V
275 A at 28 V,
100% duty cycle
(#907 510 001) Kohler
(#907 510) Kohler with GFCI
(#907 510 002) Kohler w/electric fuel pump*
(#907 512) EFI Kohler
(#907 512 001) EFI Kohler with Excel power
(#907 512 002) EFI Kohler with Excel power and
battery charge/jump start
(#907 512 003) EFI Kohler with Excel power and GFCI
CC/DC
Stick/TIG
10–325 A
325 A at 28 V,
100% duty cycle
Peak:
12,000 watts
11,000 watts (LP)
Continuous:
10,500 watts
9,500 watts (LP)
CV/DC
MIG/FCAW
10–35 V
325 A at 28 V,
100% duty cycle
(#907 566 001) Kubota
(#907 566) Kubota with GFCI
(#907 566 002) Kubota with Excel power
CC/DC
Stick/TIG
10–325 A
325 A at 33 V,
100% duty cycle
CV/DC
MIG/FCAW
10–35 V
325 A at 33 V,
100% duty cycle
Stock Number
Trailblazer
275
Gasoline
Trailblazer
325
Diesel
Welding
Mode
Model
Trailblazer
325 Diesel
Excel power (optional)
2,400 watts
20 A at 120 V, 60 Hz
pure generator power
at idle speed and
while welding.
Dimensions
Net
Weight
H: 28 in. (711 mm)
H: 32.75 in. (832 mm)
to top of exhaust
W: 20 in. (508 mm)
D: 40.5 in. (1,029 mm)
459 lb.
(208 kg)
H: 28 in. (711 mm)
H: 32.75 in. (832 mm)
to top of exhaust
W: 20 in. (508 mm)
D: 40.5 in. (1,029 mm)
460 lb.
(209 kg)
H: 28 in. (711 mm)
H: 34.5 in. (876 mm)
to top of exhaust
W: 20 in. (508 mm)
D: 45.5 in. (1,156 mm)
620 lb.
(281 kg)
71
Engine-Driven
Trailblazer 302 Air Pak
Heavy industrial
™
®
See literature no. ED/4.78
Processes
Powerful all-in-one tool designed for repair and construction with multiprocess weld quality,
generator power, air compressor and battery charge/jump start.
1
2
Superior arc performance. Preset dig settings optimized for the majority
of stick welding applications, best-in-class wire arc performance, and two
Lift-Arc™ TIG modes for most DC TIG applications.
Strongest combined generator/compressor power. Delivers an
industry-leading 13,000 watts of peak generator power independent of
weld settings — can power a Spectrum® 875 plasma cutter, and provide
air for plasma cutting at the same time (rated 5/8-inch mild steel).
Rotary screw air compressor. Delivers up to 31 cfm and 160 psi of
air with no storage tank. Gives 100 percent deliverable air and runs
many tools at idle speed. Air outputs are rated at an industry-high
104 degrees Fahrenheit (40°C). Front panel air pressure adjustment and
automatic overpressure shutdown with indication. Designed for more than
30,000 hours of operation and warranted for three years by Miller.
1
3
capable 1/4 in. carbons)
1 With
wire feeder.
Dynasty® 210 Series or
HF-251 (non-critical).
3 Two-piece TIG torch recommended.
2 With
Gasoline engine
Kohler CH750: 27 hp at 3,600 rpm
V-twin-cylinder, four-cycle, overhead
valve, industrial, air-cooled
Note: Engine is warranted separately
by engine manufacturer.
Most popular accessories
30A Aluminum
• Spoolmatic
Spool Gun / WC-24 Control
®
•
•
Battery charge/jump start. Provides selectable 12- or 24-volt battery
charging capability with up to 450 amps of battery jump-starting
capability. Convenient front panel battery charger/jump starter access.
See page 113
stick (SMAW)
• AC/DC
(GMAW) • Flux-cored (FCAW)
• MIG
/DC TIG (GTAW)
• ACAir carbon
arc cutting and gouging
• (CAC-A) (rated
3/16 in. carbons,
#130 831 / #137 549 (pg 19)
SuitCase® X-TREME™ 12VS (pg 42)
25 ft. Battery Charge/Jump Cables
with Plug #300 422
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Note: Battery charge/jump cables (#300 422) must be ordered separately.
Gasoline
*Recommended for operation at altitudes above 5,000 feet.
Stock Number
(#907 549 001) Kohler
(#907 549) Kohler with GFCI and electric fuel pump*
(#907 549 003) Kohler with GFCI, cooler/separator
and electric fuel pump*
Air Compressor
Welding
Mode
Process
Amp/Volt
Ranges
Rated Weld Output
at 104°F (40°C)
Single-Phase Generator
Power at 104°F (40°C)
CC/DC
Stick/TIG
10–300 A
280 A at 32 V, 100% duty cycle
CV/DC
MIG/FCAW
13–35 V,
350 A
300 A at 32 V, 100% duty cycle
350 A at 32 V, 60% duty cycle
Peak: 13,000 watts
Continuous: 11,000 watts
CC/AC
TIG/stick
10–225 A
200 A at 25 V, 60% duty cycle
Net
Weight
Dimensions
H: 28 in. (711 mm)
H: 34.5 in. (876 mm) to top of exhaust
W: 20 in. (508 mm)
D: 59.625 in. (1,514 mm)
771 lb.
(350 kg)
Features
Free Air Delivery
at 3,600 RPM
Free Air Delivery
at 3,000 RPM
Free Air Delivery
at 2,400 RPM (idle)
Working Pressure
Constant
Duty
Cycle
Oil
Capacity
Rotary screw with electric clutch for on/off,
oil change intervals of 500 hours
31 cfm
(0.88 m3/min.)
28 cfm
(0.79 m3/min.)
22 cfm
(0.62 m3/min.)
80–160 psig
100%
1.75 qt.
(1.7 L)
Bobcat™ Diesel • Trailblazer®Diesel • Big Blue®350 PipePro®• Big Blue®400 Pro
Big Blue®450 Duo CST ™ • Big Blue®500 Pro • Big Blue®600 Pro
Big Blue®800 Duo Pro • Big Blue®800 Duo Pro SF • Big Blue®800 Duo Air Pak™
EPA Tier 4 Final
Cleaner Equipment, Cleaner Air
Tier 4 Final (T4F) is the U.S. Environmental
Protection Agency’s (EPA’s) latest step in a series
of increasingly strict emission standards for diesel
engines. It has resulted in diesel engines that
not only operate more cleanly, but also produce
power more efficiently. As the world becomes
more environmentally conscious to care for future
generations; Miller has redesigned its diesel
engine-driven welder/generator product line.
For every job, there’s a Miller®welder/generator to get the
job done right.
Selecting the right size of welder/generator helps maximize your resource efficiency and
reduce your emissions footprint. Demanding tasks such as welding thick metals and
gouging large-diameter carbons may require amperage that only a higher-horsepower
machine can provide. Jobs requiring less amperage often can be handled by machines
having less than 25 hp, which are not subject to the same T4F regulations.
Learn more at MillerWelds.com/tier4
72
Engine-Driven
Tier 4 Final (T4F) questions?
Call 920.831.4851 or email
[email protected]
Big Blue 350 PipePro
®
®
Heavy industrial
See literature no. ED/5.4
Processes
Designed for transmission pipeline work, this system offers a complete welding solution. With
stick as well as MIG/FCAW welding capabilities it is ideal for the most demanding pipeline jobs.
Easy arc starts and better arc control provide improved
performance to produce more consistent welds.
Enhanced MIG/FCAW arc control for best in
class performance.
The vault — ultimate control board reliability. A sealed
aluminum case protects the circuit board from dust, dirt,
moisture and heat.
Low OCV stick (VRD) for improved operator safety
without compromising arc starts.
Auto Remote Sense™ (ARS) eliminates confusion of a
remote/panel switch.
Compact size and weight optimizes truck space.
LINE-X® cover provides superior impact, corrosion and
abrasion protection.
Quiet operation. Only 70.7 decibels (95.5 Lwa) under
full load. Improves jobsite communication and safety.
EPA, CSA, IEC and NEMA compliant.
Standard features include digital preset weld meters, auto
idle, 120-volt block heater and output contactor control.
Optional stainless steel package available.
See page 113.
Wireless
antenna kit
(#300 749)
recommended.
System components (order items separately)
Miller® Big Blue 350 PipePro engine drive
Miller SuitCase® X-TREME ™ wire feeder
(now both 8VS and 12VS meet PipePro system needs,
see page 43 for specs)
Bernard™ PipePro Dura-Flux™ gun
Hobart® Fabshield® 71T8/X80 wire
Miller wireless remote hand control
•
•
Diesel
•
•
•Visit MillerWelds.com/pipepro for complete information and spec sheets.
Stock Number
Big Blue 350 PipePro (engine drive only)
(#907 478) CAT Turbo
(#907 478 001) CAT Turbo w/stainless steel
(#907 428) Mitsubishi
(#907 428 001) Mitsubishi w/stainless steel
Welding
Mode
Process
Amp/Volt
Ranges
CC/DC
TIG/stick
20–400 A
CV/DC
MIG/FCAW
14–40 V
Big Blue 400 Pro
®
Rated Output at 104°F (40°C)
300 A at 32 V, 100% duty cycle
350 A at 27 V, 100% duty cycle
400 A at 24 V, 100% duty cycle
Single-Phase Generator
Power at 104°F (40°C)
Peak: 12,000 watts
Continuous: 10,000 watts
Diesel
Stock Number
(#907 606) Kubota
(#907 605) Mitsubishi
Diesel engines
EPA Tier 4 Final choices
CAT C1.5T: 24.7 hp at 1,800 rpm
Turbo 3-cylinder, industrial, liquid-cooled
Mitsubishi S4L2: 24.7 hp at 1,800 rpm
Four-cylinder, industrial, liquid-cooled
Note: Engines are warranted separately
by engine manufacturer.
Big Blue 350 PipePro System
(order items separately)
Big Blue 350 PipePro engine drive
SuitCase X-TREME feeder
with Bernard PipePro Dura-Flux gun
#951 593 8VS
#951 592 12VS
Bernard PipePro Dura-Flux gun with
10 ft. (3 m) cable #301 011
(included with feeders above)
Hobart Fabshield wire
#S228519-P32 FS 71T8 1/16 in.
#S228525-P32 FS 71T8 5/64 in.
#S228825-P32 FS X80 5/64 in.
Wireless Remote Hand Control/
Wireless Antenna Kit
#300 430/#300 749 (pg 113)
•
•
•
•
•
Visit MillerWelds.com or your distributor
for Miller® options and accessories.
Dimensions
Net Weight
H: 32 in. (813 mm)
W: 26.25 in. (667 mm)
D: 56 in. (1,422 mm)
Caterpillar
1,063 lb. (482 kg)
Mitsubishi
1,018 lb. (462 kg)
Heavy industrial
See literature no. ED/5.7
Processes
(SMAW) • MIG (GMAW)
• Stick
(FCAW) • TIG (GTAW)
• Flux-cored
carbon arc cutting and gouging
• Air(CAC-A)
(rated 3/16 in. carbons)
Clean, quiet and reliable low-speed EPA-compliant diesel is more efficient than ever before.
Ideal for construction, piping and fleet use.
See page 113. Wireless antenna kit
(#300 749) recommended.
(SMAW) • MIG (GMAW)
• Stick
(FCAW) • TIG (GTAW)
• Flux-cored
carbon arc cutting and gouging
• Air(CAC-A)
(rated 1/4 in. carbons)
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 aluminum 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.
EPA, CSA, IEC and NEMA compliant.
Standard features include digital weld meters, auto idle, 120-volt block
heater and output contactor control.
Welding
Mode
Process
Amp/Volt
Ranges
CC/DC
TIG/stick
20–400 A
CV/DC
MIG/FCAW
14–40 V
Rated Output at 104°F (40°C)
300 A at 32 V, 100% duty cycle
350 A at 27 V, 100% duty cycle
400 A at 24 V, 100% duty cycle
Single-Phase Generator
Power at 104°F (40°C)
Peak: 12,000 watts
Continuous: 10,000 watts
Diesel engines
EPA Tier 4 Final choices
Kubota V1505: 20.2 hp at 1,800 rpm
Four-cylinder, industrial, liquid-cooled
Mitsubishi S4L2: 24.7 hp at 1,800 rpm
Four-cylinder, industrial, liquid-cooled
Note: Engines are warranted separately
by engine manufacturer.
Most popular accessories
Feeders (pg 42)
• SuitCase
210 Series (pg 54)
• Dynasty
875 (pg 82)
• Spectrum
Cover #195 301 (pg 108)
• Protective
Remote Hand Control/
• Wireless
Wireless Antenna Kit
®
®
®
#300 430/#300 749 (pg 113)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Dimensions
Net Weight
H: 32 in. (813 mm)
W: 26.25 in. (667 mm)
D: 56 in. (1,422 mm)
Kubota 950 lb. (431 kg)
Mitsubishi 993 lb. (450 kg)
73
Engine-Driven
Big Blue 500 and 600 Pro
®
See literature no.
ED/11.0 (500) and ED/11.5 (600)
Clean, quiet, multiprocess machines designed to give welders the output they need for
heavy-duty applications on construction and fabrication sites.
Heavy industrial
Processes
(SMAW) • MIG (GMAW)
• Stick
(FCAW) • DC TIG (GTAW)
• Flux-cored
carbon arc cutting and gouging
• Air(CAC-A)
(500: rated 5/16 in. carbons;
600: rated 3/8 in. carbons)
Diesel engines
See page 113.
Wireless antenna kit
(#300 749)
recommended.
EPA Tier 4 Final choices
500 Pro — Deutz D2.9 L4
34.8 hp at 1,800 rpm
Four-cylinder, industrial, liquid-cooled
500 Pro — Perkins 404D.22
32.6 hp at 1,800 rpm
Four-cylinder, industrial, liquid-cooled
600 Pro — Kubota V2403
48.9 hp at 1,800 rpm
Four-cylinder, industrial, liquid-cooled
EPA Tier 4i CA model
500 Pro — Deutz D2011L03
32 hp at 1,800 rpm
Three-cylinder, industrial, air/oil-cooled
Note: Engines are warranted separately
by engine manufacturer.
CA models NOT
available for sale
in the USA!
Most popular accessories
Big Blue 500 Pro
(Deutz T4 Final)
Deluxe models shown with
vandalism lockout removed.
Big Blue 600 Pro
®
Auto Remote Sense™ (ARS) detects if a remote control
is plugged into the 14-pin receptacle and eliminates
confusion of a remote/panel switch.
Electronic engine display
simultaneously displays fuel level,
engine hours, coolant temperature,
oil pressure, battery volts, and
engine rpm. Also tracks oil change
intervals and displays engine
diagnostics for quick and easy servicing.
Not available on Perkins or CA (Tier 4i)
models which use meter maintenance
displays as seen in smaller inset photo.
X-TREME 8VS/12VS
• SuitCase
(pg 42)
KVA Adapter Cord #300 517
• Full
(pg 108)
KVA Plug Kit (pg 108)
• Full
#119 172 Single-phase
Thermal overload protection prevents machine damage
if the duty cycle is exceeded or airflow is blocked.
•
•
EPA, CSA, IEC and NEMA compliant.
•
Standard features include digital
preset weld meters, automatic idle,
and cold weather starting aids.
™
#254 140 Three-phase
Protective Covers (pg 108)
#301 113 Deutz/Kubota T4F models
#194 683 Perkins/Deutz CA models
Wireless Remote Hand Control/
Wireless Antenna Kit
#300 430/#300 749 (pg 113)
Spark Arrestor Kit #195 012
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Infinite arc control allows the arc characteristics to
be changed for specific applications in stick, MIG and
flux-cored welding.
Deluxe model adds a polarity
reversing switch and a vandalism
lockout (protects control panel and
Low OCV stick (VRD) for improved operator safety without receptacles, see photo at right).
compromising arc starts.
Amp/Volt
Ranges
Tier 4 Final
(#907 561) Deutz
(#907 561 001) Deutz Deluxe model
(#907 667) Perkins
(#907 667 001) Perkins Deluxe model
Tier 4i CA model (NOT available for sale in the USA)
(#907 635) Deutz
(#907 635 001) Deutz Deluxe model
CC/DC
(Stick/TIG)
20–500 A
CV/DC
(MIG/FCAW)
14–40 V
Tier 4 Final
(#907 695) Kubota
(#907 695 001) Kubota Deluxe model
CC/DC
(Stick/TIG)
20–600 A
CV/DC
(MIG/FCAW)
14–44 V
Big Blue
500 Pro
Diesel
Stock Number
Big Blue
600 Pro
74
Welding
Mode/Process
Model
Rated Output at 104°F (40°C)
Generator Power at
104°F (40°C)
Dimensions
Net Weight
Deutz T4F models
400 A at 36 V, 100% duty cycle
450 A at 38 V, 60% duty cycle
500 A at 38 V, 40% duty cycle
Perkins/Deutz CA models
400 A at 36 V, 100% duty cycle
450 A at 33 V, 60% duty cycle
500 A at 30 V, 40% duty cycle
Three-phase
Peak: 21,000 watts
Continuous: 15,000 watts
Single-phase
Peak: 15,000 watts
Continuous: 12,000 watts
Deutz T4F models
H: 46 in. (1,168 mm)
W: 28.5 in. (724 mm)
D: 69.5 in. (1,765 mm)
Perkins/Deutz CA models
H: 42 in. (1,067 mm)
W: 28.5 in. (724 mm)
D: 65.125 in. (1,654 mm)
Deutz T4F models
1,800 lb. (816.5 kg)
Perkins models
1,530 lb. (694 kg)
Deutz CA models
1,550 lb. (703 kg)
500 A at 40 V, 100% duty cycle
550 A at 42 V, 60% duty cycle
600 A at 42 V, 40% duty cycle
Three-phase
Peak: 27,000 watts
Continuous: 20,000 watts
Single-phase
Peak: 15,000 watts
Continuous: 12,000 watts
H: 46 in. (1,168 mm)
W: 28.5 in. (724 mm)
D: 69.5 in. (1,765 mm)
1,750 lb. (794 kg)
Engine-Driven
Tier 4 Final (T4F) questions?
Call 920.831.4851 or email
[email protected]
Big Blue 450 Duo CST
®
Heavy industrial
™
See literature no. ED/5.5
Processes
Durable dual-operator welder/generator delivers proven CST 280 stick/TIG performance for
maximum productivity and efficiency. Two separate outputs powered by one low-speed diesel
engine delivers up to 280 amps of output per operator.
(SMAW) • TIG (GTAW)
• Stick
carbon arc cutting and gouging
• Air(CAC-A)
(rated 3/16 in. carbons,
capable 1/4 in. carbons)
Diesel engine
Diesel
See page 113. Wireless antenna kit
(#300 749) recommended.
Stock Number
(#907 477)
Mitsubishi
Two superior arcs in one compact package. See CST 280 (page 50)
for additional details.
Save fuel, reduce maintenance costs and increase productivity.
Quiet operation. At 72.2 decibels (97 Lwa) under full load,
it’s quieter than most single-operator models. Improves jobsite
communication and safety.
Vandalism lockout kit (not shown). Lockable hinged steel panel
protects front control and ignition switch.
Simple-to-operate process selector knob automatically sets proper
DIG setting on E6010 and E7018 electrodes providing superior
stick performance.
Lift-Arc™ start for TIG starts without the use of high frequency.
Remote amperage control permits the use of standard and wireless
amperage control devices.
Increased efficiency. More arcs and better fuel economy equal
increased profits for your business. Estimated savings are 34 percent
with a dual-operator unit versus two single-operator units.
Process
Output Mode
Amperage Range
Rated Output at 122°F (50°C)
Single-Phase Generator
Power at 122°F (50°C)
DC stick/TIG
Separate (dual outputs)
5–225 A (each side)
5–280 A (one side only)
175 A at 27 V, 100% duty cycle
Continuous: 10,000 watts
Paralleled (combined)
10–450 A
350 A at 27 V, 100% duty cycle
Big Blue 700 Duo Pro
®
Diesel
See page 113. Wireless Antenna Kit
(#300 749) recommended.
Stock Number
(#907 461)
Deutz
Note: Engine is warranted separately
by engine manufacturer.
Most popular accessories
875 (pg 82)
• Spectrum
Full
KVA
Adapter
• (pg 108) Cord #300 517
Full KVA Plug Kit
• Single-Phase
#119 172 (pg 108)
Cover #195 301 (pg 108)
• Protective
Wireless
Remote
Control/
• Wireless AntennaHand
Kit
®
•
#300 430/#300 749 (pg 113)
Spark Arrestor Kit #195 012
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Net
Weight
Dimensions
H: 32 in. (813 mm)
W: 26.25 in. (667 mm)
D: 56 in. (1,422 mm)
1,064 lb.
(483 kg)
Heavy industrial
See literature no. ED/5.6
Processes
Complete multiprocess and multioperator welder/generator in one rugged package. Up to 400 amps
of output per operator can be paralleled with a single switch to provide up to 800 amps of power.
NOT available
for sale in
the USA!
EPA Tier 4 Final
Mitsubishi S4L2: 24.7 hp at 1,800 rpm
Four-cylinder, industrial, liquid-cooled
Two independent pipe quality arcs in one compact package.
Multiprocess CC/CV provides independent operator controls and the
best stick, flux-cored and TIG performance available with no interaction.
Easy arc starts and better arc control for best-in-class performance.
Quiet operation. At 74.7 decibels (99.5 Lwa) under full load,
it’s quieter than many single-operator models. Improves jobsite
communication and safety.
Independent remote control connections allow the use of standard
and wireless volt/amperage control devices for each operator.
Compatible with Big Blue® 350 PipePro® system components
(see page 73).
Standard features include oil pan heater, intake manifold heater,
output paralleling switch and automatic idle.
Increased efficiency. More arcs and better fuel economy equal
increased profits for your business. Estimated savings are 34 percent
with a dual-operator unit versus two single-operator units.
(SMAW) • MIG (GMAW)
• Stick
Flux-cored
• Air carbon (FCAW)
• TIG (GTAW)
arc cutting and gouging
• (CAC-A) (rated
3/8 in. carbons)
Diesel engine
EPA Tier 4i
Deutz D2011L04i: 48.6 hp at 1,800 rpm
Four-cylinder, industrial, air/oil-cooled
Note: Engine is warranted separately
by engine manufacturer.
Most popular accessories
X-TREME 8VS/12VS
• SuitCase
(pg 42)
KVA Adapter Cord #300 517
• Full
(pg 108)
KVA Plug Kit (pg 108)
• Full
#119 172 Single-phase
®
•
•
•
™
#254 140 Three-phase
Protective Cover #194 683 (pg 108)
Wireless Remote Hand Control/
Wireless Antenna Kit
#300 430/#300 749 (pg 113)
Spark Arrestor Kit #195 012
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Process
Output Mode
Amp/Volt Ranges
Rated Output at 104°F (40°C)
Generator Power at 104°F (40°C)
Dimensions
Net Weight
DC stick/TIG/
MIG/FCAW
Separate
(dual outputs)
20–400 A
14–40 V
300 A at 28 V, 100% duty cycle
400 A at 36 V, 40% duty cycle
40–800 A
14–40 V
500 A at 34 V, 100% duty cycle
700 A at 24 V, 60% duty cycle
H: 43 in. (1,092 mm)
W: 28.5 in. (724 mm)
D: 65.125 in. (1,654 mm)
1,729 lb.
(784 kg)
Paralleled
(combined)
Single-phase: 4,000 watts continuous
Additional generator power
Three-phase: 20,000 watts continuous or
Single-phase: 12,000 watts continuous
75
Engine-Driven
Big Blue 800 Series
®
Heavy industrial
See literature no. ED/14.0
Processes
(SMAW) • MIG (GMAW)
• Stick
Flux-cored (FCAW) • DC TIG (GTAW)
• RMD*
MIG (GMAW-P)*
• Air carbon
• Pulsed
arc
cutting
gouging
• (CAC-A) (rated 1/2 in.andcarbons)
• Stud (1/2 in.)
The most powerful lineup of diesel welder/generators in the industry. All offer robust output for
welding and power generation, and are ideal for dual-operator applications on labor intensive
jobsites, or jobsites with limited space.
*Big Blue 800 Duo Pro SF model only.
Diesel engines
EPA Tier 4 Final models
Deutz TD2.9 L4
65.7 hp at 1,800 rpm
Turbo-charged, four-cylinder, industrial,
liquid-cooled
EPA Tier 4i CA model
Deutz TD2011L04i
63.4 hp at 1,800 rpm
Turbo-charged, four-cylinder, industrial,
air/oil-cooled
See page 113.
Wireless Antenna Kit
(#300 749)
recommended.
Note: Engines are warranted separately
by engine manufacturer.
CA model NOT
available for sale
in the USA!
Big Blue 800
Duo Pro
Diesel
*Big Blue 800 Duo Air Pak has welder truck specific models
available — visit MillerWelds.com or your distributor.
Model/Stock Number*
Tier 4 Final
Big Blue 800 Duo Pro (#907 587) Deutz
Big Blue 800 Duo Pro SF (#907 587 002) Deutz
Big Blue 800 Duo Pro SF (#951 655)
Deutz with FieldPro smart feeder and MIG gun
Big Blue 800 Duo Air Pak (#907 535) Deutz
Tier 4i Big Blue 800 Duo Air Pak CA model
(NOT available for sale in the USA) (#907 634) Deutz
Ingersoll Rand CE55 G1
Air Compressor
(Air Pak only)
76
Welding
Mode/Process
CC/DC
(Stick/TIG)
CV/DC
(MIG/FCAW)
Smart Feeder
• FieldPro
(Duo Pro SF model only) #300 935
™
Big Blue 800
Duo Air Pak
Big Blue 800
Duo Pro SF
Multi-arc welding. One dependable engine — two
independent arcs with up to 400 amps each. Or plug
in additional inverters for a true multioperator work
platform! Example: Two additional XMT machines equals
four operators, up to 200 amps each. Premium quality
arcs allow operators to work independently with no arc
interaction. Multioperator welding has never been easier
or more versatile.
Ingersoll Rand ultra-reliable industrial rotary screw
compressor (Air Pak model only). 30,000-hour life
expectancy. Independent on/off control for applications
not requiring compressed air — allows greater fuel savings
and longer compressor service intervals.
Smart feeder compatible (SF model
only). Advanced RMD® and pulsed
MIG processes are now available in
an engine-driven welder/generator.
Discover increased productivity, quality,
and improved efficiency in field welding
with the new Big Blue 800 Duo Pro SF
with FieldPro™ Smart Feeder.
Low OCV stick (VRD) reduces the open-circuit voltage
to 15 volts when the welding power source is not in use,
increasing operator safety without compromising arc starts.
Most popular accessories
(pg 38)
X-TREME 8VS/12VS
• SuitCase
(pg 42)
KVA Adapter Cord #300 517
• Full
(pg 108)
KVA Plug Kit (pg 108)
• Full
#119 172 Single-phase
®
Auto Remote Sense™ (ARS) detects if a remote control
is plugged into the 14-pin receptacle and eliminates
confusion of a remote/panel switch.
Electronic engine display simultaneously displays fuel
level, engine hours, coolant temperature, oil pressure,
battery volts and engine rpm. Also tracks oil change
intervals and displays engine diagnostics for easier
servicing. Air Pak model adds air pressure and
compressor hours displays.
Increased efficiency. More arcs and better fuel
economy equal increased profits for your business.
Estimated savings are 34 percent with a dual-operator
unit versus two single-operator units.
Infinite arc control allows the arc characteristics to
be changed for specific applications in stick, MIG and
flux-cored welding.
Thermal overload protection prevents machine damage
if the duty cycle is exceeded or
airflow is blocked.
Standard features include digital
weld meters, automatic idle, 120-volt
block heater, lockout/tagout battery
disconnect switch and vandalism
lockout (protects control panel and
receptacles, see photo at right).
™
#254 140 Three-phase
Cover #301 113 (pg 108)
• Protective
Remote Hand Control/
• Wireless
Wireless Antenna Kit
#300 430/#300 749 (pg 113)
Air Dry System
• Desiccant
(Air Pak only)
•
#195 117
Side mount
#195 117 001 Rear mount
Eliminates moisture in the air stream
and prevents air line freeze-ups in
cold climates.
Spark Arrestor Kit #195 012
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Output Mode
Amp/Volt
Ranges
Rated Output at 100% Duty
Cycle at 104°F (40°C)
Generator Power
at 104°F (40°C)
Dimensions
Net Weight
Separate (dual outputs)
20–400 A
400 A at 36 V (each side)
Paralleled (combined)
40–800 A
700 A at 44 V, 800 A at 38 V
Separate (dual outputs)
14–40 V
400 A at 34 V (each side)
Paralleled (combined)
14–40 V
750 A at 40 V, 800 A at 38 V
Three-phase
Peak: 27,000 watts
Continuous: 20,000 watts
Single-phase
Peak: 15,000 watts
Continuous: 12,000 watts
H: 46 in.
(1,168 mm)
W: 28.5 in.
(724 mm)
D: 69.5 in.
(1,765 mm)
Duo Pro
1,869 lb. (848 kg)
Duo Pro SF
1,930 lb. (875 kg)
Duo Air Pak
2,095 lb. (968 kg)
Features
Free Air Delivery
Working Pressure Constant
Duty Cycle
Oil Capacity
Automatic Compressor Shutdowns
Rotary screw with electric clutch for on/off, oil change
intervals of 500 hours, life expectancy of 30,000 hours
Idle: 40 cfm (1.13 m3/min.)
Weld: 60 cfm (1.70 m3/min.)
100 psig (7 bar)
100%
4 qt. (3.79 L)
Oil temperature
For more detailed
information, visit
MillerWelds.com/spotwelders
Spot Welders
Tongs
Tongs and tips. Miller offers a wide variety of both symmetrical and
asymmetrical tong and tip configurations. Maximum capabilities of
spot welders are obtained with minimum tong lengths. Tips are
made of durable Class 2, long-wearing copper alloy.
See literature no. SW/1.0 for full range of tongs and tips.
Standard
Air-Cooled Spot Welders
Tips
Optional
Standard
See literature no. SW/1.0
Flat
Offset
Process
• Resistance Spot Welding
MSW and LMSW Series lightweight, air-cooled units are portable, easy to operate, and provide
a quick and effective means for spot welding mild, galvanized or stainless materials.
Note: Not recommended for welding
aluminum, copper or copper alloys.
Most popular accessories
“T” models include timer panel with a 0 to 5 second weld timer and power
on/off switch. Timer panel can be mounted on the optional SWP-2 pedestal
or any other convenient location. Includes 10-foot (3 m) input power and
interconnecting cords.
Hand lever locks tongs firmly on material, ensuring positive, accurate fit-up.
Accommodates a wide variety of tongs and tips (ordered separately).
Quick and easy adjustment for material thickness.
Reversible for left- or right-hand operation.
*Tongs and tips must be ordered separately — see literature no. SW/1.0 for full range of tongs and tips.
Work Capacity (Combined
thickness uncoated mild steel using
6 in. [152 mm] tongs)
Rated Output
Bail
• Gyro
#041 979
•
Supports weight of
welder. Operates
with boom and
counterweight or from spring-loaded
cable (sold separately). Spot welds in
any position.
Spot Welder Pedestal #040 872
Note: Tongs/tips must be ordered
separately. One standard set of tips is
supplied with each set of tongs; see
diagram above.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Rated Output Calibrated with Standard-Type Tongs
6 in. (152 mm) 12 in. (305 mm) 18 in. (457 mm)
Max OpenCircuit
Voltage
Model/Stock Number*
Input Power
Dimensions
Net Weight
MSW-41 (#900 371)
MSW-41T (#901 345)
with timer
110 V,
30 A,
50/60 Hz
1/8 in. (3.2 mm) or two pieces of
20 ga. (1.8 mm) galvanized steel
1.5 kVA at
50% duty cycle
5,550 A
4,500 A
3,600 A
1.6 VAC
H: 6 in. (152 mm)
W: 3.75 in. (95 mm)
D: 13 in. (330 mm)
22 lb. (10 kg)
34 lb. (15 kg)
with timer
LMSW-52 (#900 377)
LMSW-52T (#901 357)
with timer
220 V,
30 A,
50/60 Hz
3/16 in. (4.7 mm) or two pieces of
16 ga. (3.0 mm) galvanized steel
2.5 kVA at
50% duty cycle
6,750 A
5,800 A
4,850 A
2.5 VAC
H: 6 in. (152 mm)
W: 3.75 in. (95 mm)
D: 16 in. (406 mm)
30 lb. (14 kg)
42 lb. (19 kg)
with timer
MillerWeldsStore.com
Buy Miller®Gear Online. Shirts, hats, mugs, banners and more!
77
Submerged Arc
For more detailed
information, visit
MillerWelds.com/subarc
Miller offers an array of versatile Submerged Arc components, including power sources,
controls, wire drives, torches, tractors and a variety of other accessories.
SubArc Digital Series
Heavy industrial
SubArc DC Series
is DC only.
See literature no. AD/7.3
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.
Processes
arc (SAW)
• Submerged
(ESW)
• Electroslag
carbon arc cutting and gouging
• Air(CAC-A)
Most popular accessories
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
IP-23 rated providing a high level of
protection for harsh environments.
SubArc DC
1000 Digital
SubArc DC
650 Digital
m) SubArc Parallel Cable
• 15#260ft. (4.6
775 015 (pg 111)
m) SubArc Tandem Cable
• 15#260ft. (4.6
878 015 (pg 111)
Insight Core Module #301 072
• 14-pin
(requires Insight Core to SubArc
Digital Series Adapter Kit #301 295)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Easy to integrate. Our SubArc
power sources are easy to integrate
by using a standard Modbus®
connection.
SubArc AC/DC
1000 Digital
All power sources also feature
thermal overload protection,
line voltage compensation and
Fan-On-Demand.™
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).
*While idling.
Amperage Range
(CC Mode)
Voltage Range
(Subarc Mode)
SubArc DC 650 Digital
(#907 622) 230/460/575 V
50–815 A
SubArc DC 1000 Digital
(#907 624) 230/460/575 V
SubArc AC/DC 1000 Digital
(#907 620) 460 V
Model/Stock Number
Rated Output
Amps Input at Rated Output, 60 Hz
230 V 460 V 575 V KVA KW
Max OpenCircuit Voltage
Dimensions (Includes lift eye,
but not strain relief)
20–44 V
650 A at 44 V,
100% duty cycle
126 63
50.4 50
34.8
3.8* 1.9* 1.4* 1.52* 0.76*
75 Vpk
593 lb.
(269 kg)
100–1,250 A
20–44 V
1,000 A at 44 V,
100% duty cycle
180 90
72
73
5.8* 2.9* 2.4* 3.2*
68 Vpk
H: 30 in. (762 mm)
W: 23 in. (584 mm)
D: 38 in. (965 mm)
300–1,250 A
20–44 V
1,000 A at 44 V,
100% duty cycle
—
—
H: 43 in. (1,092 mm)
W: 28 in. (711 mm)
D: 48 in. (1,219 mm)
1,187 lb.
(538 kg)
SubArc Interface Controls
122 —
3.0* —
53
0.5*
98
53
2.37* 0.95*
93 Vpk
682 lb.
(309 kg)
Most popular accessories
Control Cables (pg 111)
• SubArc
#260 622 030 30 ft. (9 m)
See literature no. AD/7.3
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.
Internal terminal strip is able to integrate with
positioners, sidebeams, turning rolls and other
peripheral equipment.
SubArc Interface Digital
Net Weight
#260 622 050
#260 622 080
#260 622 100
#260 622 120
#260 622 200
50 ft. (15 m)
80 ft. (24.4 m)
100 ft. (30.5 m)
120 ft. (36.6 m)
200 ft. (61.0 m)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
SubArc Interface Analog
Input Power from
Welding Power Source
Welding Power Source Type
Dimensions
Net Weight
SubArc Interface Digital (#300 936)
24 VAC, 1-phase,
25 A, 50/60 Hz
Constant voltage (CV), AC or DC, with remote contactor
and output control capabilities
18 lb.
(8.2 kg)
SubArc Interface Analog (#300 937)
24 VAC, 1-phase,
25 A, 50/60 Hz
Constant current (CC), constant voltage (CV), DC, with
remote contactor and output control capabilities
H: 7 in. (178 mm)
W: 11.25 in. (286 mm)
D: 11.5 in. (292 mm)
Model/Stock Number
78
Submerged Arc
SubArc Wire Drive Assemblies
Most popular accessories
See literature no. AD/7.3
SubArc Strip Drive 100 Digital Low Voltage
is a heavy-duty, right-angle 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.
SubArc Strip Drive 100
Digital Low Voltage
SubArc Wire Drive 400
Digital Low Voltage
Extension Cables (pg 111)
• Motor
#254 232 005 5 ft. (1.5 m)
•
•
•
•
#254 232 010 10 ft. (3 m)
#254 232 025 25 ft. (7.6 m)
#254 232 065 65 ft. (19.8 m)
Single-Wire Straightener #199 733
(pg 111)
Twin-Wire Straighteners
(for Twin-Wire torches only) (pg 111)
#301 160 Single adjustment
#301 162 Double/separate adjustment
Drive Rolls (pg 111)
Manual Slides (pg 111)
#301 137 Single slide
#301 138 Cross slide
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
*Includes adapter plate allowing mounting to 2.5-, 4.25-, and 4.625-inch bolt-hole patterns.
Model
Stock Number
Input Power
Input Power Cord
Rating
Wire Feed Speed
Wire Diameter Capacity
Net Weight
SubArc Strip Drive 100
Digital Low Voltage
(#300 939) Drive only
(#300 940)* With mounting bracket
38 VDC
4 ft. (1.2 m)
1/5 hp, 21 rpm
10–69 ipm
(0.3–1.6 m/min.)
N/A (strip cladding applications)
20 lb. (9.1 kg)
SubArc Wire Drive 400
Digital Low Voltage
(#300 938)* Standard speed
(#300 938 001) Standard speed,
for use with tractor
38 VDC
4 ft. (1.2 m)
1/5 hp, 85 rpm
30–400 ipm
(0.8–10.2 m/min.)
3/32–3/16 in. (2.4–4.8 mm)
33 lb. (15 kg)
SubArc Wire Drive 780
Digital Low Voltage
(#300 941)* High speed
38 VDC
4 ft. (1.2 m)
1/4 hp, 143 rpm
50–780 ipm
(1.3–19.8 m/min.)
1/16–1/8 in. (1.6–3.2 mm)
33 lb. (15 kg)
SubArc Torches
Most popular accessories
600 Torch Body Extensions
• OBT
(pg 111)
See literature no. AD/7.3
OBT 600 (#043 923) is a 600-amp, 100 percent duty cycle torch
with concentric flux flow nozzle. Can be used with 1/16–3/16 inch
(1.6–4.8 mm) wire.
OBT 1200 (#043 900) is a 1,200-amp, 100 percent duty
cycle torch with concentric flux flow nozzle. Can be used with
1/16–3/16 inch (1.6–4.8 mm) wire. OBT 1200 features a
replaceable breakaway adapter end to prevent costly damage
should torch run into an obstruction.
OBT 600
OBT 1200
1200-Amp Twin-Wire
•
•
#043 967 1 inch (25.4 mm)
#043 969 2 inch (50.8 mm)
#043 973 4 inch (101.6 mm)
#043 975 6 inch (152.4 mm)
OBT 1200 Torch Body Extension
#043 981 (pg 111)
Contact Tips (pg 111)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
1200-Amp Single-Wire Torch (#301 141 short)
1200-Amp Twin-Wire Torch (#301 143 short, #301 144 long)
Both of the short torches are 11.3 inches (288 mm) in length and
the long torch is 16.8 inches (427 mm). The single-wire torch uses
1/16–5/32 inch (1.6–4.0 mm) consumables and the twin-wire
torches use 3/64–3/32 inch (1.2–2.4 mm) consumables.
SubArc Flux Hopper
Most popular accessories
Flux Hopper Extension Cables (pg 111)
• #260
623 010 10 ft. (3 m)
See literature no. AD/7.3
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.
#260 623 025 25 ft. (7.6 m)
#260 623 065 65 ft. (19.8 m)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
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.
Model/Stock Number
Input Power
Input Power Cord
Flux Capacity
Net Weight
SubArc Flux Hopper Digital Low Voltage (#300 942)
12 VDC (PWM signal from SubArc Interface)
11 ft. (3.3 m)
25 lb. (11 kg)
23 lb. (10.4 kg)
79
Submerged Arc
SubArc Tractor
Tractor with remote start/stop
• SubArc
control and guide rolls
Interface weld controller
• SubArc
(analog or digital)
Wire Drive 400 for Tractor
• SubArc
• 25withlb.valve(11.3 kg) capacity flux hopper
kg) wire reel
• 60OBTlb.600(27torch
• Wire straightener
•
Most popular accessories
Control Cables (pg 111)
• SubArc
Tips (pg 111)
• Contact
Drive
Rolls
(pg 111)
•
See literature no. AD/7.5
Designed and built to provide maximum reliability in the toughest
conditions. This simple-to-use self-propelled submerged arc welding
tractor can easily connect to SubArc DC or AC/DC Digital power supplies.
Vertical, horizontal and rotary torch adjustment allows for greater
access to hard-to-reach spots.
Heavy-duty, four-wheel, chain-driven trackless operation with rubber
wheels provides superior and reliable mobility.
Manual clutch enables freewheeling movement of the tractor.
Travel speed is precisely controlled by a closed-loop microprocessor
control with tach feedback.
Digital weld
controller package
shown.
Stock Number
(#951 614) with
SubArc Interface Digital
(#951 615) with
SubArc Interface Analog
Packages include
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Input Power from Welding Power Source
Wire Feed Speed
Wire Diameter Capacity
Gun Positioning Slides
Drive Motor
Travel Speed
Dimensions
Net Weight
24 VAC, 1-phase, 50/60 Hz, 200 watts
30–400 ipm
(0.8–10.2 m/min.)
1/16–3/16 in.
(1.6–4.8 mm)
4 in. (101.6 mm)
vertical and horizontal
24 VDC
permanent
magnet gear
motor
4–66 ipm
(10–168 cm/min.)
H: 43.375 in. (1,102 mm)
W: Varies depending on
system configuration
D: 35.5 in. (903 mm)
162 lb.
(73 kg)
without flux
or wire
SubArc Portable Welding System
Self-contained system for pressure vessel, pipe and general
welding applications. Houses a power source, mast and boom
on a mobile platform.
Built-in fork pockets and caster wheels allows welding system
to be brought to the joint.
Ease of positioning the weld head through use of integrated
motorized mast, manual telescoping boom, cross slides and
360-degree mast rotation.
Motorized mast with pendant control and manual
telescoping boom provide 44 inches (1,117 mm) of vertical
travel and 31 inches (787 mm) of horizontal travel respectively.
Manual cross slides provide 7.87 inches (200 mm) of fine
vertical and horizontal torch adjustment.
Available
1st quarter!
SubArc DC 650
Digital portable
system shown.
Stock Number
(#951 675) w/SubArc DC 650 Digital
(#951 676) w/SubArc DC 1000 Digital
(#951 677) w/SubArc AC/DC 1000 Digital
(See page 78 for power source specs)
See literature
no. AD/7.6
Supply Voltage
120 V, 1-phase, 60 Hz
(See page 78 for power
source requirement)
Mast
Stroke
Mast
Travel
Boom
Stroke
44 in.
(1,117 mm)
Constant
speed
31 in.
Manual
(787 mm)
Boom
Travel
Base
Rotation
360°
Systems include
mast and boom
• Portable
power source
• SubArc
Interface Digital and
• SubArc
control cable
Wire Drive 400 Digital
• SubArc
Low Voltage
• 25withlb.valve(11.3 kg) capacity flux hopper
lb. (27 kg) wire reel and support
• 60assembly
600 torch (650 system) or
• OBT
OBT 1200 torch (both 1000 systems)
straightener
• Wire
• Manual cross slides
Most popular accessories
Tips (pg 111)
• Contact
• Drive Rolls (pg 111)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Overall
Height
Minimum Working Height
Maximum Working Height
DC 650: 33.5 in. (851 mm)
DC 1000: 26.25 in. (667 mm)
AC/DC 1000: 26.25 in. (667 mm)
DC 650: 77.5 in. (1,969 mm)
102 in.
DC 1000: 70.25 in. (1,784 mm)
(2,590 mm)
AC/DC 1000: 70.25 in. (1,784 mm)
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.
80
For more detailed
information, visit
Plasma
Product
Guide
Page
Class
Gouging
Piercing
MillerWelds.com/plasmacutters
Plasma Cutters
Rated Output/
Duty Cycle
Rated Cutting Thickness*
Mild
Stainless
Steel Steel
Aluminum
Max. Sever
Thickness
Mild Steel Special Features
Typical Applications
30 A at 35%
3/8 in.
3/8 in.
1/4 in.
5/8 in.
Auto-Line™: 120–240 V, MVP™ plugs, Auto-Refire,™
automatic air regulation, only 19 lb., XT30 torch
HVAC, maintenance, light construction,
hobbyist, auto restoration, fabrication
Spectrum® 625
X-TREME™
82
40 A at 50%
5/8 in.
1/2 in.
3/8 in.
7/8 in.
Auto-Line™: 120–240 V, MVP™ adapters,
Auto-Refire,™ automatic air regulation, only 21 lb.,
XT40 or XT40M torch
Maintenance, light construction,
body shops, prototyping
Spectrum® 875
82
60 A at 50%
7/8 in.
7/8 in.
5/8 in.
1-1/4 in.
Auto-Refire,™ automatic air regulation, only 49 lb.,
XT60 or XT60M torch
Construction, maintenance/repair,
fabrication
Spectrum® 875
Auto-Line™
82
208: 60 A at 40%
230–380 V: 60 A at 50%
380–575 V: 60 A at 60%
7/8 in.
7/8 in.
5/8 in.
1-1/4 in.
Auto-Line™: 208–575 V, Auto-Refire,™
automatic air regulation, only 54 lb.,
XT60 or XT60M torch
Construction, maintenance/repair,
fabrication
Continuous
Generator Power
Blue Star® 185
6.2 kW
Bobcat™ and
Trailblazer®
Spectrum 375 X-TREME
Steel Cut / Output Amp Setting**
Spectrum 625 X-TREME
Steel Cut / Output Amp Setting**
Spectrum 875 / 875 Auto-Line
Steel Cut / Output Amp Setting**
3/8 in. / 30 A
Not recommended
Not recommended
9.5/10.5 kW
3/8 in. / 30 A
5/8 in. / 40 A
1/2 in. / 45 A
Big Blue® 350 PipePro,® 400 Pro
and 450 Duo CST ™
10 kW
3/8 in. / 30 A
5/8 in. / 40 A
1/2 in. / 45 A
Big Blue® 500 Pro
1-ph: 12 kW, 3-ph: 15 kW
3/8 in. / 30 A
5/8 in. / 40 A
5/8 in. / 50 A
Big Blue® 600 Pro, 800 Duo Pro
and 800 Duo Air Pak™
1-ph: 12 kW, 3-ph: 20 kW
3/8 in. / 30 A
5/8 in. / 40 A
7/8 in. / 50 A
Cutting w/Engine Drives
Engine-Driven Welder/Generator
1&3-Ph
82
1-Phase
Spectrum® 375
X-TREME™
*Note on cut capacity ratings: The Spectrum Series rating system is designed to provide a guide to help our customers choose the right machine for their application. Rated cut
capacity is based on traveling approximately 15 inches per minute to achieve a steady, precise cut. This is the key rating that should meet or exceed your typical cutting thickness
requirements. Sever cut is the maximum cut achieved in ideal conditions. Some factors that dictate actual cut speeds, thickness capacity and duty cycles are: types of thermally
conductive material being cut, available input power, output power settings and operator technique. For aluminum and other metals with high thermal conductivity, cutting capacities
may be derated as much as 30 percent.
Product Key
Class:
Light Industrial
Industrial
Heavy Industrial
Capability:
Designed for this process
*See note on cut capacity ratings above. **240 V, full KVA plug. Derate cut capacity with less generator power.
For more detailed information, see individual specification sheets.
Capable of this process
81
Plasma Cutters
Spectrum®
Series
Plasma Cutters
Our Spectrum line of plasma
cutters provides big cutting
power in portable packages and
with features like flexible cables
and Auto-Refire technology they
are better than ever. Step up to
Spectrum 625 X-TREME™ or
875/875 Auto-Line™ models
to add Ultra-Quick Connect
hand-held torches and machine
torch capabilities.
375 625
X-TREME
875
875 Auto-Line
Non-high-frequency arc starting does not interfere
with or damage controls or computers.
Auto-Refire™ provides ultimate convenience by
automatically controlling the pilot arc when cutting
expanded metal or multiple pieces of metal.
Built-in gas/air filter and regulator. Provides
air filtration of airborne particles five microns and
larger. Additional filtration and water separation
recommended.
LVC™ line voltage compensation provides peak
performance power under variable input voltage
conditions for clean, steady cuts.
Wind Tunnel Technology™ prevents abrasive dust
and particles from damaging internal components.
Spectrum 875
Spectrum 875 Auto-Line
Spectrum 625 X-TREME and 875/875
Auto-Line hand-held and machine torches
Ultra-Quick Connect™
hand-held torches
with flexible cables.
XT40 (625 X-TREME)
and XT60 (875 models)
hand-held torches feature
quick torch connection,
ergonomic handles to help prevent operator fatigue
and flexible cables that make maneuvering easier.
Machine torch capable.
625 X-TREME and both
875 models can be ordered
with a machine torch or
can be converted to use a
machine torch with optional
automation kits (page 110).
Long and short body
machine torches. XT40M
(625 X-TREME) and XT60M
(875 models) machine
torches are available in long
or short body configurations.
XT60M is also available in
25- or 50-foot cable lengths.
Fan-On-Demand™ cooling system only operates
when needed, reducing the amount of airborne
dust/dirt pulled through the unit.
Quick connect flexible work cable with
heavy-duty clamp.
5/8 in.
(15.9 mm)*
Spectrum
LED indicators for easy troubleshooting.
7/8 in.
(22.2 mm)
Aluminum
Power factor correction (PFC). Uses less energy by
utilizing input power more efficiently and increases
productivity by reducing nuisance circuit breaker trips.
Steel/Stainless/Aluminum
Rated Cutting Capacity
Steel/
Stainless
Spectrum 625 X-TREME
Postflow cooling circuitry extends life of the
consumable and torch by cooling them with
postflow air after trigger is released.
Spectrum Features
Feature
Auto-Line (120–240 V)
Auto-Line (208–575 V)
MVP™ plugs/adapters
Ultra-Quick Connect
torch with flexible cable
Quick connect flexible
work cable with clamp
Built-in gas/air filter
and regulator
Auto-Refire
Auto postflow
Auto air regulation
X-CASE™
Machine torch capable
Spectrum 375 X-TREME
3/8 in.
(9.5 mm)
1/4 in.
(6.4 mm)
375
X-TREME
3/8 in.
(9.5 mm)
625
X-TREME
5/8 in.
(15.9 mm)
875/
875 Auto-Line
Spectrum 375 X-TREME
hand-held torch package
(#907 529) shown.
Models/
packages
Spectrum 875 Auto-Line
machine torch package
(#907 584 002) shown.
*Stainless: 1/2 in. (12.7 mm) for Spectrum 625 X-TREME.
Cut capacity ratings are based on traveling speed
of approximately 15 inches per minute to achieve
a precise cut. This is the key rating that should
meet or exceed your typical cutting thickness
requirements. Factors that can affect actual cut
speeds, thickness capacity and duty cycles are:
types of thermally conductive material being cut,
available input power, output power settings and
operator technique. For highly thermal conductive
metals such as aluminum, cutting capacities may be
reduced up to 30 percent compared to mild steel.
82
Machine Torch Packages
Hand-Held Torch Packages
50 ft. (15.2 m)
25 ft. (7.6 m)
50 ft. (15.2 m)
Long Body
Short Body
Long Body
Short Body
—
—
—
—
—
(#907 579 002) (#907 579 003) —
—
(#907 583)
(#907 583 001) (#907 583 002) (#907 583 003) —
—
(#907 584)
(#907 584 001) (#907 584 002) (#907 584 003) (#907 584 004) (#907 584 005)
Model
12 ft. (3.7 m) 20 ft. (6.1 m)
Spectrum 375 X-TREME
(#907 529)
—
Spectrum 625 X-TREME
(#907 579)
(#907 579 001) —
Spectrum 875
—
Spectrum 875 Auto-Line
—
Plasma Cutters
™
Spectrum® 375 X-TREME /625 X-TREME
™ See literature no. PC/9.2 (375 X-TREME)
and PC/9.6 (625 X-TREME)
Only 875 Auto-Line has
3-phase capabilities.
Allows for any input voltage
hook-up (120–240 V, singlephase, 50/60 Hz for 375 X-TREME and 60 Hz for
625 X-TREME) with no manual linking, providing
convenience in any job setting.
Processes
plasma cutting
• AirAir plasma
gouging (625/875 models)
•
375 X-TREME
comes complete with
™
X-CASE provides the ultimate protection during transport
and storage. Additional space is ideal for MVP plugs,
consumables box, gloves, etc.
Spectrum 625
X-TREME shown.
Multi-voltage plug (MVP™) on 375 X-TREME or
MVP™ adapter on 625 X-TREME allows connection to
120- or 240-volt receptacles without tools.
375 X-TREME model includes XT30 hand-held torch
with ergonomic design and flexible cable.
Automatic gouging consumable detection
(625 X-TREME only). Detects gouging consumable
and adjusts gas pressure to optimize performance,
eliminating the need for a manual regulator.
625 X-TREME model includes Ultra-Quick Connect™
XT40 hand-held torch with ergonomic design and flexible
cable; or XT40M long body or short body machine torch.
Spectrum® 875/875 Auto-Line
™
Spectrum 875 shown.
Spectrum 625
X-TREME
120–240 V,
60 Hz
Singlephase
hand-held torch with
• XT40
12 ft. (3.7 m) or 20 ft. (6.1 m) cable;
OR XT40M long body or short body
machine torch with 25 ft. (7.6 m)
cable
Heavy-duty work clamp and flexible
cable with quick connect
12 ft. (3.7 m) power cord with 240 V,
L6-30P twist lock plug
MVP adapters with 5-15P (120 V, 15 A)
and 6-50P (240 V, 50 A) plugs
X-CASE for protection and storage
Shoulder strap
Consumables box with two electrodes,
two 40 A tips and one 30 A tip, 30 A
drag shield, deflector and air fitting
Machine torch packages include
corresponding automation kit
875 and 875 Auto-Line
come complete with
Automatic air regulation compensates for input
pressure variation to provide constant recommended
torch pressure for optimum cutting performance.
Singlephase
625 X-TREME
comes complete with
•
Consumables storage compartment provides
convenient access to consumables and parts.
Spectrum 375
X-TREME
120–240 V,
50/60 Hz
for protection and storage
• X-CASE
Shoulder
strap
• Consumables
box with two electrodes,
• two tips, deflector
and air fitting
•
•
•
•
•
•
See literature no. PC/9.8
Spectrum 875 Auto-Line model
allows for any input voltage
hook-up (208–575 V, single- or three-phase) with no
manual linking, providing convenience in any job setting.
Standard Spectrum 875 model operates on 208/230 V,
single-phase input voltage only.
Input
Power
hand-held torch with
• XT30
12 ft. (3.7 m) cable
work clamp with
• Heavy-duty
12 ft. (3.7 m) flexible cable
(3 m) power cord with
• 10MVPft.5-15P
(120 V, 15 A) and
6-50P (240 V, 50 A) plugs
Automatic air regulation compensates for input
pressure variation to provide constant recommended
torch pressure for optimum cutting performance.
Model
Light industrial 375/625 models
Industrial
875 models
Includes Ultra-Quick Connect™ XT60 hand-held torch
with ergonomic design and flexible cable; or XT60M long
body or short body machine torch.
Rated Output at 104°F (40°C)
Amps Input at
Rated Output
KVA
KW
120 V (15 A): 20 A at 88 VDC, 35% duty cycle
18.1
2.2
2.1
120 V (20 A): 27 A at 91 VDC, 20% duty cycle
25.6
3.1
3.0
240 V: 30 A at 92 VDC, 35% duty cycle
13.6
3.3
3.1
120 V (15 A): 20 A at 88 VDC, 35% duty cycle
18.1
2.2
2.1
120 V (20 A): 27 A at 91 VDC, 20% duty cycle
25.6
3.0
2.9
240 V: 40 A at 140 VDC, 50% duty cycle
13.6
6.4
6.3
9.8
Spectrum 875
208/230 V,
50/60 Hz
Singlephase
208 V: 60 A at 140 VDC, 40% duty cycle
230 V: 60 A at 140 VDC, 50% duty cycle
208 V: 47
230 V: 42
9.9
Spectrum 875
Auto-Line
208–575 V,
50/60 Hz
Threephase
208 V: 60 A at 140 VDC, 40% duty cycle
230–380 V: 60 A at 140 VDC, 50% duty cycle
380–575 V: 60 A at 140 VDC, 60% duty cycle
380–575 V: 50 A at 140 VDC, 100% duty cycle
208 V: 27.5
230 V: 25
380 V: 15
460 V: 12.4
575 V: 9.8
9.9
9.4
Singlephase
208 V: 60 A at 140 VDC, 40% duty cycle
230 V: 60 A at 140 VDC, 40% duty cycle
230 V: 50 A at 140 VDC, 100% duty cycle
208 V: 47.4
230 V: 42.2
9.9
9.7
Compressor
Requirement
Dimensions
Net Weight
with Torch
5.0 cfm
(142 L/min.)
at 90 psi
(621 kPa)
H: 9 in. (229 mm)
W: 5.5 in. (140 mm)
D: 13.25 in. (337 mm)
19 lb.
(8.6 kg)
6.0 cfm
(170 L/min.)
at 90 psi
(621 kPa)
H: 9 in. (229 mm)
W: 5.5 in. (140 mm)
D: 13.25 in.(337 mm)
12 ft. 21 lb.
(9.5 kg)
20 ft. 23 lb.
(10.5 kg)
25 ft. 24 lb.
(10.7 kg)
6.75 cfm
(191 L/min.)
at 90 psi
(621 kPa)
H: 13.5 in. (343 mm)
W: 8.75 in. (222 mm)
D: 18.5 in. (470 mm)
20 ft. 49 lb.
(22.2 kg)
50 ft. 58 lb.
(26.3 kg)
hand-held torch with
• XT60
20 ft. (6 m) or 50 ft. (15.2 m) cable;
•
•
•
•
OR XT60M long body or short body
machine torch with 25 ft. (7.6 m) or
50 ft. (15.2 m) cable
Heavy-duty work clamp and flexible
cable with quick connect
10 ft. (3 m) power cord
Extra consumables
Machine torch packages include
corresponding automation kit
Most popular accessories
Kits (pg 110)
• Automation
Cables
and
Cable
(pg 110)
• Cutting Guides (pgCovers
• Filters (pg 110) 110)
• Plugs and Cords (pg 110)
• Protective Covers/Cases (pg 110)
• Torches (pg 110)
• Torch Consumables (pg 110)
•
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
20 ft. 54 lb.
(24.5 kg)
25 ft. 56 lb.
(25.4 kg)
50 ft. 63 lb.
(28.6 kg)
83
Plasma Cutters
Spectrum Automation-Ready Machines
®
See literature no. PC/9.6 (625 X-TREME) or PC/9.8 (875 models)
X-TREME™
Spectrum 625
machine torch package
(#907 579 002) shown.
Spectrum 875 Auto-Line™
machine torch package
(#907 584 002) shown.
Spectrum 875 machine
torch package also
available (without remote
pendant control).
Automation Kits
Converts hand-held torch packages
to add machine torch capabilities.
Machine torches are NOT included in
automation kits and must be ordered
separately (see page 110).
625 X-TREME
• Spectrum
Automation Kit #301 158 (pg 110)
Note: Requires a Spectrum 625 X-TREME
with Ultra-Quick Connect™ feature for unit
to be converted for use with long or short
body machine torches.
Machine torch capable. 625 X-TREME and both 875 models can
be ordered with a machine torch (see page 82) or can be converted
to use a machine torch with optional automation kits (at right).
Long and short body machine torches. XT40M (for 625 X-TREME) and
XT60M (for 875 models) machine torches can be ordered separately
(see page 110) and are available in long or short body configurations.
XT60M is also available in 25- or 50-foot cable lengths.
875 Automation Kit
• Spectrum
#301 156 (pg 110)
Note: Machine torch packages above are shown with long body torches.
875 Auto-Line
• Spectrum
Automation Kit #301 157 (pg 110)
Includes remote pendant control for
manual on/off.
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®
Are you a professional fabricator, or do you
like to repair everyday items in your home
garage? Sign up for the Miller PRO and DIY
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84
For more detailed
information, visit
MillerWelds.com/gasequipment
Gas Equipment
Regulators
1
Heavy-duty and medium-duty single-stage pressure regulators
Series 40
Series 30
Our Series 40™ and Series 30™ industrial-grade pressure regulators
provide accurate pressure readings for welding, cutting, heating and
other applications. Extremely durable construction and simplified design
provide consistent gas flow and longer trouble-free operation. Covered
by a three-year warranty. See page 87 for optional Hard Hat™ regulator
guards designed to help prevent broken gauges.
Also available
Stock
Number
HTP2
Series 30
single-stage
regulator
twin packs
HTP5
Gas
Oxygen
LP or Acetylene
Regulator
30-100-540
30-15-510
Max. Delivery
Pressure or Flow
100 psig (7 bar)
15 psig (1 bar)
Oxygen
Acetylene
30-100-540
30-15-300
100 psig (7 bar)
15 psig (1 bar)
Inlet
Connection
CGA 540
CGA 510
CGA 540
CGA 300
5
Series 40 shown.
6
2
3
7
7
4
Sure Seat filtered
high-pressure seat assembly.
1 Resin bonnet insert (Series 40/46 only)
Allows smooth, easy adjustment even at
high-pressure levels.
2 Stainless steel diaphragm
Resists corrosion, leaking and freeze-up if
used with liquid (cryogenic) gases for
extended service life.
Note: Series 30/36 has neoprene composite
diaphragm.
Heavy-duty and medium-duty single-stage
station regulators
Series 46
Series 36
Our Series 46™ and Series 36™ brass line regulators are rugged, accurate
and corrosion-resistant. Station regulators are used to connect pipeline
gas delivery systems to the welding stations. Because the pipeline
pressure is regulated upstream, station regulators only require a single
delivery pressure gauge. Covered by a three-year warranty.
*In the chart below, oxygen “C” size inlet connection CGA 024 (7/8"-14 RH) fits station valve Rego. No. 7160.
Fuel gases “C” size inlet connection CGA 025 (7/8"-14 LH) fits station valve Rego. No. 7161.
Note: Body inlet is 1/4-inch (6 mm) NPT.
Two-stage regulators
Series 30 two-stage regulators drop cylinder pressure to working pressure
in two stages for consistent and accurate outlet pressure and flow
regardless of inlet pressure. Recommended where outlet pressure and flow
must be maintained without variation. Covered by a three-year warranty.
3 Color-coded labels
Supplies performance capabilities, easy gas
service identification and technical information.
4 External relief valve
Protects regulator from damage due to
inadvertent high-pressure surge. Relief
valve will release excessive pressure and
automatically reset.
5 Nickel-plated bonnet
Along with brass body protects regulator
against corrosion.
6 Gauges and lenses
2.5-inch corrosion-resistant polished
brass gauges with shatter-resistant
polycarbonate lenses.
Note: Series 30/36 has 2-inch painted steel gauges.
7 Sure Seat™ dual-filtered seat assembly
Protects high-pressure seat from debris for
reliable operation and long service life.
Model
Heavy-Duty Series 40
Single-Stage
Pressure Regulators
Stock Number
40-175-540 Single-stage
40-275-540 Single-stage
40-15-510 Single-stage
40-15-300 Single-stage
40-50-510 Single-stage
40-275-580 Single-stage
Gas
Oxygen
Oxygen
Acetylene
Acetylene
LP gas
Inert gas
Max. Delivery Pressure
175 psig (12 bar)
275 psig (19 bar)
15 psig (1 bar)
15 psig (1 bar)
50 psig (3 bar)
275 psig (19 bar)
Max. Inlet Pressure
3000 psig (207 bar)
3000 psig (207 bar)
400 psig (28 bar)
400 psig (28 bar)
400 psig (28 bar)
3000 psig (207 bar)
Outlet Connection
9/16"-18 RH
9/16"-18 RH
9/16"-18 LH
9/16"-18 LH
9/16"-18 LH
5/8"-18 RH internal
Inlet Connection
CGA 540
CGA 540
CGA 510
CGA 300
CGA 510
CGA 580
Medium-Duty Series 30
Single-Stage
Pressure Regulators
30-100-540 Single-stage
30-20-540 Single-stage
30-15-510 Single-stage
30-15-300 Single-stage
30-15-520 Single-stage
30-15-200 Single-stage
30-50-510 Single-stage
30-150-580 Single-stage
30-150-320 Single-stage
30-100-350 Single-stage
Oxygen
Oxygen
Acetylene
Acetylene
Acetylene
Acetylene
LP gas
Argon/nitrogen
CO2
Hydrogen/methane
100 psig (7 bar)
20 psig (1.4 bar)
15 psig (1 bar)
15 psig (1 bar)
15 psig (1 bar)
15 psig (1 bar)
50 psig (3 bar)
150 psig (10 bar)
150 psig (10 bar)
100 psig (7 bar)
3000 psig (207 bar)
3000 psig (207 bar)
400 psig (28 bar)
400 psig (28 bar)
400 psig (28 bar)
400 psig (28 bar)
400 psig (28 bar)
3000 psig (207 bar)
3000 psig (207 bar)
3000 psig (207 bar)
9/16"-18 RH
9/16"-18 RH
9/16"-18 LH
9/16"-18 LH
9/16"-18 LH
9/16"-18 LH
9/16"-18 LH
5/8"-18 RH internal
5/8"-18 RH internal
9/16"-18 LH
CGA 540
CGA 540
CGA 510
CGA 300
CGA 520
CGA 200
CGA 510
CGA 580
CGA 320
CGA 350
Heavy-Duty Series 46
Station Regulators
46-175 Single-stage
46-15 Single-stage
46-50 Single-stage
Oxygen
Acetylene
LP gas
175 psig (12 bar)
15 psig (1 bar)
50 psig (3 bar)
200 psig (14 bar)
200 psig (14 bar)
200 psig (14 bar)
9/16"-18 RH “B”
9/16"-18 LH “B”
9/16"-18 LH “B”
CGA 024*
CGA 025*
CGA 025*
Medium-Duty Series 36
Station Regulators
36-150 Single-stage
36-15 Single-stage
36-50 Single-stage
Oxygen
Acetylene
LP gas
150 psig (10 bar)
15 psig (1 bar)
50 psig (3 bar)
200 psig (14 bar)
200 psig (14 bar)
200 psig (14 bar)
9/16"-18 RH “B”
9/16"-18 LH “B”
9/16"-18 LH “B”
CGA 024*
CGA 025*
CGA 025*
Series 30
Two-Stage Regulators
35-125-540 Two-stage
35-15-510 Two-stage
35-50-580 Two-stage
Oxygen
Acetylene
Inert gas
125 psig (9 bar)
15 psig (1 bar)
50 psig (3 bar)
3000 psig (207 bar)
400 psig (28 bar)
3000 psig (207 bar)
9/16"-18 RH “B”
9/16"-18 LH “B”
5/8"-18 RH internal
CGA 540
CGA 510
CGA 580
85
Gas Equipment
Flow
Data
Regulators
Data can be obtained at
Millerwelds.com/flowdata
6
1
7
Read center of ball
on flowmeters
2
3
Heavy-duty
flowmeter
Heavy-duty
flowmeter
regulator
Heavy-duty two-stage
high-flow CO2
flowmeter
regulator
Miller
exclusive
self-centering
ball guide
4
5
Heavy-duty model features
Heavy-duty flowmeter regulators and flowmeters
™
Our Series 30 heavy-duty flowmeter regulators and flowmeters feature an exclusive self-centering ball guide
which provides accurate readings even if tipped. This ensures optimum weld quality and gas savings. Others
use a non-self-centering flow tube ball that tends to float off center causing actual gas flow to be up to two
times greater than indicated. Covered by a three-year warranty.
Economy flowmeter
regulators and flowmeters
Our economy flowmeter regulators
and flowmeters combine
exceptional value and a compact
design with precise shielding gas
regulation for MIG and TIG welding
applications and more. Covered by
a three-year warranty.
Economy
flowmeter regulator
Dual flowmeter regulator
8
Economy
flowmeter
1 Protective housing
Protects flow tubes from damage while
offering unobstructed view of flow reading.
2 Extra-long flow tube
Expanded scales are easy to read and
accurate within 5 percent of full reading.
Can be attached to regulators or pipeline
installations.
3 Shatter-resistant multi-scale flow tube
Made of shatter-resistant polycarbonate resin
and features multiple scales. Selec-O-Gas™
model provides four separate, easy-to-read
scales for CO2, argon, argon/CO2 mix, helium
and a general scale for other non-corrosive
gases. Rotate outer tube to desired scale.
4 Auto-reset pressure-relief valve
Protects regulator from damage due to
high-pressure surge. Relief valve will release
excessive pressure and automatically reset.
5 Sure Seat™ dual-filtered seat assembly
Protects high-pressure seat from debris for
reliable operation and long service life.
Economy model features
Single-stage flow gauge regulators
Series 30™ single-stage flow gauge regulators are compact and feature a
forged brass body and a self-resetting pressure relief valve. They include
a Sure Seat™ protective inlet filter and a durable neoprene-composite
diaphragm. Covered by a three-year warranty.
Model
Series 30 Heavy-Duty
Flowmeter Regulators
Stock Number
32-80-580 Single-stage
32-80-320 Single-stage
32-30-580 Single-stage
32-30-580-6 Single-stage w/gas hose
6 Built-in rupture disc
Reduces possibility of flow tube damage due
to high-pressure surge. Must be replaced if
ruptured — not auto-resetting.
7 Shatter-resistant triple-scale flow tube
Made of shatter-resistant polycarbonate resin
and can be rotated to position desired scale
for easy reading. Scaled for CO2, argon and
argon/CO2 mix, and helium.
8 Precision flow-adjustment valve
Allows easy adjustment to desired setting.
Gas
Argon/CO2
CO2
Argon/CO2
Helium
CO2
Flow Range
10–80 scfh (5–38 lpm)
10–80 scfh (5–38 lpm)
10–60 scfh (5–28 lpm)
20–190 scfh (10–90 lpm)
10–80 scfh (5–38 lpm)
Max. Inlet Pressure
3000 psig (207 bar)
3000 psig (207 bar)
3000 psig (207 bar)
3000 psig (207 bar)
3000 psig (207 bar)
Outlet Connection
5/8"-18 RH internal
5/8"-18 RH internal
5/8"-18 RH internal
Inlet Connection
CGA 580
CGA 320
CGA 580
5/8"-18 RH internal
CGA 320
Heavy-Duty Flowmeters
H1105 Argon, CO2
H1240 Multi-scale (Selec-O-Gas™)
Argon, CO2
Argon, helium, CO2
General gas
10–80 scfh (5–38 lpm)
Depends on gas
Depends on gas
80 psig (6 bar) recommended
30 psig (2 bar) recommended
30 psig (2 bar) recommended
5/8"-18 RH internal
1/4" NPT male
H2051 Series Economy
Flowmeter Regulators
H2051B-580 Single-stage
H2051B-580H Single-stage w/gas hose
33A-50-580 Single-stage dual flowmeter regulator
Argon
CO2
Helium
0–60 scfh (0–28 lpm)
0–50 scfh (0–24 lpm)
0–160 scfh (0–78 lpm)
3000 psig (207 bar)
3000 psig (207 bar)
3000 psig (207 bar)
5/8"-18 RH internal
CGA 580
Economy Flowmeters
H2230A Multi-scale
H2231A Multi-scale
Argon, helium, CO2
Depends on gas
50 psig (3 bar) recommended
5/8"-18 RH internal
1/4" NPT male
5/8"-18 RH external
Series 30 Flow Gauge
Regulators
31-50-580 Single-stage
31-50-580-6 Single-stage w/gas hose
31-50-320 Single-stage
Argon
0–50 scfh (0–24 lpm)
3000 psig (207 bar)
5/8"-18 RH internal
CGA 580
CO2
0–50 scfh (0–24 lpm)
3000 psig (207 bar)
5/8"-18 RH internal
CGA 320
35-30-320 Two-stage high-flow CO2
86
Flow
Data
Gas Equipment
Data can be obtained at
Millerwelds.com/flowdata
Most popular accessories
Regulators
HVAC/refrigeration purge/leak test regulator
Our single-stage nitrogen regulator is specially designed to meet the specifications of HVAC
refrigerant purging applications. This regulator is used with nitrogen to test HVAC systems to
locate leaks and to purge an area for installation and repair. It is economical, accurate and
its compact size is useful where space is limited. Covered by a one-year warranty.
2-inch (51 mm) gauges with shatter-resistant lenses and solid brass body for durability
Large durable nylon knob for easy pressure adjustment
•
•
Stock Number
30-450-580
Gas
Nitrogen
Outlet Connection
7/16"-20 external flair fitting
Max. Inlet Pressure
3000 psig (207 bar)
Max. Delivery Pressure
450 psig (31 bar)
HB190
•
H195
Hard Hat™ Regulator Guards
HB190 For Series 40
H195 For Series 30
Inlet Connection
CGA 580
H697
Heavy-duty high-pressure regulator
820 Series regulators are for use on cylinders with a wide variety of non-corrosive inert
gases. Typical applications include high-pressure testing, purging/charging, calibration kits,
airline charging carts, chemical plants, manufacturing processes, research/development and
laboratories. Covered by a two-year warranty.
Piston-sensor design gives structural reliability in high-pressure use
Low-torque-control adjusting screw for easy pressure adjustments in closed/dead end systems
Due to specific configurations, we cannot accept returns of 820 Series regulators
H698
Check Valve Set
• Reverse-Flow
(oxy and fuel)
H697
H698
Torch mount
Regulator mount
H753
•
•
•
Model
Series
823
824
825
826
827
Max. Inlet
Pressure
6000 psig
Max. Delivery Pressure
500 psig
1000 psig
2000 psig
4000 psig
6000 psig
Option 1
Outlet pressure
823 0–500 psig
824 0–1000 psig
825 0–2000 psig
826 0–4000 psig
827 0–6000 psig
Model Configuration
825 - 66 26
Option 2 Outlet connection
00 1/4" FNPT
66 Stainless steel needle valve
with 1/4" NPT
Option 3 Inlet connection (additional inlet
connections available)/Max. inlet pressure
00 1/4" FNPT
08 CGA 540 (oxygen)
3000 psig
09 CGA 580 (inert)
3000 psig
26 CGA 347 stainless steel
5500 psig
27 CGA 677 stainless steel
7500 psig
28 CGA 680 stainless steel
5500 psig
Arrestor Set (oxy and fuel)
• Flashback
H743 Torch mount
H753
Regulator mount
Rear-entry liquid cylinder regulator
250 Series regulators are ideal for non-corrosive high-purity applications and have a
rear-entry connection that provides clearance of the liquid cylinder ring for easier gauge
reading. Covered by a two-year warranty.
Easy-to-read single-scale 2.5-inch (64 mm) gauge with shatter-resistant lens
Nickel-plated brass body for corrosion resistance
Large 1-7/8-inch stainless steel diaphragm for precise control of pressure
Large durable nylon knob for easy pressure adjustment
Due to specific configurations, we cannot accept returns of 250 Series regulators
•
•
•
•
•
• GASAVER
WDW100 Propylene/oxygen
™
WDW101 Acetylene/oxygen
WDW104 Propane or natural
gas/oxygen (4 psi and above)
- For repetitious brazing and soldering
- Hang torch to shut off
- Pilot light for relighting
- Eliminates flame readjustment
Note: Use Series 40™ heavy-duty regulators constructed with a stainless steel diaphragm for high-volume or liquid (cryogenic) cylinder applications.
Model
Series
252
254
255
256
Max. Delivery Pressure
100 psig
200 psig
350 psig
500 psig
Max. Inlet
Pressure
3500 psig
Option 1
Outlet pressure
252 0–100 psig
254 0–200 psig
255 0–350 psig
256 0–500 psig
Model Configuration
252 - 20 08
Option 2 Outlet connection
00 1/4" FNPT
20 Chrome needle valve with 1/4" NPT
82 9/16"-18 RH “B”
Option 3
Inlet connection
00 1/4" FNPT
02 CGA 320
08 CGA 540
09 CGA 580
Three-stage nitrogen low-pressure regulator
16391 (without
pressure switch)
16347-3 (with
pressure switch)
These preset regulators are specially designed to deliver a highly
accurate and consistent 0.50 psig supply of nitrogen to the head
space of oil-filled power transformers. Available with or without
electronic pressure switch. Covered by a one-year warranty.
Built-in self-relieving valve set at 8 psig protects the system from
over-pressurization due to temperature variation
Rapid-fill bypass pressure valve allows rapid filling of the
transformer with 6 psig of pressure
•
•
Adaptors and
• Fixed-Flow
Surge Protectors
H1400 Series fixed-flow adaptors
are for welding operations requiring
fixed-flow gases. 15001 Series
surge protectors are for MIG welding
applications to eliminate sudden
surges of shielding gas in the wire
feeder. Visit MillerWelds.com for
more information.
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Note: Operation temperature: -40° to +180° Fahrenheit. Operation voltage (model 16347-3): 5 amps at 12/24 volts DC or 125 volts AC. 3 amps at 250 volts.
Pressure switch setting: Adjustable from 70–300 psig (ships preset at 250 psig), 3/32-inch Allen head screw switch.
Switch wiring: Normally open or normally closed (DPDT), three 18-inch flying leads.
Stock Number
16391 without pressure switch
16347-3 with pressure switch
Preset Outlet Pressure
1st Stage
2nd Stage
150 psig
8 psig
(10 bar)
(0.6 bar)
into 2nd stage into 3rd stage
3rd Stage (delivery pressure)
0.4–0.6 psig (0.03–0.04 bar)
into outlet
Bypass Rapid
Fill/Purge
6 psig
(0.4 bar)
Max. Inlet
Pressure
3000 psig
(207 bar)
Outlet
Connection
1/2"
FNPT
Inlet
Connection
CGA 580
87
Gas Equipment
Heavy-duty torch tips
Heavy-Duty Outfits
Combination torch outfits (acetylene or LP)
HBA-40510
Oxy-fuel outfits include just about everything needed for your
cutting, welding, brazing or heating project.
Heavy-duty Series 40™ or medium-duty Series 30™ regulators
with three-year warranty
Heavy-duty torches with lifetime warranty
Torch-mount flashback arrestors for added safety
(acetylene outfits only)
Exclusive long-lasting Graf-Tite® soft-seat cutting tips with
in-tip gas mixing for added resistance to flashbacks
Both HBA-40510 and HBA-40300 outfits cut up to
1-1/4 inch (32 mm) with tip included, other outfits cut up to
5/8 inch (16 mm)
All outfits cut up to 8 inches (203 mm) with optional tips
•
•
•
•
•
•
Combination torch and tip kits (acetylene or LP)
16206
16280
Combination kits are available with cutting, welding and
heating tips or with multiple cutting tips.
Heavy-duty torches with lifetime warranty
Torch-mount flashback arrestors for added safety
Exclusive long-lasting Graf-Tite® soft-seat cutting tips with
in-tip gas mixing for added resistance to flashbacks
Cuts up to 5/8 inch (16 mm) with tip included
Cuts up to 8 inches (203 mm) with optional tips
•
•
•
•
•
Cutting torch outfits (acetylene)
HBS-H510S
Hand cutting torch outfits are built for the toughest jobs.
Corrosion-resistant regulators feature shatter-resistant
polycarbonate gauge lenses
21-inch nickel-plated torch with lifetime warranty has
reversible (top or bottom) mount cutting lever and an ease-on
oxygen feature that reduces slag blowback when piercing
Exclusive long-lasting Graf-Tite® soft-seat cutting tips with
in-tip gas mixing for added resistance to flashbacks
HBS outfits include heavy-duty Series 40™ regulators with
three-year warranty and Hard Hat™ gauge/regulator guards
HBAS outfits include medium-duty Series 30™ regulators with
three-year warranty, torch-mount flashback arrestors for added
safety, plus hose, lighter, safety glasses and tip cleaner
HBS outfits cut up to 1-1/4 inch (32 mm) with tip included,
HBAS outfits cut up to 5/8 inch (16 mm)
All outfits cut up to 12 inches (305 mm) with optional tips
•
•
•
•
•
HBAS-30510
Stock
Number
Max. Metal
Thickness
Inches (mm)
Cutting
Jet Drill
Size
Acetylene Cutting
SC12-00 3/16 (5)
68
SC12-0
3/8 (10)
62
SC12-1
5/8 (16)
56
SC12-2
1-1/4 (32)
54
SC12-3
2 (51)
51
SC12-4
4 (102)
45
SC12-5
8 (203)
41
SC12-6
12 (305)
32
Propane/Natural Gas Cutting
SC50-00 3/16 (5)
SC50-0
3/8 (10)
SC50-1
5/8 (16)
SC50-2
1-1/4 (32)
SC50-3
2 (51)
SC50-4
4 (102)
SC50-5
8 (203)
12 (305)
SC50-6
SC50-7
14 (354)
SC50-8
18 (457)
SC50-9
20 (508)
Propylene Cutting
68
62
56
54
51
45
41
32
28
17
3
SC60-0
1/4 (6)
SC60-1
5/8 (16)
SC60-2
1-1/4 (32)
SC60-3
2 (51)
SC60-4
4 (102)
SC60-5
8 (203)
SC60-6
12 (305)
Acetylene Gouging
62
56
54
51
45
41
32
SC13-3
3/8 (10) wide, 1/4 (6) deep
Propane/Natural Gas Gouging
3/8 (10) wide, 1/4 (6) deep
SC23-3
Propylene Gouging
SC23-3M 3/8 (10) wide, 1/4 (6) deep
Acetylene Heating
ST602
ST603
ST605
ST610
40,000 Btu
72,000 Btu
125,000 Btu
195,000 Btu
See Gas Equipment catalog (#264 059), or
visit MillerWelds.com or your distributor for
additional tips, options and accessories.
•
•
*Acetylene regulator has CGA 300 inlet fitting.
Outfit
Stock Number
Fuel
Cut Tip
Weld Tip
Heat Tip
Description
Typical Applications
Combination Torch
Complete Outfits
HBA-40510
HBA-40300*
Acetylene
SC12-1
SC12-2
SW205
ST602
Heavy-duty combination torch, heavy-duty regulators, 25 ft. (7.6 m) hose,
lighter, safety glasses, tip cleaner and flashback arrestors
HBA-30510
HBA-30300*
Acetylene
SC12-1
SW205
ST602
Heavy-duty combination torch, medium-duty regulators, 25 ft. (7.6 m) hose,
lighter, safety glasses, tip cleaner and flashback arrestors
Heavy fabrication,
construction, pipeline,
maintenance/repair,
rail and truck repair
HBA-30510LP
Propane
SC40-1
—
ST615
HBA-30510MP
Propylene
SC60-1
—
ST815
Heavy-duty combination torch, medium-duty regulators, 20 ft. (7.6 m)
“T”-grade hose, lighter, safety glasses, tip cleaner and check valves
16206
Acetylene
SC12-1
SW203
ST602
Heavy-duty combination torch and flashback arrestors
16280
Acetylene
SC12-0, SC12-1
—
—
16280LP
Propane
SC40-0, SC40-1
—
—
Heavy fabrication,
construction, pipeline,
maintenance/repair,
rail and truck repair
HBS-H510S
HBS-H300S*
Acetylene
SC12-2
—
—
Heavy-duty SC229 hand cutting torch and heavy-duty regulators
with Hard Hat™ gauge guards
HBAS-30510
HBAS-30300*
Acetylene
SC12-1
—
—
Heavy-duty SC229 hand cutting torch, medium-duty regulators, 20 ft. (7.6 m)
hose, lighter, safety glasses, tip cleaner and flashback arrestors
Heavy fabrication,
construction,
shipyard, rail car,
rail and truck repair
Combination Torch
and Tip Kits
Cutting Torch
Outfits
88
Gas Equipment
Medium-duty torch tips
Medium-Duty Outfits
MBA-30510
Combination torch outfits (acetylene or LP)
Stock
Number
Oxy-fuel outfits include just about everything needed for your cutting,
welding, brazing or heating project.
Medium-duty Series 30™ regulators with three-year warranty
Medium-duty torches with lifetime warranty
Torch-mount flashback arrestors for added safety (acetylene outfits only)
Exclusive long-lasting Graf-Tite® soft-seat cutting tips with in-tip gas
mixing provides for resistance to flashbacks
Cuts up to 5/8 inch (16 mm) with tip included
Cuts up to 6 inches (153 mm) with optional tips
MC12-00
MC12-0
MC12-1
MC12-2
MC12-3
MC12-4
MC12-5
•
•
•
•
•
•
Combination torch and tip kits (acetylene or LP)
16205
16281
Combination kits are available with cutting, welding and heating tips or
with multiple cutting tips.
Medium-duty torches with lifetime warranty
Torch-mount flashback arrestors for added safety
Exclusive long-lasting Graf-Tite® soft-seat cutting tips with in-tip gas
mixing for added resistance to flashbacks
Cuts up to 5/8 inch (16 mm) with tip included
Cuts up to 6 inches (153 mm) with optional tips
•
•
•
•
•
MB55A-510
Economy outfits include many features found on more expensive outfits.
Medium-duty Series 30™ regulators and medium-duty torches with
three-year warranty
Check valves for added safety and torch life
Exclusive long-lasting Graf-Tite® soft-seat cutting tips with in-tip gas
mixing for added resistance to flashbacks
Cuts up to 5/8 inch (16 mm) with tip included
Cuts up to 6 inches (153 mm) with optional tips
•
•
•
•
•
Cutting
Jet Drill
Size
Acetylene Cutting
3/16 (5)
3/8 (10)
5/8 (16)
1 (25)
2 (51)
4 (102)
6 (152)
68
62
55
54
51
45
41
Propane/Natural Gas Cutting
MC40-00
MC40-0
MC40-1
MC40-2
MC40-3
MC40-4
3/16 (5)
3/8 (10)
5/8 (16)
1-1/4 (32)
2 (51)
4 (102)
68
62
55
54
51
51
Propylene Cutting
MC60-1
MC60-2
MC60-3
MC60-4
5/8 (16)
1-1/4 (32)
2 (51)
4 (102)
55
54
51
45
Acetylene Gouging
MC13-3
Toughcut™ combination torch outfits (acetylene or LP)
Max. Metal
Thickness
Inches (mm)
3/8 (10) wide, 1/4 (6) deep
Note: Tips above fit medium- and standardduty torches.
Acetylene Heating
MT603
MT605
MT610
40,000 Btu
73,000 Btu
129,000 Btu
See Gas Equipment catalog (#264 059), or
visit MillerWelds.com or your distributor for
additional tips, options and accessories.
Tag-A-Long™ and Versa-Torch™ portable outfits (acetylene)
Complete, portable outfits housed in carriers designed for mobility and
ease of storage, plus long-lasting Graf-Tite® soft-seat cutting tips and
check valves for added safety and torch life.
Tag-A-Long includes medium-duty Series 30™ regulators and
medium-duty torch with three-year warranties
Versa-Torch includes Series 30™ regulators with three-year warranty
and standard-duty torch with lifetime warranty
•
•
Tag-A-Long TL-550
Versa-Torch VT-4T
*Acetylene regulator has CGA 300 inlet fitting.
Outfit
Stock Number
Fuel
Weld Tip
Heat Tip Description
Typical Applications
Combination
Torch
Complete
Outfits
MBA-30510
MBA-30300*
MBA-30510LP
MBA-30510MP
Acetylene MC12-0
MC12-1
Propane MC40-1
Propylene MC60-1
MW205
MT603
—
MT805
Medium-duty combination torch, medium-duty regulators, 25 ft. (7.6 m) hose, lighter, safety glasses,
tip cleaner and flashback arrestors
Medium-duty combination torch, medium-duty regulators, 20 ft. (7.6 m) “T”-grade hose, lighter,
safety glasses, tip cleaner and check valves
Fabrication, farm and
ranch, pipe, truck and
auto, refrigeration,
maintenance/repair
Combination
Torch
and Tip Kits
16205
Acetylene MC12-1
MW203
MT603
Medium-duty combination torch and flashback arrestors
16281
Acetylene MC12-0, MC12-1 —
—
16281LP
Propane
MC40-0, MC40-1 —
—
Fabrication, farm and
ranch, pipe, truck and
auto, refrigeration,
maintenance/repair
MB55A-510
MB55A-300*
MB54A-510
MB54A-300*
MB54-510L
MB54-300L*
MB54A-510LP
MB54A-510MP
Acetylene MC12-1
MW205
MT603
Medium-duty combination torch, medium-duty regulators, 20 ft. (7.6 m) hose, lighter, safety glasses
and check valves
Acetylene MC12-1
MW205
—
Fabrication, farm and
ranch, pipe, hobby,
auto, refrigeration,
maintenance/repair
Acetylene MC12-1
MW205
—
Medium-duty combination torch, medium-duty regulators, safety glasses and check valves
Propane MC40-1
Propylene MC60-1
—
—
Medium-duty combination torch, medium-duty regulators, 20 ft. (7.6 m) “T”-grade hose, lighter,
safety glasses and check valves
Acetylene MC12-0
MW203
—
Acetylene MC12-00
LT103, 104, 106 13716
Medium-duty (TL500/TL550) or standard-duty (VT-4T) combination torch, medium-duty regulators,
12.5 ft. (3.8 m) hose, carrier, lighter, safety glasses, check valves and cylinders (cylinders NOT
included with TL-500)
Toughcut
Economy
Combination
Torch Outfits
Combination TL-500 (no tanks)
Torch Portable TL-550
Outfits
VT-4T
Cut Tip
Farm and ranch, hobby,
DIY, auto, refrigeration,
maintenance/repair
89
Gas Equipment
Torches
Torches
Cutting torches (acetylene, natural gas or
propane/propylene-based fuels)
Gas Axe™ extra-heavy-duty cutting torches are ideal for
scrap and salvage.
Covered by one-year warranty
Reversible (top or bottom) mount cutting lever
Available in four lengths and three different head angles
Uses our exclusive long-lasting Graf-Tite® soft-seat
cutting tips with in-tip gas mixing for added resistance
to flashbacks
Cuts up to 24 inches (610 mm)
Gas Axe
SC929
•
•
•
•
Heavy-duty torches
•
SC229
MC509
WH200A
WH100
AC309
Length
Inches (mm)
Gas Axe Extra Heavy-Duty
Cutting Torches
SC925
SC929
SC935
SC939
SC930
SC945
SC949
SC940
SC965
SC969
SC960
75
90
75
90
180
75
90
180
75
90
180
21 (533)
21 (533)
36 (914)
36 (914)
36 (914)
48 (1219)
48 (1219)
48 (1219)
72 (1829)
72 (1829)
72 (1829)
SC175
SC179
SC225
SC225S
SC229
SC229S
SC220
SC365
SC369
SC360
Combination torches (acetylene, natural gas
or propane/propylene-based fuels)
Medium-Duty Combination Torches
•
SC209
Head Angle
in Degrees
Heavy-duty cutting torches feature solid construction
and ease of operation for industries such as
construction, fabrication, shipyards and salvage.
Covered by lifetime warranty
Nickel-plated finish for added corrosion resistance and
to reflect residual heat
Reversible (top or bottom) mount cutting lever
Available in three lengths and three different head angles
Uses our exclusive long-lasting Graf-Tite® soft-seat
cutting tips with in-tip gas mixing for added resistance
to flashbacks
Cuts up to 12 inches (305 mm)
•
•
•
•
•
SC229S
Stock
Number
Constructed to last a lifetime for safe performance
under rugged conditions.
Covered by lifetime warranty
Ease-on cutting oxygen valve to reduce slag blowback
when piercing
Thick-wall brass head forgings resist warping and
distortion
Heavy- and medium-duty models are available with
75 or 90 degree head angles
Uses our exclusive long-lasting Graf-Tite® soft-seat
cutting tips with in-tip gas mixing for added resistance
to flashbacks
Heavy-duty torches cut up to 8 inches (203 mm),
medium-duty up to 6 inches (152 mm) and
standard-duty up to 3 inches (76 mm)
•
•
•
•
•
Heavy-Duty Cutting Torches
75
90
75
75
90
90
180
75
90
180
17 (432)
17 (432)
21 (533)
21 (533)
21 (533)
21 (533)
21 (533)
36 (914)
36 (914)
36 (914)
Heavy-Duty Combination Torches
SC205
75
SC209
90
WH200A Handle
MC505
MC509
WH100
75
90
Handle
12.5 (318)
12.5 (318)
7.5 (191)
11.25 (286)
11.25 (286)
7 (178)
Standard-Duty Combination Torches
AC309
AW1A
90
Handle
8.5 (216)
5.75 (146)
Machine Torches
SC781A —
SC772A —
SC770
—
15.5 (394)
13.75 (349)
8 (203)
Most popular accessories
•
AW1A
• Circle Cutter Guide 16229
H753
Machine torches (acetylene, LP or natural gas)
SC781A
Superior performance with solid construction.
Covered by lifetime warranty
Torch barrels are adjustable to four positions at
90-degree increments and barrel diameters are
1-3/8 inches (9.5 mm) to fit most machines
Rack pitch is 32-8 teeth per inch
Uses our exclusive long-lasting Graf-Tite® soft-seat
cutting tips with in-tip gas mixing for added resistance
to flashbacks
SC781A high-capacity three-hose torch cuts up to
24 inches (610 mm) with acetylene and 20 inches
(508 mm) with LP or natural gas
SC770 and SC772A two-hose torches cut up to
12 inches (305 mm) with acetylene, LP or natural gas
•
•
SC772A
•
•
SC770
•
•
90
Arrestor Set (oxy and fuel)
• Flashback
H743 Torch mount
H753 Regulator mount
Glasses
• Safety
(see pg 96 for more styles)
•
#235 661 Blue frame/shade 3
#235 657 Blue frame/shade 5
Safety Gloves (pg 98)
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
Gas Equipment
Proportional Gas Mixers
Our line of proportional gas mixers can help your operation save money, work more efficiently and produce better-quality
welds by providing proper shielding gas mixtures for frequently used welding processes.
Accurate, on-site shield gas mixing. Various welding processes require different gas mixes for the
best results. Our proportional gas mixers are accurate and allow custom mixtures for optimal welds.
No stocking or handling of premixed gases saves time, money and reduces the number of
cylinders that need to be stored.
Reduces setup time. No need to change cylinders, regulators, flow control devices or hoses when
switching from one range of mixed gas to another.
Ideal for education and training. Operators can quickly see the effect of various gas mixtures on
weld appearance, quality and penetration.
Easy operation. Simply set the dials for the desired mix and flow. Mixers are mechanical, no
electricity is required.
Serves from one to five welding stations with a single mixer. Delivers accurate mixtures at flows
ranging from 10 to 180 scfh.
Covered by a one-year warranty.
Argon/CO2 gas mixer
299-006-1C shown.
Stock Number
Gases
Adjustment % Range
Flow Range
Outlet Pressure
Required Inlet Pressure
Outlet Connection
Inlet Connection
Conversion Tables
299-006-1C
Argon
0–100%
10–180 scfh
5/8"-18 RH internal
100–0%
105–115 psig
(7.3–7.9 bar)
5/8"-18 RH internal
CO2
50 psig
(3.5 bar)
Argon/helium
Argon/oxygen
CO2/oxygen
Argon
0–100%
10–180 scfh
100–0%
105–115 psig
(7.3–7.9 bar)
5/8"-18 RH internal
Helium
50 psig
(3.5 bar)
Argon
50–100%
10–180 scfh
50 psig
(3.5 bar)
105–115 psig
(7.3–7.9 bar)
5/8"-18 RH internal
Hydrogen
50–0%
Argon
80–100%
Oxygen
20–0%
299-006-3C
299-011-1C
299-014-1C
5/8"-18 RH internal
5/8"-18 RH internal
5/8"-18 RH internal
5/8"-18 RH internal
9/16"-18 LH external
10–180 scfh
50 psig
(3.5 bar)
105–115 psig
(7.3–7.9 bar)
5/8"-18 RH internal
5/8"-18 RH internal
5/8"-18 RH internal
Stay Connected with Miller
Argon/CO2
Argon/oxygen
CO2/oxygen
Argon/helium
Nitrogen/hydrogen
Argon/oxygen
Argon/CO2
Argon/CO2
Argon/hydrogen
Argon/helium
Nitrogen/hydrogen
®
Join the Miller community to keep up to date with the welding
industry, ask and get answers to your questions and share
your welding experiences.
Our YouTube channel is the welder’s destination
for helpful tips and welding instruction, product
overviews and demonstrations, welding process
information and engaging stories and applications.
The Miller LinkedIn page is the best
source for company news, industry
news and solutions that help
customers make informed business
decisions that better their bottom line.
We hope you’ll join us!
91
Training Solutions
For more detailed
information, visit
MillerWelds.com/livearc
LiveArc
™
Welding Performance
Management System
The LiveArc system is built to deliver
a real-world, arc-on welding experience.
Advanced motion-tracking technology
provides feedback on technique
parameters during initial simulation
(practice) mode as well as live arc
training mode.
higher skill levels
• Builds
Produces faster results
• Provides a cost-effective solution
•
92
The reality-based recruiting, screening, training, and re-qualification solution
for industrial, manufacturing and educational markets.
The LiveArc welding performance management system is a new and innovative reality-based
training system that utilizes a live welding arc, unlike other virtual training solutions. It’s designed
to recruit, screen, train, re-qualify and manage the performance of weld operators — better, faster
and more cost-effectively than traditional methods.
Advanced motion-tracking technology provides the critical feedback required for improvement of
baseline welding skills. Guided by an easy-to-understand interface with graphical icons and
instructional pop-ups, users will find navigation intuitive with a quick learning curve. Scoring
and performance feedback engage and foster independent self-improvement through repetition.
Users can guide themselves through assignment selection and simulated welding runs to acquire
desired techniques before moving to actual live arc training experiences.
The system also gives welding instructors the ability to configure assignments and technique
parameters. It stores the detailed performance history of each operator. LiveArc is a powerful
teaching tool that allows instructors to better manage their time, reduces the cost of teaching
materials and accelerates student progress.
Check out MillerWelds.com/livearc for videos, product information and more!
Training Solutions
Intuitive user interface
LiveArc System
™
Powerful industrial computer at the heart of the system
features solid-state technology and filterless, fanless cooling.
The system is compatible with Miller® wire feed power
sources and is capable of MIG and flux-cored applications.
Touch screen monitor works with a gloved hand and
features a 21.5-inch widescreen HD display.
NEW! Multi-pass groove and fillet assignments designed by
Miller and the capability to develop customized assignments
based on user applications.
NEW! LiveArc PC software is available for free installation on
a separate PC. Data can be transferred to and from PC for
reviewing student progress and managing assignments/users.
NEW! English and Spanish translations are available on
all LiveArc systems.
Motion-tracking cameras provide
feedback on gun parameters.
SmartGun is an industryexclusive 400-amp MIG gun
featuring built-in LEDs that are
tracked by the system’s
cameras. The ergonomic softgrip handle provides tactile
vibration feedback that helps
guide real-time performance
adjustments, reinforcing optimal
position and movement.
LiveArc system
shown with
optional welding
positioning arm.
LiveArc system
comes complete with
with 15 ft. (4.6 m) cable
• SmartGun
(#270 698)
tool (#266 768)
• Calibration
Two
table
clamps
(#257 285)
• Extra Tregaskiss consumables
•
LiveArc system with
welding positioning arm
includes above plus
assembly (#270 727)
• Arm
assembly (#270 725)
• C-clamp
arm extension for right• Removable
and left-hand applications (#270 728)
update for welding
• Software
positioning arm
Stock Number
(#301 233) LiveArc system only
(#301 233 001) LiveArc system with
welding positioning arm
(#301 234) Welding positioning arm
only (includes software for arm)
OLED display on gun provides initial visual
feedback to guide proper gun positioning.
Pushbuttons provide a convenient alternative
to the touch screen for navigation.
Rugged ArcStation™ base features a 1/2-inch reversible
steel table top and ships complete with drawers, gun holder,
quick-release clamps and heavy-duty casters for mobility.
Calibration tool is easy
to use and enables
flexible coupon placement by making the
system aware of the
exact joint location.
Optional welding
positioning arm is
available for training
in out-of-position
welding applications.
Assignment selection screen
Guides the user through a range of
targeted exercises
Includes a library of Miller-designed
assignments and the flexibility to
configure customized assignments
Offers assignment completion status,
history summary and easy access to
detailed performance history data
•
•
•
Welding procedure specification
(WPS) screen
Guides the user through proper selection
and preparation of materials
Provides correct power source and wire
feeder settings
Provides target values and limits for
various parameters
Assignment parameters can be
configured to suit the skill level
(and scoring potential) of the user
Displays instructor-determined target
score and assignment completion criteria
•
•
•
•
•
Post-weld feedback screen
Data is provided following tests in both
simulation and live arc modes
Performance feedback on various
parameters is provided
All test data is stored and allows for
monitoring and evaluation
•
•
•
Process
Position
Multi-Pass
Input Power
Rated Output
Computer
Monitor
Dimensions
Net Weight
GMAW/GMAW-S/
GMAW-P/FCAW-G
2F/3F/4F/1G/
2G/3G/4G
Groove
and fillet
up to 1 in.
(25 mm)
plate
120 V, 60 Hz
Compatible with
Miller wire feed
power sources
400 A at
60% duty cycle
(mixed gases)
Intel core i7,
128 GB SSD,
fanless cooling,
HDMI port supports
secondary monitor
(not included)
21.5 HD
LCD touch
screen
display
H: 77.5 in. (1,969 mm)
W: 41.5 in. (1,054 mm)
W: 46 in. (1,168 mm)
with welding positioning arm
D: 31 in. (787 mm)
System only
366 lb. (166 kg)
System with arm
480 lb. (218 kg)
Arm only
72 lb. (33 kg)
93
Welding Safety & Health
All of our products are designed and built to protect the welder behind the hood and their environment —
because that’s what we know. By listening to welders and working with them side-by-side, we understand their
pain points and have developed products that offer protection from the unique physical dangers and health risks
prevalent within welding applications. Miller’s complete line of Head and Face, Hand and Body, Heat Stress, and
Weld Fume protection is designed to protect and perform in demanding welding, cutting and grinding applications.
Welding Helmets
For more detailed
information, visit
MillerWelds.com/safety
Serious dependability backed with a
three-year warranty (unless noted).
See page 96 for helmet accessories and packages.
Digital
Titanium
9400i™
Digital
Titanium
9400™
Digital
Titanium
7300™
Titanium
1600i™
Titanium
1600™
Digital
Infinity™
Digital
Elite™
Digital
Performance™
Classic
Series
VSi™
Classic
Series
VS
Classic
Series
FS#10
Flip-Up
Classic
Series
FS#10
9.2 sq. in.
9.2 sq. in.
7.2 sq. in.
16 sq. in.
16 sq. in.
13.4 sq. in.
9.2 sq. in.
7.2 sq. in.
5.9 sq. in.
5.2 sq. in.
5.1 sq. in.
5.2 sq. in.
Yes
Yes
Yes
—
—
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Shades
Cut: 5–8
Weld: 8–13
Cut: 5–8
Weld: 8–13
Cut: 5–8
Weld: 8–13
10
10
Cut: 5–8
Weld: 8–13
Cut: 5–8
Weld: 8–13
Cut: 5–8
Weld: 8–13
8–13
8–12
10
10
Modes
Weld/Cut/
X-Mode/
Flip grind
Weld/Cut/
X-Mode/
External grind
Weld/Cut/
X-Mode/
External grind
Passive weld
Passive weld
Weld/Cut/
Grind/X-Mode
Weld/Cut/
Grind/X-Mode
Weld/Cut/
Grind
Weld/X-Mode/
Flip grind
Weld
Weld/
Flip grind
Weld
Integrated
Grind Shield
Yes
—
—
Yes
—
—
—
—
Yes
—
Yes
—
Auto-on
Yes
Yes
Yes
—
—
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Sensors
4
4
3
—
—
4
4
3
3
2
2
2
5 amps/below
5 amps/below
5 amps/below
—
—
5 amps/below
5 amps/below
5 amps
5 amps/below
20 amps
20 amps
20 amps
Switching Speed
1/20,000
1/20,000
1/20,000
—
—
1/20,000
1/20,000
1/20,000
1/20,000
1/10,000
1/3,600
1/3,600
Digital Controls
Yes
Yes
Yes
—
—
Yes
Yes
Yes
—
—
—
—
Prem. Headgear
Yes
Yes
Yes
—
—
Yes
Yes
Yes
—
—
—
—
InfoTrack™
Yes
Yes
Yes
—
—
Yes
—
—
—
—
—
—
24 oz. (680 g)
20 oz. (567 g)
23 oz. (652 g)
18 oz. (510 g)
17 oz. (482 g)
23 oz. (652 g)
16 oz. (454 g)
14 oz. (396 g)
16 oz. (454 g)
3 years
3 years
3 years
3 years
3 years
2 years
2 years
2 years
2 years
Viewing Area
Auto-Darkening
TIG Rating
Weight
Warranty
See chart
above for
feature
availability.
19 oz. (539 g) 22.5 oz. (638 g) 17 oz. (482 g)
3 years
30 days
30 days
X-Mode.™ Electromagnetically senses the weld to eliminate
sunlight interference and continuously detects the arc even if
sensors are blocked.
Industry’s largest viewing area. Digital Infinity™ Series helmets
feature a 13.4 square inch viewing area allowing for a wide
range of view.
InfoTrack™ arc tracking technology features arc time, time
and timer functions, and a multi-language help menu.
Premium headgear. Features ample adjustability settings and
enhanced support for the perfect fit, maximizing comfort.
Titanium Series™
Designed to perform in the most intense industrial applications. See literature no. AY/41.0
operating modes: weld, cut,
• Four
grind and X-Mode (not available
on 1600/1600i models)
shell reflects heat to keep
• Silver
helmet and user cool
heat shield protects
• Aluminum
auto-darkening lens in
™
high-amperage applications
Titanium 9400i™
#256 177
(features integrated grinding shield)
94
Titanium 9400™
#256 176
Titanium 7300™
#256 175
Titanium 1600i™
#255 519
(features integrated grinding shield)
Titanium 1600™
#245 799
Welding Safety & Health
Digital Infinity™ Series
Largest-view helmets for demanding applications. See literature no. AY/42.0
viewing area in the
• Largest
industry at 13.4 square inches
arc sensors and four modes:
• Four
weld, cut, grind and X-Mode
™
Black
#271 329
Departed™
#271 332
Black Ops™
#271 333
Digital Elite™ Series
Black
#257 213
Camouflage
#271 331
Stars and Stripes™
#271 330
Versatile helmets for demanding applications. See literature no. AY/43.0
Lucky’s Speed Shop™
#257 214
Vintage Roadster ™
#259 485
Inferno™
#257 217
Camouflage
#256 173
Pink Camo
#273 953
square inch viewing area
•• 9.2
Four arc sensors and four modes:
weld, cut, grind and X-Mode
™
Includes $10 Donation
to The National League
of POW/MIA Families
©2015 Caterpillar. CAT,
CATERPILLAR, BUILT FOR IT
and their design marks are
registered trademarks of
Caterpillar. Miller Electric Mfg. Co.
is a licensee of Caterpillar Inc.
Cat® Edition 1
#268 618
Stars and Stripes™ III
#264 852
Blue Flame
#269 273
Digital Performance™ Series
Hot Rod Garage™
#269 946
Not Forgotten™
#260 127
Miller will be donating
$10 to the National League
of POW/MIA Families
(pow-miafamilies.org)
for each Not Forgotten
helmet sold.
Mid-range helmets for most welding applications. See literature no. AY/44.0
square inch viewing area
•• 7.2
Three arc sensors and three
modes: weld, cut and grind
Black
#256 159
Cat® Edition 1
#268 739
Classic Series
America’s Eagle™ II
#264 851
Blue Rage™
#256 164
’64 Custom™
#256 160
Camouflage
#256 163
MP-10™ Series
Helmets for the value-minded welder. See literature no. AY/45.0
Passive, non-auto-darkening helmets.
VSi ™
#260 938
Black (VS)
#251 292
Stars and
Stripes™
#271 345
Metalworks™
#271 346
Red Flame
#271 347
Camouflage
#271 348
VS graphic models
FS#10
Flip-Up
#263 038
shade
• Passive
10 lens
to
• Upgradable
auto-darkening
FS#10
#231 703
(4 pack)
Flip-Up and VSi models
• FS#10
feature integrated grinding shield
• VSi model features X-Mode
lens with kit
#236 052
Black
Inferno™
#238 497 (each) #238 496
#235 626 (6 pack)
95
Welding Safety & Health
Helmet Accessories and Packages
Gen II Headgear #256 174
2x4 Auto-Darkening Lens
•
#770 660 Shade 8
#770 659 Shade 9
#770 226 Shade 10
#770 961 Shade 11
Fits all 2x4-inch windows
Solar powered, two arc sensors
Light state shade 3
Two-year warranty
Extensive adjustability settings
and a pivoting top for better fit
and comfort
••
••
Helmet Hook #251 018
welding helmets,
• Holds
grinding shields or other
helmets with a headgear
strap secures the
• Silicone
helmet in place
Gen III Headgear #271 325
comfort cushion
• Oversized
provides extensive adjustability,
settings, and enhanced support
Slotted Hard Hat Adapter
#259 637
Compatible with most slotted
hard hats. Helmet and hat not
included
•
Protection Paks
Pak
• Starter
Includes #251 292 Classic VS helmet
Helmet Bib #253 882
•
Hard Hat Adapter
#213 110 XL and XLi
#222 003 All other Miller Series
Compatible with Fibre Metal and
MSA hats. Other brands may fit
depending on size and shape.
Helmet and hat not included
Attaches to bottom of the helmet
with hook-and-loop fasteners for
added neck coverage
Jobsite Tool Bag #228 028
•
•
twenty separate pockets
•• Over
Opening of 12 x 18.5 inches
(305 x 470 mm)
Goggles
Weld-Mask™
Auto-Darkening
Goggles
Performance
Pak shown.
and Classic Cloth jacket
#255 848 Large
#255 850 X-Large
#255 851 2X-Large
Performance Pak
Includes #256 159 Performance helmet
and Indura® Cloth jacket
#240 886 Large
#240 887 X-Large
#240 888 2X-Large
Safety Glasses
Classic
#267 370
See literature no. AY/40.0
Slag
Spark
Classic w/strap
Spatter
coating and high-quality
designs meet ANSI
lenses provide shade
• Anti-fog
• Wrap-around
• Smoke
optics
side shield requirements
protection in outdoor applications
orbital eye coverage
(indoor/outdoor) lenses feature • Shade 3 and 5 green IR lenses are
•• Form-fitting
• I/O
Shatterproof polycarbonate lenses
light shading with a mirrored finish
for cutting, brazing or soldering
ANSI Z87.1+ compliant
•
Safety and Cutting Glasses Chart See literature no. AY/41.0
design allows users to weld in spaces where access
• Compact
with traditional welding helmets is limited
for maintenance, repair, and installation or as an
• Ideal
alternative for plasma cutting glasses
design virtually eliminates neck strain and eye
• Lightweight
covering fits tightly to face to block out light for precision
welding in bright areas
shield and head cover provide coverage for UV/IR rays
• Face
and applications with limited spatter
• Goggles feature shades 5, 7, 9, 11 and 13 (light state shade 3)
Head Threads
•
•
Bandannas have a sewn-in sweatband
Caps are reversible with a low, soft bill
96
Frame Style/Color
Clear
I/O
Smoke
Shade 3
Shade 5
Classic
#272 187
—
—
—
—
Classic with Strap
#272 188
—
—
—
—
Spark™
#272 190
—
—
—
—
Spatter™ - Black
#272 191
—
#272 195
—
—
Spatter™ - White
#272 198
—
#272 199
—
—
Slag™ - Black
#272 201
#272 202
#272 203
#272 204
#272 205
Slag™ - White
#272 206
#272 207
#272 208
#272 196
#272 209
Gen I - Black
#238 979
—
#235 656
#235 662
#235 658
Head Thread Size Chart
Caps
Size 7
Size 7-1/8
Size 7-1/4
Size 7-3/8
Size 7-1/2
Size 7-3/4
American Pride
#230 553
#230 554
#230 555
#230 556
#230 557
#230 558
Blue Flame
#230 535
#230 536
#230 537
#230 538
#230 539
#230 540
Dragon
#230 547
#230 548
#230 549
#230 550
#230 551
#230 552
Ghost Skulls
#230 541
#230 542
#230 543
#230 544
#230 545
#230 546
Bandannas
Black
#250 904
Dragon
#230 560
Maple Leaf
#250 905
Skull & Barbed Wire
#230 559
(One size only)
Welding Safety & Health
Welding Apparel
Men’s
Women’s
Leather Jacket
WeldX™ Jacket
Combo Jacket
Indura® Cloth Jacket
Classic Cloth Jacket
(See size chart)
Top grain leather
Expandable leather strategically
placed for optimal mobility
Flame-resistant inside cuff
Satin lined
Tapered, athletic cut
(See size chart)
Lightweight exclusive material with
extreme flame-resistant properties
7-ounce WeldX front and flameresistant navy cotton back
Vented back/extended rear tail
Zipper closure with hook-andloop fastened flap
Chromium free
(See size chart)
Indura® flame-resistant cotton
(flame resistance guaranteed for
life of jacket)
Top grain leather
Allows for patented bib/apron
attachment
Men’s and Women’s
(See size chart)
Indura® flame-resistant cotton
(flame resistance guaranteed for
life of jacket)
Nomex® flame-resistant thread
(See size chart)
9-ounce flame-resistant navy
cotton
Pre-shrunk fabric
Fold-in sleeve snaps
Finished hems and reinforced
stitching
••
••
•
WeldX™ Cape Sleeves
(See size chart)
7-ounce WeldX front and
flame-resistant navy cotton
back
Fold-in sleeve snaps
Allows for bib attachment
(sold separately)
•
••
•
•
••
•
•
••
•
•
•
••
•
Classic Cloth Cape
Sleeves
Classic Cloth Lab Coat
WeldX™ Apron
Classic Cloth Apron
Bib/Apron
(See size chart)
9-ounce flame-resistant
navy cotton
Fold-in sleeve snaps
Allows for bib attachment
(sold separately)
(See size chart)
40-inch length
9-ounce flame-resistant
navy cotton
Fold-in sleeve snaps
Finished hems and
reinforced stitching
••
••
#247 134
35-inch length with
accessible front pocket
Adjustable drawstring
ensures a good fit
#247 149
35-inch length with
accessible front pocket
Adjustable drawstring
ensures a good fit
#231 125
Attaches to Indura®
combo jacket with
snaps across the chest
as a bib or along the
bottom as an apron
•
••
•
•
•
•
•
WeldX™ Bib
Classic Cloth Bib
WeldX™ Sleeves
Classic Cloth Sleeves
Combo Sleeves
#247 133
19-inch length
Attaches to cape sleeves
#247 147
19-inch length
Attaches to cape sleeves
#247 137
18-inch length
Fold-in sleeve snaps
One-handed cinch closure
#247 148
18-inch length
Fold-in sleeve snaps
One-handed cinch closure
#231 096
Indura® flame-resistant
cotton/top grain leather
21-inch (533 mm) length
••
••
Welding Apparel Size Chart
••
•
••
•
•
•
Apparel
Small
Medium
Large
X-Large
2X-Large
3X-Large
4X-Large
Leather Jacket
#231 088
#231 089
#231 090
#231 091
#231 092
#231 093
#231 094
#231 095
WeldX Jacket
#247 114
#247 115
#247 116
#247 117
#247 118
#247 119
#247 120
#247 121
Combo Jacket
#231 080
#231 081
#231 082
#231 083
#231 084
#231 085
#231 086
#231 087
Indura Cloth Jacket (Men’s)
#258 095
#258 097
#258 098
#258 099
#258 100
#258 101
#258 102
#258 104
Indura Cloth Jacket (Women’s)
#264 379
#264 380
#264 381
#264 382
#264 383
Classic Cloth Jacket
#244 749
#244 750
#244 751
#244 752
#244 754
#244 755
WeldX Cape Sleeves
#247 122
#247 123
#247 124
#247 126
#247 127
#247 128
#247 130
#247 131
Classic Cloth Cape Sleeves
#247 138
#247 139
#247 140
#247 142
#247 143
#247 144
#247 145
#247 146
#252 000
#252 001
#252 002
Classic Cloth Lab Coat
—
—
—
—
—
#244 756
—
5X-Large
—
#244 758
—
97
Welding Safety & Health
Welding Gloves
Performance — unprecedented comfort and performance, redefining the welding glove industry.
Three-dimensional pattern, select-grade leather and precision craftsmanship with unique design
features for specific welding applications. Exceptional dexterity and flexibility.
Extra Heavy-Duty MIG/Stick
Heavy-Duty MIG/Stick
(Long Cuff)
Heavy-Duty
MIG/Stick
•
•
•
#263 342 X-Large
Padded forearm for additional
protection and comfort
Triple-layered insulated back
Strategically placed patches on
pig grain palm and cow split back
for extended glove life
Heavy-Duty MIG/Stick
MIG/Stick
#271 877 Large
#271 887 X-Large
Reflective insulation
on back reduces
heat impact
Moisture-wicking
fleece and foam
insulation
Pig grain palm, pig
split back and cuff
#263 339 Large
#263 340 X-Large
#269 615 2X-Large
Strategically placed patches on
palm and back for extended
glove life
Double-layered insulated palm
and back
Pig grain leather palm provides
extreme durability and protection
#263 343 Large
#263 344 X-Large
#269 616 2X-Large
Dual-padded palm for added
comfort
Wool back provides ultimate
insulation
Cow split leather provides extreme
durability and protection
MIG (Lined)
MIG (Unlined)
#263 330 X-Small (Women’s)
#263 331 Small (Women’s)
#263 332 Medium
#263 333 Large
#263 334 X-Large
#269 618 2X-Large
Dual-padded palm
Fleece insulated palm, foam
insulated back
Cow grain palm, pig split back and
goat grain inner fingers provide
exceptional dexterity and comfort
#263 335 Medium
#263 336 Large
#263 337 X-Large
#269 619 2X-Large
Unlined palm for heightened feel
and dexterity
Double-layer insulated back and
dual-padded palm for added
comfort
Cow grain palm, cow split back
and goat grain inner fingers provide
exceptional dexterity and comfort
TIG
TIG/Multitask
#263 345 X-Small (Women’s)
#263 346 Small (Women’s)
#263 347 Medium
#263 348 Large
#263 349 X-Large
Completely unlined for heightened
feel and dexterity
Triple-padded palm for added
comfort
Goat grain leather offers superior
flexibility and dexterity
#263 352 Small
#263 353 Medium
#263 354 Large
#263 355 X-Large
Dual-padded palm for added
comfort
Wool back provides ultimate
insulation
Goat grain leather offers superior
flexibility and dexterity
Work
Metalworker
#266 041 Medium
#266 042 Large
#266 043 X-Large
Dual-padded palm for added
durability
Fleece back provides ultimate
insulation
Cow grain leather offers superior
durability and abrasion resistance
#251 066 Medium
#251 067 Large
#251 068 X-Large
Durable top grain leather and
spandex back for enhanced
durability and dexterity
Neoprene wrist with hook-and-loop
closure increases fit and support
Padded, reinforced palm and
thumb saddle for extended wear
#263 350 Large
#263 351 X-Large
An industry first! Silicone
patches on back for heat and
spatter protection
Multi-layered insulated palm
and back
Dual-padded, pig grain palm for
added comfort
•
•
•
••
•
•
•
•
•
•
•
98
Classic —
traditional design for the
value-minded welder.
•
••
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
MIG
#271 888 Large
#271 889 X-Large
Reinforcement
patches enhance
durability
Moisture-wicking
fleece and foam
insulation
Pig split leather
palm, back and cuff
•
•
•
MIG
#271 890 Large
#271 891 X-Large
Reinforcement
patches enhance
durability
Moisture-wicking
fleece and foam
insulation
Goat split palm, pig
split back and cuff
•
•
•
TIG
#271 892 Medium
#271 893 Large
#271 894 X-Large
Thin internal padding
for added comfort
Unlined palm for
precise dexterity
Sheep grain palm,
goat split back, pig
split cuff
•
•
•
Welding Safety & Health
Respiratory
N95 Disposable Mask Respirator See literature no. AY/4.8
#267 334 Respirator, 10 pack
#267 334-2 Respirator, 2 pack
#267 335 Respirator with nuisance level OV relief, 10 pack
#267 335-2 Respirator with nuisance level OV relief, 2 pack
Flame-retardant outer layer designed for welding applications
Exhaust valve reduces heat build-up and user fatigue
Ergonomic design and adjustable nose clip for customized fit
Full inside foam seal enhances fit and overall protection
Fit testing is required for mandatory use
N95 filters provide 95-percent filtration of airborne particles, specifically:
hexavalent chromium, zinc oxide, manganese, aluminum, cadmium and lead
NIOSH 42 CFR 84 certified, assigned protection factor of 10
••
••
••
•
PAPR Powered Air-Purifying Respirator See literature no. AY/4.0
LPR-100™ Half Mask Respirator See literature no. AY/4.5
#ML00894 Respirator with P100 filters, small/medium
#ML00895 Respirator with P100 filters, medium/large
#ML00994 Respirator with P100 nuisance level OV relief filters, small/medium
#ML00995 Respirator with P100 nuisance level OV relief filters, medium/large
Filters and accessories
#SA00818 P100 filters, one pair
#SA00819 P100 nuisance level OV relief filters, one pair
#261 086 Quantitative fit-test kit adapter
Low-profile design fits under most welding helmets and provides maximum field
of vision
Wrap-around spark guard protects filters from spatter and other debris
Large exhaust valve eases breathing
Odor-free, non-allergenic, latex and silicone free, made from medical-grade materials
Exclusive pleated filter design provides additional surface area for extended filter life
Fit testing is required for mandatory use
P100 filters provide 99.97-percent filtration of airborne particles and oil aerosols,
specifically: hexavalent chromium, zinc oxide, manganese, aluminum, cadmium
and lead
NIOSH 42 CFR 84 certified, assigned protection factor of 10
•
••
••
••
•
Available packages:
With hard hat
#261 659 With Titanium 9400i™ helmet
#259 385 With Titanium 9400™ helmet
#259 386 With hard hat only
With Titanium 9400i™ helmet
#264 877 With auto-darkening lens assembly
#264 878 Without auto-darkening lens assembly
With Titanium 9400™ helmet (external grind button)
#264 879 With auto-darkening lens assembly
#264 882 Without auto-darkening lens assembly
Lightweight, low-profile blower design provides enhanced comfort and
unrestricted movement
Comfortable load-bearing shoulder straps reduce back strain
Dual air speeds for maximized comfort in varied conditions
Audible and vibrating alarms notify users in noisy environments
HEPA filter provides 99.97-percent filtration of airborne particles and oil aerosols,
specifically: hexavalent chromium, zinc oxide, manganese, aluminum, cadmium
and lead
NIOSH 42 CFR 84 certified, assigned protection factor of 25
•
••
••
•
Heat Stress
Note: Not compatible
with XL Series™ helmets.
Note: Not compatible with
XL Series™, Classic VSi ™ and
Titanium 9400i ™ helmets.
CoolBand™ II Integrated Headgear Cooling System #261 970
CoolBelt™ Belt-Mounted Cooling System #245 230
••
••
to 17 degrees Fahrenheit cooler under the hood
•• UpProvides
all-day comfort through maximized airflow power
airflow speeds eliminate stagnant air and reduce fogging
•• Multiple
Lightweight design extends wearability
Up to 8 degrees Fahrenheit cooler under the hood
Strategically placed air vents reduce fogging
Constant air movement removes stagnant air
Comes with headgear (#256 174)
99
Welding Safety & Health
Choose the Right Fume Extractor
Miller’s complete line of FILTAIR® fume extractors are designed specifically for welding — drawing
weld fumes away from the user’s breathing zone and keeping your facility clean. We offer many
types of fume extraction equipment to best fit your environment and fume control needs.
For more detailed
information, visit
MillerWelds.com/filtair
FILTAIR
130
400
SWX
MWX
Capture 5
2000–12000
Weld Fume
Extractor Type
Portable, high-vacuum
Stationary, high-vacuum
suited for use with fume
guns and/or attachments
Stationary, low-vacuum
suited for wall or column
mounting
Mobile, low-vacuum
Mobile, low-vacuum with
the industry’s largest
capture zone
Centralized, low-vacuum
customizable systems
Ideal For
Contractors, maintenance
and repair operations,
light fabrication work and
light manufacturing
Fabrication, manufacturing,
and maintenance and repair
operations
Fabrication shops,
manufacturing, and training
centers where weld areas
are near filtration system
Fabrication shops,
manufacturing, and
training centers
Manufacturing and
fabrication — the best
solution for weldments
over 18 inches long
Manufacturing, hand-held and
automation, fabrication shops,
and training facilities
Welding Arcs
1
Up to 6 per unit
Up to 2 per unit
1
1
Up to 16 per unit
Filter Type
Manual cleaning
Self-cleaning (automatic)
SWX-D: Disposable
SWX-S: Self-cleaning
MWX-D: Disposable
MWX-S: Self-cleaning
Self-cleaning (automatic)
Self-cleaning
(automatic/programmable)
Processes
®
FILTAIR 130 and 400
See literature no. AY/3.1 (130) and AY/3.3 (400)
Portable (130 model) and stationary (400 model) high-vacuum weld fume extractors designed
for use with accessories like nozzles and fume guns to collect weld fume particles at the source.
Features common to all models
FILTAIR 130
(includes 8-ft.
collection hose)
Designed to capture weld fume. The MERV 15 rating
of FilTek XL filters provides superior filtering of up to
95 percent of weld fume particulate.
(SMAW) • Flux-cored (FCAW)
• Stick
• MIG (GMAW) • TIG (GTAW)
Comes with
XL filter
• FilTek
hose (130 model only)
• 820ft.ft.collection
power
cord
(130 model only)
•
Most popular consumables
Filters
• Replacement
#301 267 For 130 model (cleanable)
®
#300 925 For 400 model
Most popular accessories
Hose
• Collection
#300 672 17 ft. (5.2 m)
FILTAIR 130 features
Unrivaled filtering performance. Designed to capture
weld fume particles with a cleanable filter and safely
deposit them in an integrated particle bin.
#300 673 34 ft. (10.4 m)
Nozzles
• Magnetic
#300 669 11.8 in. (300 mm) width
Less noise. Up to 70 percent quieter than some other
extractors. Only 68.5 decibels at five feet.
#300 670 23.6 in. (600 mm) width
(400 model only)
Portable and compact. At only 46 pounds (21 kg) the
vertical-shaped machine is easy to move around.
Funnel Magnetic Nozzle
• Flexible
#300 668
Hose Inlet
• Dual
to Duct Adapter
FILTAIR 400 features
FILTAIR 400
(collection hoses
not included,
order separately)
Extraction flexibility. Capable of utilizing more than
60 feet of collection hose to extend accessories for
fume extraction. Rigid ducting can be used to extend
overall reach.
User flexibility. With four-port access, the unit can
remain centrally located while providing mobility of
source capture accessories.
•
Extract at the source. Designed for solid and flux-cored
wires for most welding applications. MIG fume guns are
available in models ranging from 300 to 600 amps.
•
Model/Stock Number
Accu-Rated™ Airflow
Sound Level
Motor
Input Power
Dimensions
Net Weight
FILTAIR 130 (#300 595)
132 cfm (62 L/sec.)
68.5 dBA at
5 ft. (1.5 m)
1 hp
115 V, 1-phase, 60 Hz
at 11 A
H: 23 in. (584 mm)
W: 12 in. (305 mm)
D: 12 in. (305 mm)
46 lb.
(21 kg)
FILTAIR 400 (#300 894)
400 cfm (189 L/sec.)
74 dBA at
5 ft. (1.5 m)
8.85 hp
460 V, 3-phase, 60 Hz
H: 54 in. (1372 mm)
W: 26 in. (660 mm)
D: 48 in. (1,219 mm)
551 lb.
(250 kg)
100
(400 model only)
#301 070
Y-shaped adapter
connects duct to
one or two hose
attachments.
Bernard™ FILTAIR
Fume Extraction
MIG Gun (pg 47)
Ideally suited for
almost any solid-wire
welding application.
Available in 300 and
400 A models.
Bernard™ Clean Air™
Fume Extraction
MIG Gun (pg 47)
Suited for use with
solid and flux-cored
wires. Available in
400, 500 and
600 A models.
Welding Safety & Health
®
FILTAIR SWX and MWX Series
See literature no. AY/3.2
(SWX) and AY/3.0 (MWX)
Powerful systems mounted next to the weld area or easily positioned near the weld area.
Disposable or cleanable filter models for multiple applications.
Features common to all models
Designed to capture weld fume. The MERV 15
rating of FilTek XL filters provides superior filtering
of up to 95 percent of weld fume particulate.
Class-leading suction power of 875 cfm is
Accu-Rated™ at the hood to better capture weld
fumes and provide a cleaner environment.
SWX wall- or column-mounted
fume extraction systems
designed specifically
for welding.
Superior filters. Our FilTek XL filters are specifically
designed for welding with a MERV 15 rating to
outlast, out-filter, and outperform all the rest.
SWX-D (disposable filter)
model with telescoping
arm shown.
SWX models are available with telescoping arm which
can extend from 3 to 4.5 feet, making them ideal for
smaller spaces.
Durable aluminum pre-assembled extraction
arm with external adjustments for better airflow
and longer life.
Self-cleaning models additional features
(SMAW) • Flux-cored (FCAW)
• Stick
• MIG (GMAW) • TIG (GTAW)
Comes with
XL filter
• FilTek
• Pre-assembled arm
Most popular consumables
Filters
• Replacement
#300 540
®
Self-cleaning models
#300 539
Disposable filter models
FilTek XL filters efficiently capture the
smallest weld fume particles and
offer superior filter life.
Most popular accessories
Light with
• Hood
Arc Sensor
#300 763
For SWX Series
#300 689
For MWX Series
Illuminates the welding zone and
enables the fume extractor to start
automatically when welding begins.
Unrivaled filtering performance. Designed to
capture weld fume particles with a cleanable
filter and safely deposit them in an integrated
particle bin.
Quick and efficient cleaning cycle operates with
a push of a button on the control panel.
Note: Compressed air required to operate cleaning mechanism.
Disposal drawer provides easy and convenient
access to empty out collected particles. Handle
releases drawer allowing it to slide out.
MWX mobile fume
extraction systems
designed specifically
for welding.
Processes
Upgrade to self-cleaning models for high arc-on
time, extracting from heavy fume processes, or
when welding aluminum or galvanized materials.
Dual-Arm Add-On Packages
• SWX
#951 621 With telescoping arm
#951 519 With 7 ft. standard arm
#951 520 With 10 ft. standard arm
#951 521 With 12 ft. standard arm
Includes 8-inch diameter arm, blower,
control box, mounting bracket, duct
and back draft dampers to turn
single-arm weld fume extractor into
dual-arm extractor.
MWX-S (self-cleaning)
model with 10 ft.
extraction arm shown.
Filter
Media
Accu-Rated™
Airflow
Extraction
Arm
Diameter
Sound Level
Motor
Input Power
Dimensions
Net Weight without Arm
SWX-S (Self-Cleaning Model) Pkg
(#951 620) Telescoping arm
(#951 516) 7 ft. standard arm
(#951 517) 10 ft. standard arm
(#951 518) 12 ft. standard arm
SWX-D (Disposable Filter) Pkg
(#951 619) Telescoping arm
(#951 513) 7 ft. standard arm
(#951 514) 10 ft. standard arm
(#951 515) 12 ft. standard arm
490 sq. ft.
(45.52 sq. m)
875 cfm
(413 L/sec.)
8 in.
(203 mm)
Approximately
74 dBA at
5 ft. (1.5 m)
1 hp,
3,450
rpm
115 V, 1-phase,
60 Hz at
approximately
11.9 A
SWX-S H: 33 in. (838 mm)
SWX-D H: 29 in. (737 mm)
W: 27.25 in. (692 mm)
D: 33 in. (838 mm)
SWX-S 195 lb. (88 kg)
SWX-D 130 lb. (59 kg)
Blower/bracket
95 lb. (43 kg)
MWX-S (Self-Cleaning Model) Pkg
(#951 510) 7 ft. standard arm
(#951 511) 10 ft. standard arm
(#951 512) 12 ft. standard arm
MWX-D (Disposable Filter) Pkg
(#951 507) 7 ft. standard arm
(#951 508) 10 ft. standard arm
(#951 509) 12 ft. standard arm
490 sq. ft.
(45.52 sq. m)
875 cfm
(413 L/sec.)
8 in.
(203 mm)
Approximately
70 dBA at
5 ft. (1.5 m)
1 hp,
3,450
rpm
115 V, 1-phase,
60 Hz at
approximately
11.9 A
H: 34.75 in. (883 mm)
W: 31.75 in. (806 mm)
D: 48 in. (1,219 mm)
MWX-S 300 lb. (136 kg)
MWX-D 238 lb. (108 kg)
Model/Stock Number
101
Welding Safety & Health
Processes
®
FILTAIR Capture 5
See literature no. AY/3.5
The capture zone redefined. Innovative, extended-capture fume extraction system designed
specifically for welding.
(SMAW) • Flux-cored (FCAW)
• Stick
• MIG (GMAW) • TIG (GTAW)
Comes with
XL filter
• FilTek
Durable, easy-to-move, pre-assembled,
• aluminum
extraction arm with toolless
®
external adjustments for higher
airflows and longer filter life
Most popular consumable
Capture
Zone
Conventional
Capture 5
ZoneFlow
Conventional technology
capture zone is a maximum
of 18 inches. ZoneFlow
technology increases the
capture zone up to 5 feet!
FilTek XL Filter
• Replacement
#301 106
Filter is designed for the Capture 5
automatic self-cleaning system.
ZoneFlow™ technology. Extends the capture area up
to five feet versus 12 to 18 inches with conventional
source capture arms. See illustration above.
Minimizes downtime with fewer fume extractor
adjustments. With increased capture area, arm
interactions are dramatically minimized.
Designed to capture weld fume. The MERV 15 rating
of FilTek XL filters provides superior filtering of up to
95 percent of weld fume particulate.
Source capture is designed to draw weld fume
away from the welder’s breathing zone and keep the
facility clean.
Stock Number
Inc
rea
sin
g
Eff
ect
ive
ne
ss
With 10 ft. Extraction Arm
(#951 639) 208/230 V
(#951 574) 460 V
(#951 594) 575 V
With 12 ft. Extraction Arm
(#951 640) 208/230 V
(#951 575) 460 V
(#951 595) 575 V
Filter
Media
Accu-Rated™
Airflow
Extraction
Arm Diameter
452 sq. ft.
(42 sq. m)
900 cfm
(425 L/sec.)
10 in.
(254 mm)
Process Change
Hobart® Element™ Wire
Process Miller® Welding Automation
Modification Miller® Advanced Pulse Processes
/Substitution
Engineering
Controls
Fume Capture
Miller® FILTAIR® Fume Extractors
Bernard™ Fume Guns
Work Practice Controls
Personal Protective Equipment
102
Training
Miller®LiveArc™ Training System
Miller® Welding Helmets
Respirators
Miller®Respirators
Sound Level
Motor
Input Power
Dimensions
Net Weight
Approximately
77 dBA at
5 ft. (1.5 m)
3 hp,
3,450 rpm
208/230 V, 1-phase, 60 Hz at 13.5 A
460 V, 3-phase, 60 Hz at 3.7 A
575 V, 3-phase, 60 Hz at 3.0 A
H: 43 in. (1,092 mm)
W: 36 in. (915 mm)
D: 48 in. (1,219 mm)
620 lb. (282 kg)
with 12 ft. arm
Weld Fume
Management
We are committed to providing exclusive
technologies designed specifically around your
weld fume challenges. Find out how our portfolio
of solutions fulfills each tier of OSHA’s Hierarchy
of Controls at MillerWelds.com/fumesolutions.
Welding Safety & Health
Processes
®
FILTAIR 2000–12000
See literature no. AY/3.4
The industrial centralized weld fume extractors are custom engineered solutions designed for
multiple capture sources which require ducting and accessories to complete the system.
(SMAW) • Flux-cored (FCAW)
• Stick
• MIG (GMAW) • TIG (GTAW)
Custom solutions
to source fume extraction
• Configured
for ambient push-pull
• Configured
collection
Comes with
FILTAIR engineering resources. Design and engineering resources
recommend, develop and support custom-engineered solutions.
Improves operating efficiency. Creates a cleaner shop with less
downtime spent cleaning equipment. Raises productivity with more
motivated employees and fewer absences and helps meet OSHA
and EPA compliance.
XL filter
• FilTek
Top
or
front
inlet
• Configured forairindoor
or outdoor
• mounting (outdoor models
are wind
®
load and seismic rated and include
remote-mounted control box)
Most popular consumable
Stand-alone space saver. Our fully assembled fume extractor
provides up to a 65 percent smaller footprint versus traditional
cartridge-style extractors. It provides all the necessary extraction
tools, while offering customizable options.
Less noise. Up to 75 percent quieter than cartridge-style extractors.
High-efficiency motors and integrated silencer housing create a
quieter, more productive work area.
Integrated electrical controls. Control panel manages all of the
collector functions, including the fan, the filter differential, and the
pulse cleaning system.
24 VDC motor start/stop feedback
relay allows an external signal to
automate the remote start of
collector fan from other equipment.
High-Efficiency Filter
• Replacement
#300 927
Most popular accessories
Arms (pg 104)
• Extraction
Mounting Bracket Kit (pg 104)
• Arm
Profile Hoods (pg 104)
• Low
Call
us
toll-free at 855-FILTAIR
• (855-345-8247)
for information on
factory options such as HEPA filter
kit, weather hood, Spark Cooler® and
integration services.
FilTek XL filters
Easy-clean filter with surface-loaded filter technology allows
for more effective weld fume pulse cleaning without penetration
into the filter. This provides an easier filter cleaning process, while
outlasting conventional cartridge filters.
FILTAIR 4000 model shown. Other models are available
(2000, 6000, 8000, and 12000).
Call us toll-free at 855-FILTAIR
(855-345-8247) for information
and requests for quotes on
custom engineered solutions to
fit your needs.
1 FilTek XL
Filter Pack
Replaces
Up To
3 Traditional
Filters
Smaller size and fewer filters. One FilTek XL filter replaces up to
three cartridge-style filters increasing efficiency, reducing extractor
size, and lowering operational costs.
*Based on clean filters. **Dimensions for base models without factory options.
Model
Nominal Airflow Range*
Number of
Filter Packs
FILTAIR 2000
960–3,200 cfm (453–1,510 L/sec.)
2
FILTAIR 4000
1,920–5,500 cfm (906–2,596 L/sec.)
4
FILTAIR 6000
2,880–8,640 cfm (1,359–4,078 L/sec.)
6
FILTAIR 8000
3,840–11,520 cfm (1,812–5,437 L/sec.)
8
FILTAIR 12000
5,760–13,440 cfm (2,718–6,343 L/sec.)
12
Sound Level
Input Power
Dimensions** (H x W x D)
72–75 dBA at
5 ft. (1.5 m)
Peak pulse
cleaning is
92.7 dBA at
5 ft. (1.5 m)
230, 460 or
575 V,
3-phase, 60 Hz
66.6 in. (1,692 mm)
31.2 in. (792 mm)
83.2 in. (2,113 mm)
1,300 lb. (590 kg)
86.1 in. (2,187 mm)
31.2 in. (792 mm)
83.2 in. (2,113 mm)
1,600 lb. (726 kg)
117.2 in. (2,977 mm)
31.2 in. (792 mm)
83.2 in. (2,113 mm)
2,250 lb. (1,021 kg)
135 in. (3,429 mm)
37.2 in. (945 mm)
83.2 in. (2,113 mm)
2,900 lb. (1,315 kg)
120.3 in. (3,056 mm)
59.7 in. (1,516 mm)
83.2 in. (2,113 mm)
3,900 lb. (1,769 kg)
Ship Weight
103
Welding Safety & Health
FILTAIR® Industrial Centralized Systems Accessories
Miller offers a full line of accessories for complete system solutions and turnkey installation.
Spark Cooler ®
Cools sparks using the fume extractor’s airflow
Very efficient — maximizes the extractor’s power
Simple design is easy to install
•
•
•
Telescoping arm
Standard arm
Arm mounting bracket
and ducting kit
Easy-to-operate, pre-assembled extraction arms and
mounting equipment
Telescoping arms are designed to fit small booth spaces used
in training centers and educational booths. Telescopes from
3 to 4.5 feet with a wide range of motion to cover all positions
Standard arms are designed to cover larger spaces, the standard
extraction arms are available in 7-, 10-, and 12-foot versions.
External brackets and adjustments allow air to pass through with
less resistance giving you stronger cfm (airflow)
Arm mounting bracket and ducting kit includes a supporting
bracket and collar for connecting an extraction arm to ductwork
•
•
•
Model
Telescoping Arm
Standard Arm
Arm Mounting Bracket
and Ducting Kit
6-Inch Diameter
(#301 242)
(#300 953) 7 ft. arm
(#300 954) 10 ft. arm
(#300 955) 12 ft. arm
(#300 952)
8-Inch Diameter
(#301 237)
(#300 980) 7 ft. arm
(#300 981) 10 ft. arm
(#300 982) 12 ft. arm
(#300 771)
FILTAIR low profile hood
Available in sizes from 4 x 4 feet up to 16 x 16 feet in one-foot increments
Exclusive design — capture velocity zone is maximized and distributed
over the work area
Hood airflow design reduces sound for better communication
Unique airflow offers spark abatement in the extraction rail, and also in
the recommended Spark Cooler
Clear, UV-protected polycarbonate ceiling panels allow maximum light
into the cell
Corner lift hooks are convenient for installing or hanging over a work area.
The hood can also be placed on an existing cell enclosure or supported
with post assemblies
•
•
•
•
•
•
More FILTAIR accessories are available to build your system. Call us toll-free at 855-FILTAIR (855-345-8247) for information.
Cleaner air with FilTek® XL filters
The FilTek XL filter’s higher MERV rating means unrivaled filtering performance.
MERV Comparison
Applicable Weld Fume
MERV Rating Categories1
Particle Size Range Efficiency %2
0.3 to 1 µm
1 to 3 µm
3 to 10 µm
10
Not Rated
50–65%
85%
11
Not Rated
65–80%
85%
12
Not Rated
80–90%
85%
13
<75%
90%
90%
14
75–85%
90%
90%
85–95%
>95%
90%
>95%
90%
>95%
>99.97%
>99.97%
>99.97%
75–95%
< 15%
< 10%
15
Miller® FilTek XL
16
Miller® FilTek XL
HEPA3
4
Weld Fume Composition
1
American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) 52.2
National Air Filtration Association (NAFA) Guide
3
HEPA filters are depth loading and have high restrictions to air flow, reducing system performance versus FilTek XL filters.
4
Jenkins, Pierce, Edgar, Particle Size Distribution of GMAW and FCAW
2
104
Filters are rated on a MERV scale, which measures filter
efficiency based on particle count. MERV ratings range
from 1–16, with 16 being the best at filtering small
particles — such as those found in weld fumes. The vast
majority of weld fumes are less than one micron in
diameter, or roughly 1/100th the width of a human hair.
Filters in common air filtration systems often have
MERV ratings between 7–11. FilTek XL filters are rated at
class-leading MERV 15–16 to capture up to 95 percent
of weld fume particulates including those found in
hexavalent chromium.
Workstations
For more detailed
information, visit
MillerWelds.com/arcstation
Count on Miller to design the perfect workbench to make welding projects faster and easier. The Miller® ArcStation is
the first-ever, all-in-one workstation designed for welding and metalworking. It’s versatile, affordable and just the right
height to work comfortably. You can organize equipment, tools, and raw materials into one convenient workspace.
And you can also customize your workbench with a wide range of handy accessories.
S-Series ArcStation
™
Four S-Series models available, depending on
your needs:
30S (30 x 30 inch with solid tabletop)
30SX (30 x 30 inch with X-pattern tabletop)
60S (30 x 60 inch with solid tabletop)
60SX (30 x 60 inch with X-pattern and
solid tabletop combo)
SX model includes X-pattern tabletop for troublefree clamping!
Durable 1/8-inch steel frame with cross bar and
heavy-duty tabletops provide a sturdy area for
welding or metalworking.
Lower shelf provides a convenient place to store
equipment, tools and raw materials.
Adjustable leveling feet keep bench rock-steady.
Customize with a wide range of handy accessories
to make this the ultimate workbench (see at right).
6
•
•
•
•
1
8
5
2
3
4
9
10
Fully loaded 60SX model (#951 413) shown.
See below for other models.
The S-Series is perfect for the welder who
needs a tough workbench for the fab shop
or the home garage.
7
F-Series ArcStation
™
Shown with optional
5-inch X-clamps.
When portability or space-savings is
a concern, the F-Series ArcStation is
your solution.
Wheels, handle, and fold-up design make unit
easy to take to the jobsite or move around the shop.
Compact size makes storing unit a breeze. Unit folds
down to 6 x 29 x 48 inches (152 x 737 x 1219 mm).
30 x 30 inch size tabletop provides plenty of
work surface.
3/16-inch X-pattern steel tabletop allows troublefree clamping.
1.5-inch diameter steel tube frame provides
strength and durability.
Includes removable gun holder.
Add the optional 5-inch X-clamps (#300 850)
to make this the ultimate portable workbench.
S-Series accessories
Miller ArcStation accessories allow you
to get the most out of your ArcStation.
1 X-clamps
#300 613 6-inch
#300 850 5-inch
2 Side shelf #300 680
3 Tool chest with ball-bearing slides
#300 610
4 Interior shelf #300 679
5 Quick-remove vise
#300 611 5-inch vise and mount
#300 612 Mount only
6 Weld curtain
#300 685 30S series
#300 686 60S series
7 Casters
#300 849
Convenience kit #300 614 includes
the following:
8
8 Gun holder
9 Tool holder
10 Clamp bar
Visit MillerWelds.com or your distributor
for other Miller® options and accessories.
F-Series accessories
5-inch X-clamps #300 850
60SX (#951 170)
60SX Fully Loaded (#951 413)
Model/Stock Number
30FX (#300 837)
30S (#951 167)
30SX (#951 168)
60S (#951 169)
Steel Top
(1) 29 x 29 x 3/16 in. X-pattern
(1) 29 x 29 x 3/16 in. solid
(1) 29 x 29 x 3/8 in. X-pattern
(2) 29 x 29 x 3/16 in. solid
Load Capacity
500 lb. (227 kg)
1,000 lb. (454 kg)
1,000 lb. (454 kg)
1,000 lb. (454 kg)
1,000 lb. (454 kg)
Dimensions
35 x 29 x 35 in.
(889 x 737 x 889 mm)
35 x 29 x 29 in.
(889 x 737 x 737 mm)
35 x 29 x 29 in.
(889 x 737 x 737 mm)
35 x 58 x 29 in.
(889 x 1,473 x 737 mm)
35 x 58 x 29 in.
(889 x 1,473 x 737 mm)
Weight
74 lb. (34 kg)
123 lb. (56 kg)
177 lb. (80 kg)
230 lb. (104 kg)
318 lb. (144 kg)
(1) 29 x 29 x 3/8 in. solid
(1) 29 x 29 x 3/8 in. X-pattern
105
Accessories
Automated MIG 106
Cable Connectors and Adapters 106, 113
Carts, Cylinder Racks and Running Gear
106–108
Coolant Systems 107
Engine Drive Accessories 108–109
Blue Accessories • Blue Star Accessories
• Big
and Trailblazer Accessories
• Bobcat
Generator
Accessories • Protective Covers • Trailers
•
Load Banks 109
Automated MIG
For adapters and drive motors, visit MillerWelds.com.
Coolant Flow Switch
#195 461
For Auto-Axcess. To ensure
coolant is flowing in the
system. Lack of coolant
flow may cause damage to
water-cooled guns. Module allows wiring into the peripheral
connector port. 50-foot (15.2 m) cable with connector and
separate shell connector for simple modification to desired
length in the field. It can be mounted on Auto-Axcess or as
desired elsewhere. Quarter-turn quick connection.
MCS-2 Motorized Cross Slide
#098 380 Control
#045 623 Adapter Plate*
Provides accurate weld head adjustment with convenient
motorized control. Used to align the welding head (gun)
to the weld joint, by providing vertical or horizontal
adjustments, based on mounting preferences.
*Required when using two slides.
Cable Connectors and Adapters
Also see Torch and Weld Cable Connectors in TIG
Accessories on page 113.
For Invision 352 MPa, AlumaFeed System, XMT 304/350,
CST 280, Maxstar, Dynasty, and Syncrowave. These power
sources are equipped with Dinse- or Tweco-style connectors
for secondary connections. Power sources are shipped with
two male plugs for use with #4 to #1/0
AWG cable.
Dinse-Style Connector Kits
#042 418 Accepts #4 to #1/0 AWG cable
#042 533 Accepts #1/0 to #2/0 AWG 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
#042 419 Accepts #4 to #1/0 AWG 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
#134 460 Male Dinse-style plug
#136 600 Female Dinse-style receptacle
Used to adapt or extend weld and/or work cables.
Accepts #1/0 to #2/0 AWG cable.
106
MIG Accessories 109
• Gun and Machine Accessory Kits • Protective Covers
Plasma Cutter Accessories 110
Kits • Cables and Cable Covers
• Automation
Guides • Filters • Plugs and Cords
• Cutting
• Protective Covers • Torches
Polarity Switches/Controls 111
Remote Controls and Wireless Remote Controls
111–113
Stick Accessory Kits 111
Tweco®-Style Connector
#191 981
Accepts #1/0 to #2/0
AWG cable. Kit includes one Tweco-style male plug which
attaches to the work and/or weld cables and plugs into the
Tweco-style receptacles on the power source.
#042 465
Dinse/Tweco® Adapter
Dinse/Cam-Lok Adapter #042 466
One-piece adapter with Dinse-style male
plug (to power source) on one end and
Tweco or Cam-Lok female receptacle (for weld cable
connection) on other end.
Tweco®/Dinse Adapter #210 061
One-piece adapter with Tweco-style
male plug (to power source) on one
end and Dinse-style female receptacle (for weld cable
connection) on other end.
Carts, Cylinder Racks and Running Gear
Also see Engine Drive Accessories on page 108 and
Plasma Accessories on page 110.
Carrying Cart #056 301
For XMT, CST 280, smaller
Maxstar/Dynasty, and wire
feeders. Cart is 34 inches high
x 30 inches wide x 17 inches
deep (864 x 762 x 432 mm).
Cylinder Cart #042 537
For Invision, XMT, and CST
280. Has adjustable handles
and is slanted for convenient
access to power source front
panel controls. Carries two
160-pound (72.6 kg) gas
cylinders with feeder mounted
to tray above power source.
Accommodates Coolmate 3 or
4 coolant system.
Universal Cart and
Cylinder Rack #042 934
For Invision 352 MPa,
XMT 304/350, CST 280,
Diversion, Maxstar 210/280,
and Dynasty 210/280. Also
accommodates a single gas
cylinder up to 56 inches (142.2 cm) high measuring 6 to 9
inches (15.2 to 22.8 cm) in diameter. Provides storage for
auxiliary items such as electrodes, helmets and gloves.
For more detailed
information, visit
MillerWelds.com/accessories
Submerged Arc Accessories 111
Accessories
• Cables
• Torch
Wire
Drive
Assembly
Accessories
•
TIG Accessories 112–113
Arc Starters and Stabilizers
• High-Frequency
Kits
Protective
Covers • Remote Controls
• Torch• and Weld Cable
Connectors
•
Wire Feeder Accessories 114
Cables (14-pin) • Power Supply Adapter
• Extension
Spool
Adapter
Gun Controls and Kits
• Turntable Assembly
• SpoolWire
•
• Straightener
Feeder Cart #142 382
A low-profile, creeper cart which
allows the operator to easily move
the feeder around the work area.
Running Gear/Cylinder Rack
#301 239
For Millermatic 125 Hobby,
141, 190, 211, and Diversion.
Heavy-duty construction with
8-inch rubber rear wheels.
Convenient front handles, cable
holders and plastic consumable
box. For gas cylinders no greater than 7 inches (178 mm)
in diameter or 65 pounds (29.5 kg) in weight.
Dual EZ-Change™ Low Cylinder
Rack with Elevated Gun and
Cable Rack #300 337
For Millermatic 212 Auto-Set
and 252, and Syncrowave 210.
Allows operators to easily roll
cylinders on and off the rack with
no lifting. Gun and cable rack
keeps cables off the floor and
tangle free.
Elevated Gun and Cable Rack #300 335
For Millermatic 212 Auto-Set and 252, and Syncrowave
210. For use with single-cylinder rack. (Included with Dual
EZ-Change Low Cylinder Rack.)
Dual Cylinder Rack #195 299
For Millermatic 350P and
350P Aluminum. Replaces
single-cylinder rack.
Standard Running Gear and
Cylinder Rack
#042 886 Running gear
#042 887 Cylinder rack
For CP-302, Deltaweld, Dimension
302/452, and Gold Star. Running
gear has 10-inch (254 mm) rear
Shown with optional
wheels and 5-inch (127 mm)
cylinder rack (#042 887). 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.
Accessories
MIGRunner ™ Cart
#195 445
For Invision, AlumaFeed
system, and XMT with single
feeders. Small footprint and
easily maneuverable, with a
dual-cylinder rack low enough
that you do not have to lift
bottles. Durable, heavy-duty
ergonomic handles are
designed for comfort.
Running Gear Cylinder Rack
#300 408
For Invision, Axcess 300/450,
Dimension 650, and XMT
with single or dual feeders.
Holds two large gas cylinders
and has gun cable hangers
and a consumable drawer in
front. A convenient handle
allows the cart to be pulled
easily through doorways.
Power source and single or
dual feeders can be mounted
to cart and secured.
Shopmate 300 Running
Gear/Dual Cylinder Rack
#300 145
For Shopmate 300 DX. The
large 10-inch (254 mm)
rear wheels and 5-inch
(127 mm) front casters on
this running gear provide excellent mobility on the shop floor,
making it easier to move the power source. Very easy to
install. Handles double as a cable holder. Holds two cylinders.
2-Wheel Trolley Cart #300 971
For Maxstar 210/280 and Dynasty
210/280 with or without Coolmate 1.3.
Easy-to-maneuver 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.
Dimension 650 Running
Gear #301 307
For Dimension 650.
Large 10-inch (254 mm)
rear wheels and 5-inch
(127 mm) front casters
provide excellent mobility.
Easy to install. Compatible
with single and dual
70 Series feeders. Handles double as a cable holder.
Small Runner™ Cart #301 318
For Maxstar 210/280 and Dynasty
210/280 with or without Coolmate 1.3.
Cart features single-cylinder rack,
foot pedal holder, two cable/torch
holders and two TIG filler holders.
Note: Does not accommodate gas cylinders. Use Running Gear
Cylinder Rack (#300 408) when gas cylinders are required.
Thunderbolt XL Running Gear
#043 927
For Thunderbolt XL. Mounts easily
to unit and provides convenient
portability. Includes two wheels,
two feet and a handle.
Continuum Running Gear/
Cylinder Rack #301 264
For Continuum 350 and 500.
Small footprint and easily
maneuverable, with cylinder
rack low enough that you do
not have to lift bottles.
Coolant Systems
Runner™ Cart #300 244
For Maxstar 350/700 and Dynasty
350/700 with or without Coolmate 3.5.
Cart features single-cylinder rack,
foot pedal holder, three cable/torch
holders and two TIG filler holders.
No. 37 Running Gear #195 282
For Syncrowave 250 DX/350 LX.
Includes two 10-inch (254 mm)
wheels, two 5-inch (127 mm)
casters, two-compartment rack
for gas cylinders, and handles.
Provides excellent mobility and
easy to install.
Coolant
See literature no. AY/7.2
*May vary with torch design and
cable length. Miller coolant systems
are backed by the best warranty in
the industry — one full year.
Coolmate 3
Coolmate 1.3
Coolmate 3.5
Coolmate 4
Coolmate™ 1.3 #300 972 115 V
For Maxstar 210/280 and Dynasty 210/280. Light industrial,
1.3-gallon cooler designed for water-cooled torches on power
sources rated up to 280 amps*.
Coolmate™ 3 #043 007 115 V #043 008 230 V
Economical, 3-gallon cooler designed for water-cooled torches
rated up to 500 amps*.
Coolmate™ 3.5 #300 245 115 V
For Maxstar 350/700 and Dynasty 350/700. Industrial, 3.5-gallon
cooler designed for water-cooled torches rated up to 600 amps*.
Coolmate™ 4 #042 288 115 V
Best performer in its class — industrial, 4-gallon cooler designed for
water-cooled torches rated up to 600 amps*.
Model
Coolmate 1.3
Motor Input Voltage
115 V, 60 Hz
Maximum Current Draw
4.7 A (60 Hz)
Maximum Cooling Capacity
3,400 W (11,600 Btu/hr.)
3.8 qt./min. (3.6 L/min.)
IEC Cooling Capacity
1,330 W (4,540 Btu/hr.)
1.1 qt./min. (1 L/min.)
Tank Capacity
1.3 gal. (4.9 L)
Coolmate 3
115 V, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
3,820 W (13,000 Btu/hr.)
4.2 qt./min. (4.0 L/min.)
1,420 W (4,840 Btu/hr.)
1.1 qt./min. (1 L/min.)
3 gal. (11.4 L)
230 V, 50/60 Hz
2.5 A (50 Hz), 3.0 A (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.)
5.0 qt./min. (4.7 L/min.)
1,660 W (5,660 Btu/hr.)
1.1 qt./min. (1 L/min.)
3.5 gal. (13.2 L)
Coolmate 4
115 V, 50/60 Hz
5.9 A (50 Hz), 4.7 A (60 Hz)
5,500 W (18,000 Btu/hr.)
5.9 qt./min. (5.6 L/min.)
1,780 W (6,070 Btu/hr.)
1.1 qt./min. (1 L/min.)
4 gal. (15 L)
Sold in multiples
of four in 1-gallon
recyclable plastic
bottles. Miller®
coolants contain
a base of ethylene
glycol and deionized water to protect
against freezing to -37° Fahrenheit (-38°C)
or boiling to 227° Fahrenheit (108°C).
Low-Conductivity Coolant
(clear, pre-mixed) #043 810
For TIG and MIG applications. NOT for use
in push-pull systems or systems where
aluminum is in coolant path/circuit.
Aluminum-Protecting Coolant
(green, pre-mixed) #043 809
Primarily used in push-pull systems where
aluminum is in coolant path/circuit and
high frequency is NOT used.
Dimensions
H: 11.25 in. (286 mm)
W: 10.38 in. (264 mm)
D: 24 in. (610 mm)
H: 13.25 in. (337 mm)
W: 12.25 in. (311 mm)
D: 23.25 in. (584 mm)
H: 11.75 in. (298 mm)
W: 15.75 in. (400 mm)
D: 26 in. (660 mm)
H: 16.25 in. (413 mm)
W: 15.25 in. (387 mm)
D: 18.75 in. (476 mm)
Net Weight
43 lb. (20 kg)
40 lb. (18 kg)
64 lb. (29 kg)
38 lb. (17 kg)
107
Accessories
Engine Drive Accessories
Also see Trailers on page 109 and HF Arc Starters on
page 112.
Big Blue Accessories
Cable Holder #043 946
For Big Blue 500 and 600 Pro,
700 Duo Pro, and 800 Series.
Vandalism Lockout Kit
#399 802 Field
For Big Blue 500 and 600 Pro, and
700 Duo Pro. Lockable hinged steel
panels cover and protect name plate
gauges and ignition switch (padlock
included). Also includes engine
compartment door lock and key.
Blue Star Accessories
Lifting Eye #195 353
For current model Blue Star 185.
Running Gear #301 246
For current model Blue Star 185.
Compact and balanced, lightweight
wheelbarrow-style running gear
provides easy onsite mobility.
Protective Cage with
Cable Holders
#300 921 For gas/LP
Bobcat and Trailblazer.
#300 473 For Trailblazer
302 Air Pak.
Rugged cage with cable
holders protects your investment. Works with Running
Gear, Gas Cylinder Mounting Assembly or LP Tank
Mounting Assembly.
Gas Cylinder Mounting
Assembly #300 918
For gas Bobcat and
Trailblazer. Designed for
use with Running Gear,
Protective Cage, or by itself.
Includes base tray with bottle
bracket, vertical support
rack and safety chain.
Note: Not for use with LP Tank Mounting Assembly.
Not recommended for use with Protective Cover.
Gas Cylinder Mounting
Assembly #195 330
For diesel Bobcat and
Trailblazer. Designed for use
with Protective Cage, or by
itself. Includes base tray
with bottle bracket, vertical
support rack and safety chain.
Note: Not recommended for use
with Protective Cover.
Generator Accessories
Female
Receptacle
Full KVA Adapter Cord #300 517
For Bobcat, Trailblazer, and Big Blue models. NEMA 14-50P
to NEMA 6-50R. Adapts engine drive 120/240-volt plug to
common Millermatic and Spectrum 240-volt plug.
Single-Phase Full KVA Plug Kit
#119 172
For Bobcat, Trailblazer, and Big Blue
models. Can be wired for 120- or
240-volt loads.
Hose and LP Tank
Mounting Assembly
#300 917
For LP Bobcat and
Trailblazer. Designed for
use with Running Gear,
Protective Cage, or by itself.
Includes bracket and clamp
to mount 33- and 43-pound
tanks horizontally, and hose with fittings to converter.
Three-Phase Full KVA Plug Kit
#165 963 For Bobcat 3 Phase.
#254 140 For Big Blue 500 and 600 Pro, 700 Duo Pro,
and 800 Series.
Note: Cannot be used with Gas Cylinder Mounting Assembly.
Not recommended for use with Protective Cover.
Protective Covers
Bobcat and Trailblazer Accessories (Gas/LP)
Multi-Terrain Running Gear
#300 913 Inner tubes.
#300 914 Never Flat ™ tires.
For gas/LP Bobcat and
Trailblazer. Includes two
heavy-duty 15-inch tires,
two 8-inch rubber swivel
casters and a heavy-duty
handle. Recommended for
all surfaces and applications and is easy to move around
the jobsite.
Off-Road Running Gear
#300 909 Inner tubes.
#300 910 Never Flat™ tires.
For gas/LP Bobcat and
Trailblazer. Includes four
heavy-duty 15-inch tires and
a rugged handle to provide
maximum maneuverability.
Off-Road Running Gear
with Protective Cage and
Never Flat™ Tires
#300 912
For gas/LP Bobcat and
Trailblazer. Running gear
and rugged cage with cable
holders protects your
investment and is easy to
move around the jobsite.
108
Remote Oil Drain and Filter Kit #300 923 Field
For gas Bobcat and Trailblazer. Front mount for Kohler
engines makes servicing easy when engine drive is mounted
in tight spots.
Bobcat and Trailblazer Accessories (Diesel)
#300 919 and #195 301 covers shown.
All-Purpose Running Gear
with Never Flat™ Tires
#300 477
For diesel Bobcat and
Trailblazer. Includes two
heavy-duty 15-inch tires,
two 8-inch rubber swivel
casters and a heavy-duty
handle. Recommended for
all surfaces and applications and is easy to move around
the jobsite.
Protective Covers
Heavy-duty, water- and mildew-resistant covers protect
and maintain the finish of the welder.
#301 245 For current model Blue Star 185.
#300 919 For current model gas Bobcat and
Trailblazer (except Air Pak) without
Protective Cage or Running Gear.
#300 920 For current model gas Bobcat and
Trailblazer (except Air Pak) with
Protective Cage or Running Gear.
#301 099 For current model diesel Bobcat and
Trailblazer without Protective Cage
or Running Gear.
#300 379 For Trailblazer 302 Air Pak.
#195 301 For Big Blue 350 PipePro, 400 Pro,
and 450 Duo CST.
#194 683 For Big Blue 500 Pro (CA model) and
700 Duo Pro.
#301 113 For Big Blue 500 Pro (T4F model), 600 Pro,
and 800 Series.
Protective Cage with
Cable Holders #195 331
For diesel Bobcat and
Trailblazer. Rugged
cage with cable holders
protects your investment.
Works with Running Gear,
Gas Cylinder Mounting Assembly or with trailer.
Note: Not for use with Protective Cover.
Accessories
Trailers
Trailer accessories
See literature no. AY/20.0
HWY-1000 Trailer #195 013
For Bobcat and Trailblazer (except Air Pak
model). A 1,000-pound (454 kg) capacity
highway trailer with welded steel tubing
frame, heavy-duty axle with roller bearing
hubs and leaf-spring suspension. Includes
jack stand, 2-inch (50 mm) ball hitch,
fenders and lights.
4 West Four-Wheel Steerable
Off-Road Trailer #042 801
For Big Blue 500 and 600 Pro, 700 Duo
Pro, and 800 Series. Heavy-duty 2,570pound (1,166 kg) capacity trailer designed
for use in mines, quarries, and other rough
terrain. Has narrow 22-foot (6.7 m) turning
radius. Includes 3-inch lunette eye,
universal hitch and safety chains.
HWY-224 Trailer #043 805
For Bobcat, Trailblazer, and Big Blue models.
A 2,650-pound (1,202 kg) capacity trailer
with welded steel tubing frame, heavy-duty
axle with roller bearing hubs and leaf-spring
suspension. Includes jack stand and 2-inch
(50 mm) ball hitch. HWY-224 also includes
fenders and lights.
Dual Hitch #300 831
For HWY-1000, and HWY-224.
Combination 2-inch (50 mm) ball and
3-inch (76 mm) lunette eye in one
reversible assembly.
Cable Tree
#195 023 For HWY-1000.
#043 826 For HWY-224.
Provides an area to conveniently wrap
weld cables and extension cords.
Fender Kit #300 160
Replacement fenders for HWY-224.
Note: Trailers are shipped unassembled. *Width at outside of fenders. **Does not include tongue.
Gross Axle
Weight Rating
Gross Vehicle
Weight Rating
Net Payload
Height
of Bed
Road
Clearance
Track (Center to
Center of tires)
Standard Tires (Standard
Rating or P-size Rating)
HWY-1000
1,500 lb.
(680 kg)
1,265 lb.
(574 kg)
1,000 lb.
(454 kg)
18.5 in.
(470 mm)
6.5 in.
(165 mm)
50 in.
(1,270 mm)
4 West
2,000 lb./axle
(907 kg/axle)
3,000 lb.
(1,361 kg)
2,570 lb.
(1,166 kg)
21.25 in.
(540 mm)
8 in.
(203 mm)
HWY-224
3,500 lb.
(1,588 kg)
2,960 lb.
(1,343 kg)
2,650 lb.
(1,202 kg)
18.5 in.
(470 mm)
7.25 in.
(184 mm)
Model
Load Banks
LBP-350 #043 329
Designed to provide an
adjustable load for
troubleshooting or
calibrating welding power
sources or generators.
Standard equipment
includes analog meters for both AC and DC output with
jacks for external metering connections. It comes with a
13-foot (4 m) 115-volt power cord and has seven 50-amp
load switches, providing a maximum capacity of 350 amps.
Welding Power Load Bank
#902 804
Designed to load test the output of
transformer-type, engine- or motordriven generator welding power
sources. This unit can be used to
test AC or DC welder outputs, and
to demonstrate welding equipment
to customers.
Dimensions
Net
Weight
4.8-12
L: 98 in. (2,489 mm)
W: 57.5 in. (1,460 mm)*
265 lb.
(120 kg)
55.25 in.
(1,403 mm)
B78-13
L: 91 in. (2,311 mm)**
W: 61.25 in. (1,556 mm)
430 lb.
(195 kg)
52 in.
(1,321 mm)
B-78-13
L: 105 in. (2,667 mm)
W: 59.5 in. (1,511 mm)*
320 lb.
(145 kg)
Aluminum Conversion Kit #172 136
For M-25 gun. Allows 10-foot (3 m) guns to feed
3/64-inch (1.2 mm) aluminum wire.
#300 405
kit shown.
Industrial MIG 4/0 Kit
#300 390 For single feeders.
#300 957 For dual feeders.
Consists of flowmeter regulator with 10-foot (3 m) gas
hose, 10-foot (3 m) 4/0 feeder weld cable with lugs, and
15-foot (4.6 m) work cable with 600-amp C-clamp. Dual
kit comes with two flowmeter regulators and gas hoses.
Industrial MIG 4/0 Kit with Dinse Connectors
#300 405 For single feeders.
#300 956 For dual feeders.
Same as above except weld and work cables have
Dinse-style connector on one end instead of lug.
Protective Covers
#301 333
For Millermatic 125 Hobby.
#301 262
For Millermatic 141, 190,
and 211.
#195 142
For Millermatic 212 Auto-Set,
252, 350P/350P Aluminum,
and Syncrowave 210. Features
side pocket.
MIG Accessories
Gun and Machine Accessory Kits
MIGmatic™ M-Series Gun Consumable Kits
#234 607 .023 in. (0.6 m) wire For M-100/M-150.
#234 608 .030 in. (0.8 m) wire For M-100/M-150.
#234 609 .035 in. (0.9 m) wire For M-100/M-150.
#234 610 .030 in. (0.8 m) wire For M-25.
#234 611 .035 in. (0.9 m) wire For M-25.
#234 612 .045 in. (1.2 m) wire For M-25.
M-100/M-150 kits contain 10 contact tips, 1 tip adapter
and 1 standard nozzle. M-25 kits add 1 nozzle adapter.
Shopmate 300 MIG Kit #300 150
Includes flow gauge regulator and 10-foot (3 m) gas hose
for argon or AR/CO2 mix, 10-foot (3 m) 1/0 interconnecting
cable, 15-foot (4.6 m) 1/0 work cable with clamp, and
consumable storage box.
109
Accessories
Filters
Plasma Cutter Accessories
Automation Kits
Automation Kit
for Spectrum 625
X-TREME
#301 158
Upgrades new quickconnect hand-held
torch packages to
add machine torch
capabilities. Includes new front panel with built-in remote
control cable receptacle. Machine torches are NOT included
in kits and must be ordered separately.
#301 157
kit shown.
Protective Covers
In-Line Air Filter Kit #228 926
For 375 X-TREME, 625 X-TREME, 875, and
875 Auto-Line. Mounts to back of the plasma
cutter. Includes male and female 1/4-inch
NPT quick-disconnect fittings and hose for
easy on/off connection. The replaceable filter
element (#228 928) filters to .85 microns for
removal of 99.9 percent of water, dirt and oil.
RTI Filter and Bracket #300 491
For 875 and 875 Auto-Line. Dryer will remove
water, dirt and oil as small as one micron
with 99.9 percent efficiency. Can be mounted
on plasma cutter or on wall. Install as close
as possible to point of air consumption.
Replaceable filter element (#212 771).
Cable Covers
#239 642 20 ft. (6.1 m)
#231 867 25 ft. (7.6 m)
#231 868 50 ft. (15.2 m)
Torches
#219 258
For power cable 6-50P
(230/240 V, 50 A).
Automation Kits for Spectrum 875 and 875 Auto-Line
#301 156 For 875.
#301 157 For 875 Auto-Line.
Automation kits upgrade hand-held torch packages to add
machine torch capabilities. Automation kit for Spectrum
875 Auto-Line (#301 157) includes a remote pendant
control for manual on/off. Machine torches are NOT
included in kits and must be ordered separately.
Flexible Work Cable
#234 838 20 ft. (6.1 m)
#234 930 50 ft. (15.2 m)
Work cable with quick connect
and heavy-duty clamp.
See your Miller® distributor for complete information on
the following XT plasma torches and their consumables:
#219 261
For power cable 5-15P
(115/120 V, 15 A).
#219 259
For power cable 5-20P
(115/120 V, 20 A).
For Spectrum 375 X-TREME, Millermatic 211, Maxstar 150
models, Diversion 180, and Multimatic 200. Allows connection
of machine to 115/120-volt or 230/240-volt receptacles
without tools — just choose the plug that fits the receptacle.
MVP™ Adapters
#254 330
For connection to 5-15P receptacle
(120 V, 15 A).
#254 331
For connection to 5-20P receptacle
(120 V, 20 A).
Plasma Circle-Cutting Guides #253 055
For XT30C, XT30, XT40 and XT60. Cut straight lines or circles
up to 12 inches in diameter.
Suction/Magnetic Pivot Base #195 979
Add this to your cutting guide for convenient attachment to
all flat surfaces. The extended arm accommodates holes up
to 30 inches in diameter.
Plasma Standoff
Roller Guide #253 054
Helps maintain
recommended standoff
distance to maximize
cutting performance and
improve tip life.
110
Spectrum Plasma Cutter Hand-Held Torches
For Spectrum 375 X-TREME
#249 949 12 ft. (3.7 m) XT30
For Spectrum 625 X-TREME
#260 633 12 ft. (3.7 m) XT40
#260 635 20 ft. (6.1 m) XT40
For Spectrum 875 and 875 Auto-Line
#249 953 20 ft. (6.1 m) XT60
#249 954 50 ft. (15.2 m) XT60
Female
Receptacle
#254 328
For connection to 6-50P receptacle
(240 V, 50 A).
Cutting Guides
#300 184
X-CASE for Spectrum
375 X-TREME and
625 X-TREME, and
Maxstar 150 models.
Plugs and Cords
MVP™ Plugs
Cables and Cable Covers
#300 388
For Spectrum 875.
Spectrum Plasma Cutter Machine Torches
For Spectrum 625 X-TREME
#259 305 25 ft. (7.6 m) long body XT40M
#257 462 25 ft. (7.6 m) short body XT40M
For Spectrum 875 and 875 Auto-Line
#249 955 25 ft. (7.6 m) long body XT60M
#249 956 50 ft. (15.2 m) long body XT60M
#257 464 25 ft. (7.6 m) short body XT60M
#263 952 50 ft. (15.2 m) short body XT60M
For Spectrum 625 X-TREME. Allows connection of machine
to 120- or 240-volt receptacles without tools — just choose
the adapter cord that fits the receptacle.
Female
Receptacle
Full KVA Adapter Cord #300 517
NEMA 14-50P to NEMA 6-50R. Adapts engine drive
120/240-volt plug to common Millermatic and Spectrum
240-volt plug.
230-Volt Extension Cord #770 644
20-foot (6.1 m) NEMA 6-50P to NEMA 6-50R heavy-duty
extension cord. 8-gauge cord has lighted ends that show
power is on and a molded, integrated strain relief.
Plasma Torch Consumable Kits
#253 520 For XT30.
#253 521 For XT40.
#256 033 For XT60.
#127 493 Empty consumable box.
Accessories
Polarity Switches/Controls
2/0 Weld Cable Extensions
#195 456 50 ft. (15 m)
#195 455 100 ft. (30 m)
Extends weld cables
(#195 457) and (#195 458).
Polarity Control #042 871
This dual-function control is designed for use with dual wire
feeders or any application where electrical isolation and/or
polarity reversing of weld current is required. Both functions
can be used at the same time.
Process Selector Control
#042 872
For CC, CV or CC/CV welding
power source. Provides easy
way to change welding
process. Also includes
features of Polarity Control.
Remote Controls
Also see Remote Controls in TIG Accessories on pages
112 and 113.
PRHC-14 Hand Control #195 511
For all solid-state power sources after
serial number JK674521. Complete
current or voltage control brings
120 volts of GFCI power to work area
in a single cord. Housed in a durable
and light aluminum case and includes
125-foot (38 m) cord with plugs.
Remote On/Off Control #242 197 025
For Deltaweld, Dimension 302/452, and Gold Star. Allows
you to turn power source on or off from a distance of 25 feet
(7.6 m). This is useful if power source is up in a mezzanine.
Submerged Arc Accessories
Cables
Flux Hopper Extension Cables
#260 623 010 10 ft. (3 m)
#260 623 025 25 ft. (7.6 m)
#260 623 065 65 ft. (19.8 m)
Cable between SubArc Interface and flux hopper.
Motor Extension Cables
#254 232 005 5 ft. (1.5 m)
#254 232 010 10 ft. (3 m)
#254 232 025 25 ft. (7.6 m)
#254 232 065 65 ft. (19.8 m)
Cable between SubArc Interface and drive motor.
SubArc Control Cables
#260 622 030 30 ft. (9.1 m)
#260 622 050 50 ft. (15 m)
#260 622 080 80 ft. (24.4 m)
#260 622 100 100 ft. (30.5 m)
#260 622 120 120 ft. (36.6 m)
#260 622 200 200 ft. (61.0 m)
Cable between SubArc Interface and power source.
SubArc Parallel Cable
#260 775 015 15 ft. (4.6 m)
SubArc Tandem Cable
#260 878 015 15 ft. (4.6 m)
2/0 Stick Cable Set
#173 851 50 ft. (15 m), 350 A
#043 952 100/50 ft. (30/15 m), 300 A
Consists of either 50- or 100-foot 2/0 electrode cable with
holder and 50-foot work cable with clamp. 100% duty cycle.
Wire Size
1/16 in. (1.6 mm)
5/64 in. (2.0 mm)
3/32 in. (2.4 mm)
7/64 in. (2.8 mm)
1/8 in. (3.2 mm)
5/32 in. (4.0 mm)
3/16 in. (4.8 mm)
1200-Amp Torch Contact Tips
Single-Wire Twin-Wire
Wire Size
—
#264 595
3/64 in. (1.2 mm)
#264 590
#264 596
1/16 in. (1.6 mm)
#264 591
#264 597
5/64 in. (2.0 mm)
#264 487
#264 588
3/32 in. (2.4 mm)
#264 593
—
1/8 in. (3.2 mm)
—
5/32 in. (4.0 mm)
#264 594
Wire Drive Assembly Accessories
Drive Rolls
#132 955 1/16 in. (1.6 mm)
#132 960 5/64 in. (2.0 mm)
#132 961 3/32 in. (2.4 mm)
#132 962 7/64 in. (2.8 mm)
#132 963 1/8 in. (3.2 mm)
#193 700 5/32 in. (4.0 mm)
#193 701 3/16 in. (4.8 mm)
V-knurled drive rolls for use with hard-shelled cored wires.
#301 138
slide shown.
Stick Accessory Kits
No. 2 Stick Cable Sets
#195 196 15 ft. (4.6 m)
#300 836 50 ft. (15 m)
Consists of either 15- or 50-foot electrode cable with holder
and work cable with clamp. 200 A, 100% duty cycle.
OBT Torch Contact Tips
OBT 600
OBT 1200
#192 700
#192 141
#192 701
#199 026
#192 702
#192 142
#192 703
#200 771
#192 704
#192 143
#192 705
#192 144
#192 706
#192 136
Manual Slides
#301 137 Single slide, 7.87 in. (200 mm)
#301 138 Cross slide, 7.87 x 7.87 in. (200 x 200 mm)
Provides smooth and accurate movement of the welding
heads. Single slide allows for 7.87 inch (200 mm) travel
adjustment and cross slide allows for 7.87 x 7.87 inch
(200 x 200 mm) with load capacity of 220 pounds (100 kg)
at 1.64 feet (500 mm). Not recommended for tandem.
Single-Wire Straightener #199 733
For SubArc Wire Drive 400 Digital Low
Voltage and SubArc Wire Drive 780
Digital Low Voltage. For 1/16–3/16 inch
(1.6–4.8 mm) wire.
Torch Accessories
OBT 600 Torch Body Extensions
#043 967 1 inch (25.4 mm)
#043 969 2 inch (50.8 mm)
#043 973 4 inch (101.6 mm)
#043 975 6 inch (152.4 mm)
Twin-Wire Straighteners
(for Twin-Wire torches only)
#301 160 Single adjustment
#301 162 Double/separate adjustment
OBT 1200 Torch Body Extension #043 981
Overall length with extension is 9 inches (228.6 mm).
Actual length of extension is 8.5 inches (215.9 mm).
Weld Cables
#195 457 Cable with electrode holder
#195 458 Cable with work clamp
Consists of a stud/Tweco® adapter and 10-foot (3 m)
2/0 weld cable with a Tweco male connector and either
an electrode holder or work clamp. Rated up to 400 A.
Wire Reel #108 008
Supports 60-pound (27 kg)
coil of wire. Requires Spool
Support Assembly (#119 438).
111
Accessories
Protective Covers
TIG Accessories
High-Frequency Arc Starters and Stabilizers
HF251D-1
#042 388 115 V
HF251-2
#042 387 230 V
These portable 250-amp,
60 percent duty cycle units add
high-frequency to the welding
circuit to help start arc when
using the TIG process.
#300 579 and #195 478 covers shown.
Secondary Contactor Kit
#041 969 Field For HF-251D-1.
#041 906 Field For HF-251-2.
For power sources without a contactor. Mounts inside
HF-251 cabinet.
#300 579
#301 381
#301 382
#195 142
#195 320
#195 478
Kits
Remote Controls
#301 311
kit shown.
Contractor Kit
#301 311 TIG/stick pkg with RCCS-14 fingertip
#301 309 TIG/stick pkg with RFCS-14 HD foot pedal
For Maxstar 210/280 and Dynasty 210/280. All-in-one
TIG/stick welding kit comes with either a RCCS-14 fingertip
control or RFCS-14 HD foot control, Weldcraft™ A-150 TIG
torch, 200-amp stick electrode holder with 15-foot (4.6 m)
cable, 300-amp work clamp with 15-foot (4.6 m) cable,
flow gauge regulator with 12-foot (3.7 m) gas hose, gas hose
coupler, AK2C torch accessory kit, and TIG torch connector.
TIG Contractor Kit #301 287
For Multimatic 200. Kit comes with Weldcraft™ A-150 TIG
torch with Dinse-style connector, RFCS-6M foot control,
flow gauge regulator with 12-foot (3.7 m) gas hose, and
AK2C torch accessory kit.
#300 990
Weldcraft™ Water-Cooled Torch Kits
kit shown.
#300 185 250 A, W-250 (WP-20)
#300 990 280 A, W-280 (WP-280)
#301 268 375 A, W-375
#300 186 400 A, W-400 (WP-18SC)
For Maxstar (except 150 models), Dynasty, and
Syncrowave 250 DX/350 LX. Kit comes with 25-foot
(7.6 m) TIG torch with Dinse-style connector (thread-lock on
400-amp kit), torch cable cover, work clamp with 15-foot
(4.6 m) cable [12-foot (3.7 m) cable on 400-amp kit],
flowmeter regulator with gas hose, and torch accessory kit.
112
For Diversion 165 and 180.
For Maxstar 210.
For Maxstar 280 and Dynasty 210/280.
For Syncrowave 210.
For Syncrowave 250 DX/350 LX.
For XMT 304 and 350.
14-Pin to 6-Pin Adapter Cord
#300 507
For Maxstar 150 STL and STH,
and Multimatic 200. 12-inch
(305 mm) cord adapts Miller®
14-pin foot control or fingertip
control to a 6-pin plug.
RCC-14 (14-pin plug) #151 086
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.
Includes 26.5-foot (8 m) cord with plug.
RCCS-6M (6-pin plug)
#195 184 13.25 ft. (4 m) cord
#195 503 26.5 ft. (8 m) cord
For Maxstar 150 STL and STH, and Multimatic 200.
RCCS-RJ45
#301 146 13.25 ft. (4 m) cord
For Diversion 165 and 180.
RCCS-14 (14-pin plug)
#043 688 26.5 ft. (8 m) cord
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.
Includes cord with plug.
RFCS-14 HD (14-pin plug) #194 744
Heavy-duty foot pedal current/contactor control provides
increased stability and durability from larger base and
heavier cord. Reconfigurable cord can exit front, back or
either side of the pedal for flexibility. Includes 20-foot
(6 m) cord with plug.
RFCS-RJ45 #300 432
For Diversion 165 and 180. Foot pedal current/contactor
control. Includes 14-foot (4.3 m) cord with plug.
RHC-14* (14-pin plug)
#242 211 020 20 ft. (6 m) cord
#242 211 100 100 ft. (30.5 m) cord
Miniature hand current/contactor control. Dimensions:
4 x 4 x 3.25 inches (102 x 102 x 82 mm). Includes cord
with plug.
*For additional lengths visit MillerWelds.com/equiptoweld.
RMLS-14 (14-pin plug) #129 337
Momentary- and maintained-contact rocker switch for
contactor control. Push forward for maintained contact and
backward for momentary contact. Includes 26.5-foot (8 m)
cord with plug.
RMS-6M (6-pin plug) #195 269
For Maxstar 150 STL and STH.
RMS-14 (14-pin plug) #187 208
Momentary-contact switch for contactor control. Rubbercovered pushbutton dome switch ideal for repetitive on-off
applications. Includes 26.5-foot (8 m) cord with plug.
RFCS-6M (6-pin plug)
#195 183 13.25 ft. (4 m) cord
#195 504 20 ft. (6 m) cord
For Maxstar 150 STL and STH, and Multimatic 200.
RFCS-5 (5-pin plug)
#043 716 20 ft. (6 m) cord
RFCS-14 (14-pin plug)
#043 554 20 ft. (6 m) cord
Foot pedal current/contactor control. Includes cord
with plug.
RPBS-14 (14-pin plug) #300 666
Attaches to the TIG torch to remotely start and stop the TIG
welding process. Includes 25-foot (7.6 m) cord with plug.
Accessories
Industrial
Wireless Remote Foot and Hand Controls
Processes
(GTAW) • Pulsed TIG (GTAW-P)
•TheTIGfollowing
processes are with
See literature no. 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
90-foot (27.4 m) 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.)
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 300 feet 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.
Model/Stock Number
Wireless Foot Control System
(#300 429)
Component
Foot control
(transmitter)
Power Supply
Three AA batteries
Battery Life
250 hours
Rated Range*
90 ft. (27.4 m)
Wireless Hand Control System
(#300 430)
Hand control
(transmitter)
Three AA batteries
250 hours
300 ft. (91 m)
TIG Accessories (continued)
Temperature
-13° to +158°F
(-25° to +70°C)
Radio Frequency
2.4 Ghz (ISM band)
Air-Cooled TIG (GTAW) Torch Connectors
#195 234 1,2
For Maxstar 150 and Multimatic 200.
25 mm (small) Dinse-style gas thru
for one-piece air-cooled torches.
#194 723 A-200 (WP26)
#194 7222 All others
For Syncrowave 210. 50 mm
Dinse-style gas thru for one-piece
air-cooled torch.
#195 379 A-200 (WP26)
#195 3782 All others
For CST 280, Maxstar 210/280/350,
Dynasty 210/280/350, and
Syncrowave 250 DX/350 LX.
50 mm Dinse-style for one-piece
air-cooled torch.
A-200 (WP26) torch.
2 A-80
Comes complete with
foot control (#300 429) or
• Wireless
hand control (#300 430) transmitter
14-pin receiver (#300 722)
• Wireless
Battery
box
(#249 297)
• Three AA batteries
• Four Easy-Glide Wear Pads
• (foot control only) (sold individually,
™
•
#248 274)
Belt clip (hand control only)
(#249 233)
RF Power
<3 mW
Look throughout this catalog for the
icon above signifying compatibility with
a wireless remote. For a complete
power source compatibility list visit
MillerWelds.com/wireless.
Antenna
Internal
Dimensions
H: 6 in. (152 mm)
W: 5.75 in. (146 mm)
D: 11.5 in. (292 mm)
H: 5 in. (127 mm)
W: 2.75 in. (70 mm)
D: 1.375 in. (35 mm)
Weight
3 lb.
(1.4 kg)
w/batteries
0.6 lb.
(0.27 kg)
w/batteries
Water-Cooled TIG (GTAW) Torch Connectors
Torch and Weld Cable Connectors
1 Except
*Only with voltage-sensing feeder.
Suggested power sources
Foot control
*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)
•
50 mm Dinse-Style Flow Thru
#195 380
For Syncrowave 210.
Used with all Weldcraft™
water-cooled torches.
50 mm Dinse-Style with Water
Return Line #195 377
For Maxstar 210/280/350,
Dynasty 210/280/350, and
Syncrowave 250 DX/350 LX.
Used with all Weldcraft™
water-cooled torches.
50 mm Thread-Lock-Style
#225 028
For Maxstar/Dynasty 700.
Used with all Weldcraft™
water-cooled torches.
Thread-Lock-Style Weld
Cable Connectors
#225 029
For Maxstar/Dynasty 700.
Contains two male connectors
that accept #1/0 to #4/0
AWG size cable.
(WP24) torches require 24-5 adapter.
113
Accessories
Wire Feeder Accessories
Power Supply Adapter
Extension Cables (14-Pin)
PSA-2 Control #141 604
Required when using SuitCase
12RC, 20 Series, and 70 Series
feeders with power sources
having only 115-volt power
available. Control is equipped
with a 14-pin receptacle and a
10-foot interconnecting cable with
Hubbell connections for older-style
power sources. Can also be used with competitive power
sources requiring a contact closure for contactor control.
8-Conductor Cables*
#242 208 025 25 ft. (7.6 m)
#242 208 050 50 ft. (15 m)
#242 208 080 80 ft. (24.4 m)
For XR-Control, SuitCase 12RC feeder, 20 Series feeders,
and 70 Series (S/D/DX model) feeders. 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*
#247 831 025 25 ft. (7.6 m)
#247 831 050 50 ft. (15 m)
#247 831 080 80 ft. (24.4 m)
For XR-AlumaFeed, MPa Plus feeders, and 60M 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.
14-Conductor Cables*
#242 205 025 25 ft. (7.6 m)
#242 205 050 50 ft. (15 m)
#242 205 080 80 ft. (24.4 m)
For HDC and WC-115 weld controls, XR-Control prior
to serial number KK309906, and 50 Series feeders.
Fully-loaded 14-pin extension cables for remote controls,
and 24-volt and 115-volt feeders.
*For additional lengths visit MillerWelds.com/equiptoweld.
PSA-2 Extension Cord #047 813
25-foot (7.6 m) cord extends 10-foot (3 m) cord supplied
with PSA-2 control (4-pin to 4-pin connection).
WC-24 Weld Control
#137 549
For Spoolmate 200 and
Spoolmatic/Spoolmatic Pro.
Easily mounts on power
source. Designed for use with
Miller CV power sources with
14-pin receptacles and
supplying 24 VAC.
Spool Adapter
#047 141
For use with 14-pound (6.4 kg) spool of Hobart or Lincoln
self-shielding wire.
Spool Gun Controls and Kits
For more information see literature no. M/1.5, M/1.73
and M/1.76.
SGA 100 #043 856
Required to connect
Spoolmate 3035 spool gun
to any Millermatic 141,
190, or 211. Also allows
connection to virtually any
similar MIG welder — Miller or other brands. Includes
10-foot (3 m) 115-volt power cable with plug, 6-foot
(1.8 m) interconnecting cable, and 5-foot (1.5 m) gas hose.
SGA 100C #043 857
SGA with contactor required
to connect Spoolmate 3035
spool gun to CV engine drives
like the Miller Bobcat. Includes
10-foot (3 m) 115-volt power
cable with plug, 6-foot (1.8 m)
interconnecting cable, and
5-foot (1.5 m) gas hose.
114
WC-115A Weld Control
#137 546 Without contactor
#137 546-01-1 With contactor
Operates on 115-volt power
and designed primarily for
constant-current DC power
sources. Can also be used
with constant-voltage power
sources or DC engine drives supplying 115 volts. Used
with a CC source, the control circuit functions in a voltagesensing mode and with a CV source, it functions as a
constant-speed circuit. Includes wire run-in and drive
motor acceleration controls which ensure optimum arc
starting performance.
Spool Gun Extension Hose and Cable Kits
#132 228 25 ft. (7.6 m)
#132 229 50 ft. (15 m)
For Spoolmatic/Spoolmatic Pro. Extends leads, etc.
between spool gun and power source.
Turntable Assembly
#146 236
Allows feeder to rotate as operator changes work position.
Reduces strain and bending of gun cable.
Wire Straightener
For 20 Series and 70 Series.
#141 580 For .035–.045 inch (0.9–1.1 mm) wire.
#141 581 For 1/16–1/8 inch (1.6–3.2 mm) wire.
When people look for solutions,
they turn to someone they can trust.
Finding the right filler metal solution for your welding needs
is critical in an industry that is about getting the job
done right. Every day, every project, every weld
is another opportunity for Hobart to help you find the
right filler metal solution — or create a new one.
To request a product catalog —
visit HobartBrothers.com or call 1-800-424-1543.
Find Your Solution. Today.
Index New! or Improved! products appear in blue type.
Welding System . . . . 17
210 Series . . . . . . . . . . 54
M-Series MIG Guns . . 11
Welders . . . . . . . . . . . . . . . 77
D Dynasty
M MIGmatic
S Spot
A AlumaFeed
ArcStation . . . . . . . . . . . . . . . . 105
Dynasty 280 Series . . . . . . . . . . 54
Millermatic 125 Hobby. . . . . . . . . 7
SubArc Digital Series . . . . . . . . . 78
Auto-Axcess Systems . . . . . . . . . 22
Automation Components . . . . . . 26
Axcess Systems . . . . . . . . . . . . . 22
Dynasty 350/700 . . . . . . . . . . . 56
F
FILTAIR 130 . . . . . . . . . . . . . . . 100
FILTAIR 400 . . . . . . . . . . . . . . . 100
FILTAIR 2000–12000. . . . . . . . 103
FILTAIR Capture 5 . . . . . . . . . . 102
FILTAIR MWX Series . . . . . . . . . 101
FILTAIR SWX Series . . . . . . . . . 101
G
Gas Equipment. . . . . . . . . . . . . . 85
Gas Mixers . . . . . . . . . . . . . . . 91
Heavy-Duty Outfits . . . . . . . . . 88
Medium-Duty Outfits. . . . . . . . 89
Regulators . . . . . . . . . . . . . . . 85
Torches. . . . . . . . . . . . . . . . . . 90
Gold Star Series. . . . . . . . . . . . . 49
MIG/Flux-Cored Guns . . 47
B Bernard
Big Blue 350 PipePro . . . . . . . . 73
Big Blue 400 Pro . . . . . . . . . . . . 73
Big Blue 450 Duo CST . . . . . . . . 75
Big Blue 500 Pro . . . . . . . . . . . . 74
Big Blue 600 Pro . . . . . . . . . . . . 74
Big Blue 700 Duo Pro . . . . . . . . 75
Big Blue 800 Series . . . . . . . . . . 76
Blue Star 185 . . . . . . . . . . . . . . 67
Bobcat 225/250 . . . . . . . . . . . 68
Bobcat 250 Diesel . . . . . . . . . . . 68
Bobcat 3 Phase . . . . . . . . . . . . . 68
Systems . . . . . . . . . . 23
C Continuum
Coolant Systems . . . . . . . . . . . 107
CP-302 . . . . . . . . . . . . . . . . . . . 12
CST 280. . . . . . . . . . . . . . . . . . . 50
CST 280 Racks . . . . . . . . . . . . . 50
Series . . . . . . . . . . . . 12
D Deltaweld
Dialarc 250 AC/DC . . . . . . . . . . 48
Dimension 650 . . . . . . . . . . . . . 33
Dimension 650 ArcReach. . . . . . 33
Dimension 650 Racks . . . . . . . . 33
Dimension Series . . . . . . . . . . . . 32
Diversion 165/180 . . . . . . . . . . 52
I
Insight Centerpoint. . . . . . . . . . . 25
Insight Core . . . . . . . . . . . . . . . . 24
Invision MPa Plus System . . . . . 13
L LiveArc . . . . . . . . . . . . . . . . . . . . 92
150 S . . . . . . . . . . . . . . 49
M Maxstar
Maxstar 150 STL/STH . . . . . . . . 52
Maxstar 210 STR . . . . . . . . . . . . 49
Maxstar 210 Series . . . . . . . . . . 54
Maxstar 280 Series . . . . . . . . . . 54
Maxstar 350/700 . . . . . . . . . . . 56
Millermatic 141 . . . . . . . . . . . . . . 8
Millermatic 190 . . . . . . . . . . . . . . 8
Millermatic 211 . . . . . . . . . . . . . . 9
Millermatic 212 Auto-Set . . . . . . . 9
Millermatic 252 . . . . . . . . . . . . . 10
Millermatic 350P . . . . . . . . . . . . 10
Millermatic 350P Aluminum. . . . 16
Millermatic 350P Auto Body
Aluminum Repair System . . . . 15
Multimatic 200 . . . . . . . . . . . . . 31
Robotic
P PerformArc
Welding Systems . . . . . . . . . . 26
PipeWorx 350 FieldPro Racks . . 39
PipeWorx 350 FieldPro System. . 38
PipeWorx 400 Welding System. . 38
R Remote Controls . . . . . . . 111/112
Series . . . . . . . . . . . . . . . . . . 44
S 70
70 Series Remote Configurations. 46
70 Series Swingarc . . . . . . . . . . 46
Shopmate 300 DX . . . . . . . . . . . 31
Spectrum Automation. . . . . . . . . 84
Spectrum 375 X-TREME . . . . . . . 82
Spectrum 625 X-TREME . . . . . . . 82
Spectrum 875/875 Auto-Line . . 82
Spoolmate Spool Guns. . . . . . . . 18
Spoolmatic Spool Guns . . . . . . . 19
SubArc Components. . . . . . . . . . 78
SubArc Portable Welding System. 80
SubArc Tractor . . . . . . . . . . . . . . 80
SuitCase Series . . . . . . . . . . . . . 42
Syncrowave 210 Series . . . . . . . 53
Syncrowave 250 DX/350 LX . . . 57
T
20 Series . . . . . . . . . . . . . . . . . . 44
Thunderbolt XL . . . . . . . . . . . . . 48
Tregaskiss Robotic MIG Guns . . . 29
Trailblazer 275 / 325 . . . . . . . . . 70
Trailblazer 302 Air Pak. . . . . . . . 72
Trailblazer 325 Diesel . . . . . . . . 70
Trailers. . . . . . . . . . . . . . . . . . . 109
TIG Torches. . . . . . . . . 58
W Weldcraft
Welding Safety and Health . . . . . 94
Gloves . . . . . . . . . . . . . . . . . . 98
Goggles/Glasses . . . . . . . . . . 96
Heat Stress. . . . . . . . . . . . . . . 99
Helmets . . . . . . . . . . . . . . . . . 94
Jackets/Apparel. . . . . . . . . . . 97
Respiratory . . . . . . . . . . . . . . . 99
Wireless Remote Controls . . . . 113
350/450 ArcReach . . . . . . 36
X XMT
XMT Series . . . . . . . . . . . . . . . . . 34
XR Push-Pull Guns. . . . . . . . 20/45
XR Controls . . . . . . . . . . . . . . . . 21
CONTENTS
New From Blue 3
Help Me Choose 4
WE BUILD
Connections
™
MIG (GMAW) 6
Advanced/Automated
MIG 22
Welding
Intelligence™ 24
Automation 26
Multiprocess 30
Wire Feeders 41
Stick (SMAW) 48
MillerWelds.com
TIG (GTAW) 51
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personalize — whether you’re on the job, at home or on the go.
Spot Welders 77
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Welding Safety
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Find inspiration and share welding
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Workstations 105
Protect Your Investment
Accessories 106
Register your product as a precaution
against theft or loss.
Submerged Arc 78
Plasma Cutters 81
Gas Equipment 85
Training Solutions 92
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