Miller Electric AC Generator, Air Compressor User Manual

Quick
Specs

Quiet at only 70 dB (95 Lwa) when idle,
79 dB (104 Lwa) at maximum output.
Improves work site communications.

NEW!

Meter maintenance display

• Hour meter function

• Oil Change interval

• Diesel: High coolant temperature
and low oil pressure shutdowns

• Diesel: Low fuel shutdown —
engine shuts down before
system runs out of fuel making
restarts easy

Low maintenance with easy single-side
access to engine and 500 hour oil changes for
both engine and compressor.

Arc-Drive makes welding easy.
Automatically enhances Stick
welding, especially on pipe, by
focusing the arc and preventing
the electrode from going out.

Optional

AC/DC/battery charge/

jump-start for AC TIG welding

and 12 or 24 volt batteries. Simply
select the battery voltage and
connect cables to the separate
battery output studs.

(High-frequency unit required for
AC TIG.)

Big Blue®Air Pak

™

Engine-Driven Welder/

AC Generator/Air Compressor

Issued April 2008 • Index No. ED/10.5

Hot Start™provides positive stick

electrode starts to make it easy to
start all types of electrodes.

Enclosed robust case design protects
internal components from impact and
allows air flow to cool and prolong the life
of the engine. Also reduces sound levels.

Welder/generator/air compressor.

One machine that will do it all. Designed
and built to be the most reliable high­output system in the world.

Weatherproof Lexan

®

nameplate

resists cracking and fading, and is
color-coded for ease of operation.

GFCI receptacle as required on most job sites
to protect operators from electrical hazards.

turbocharged four-cylinder diesel

engine provides ample power at high altitudes.

Independent compressor controls.

On/off switch for applications not
requiring compressed air. At idle

speed will produce 100 PSI at 40 CFM.

ultra-reliable

industrial rotary screw air compressor.

Belt-driven with automatic belt tensioner
with a life expectancy of 30,000 hrs.

The Power of Blue®.

Welder/Generator/Air Compressor is warranted

by Miller for 3 years, parts and labor.

Engine is warranted by Deutz for 3 years.

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

Web Site

www.MillerWelds.com

International Headquarters

Phone: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]

Heavy Industrial Applications

Railroad Maintenance
Mining Maintenance
Maintenance and Repair Rigs

Processes

Stick (SMAW)
MIG (GMAW)
Flux Cored (FCAW)
Submerged Arc (SAW)
AC TIG (GTAW)*
DC TIG (GTAW)

Stud Welding — 1/2 in (12.7 mm)
Air Plasma Cutting

with Optional Spectrum Models

Air Carbon Arc (CAC-A)

1/2 in (12.7 mm) Carbons
Battery Charging/Jump-Starting*
Air Compressor

Output Range

DC Stick 45–750 A MIG/FCAW 14–40 V
DC TIG 20–450 A AC 20–575 A*
Battery Charge 12/24 V, 50–750 A*

*Deluxe Model Only.

Weld Output Rated at 104°F (40°C)

Stick 600 A, 44 V, 26.4 kW, 40% Duty Cycle
Stick 550 A, 42 V, 23.1 kW, 60% Duty Cycle
MIG/FCAW 500 A, 40 V, 20 kW, 100% Duty Cycle
AC TIG 400 A, 26 V, 10.4 kW, 100% Duty Cycle*

Generator Output Rated at 104°F (40°C)

5,500 Watts Peak — 4,000 Watts Continuous
20,000 Watts 3-Phase/12,000 Watts 1-Phase

Continuous*

Air Compressor 100 PSI, 60 CFM, 100% Duty Cycle
Weight Net: 1931 lb (876 kg)

Ship: 1982 lb (899 kg)

Improved!

Maintenance Displays!

Welding
Mode

CC/DC

CV/DC

CC/AC*

Battery*
Charge
Jump-Start

Weld Output Rated at 104˚ F (40˚ C) NEMA
Amperage and Voltage

600 A, 44 V, 26.4 kW, 40% Duty Cycle
550 A, 42 V, 23.1 kW, 60% Duty Cycle
500 A, 40 V, 20 kW, 100% Duty Cycle

500 A, 40 V, 20 kW, 100% Duty Cycle

400 A, 36 V, 14.4 kW 100% Duty Cycle

750 A, 12 V, Jump-Start
750 A, 24 V, Jump-Start

Weld
Output
Range

20 – 750 A

14 – 40 V

20 – 575 A

12/24 V

Max. Open­Circuit
Voltage

95

56

64

14/28

Meets NEMA and IEC output ratings. *Only available on deluxe model. **Additional 7 in (178 mm) to top of exhaust. ***Additional 190 lb (86 kg) when fuel tank is full.

CSA approved.

Compressor
Brand

Ingersoll-Rand
CE55 G1

Free Air
Delivery at
1850 RPM

60 cfm
(1.70 m

3

/min)

Free Air
Delivery at
1235 RPM

40 cfm
(1.13 m3/min)
Idle

Features

Rotary screw with electric clutch for on/off.
Oil change intervals 500 hrs (same as engine).
Life expectancy 30,000 hrs.

Working
Pressure
Constant

100 psig
7 bar

Duty
Cycle

100%

Oil
Capacity

5 qt (4.7 L)

Automatic
Compressor
Shutdowns

Oil temperature

Engine Brand

Deutz, BF4M
2011 Diesel

Features

EPA certified, turbocharged direct-injected,
liquid-cooled (oil) engine. Right side service
access with 500 hr intervals for oil and filters.
MSHA approved with purchase of certificate
from Deutz dealer.

Type

Four-cylinder,
industrial, liquid­cooled engine

Engine
Speeds

1850 Run
1235 Idle

HP

63.4

Fuel Capacity

25 gal (95 L)

Automatic Engine
Shutdowns

Oil pressure
Oil temperature

Oil
Capacity

11 qt
(10.4 L)

Engine

7

8

9

18
19

20
21

22

7

23

International Model

1

2

10
11

12
13

4

3

5

6

15

16

17

14

2

Control Panel

Weight

Without Fuel***

Net: 1931 lb
(876 kg)

Ship: 1982 lb
(899 kg)

Deluxe Model
Net: 1956 lb

(887 kg)
Ship: 2007 lb

(910 kg)

Dimensions**

H: 43 in
(1092 mm)

W: 28-1/2 in
(724 mm)

D: 67-1/2 in
(1715 mm)

Generator Output Rated
at 104˚ F (40˚ C)

Peak: 5500 watts
Continuous: 4000 watts,

120/240 VAC, 34/17 A, 60 Hz
while welding

Optional kW

3-phase, 20 kW, 36 A, 240 VAC
1-phase, 12 kW, 50 A,
120/240 VAC while not welding

Specifications

(Subject to change without notice.)

1. AC/DC Voltmeter*

2. AC/DC Ammeter*

3. Amperage Range Switch

4. Amperage/Voltage Adjust Control

5. Amperage/Voltage Adjust Switch

and Remote Amperage/Voltage
Adjust 14-Pin Receptacle

6. Process/Contactor

Selector Switch

7. 120 VAC, 20 A GFCI

Duplex Receptacle

8. 240 VAC, 30 A TwistLock

Receptacle (NEMA L6-30)

9. Air Outlet Valve 3/4 in NPT

10. Engine Oil Pressure Gauge

11. Fuel Gauge—displays engine

hours and oil change intervals

12. Engine Coolant Temperature Gauge

13. Battery Voltmeter

14. Air Compressor Pressure Gauge

15. Air Compressor On/Off Switch

16. Engine Control Switch

17. Starting Aid Switch*

18. 20 kW, 3-Phase Generator*

19. Strain Relief*

20. 50 A, 3-Phase Circuit Breaker*

21. 50 A, 1-Phase 120/240 V

Receptacle (NEMA 14-50)*

22. AC/DC/Battery Charge/

Jump-Start Switch*

23. International Model—240 VAC,

16 A Pin and Sleeve Receptacle

*On Select Models

Air Compressor

3

Performance Data

FUEL CONSUMPTION CURVE

0.00

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

2.25

2.50

2.75

3.00

0 50 100 150 200 250 300 350 400 450 500 550 600

DC WELD AMPERES AT 100% DUTY CYCLE

US Gal./Hr.

VOLT/AMP CURVE – STICK MODE

0

20

40

60

80

100

0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

DC VOLTS

VOLT/AMP CURVE – AC TIG MODE

0

20

40

60

80

100

0 100 200 300 400 500 600 700

AC AMPERES

AC VOLTS

WELD AND AIR

WELD ONLY

IDLE WITH AIR

IDLE

AIR SUPPLY CURVE

0

20

40

60

80

100

120

140

0 10203040506070

CFM

PSI

IDLE

300–Max
185–525
125–400

55–125

VOLT/AMP CURVE – MIG MODE

0

10

20

30

40

50

60

70

80

90

100

0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

DC VOLTS

MAX

MIN

VOLT/AMP CURVE – DC TIG MODE

0

20

40

60

80

100

0 100 200 300 400 500 600

DC AMPERES

DC VOLTS

60– 450
40– 330
30– 220
20– 110

GENERATOR POWER CURVE OPTION

180

200

220

240

260

280

0 10203040506070

AC AMPERES

AC VOLTS

12 kW

1-PHASE

BATTERY CHARGE OUTPUT

0

5

10

15

20

25

30

35

40

45

50

0 100 200 300 400 500 600 700 800 900 1000

DC AMPS

DC VOLTS

20 kW

3-PHASE

Ingersoll-Rand Rotary Screw Air
Compressor

This industrial grade compressor, has a life
expectancy of 30,000 hours, is belt driven and
utilizes an electric clutch control to allow the
compressor to be turned off if not needed.
This design increases efficiency, reduces fuel
consumption and saves you money at the
pump. An automatic belt tensioner provides
proper belt tension even after years of service.
The compressor is protected by a high
temperature shutdown switch.

Toolless
Generator
Brushes

100% copper­wound
generator

features quick
and easy brush and slip ring inspection.
Brushes can be removed and/or replaced
in a matter of seconds.

The Vault

Superior Circuit Board Design

Miller’s critical circuit boards are engineered
to carry

low power

and

low heat

to reduce
thermal stress and minimize expansion and
contraction. In contrast, our competitor’s
boards carry

high power

and

high heat

, making

them more vulnerable to failure.

“The Vault” Makes Upgrading to Miller CC/CV
Units Worry-Free

Concerns with circuit board reliability have
resulted in some operators steering clear of
CC/CV welder/generators — even though they

offer a superior arc and multiple welding
processes. Miller’s circuit board reliability isn’t
a concern since all PRO 300 and Big Blue
multiprocess industrial engine drives feature
the Vault.

Created out of two aluminum halves sealed
with silicone, as well as watertight harness
connections, the Vault provides a clean circuit
board environment, protecting the electronics
— and controlling output — in heavy industrial
applications. No other competitor protects their
electronics with a sealed vault, leaving critical

circuit boards exposed to harsh elements that
can disrupt the machine’s electronics, and
therefore, its operation.