Miller Electric AC Generator, Air Compressor User Manual

Page 1
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
• 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: 920-735-4505 USA FAX: 920-735-4134 Canadian FAX: 920-735-4169 International FAX: 920-735-4125
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!
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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
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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.
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4
Genuine Miller Accessories
Field Kit Accessories
Desiccant Air Dryer System #195 117
A regenerating inline air dryer system that eliminates moisture in the air stream to prevent air tool freeze-ups in cold climates. Internal thermostat and heating elements insure good air quality in all climates. The system can be mounted on the side of the machine or remotely for truck mount installations.
AC/DC/Battery Charge/Jump-Start Switch #195 148 Field
AC TIG welding and 12/24 V battery charge/ jump-starting system.
FA-1D Lockable Flame Arrestor Fuel Cap #043 947
Fuel cap can be padlocked to prevent vandalism. A built-in flame arrestor prevents flames or sparks from entering the fuel tank.
Cold Weather Starting Aids* #043 959 Field 12 V intake manifold heater.
#195 086 Field 120 V oil pan heater element.
*Note: for extreme cold weather both starting aids can be used in conjunction.
Weld Ammeter and Voltmeter #195 131 Field
Panel-mounted AC/DC analog meters to monitor weld output.
Vandalism Lockout Kit #195 118 Field
Lockable hinged steel panels cover and protect name plate gauges and ignition switch (padlock included). Also includes engine compartment door lock and key.
Cable Holder #043 946
Saddle-bag-style cable holder. Convenient wrap­around storage of coiled cable for transportation. Stores 100 ft of 2/0 cable on each side.
Note: For best results do not weld when cable is coiled! Canvas cover cannot be used with cable
holder.
Battery Lockout/Tagout Disconnect Switch #195 120 Field
Lockable battery disconnect switch for safe routine maintenance.
Stick (SMAW) Welding
Weld Leads #173 851 2/0, 350 A, 100% duty cycle,
50 ft stinger, 50 ft work cable
#043 952 2/0, 300 A, 100% duty cycle,
100 ft stinger, 50 ft work cable
Plasma Cutting
Spectrum®375 X-TREME™#907 303 Spectrum®375 X-TREME™with X-CASE
#907 339 (not shown)
See Lit. Index No. PC/9.2.
Spectrum
®
625 #907 058
See Lit. Index No. PC/9.5.
Spectrum 2050 #903 777-01-2
See Lit. Index No. PC/7.0.
MIG/Flux Cored Welding
Millermatic®Passport®Plus #907 401
Portable, all-in-one MIG package features ultimate arc performance, self-contained gas bottle, and flexibility to plug into 115 or 230 V power with Miller exclusive Multi­Voltage Plug. See Lit. Index No. DC/12.53.
SuitCase
X-TREME™8VS Wire Feeder #300 093 SuitCase
X-TREME™12VS Wire Feeder #195 500
Lightweight, portable, voltage-sensing wire feeders include secondary contactor and gas valve. Require drive roll kit. See Lit. Index No. M/6.41.
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5
Genuine Miller Accessories (continued)
MIG/Flux Cored Welding (continued)
SuitCase™8RC Wire Feeder #194 938 SuitCase™12RC Wire Feeder #194 940
Lightweight, modular design and flexible enough to run a variety of wires up to 5/64 in diameter. Comes standard with remote voltage control. See Lit. Index No. M/6.5.
S-32SL Wire Feeder #109 294
Simple to use, but with all the features needed for heavy-duty applications up to 7/64 in wire diameter. See Lit. Index No. M/6.21.
Spoolmatic
®
30A Spool Gun
#130 831
Air-cooled, 200-amp, 1-lb spool gun for aluminum MIG. See Lit. Index No. M/1.73.
WC-24 Control #137 549
Use with Spoolmatic 30A.
XR
Wire Feeders and Guns
Push-pull system designed to handle difficult-to-feed soft alloy wires such as aluminum. See Lit. Index No. M/1.7, M/1.71, and M/1.73.
TIG (GTAW) Welding
Dynasty®200 Series
For premium portable AC/DC TIG arc quality. See Lit. Index No. AD/4.8.
HF-251 Series #042 388
HF-251D-1, 115 VAC High-frequency arc starter and stabilizer. See Accessory Lit. Index No. AY/5.0.
Remote Controls
RHC-14 Hand Control #129 340
Miniature hand control for remote current and contactor
control. Dimensions: 4 x 4 x 3-1/4 in (102 x 102 x 82 mm). Includes 20 ft (6 m) cord and 14-pin plug.
RFCS-14 HD Foot Control #194 744
Heavy-duty foot current and contactor control. Includes 20 ft (6 m) cord and 14-pin plug.
RMLS-14 #129 337
14-pin plug Momentary- and maintained­contact rocker switch for contactor control. Push forward for maintained contact and back for momen tary contact. Includes 20 ft (6 m) cord.
RCC-14 Remote Contactor and Current Control #151 086 14-pin plug
Rotary-motion fingertip control fastens to TIG torch using two Velcro
®
straps.
Includes 28 ft (8.5 m) control cord.
Extension Cords for 14-Pin Remote Controls #122 973 25 ft (7.6 m) #122 974 50 ft (15.2 m) #122 975 75 ft (23 m)
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6
A. 20 in (508 mm) B. 16-1/2 in (419 mm) C. 1-3/4 in (44 mm) D. 6-1/16 in (154 mm) E. 32-3/4 in (832 mm) F. 45-3/8 in (1153 mm) (Gas)
52 in (1321 mm) (Diesel)
G. 13/32 in (10 mm) diameter
Height:
(to top of exhaust)
33 in (838 mm) (Gas) 34-1/4 in (870 mm) (Diesel)
Width: 20 in (508 mm) Depth: 45-7/8 in (1164 mm) (Gas)
52-1/2 in (1334 mm) (Diesel)
4 Holes
Engine End
G
A
B
C
D
E
F
Mounting Specifications
HWY-224 Trailer #043 805 For highway use. OFR-224 Trailer #043 802 For off-road use.
A 2650 lb (1202 kg) capacity trailer. Welded steel tubing frame, heavy-duty axle with roller bearing hubs and leaf-spring suspension. Includes jack stand, 2 in (50 mm) ball hitch.
HWY-224 also includes fenders and lights.
Note: Trailer is shipped unassembled.
Cable Tree #043 826
Provides an area to conveniently wrap weld cables and extension cords.
Lunette Eye 2-1/2 in (64 mm) #043 824
HWY-430 Tandem Axle Trailer #043 806
Smooth riding with 3750 lb (1701 kg) capacity. Includes hand-operated parking brake, hydraulic brake system, and a break-away device to lock brakes if the trailer comes loose. Includes jack stand, fenders and lights. (Hitch must be ordered separately.)
Note: Some assembly required.
Cable Tree #043 826
Provides an area to conveniently wrap weld cables and extension cords.
Ball Hitch 2 in (50 mm) #043 864 Lunette Eye 3 in (76 mm) #043 863
4 West Four-Wheel Steerable Off-Road Trailer #042 801
A heavy-duty 2570 lb (1166 kg) capacity trailer designed for use in mines, quarries, and other rough terrain. Has narrow 22 ft (6.7 m) turning radius. Includes 3 in lunette eye, universal hitch and safety chains.
Note: Trailer is shipped unassembled.
Trailers and Hitches (Note: Trailers are shipped unassembled.)
Trailer Specifications (Subject to change without notice.)
Net Payload
2570 lb (1166 kg)
2650 lb (1202 kg)
3750 lb (1701 kg)
Gross Vehicle Weight Rating
3000 lb (1361 kg)
2960 lb (1343 kg)
4280 lb (1941 kg)
Gross Axle Weight Rating
2000 lb/axle (907 kg/axle)
3500 lb (1588 kg)
2200 lb/axle (998 kg/axle)
Model 4 West
HWY-224 OFR-224
HWY-430
Height of Bed
21-1/4 in (540 mm)
18-1/2 in (470 mm)
19-1/4 in (489 mm)
Road Clearance
8 in (203 mm)
7-1/2 in (191 mm)
8-1/2 in (216 mm)
Net Weight
430 lb (195 kg)
355 lb (161 kg)
530 lb (240 kg)
Track (Center to center of tires)
55-1/4 in (1403 mm)
52 in (1321 mm)
52 in (1321 mm)
Standard Tires (Standard rating or P-size rating)
B78-13
B78-13B
B78-13B
Dimensions
Length: 91 in (2311 mm)** Width: 61-1/4 in (1556 mm)
Length: 122-1/2 in (3112 mm) Width: HWY– 61 in (1549 mm)*
OFR–58-1/2 in (1486 mm)
Length: 156-1/2 in (3975 mm) Width: 61 in (1549 mm)*
*
Width at outside of fenders.
**
Does not include tongue.
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7
MIG Gun
Work
SuitCase
8RC/12RC
Work
Stick Electrode
Work
Flux Cored Gun
Aluminum MIG with
Spoolmatic 30A Gun
Work
Cutting Torch
Work
Spectrum
14-Pin
14-Pin
WC-24
TIG
Torch
Work
14-Pin
HF-251D-1
X-TREME 8VS/
X-TREME 12VS
Feeder
Plasma Basic Equipment
Spectrum®375 X-TREME™#907 303 Spectrum®375 X-TREME™with X-CASE
#907 339
Spectrum
®
625 #907 058
Spectrum®2050 #903 777-01-2
Stick (SMAW) Basic Equipment
Flux-Cored (FCAW) Basic Equipment
SuitCase™X-TREME™ 8VS #300 093 SuitCase
X-TREME™12VS #195 500
MIG (GMAW) Basic Equipment
SuitCase™8RC #194 938 SuitCase™12RC #194 940
Aluminum MIG (GMAW) Basic Equipment
Spoolmatic®30A #130 831 WC-24 #137 549
TIG (GTAW) Basic Equipment
Dynasty®200 Series HF-251D-1 #042 388* *TIG power cable adapter required
Typical Installations
Page 8
Litho in USA
Distributed by:
Equipment and Factory Options Stock No. Description Qty. Price
Big Blue
®
Air Pak™CC/CV Base Model #907 062 Automatic Idle, Engine Gauges, 5.5 kW AC Generator
International Model #907 062-01-1 50/60 Hz, Dry Battery, Automatic Idle, Engine Gauges, 5.5 kW AC Generator Cold Weather Model #907 062-04-1 Automatic Idle, Engine Gauges, 5.5 kW AC Generator, Weld Meters,
Battery Lockout/Tagout Disconnect Switch, 12 V Intake Manifold Heater, 120 V Oil Pan Heater
Deluxe Model #907 062-07-1 Automatic Idle, Engine Gauges, 5.5 kW AC Generator, Weld Meters,
Battery Lockout/Tagout Disconnect Switch, 12 V Intake Manifold Heater, 120 V Oil Pan Heater, Vandalism Lockout Kit, 20 kW Generator, AC/DC/Battery Charge/Jump-Start Switch
Field Kit Accessories
Weld Ammeter and Voltmeter Kit #195 131 AC/DC analog weld output meters Lockable Fuel Cap Flame Arrestor #043 947 Padlock not included Cold Weather Starting Aids #043 959 12 volt intake manifold heater
#195 086 120 volt oil pan heater Desiccant Air Dryer System #195 117 Removes moisture from air supply Vandalism Lockout Kit #195 118 Lockable front control panel and engine compartment Battery Lockout/Tagout Disconnect Switch #195 120 Allows machine battery to be disconnected and locked AC/DC/Battery Charge/Jump-Start Switch #195 148 Field Cable Holder #043 946 Stores up to 200 ft of 2/0 weld cable Protective Cover #195 159 Will not fit over machine with cable holder attached
Stick Accessories
Welding Leads #173 851 2/0, 350 A, 100% Duty Cycle, 50 ft stinger, 50 ft work clamp
#043 952 2/0, 300 A, 100% Duty Cycle, 100 ft stinger, 50 ft work clamp
Plasma Cutters
Spectrum®Plasma Cutter See page 4
Wire Feeders
SuitCase™X-TREME™ 8VS #300 093 Includes contactor and gas valve. See Lit. Index No. M/6.41 SuitCase™X-TREME™12VS #195 500 Includes contactor and gas valve. See Lit Index No. M/6.41 SuitCase™8RC #194 938 See Lit Index No. M/6.5 SuitCase™12RC #194 940 See Lit Index No. M/6.5 S-32SL Wire Feeder #109 294 See Lit. Index No. M/6.21 Spoolmatic®30A Spool Gun #130 831 Requires WC-24 Control. See Lit. Index No. M/1.73 Guns and Consumables See Lit. Index No. M/10.0 and M/13.4
TIG Accessories
HF-251D-1 #042 388 High frequency unit for AC TIG welding Water Coolant System See Lit. Index No. AY/7.2 TIG Torch, Consumables
Remote Controls
RHC-14 #129 340 Hand control RFCS-14 HD #194 744 Foot control RMLS-14 #129 337 Momentary and maintained contact switch RCC-14 #151 086 Fingertip control Extension Cords #122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.9 m)
Trailers and Hitches
HWY-224 Trailer #043 805 Highway trailer with 2650 lb (1202 kg) capacity OFR-224 Trailer #043 802 Off-road trailer with 2650 lb (1202 kg) capacity HWY-430 Tandem Axle Trailer #043 806 Highway trailer with 3750 lb (1701 kg) capacity. 4-West Trailer #042 801 Off-road steerable trailer with 2570 (1166 kg) capacity Lunette Eye #043 824 2-1/2 in (64 mm). For 224 trailers only
#043 863 3 in (76 mm). For 430 trailer only Ball Hitch #043 864 2 in (51 mm). For 430 trailer only Clevis #043 823 For 430 trailer only Cable Tree #043 826 Works on 224 and 430 trailers
Date: Total Quoted Price:
Ordering Information
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