Miller Electric Engine-Driven Welder/ AC Generator/Air Compressor, Big Blue Air Pak Specifications

Quick
Specs

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

Meter maintenance displays

• Fuel gauge

• Hour meter function

• Oil change interval

• High coolant temperature and
low oil pressure shutdowns

• 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 September 2010 • 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.

Heavy-duty low-speed
industrial turbocharged
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.

Heavy Industrial
Applications

Railroad Maintenance
Mining Maintenance
Maintenance and Repair Rigs

Processes

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

Stud Welding — 1/2 in (12.7 mm)
Air Carbon Arc (CAC-A)

1/2 in (12.7 mm) Carbons

Air Plasma Cutting

with Optional Spectrum Models
Battery Charging/Jump-Starting*
Air Compressor

Output Range

DC Stick 45–750 A AC Stick 35–575 A*
MIG/FCAW 14–40 V
DC TIG 20–450 A AC TIG 20–375 A*
Battery Charge 12/24 V, 50–750 A*

*Deluxe Model Only.

Weld Output Rated at 104°F (40°C)

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

Air Compressor 100 PSI, 60 CFM, 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*

Accu-Rated

™

–Not Inflated

Generator Power

Miller Electric Mfg. Co.

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

Web Site

www.MillerWelds.com

Equipment Sales US and Canada

Phone: [phone]
FAX: [phone]
International Phone: [phone]
International FAX: [phone]

EPA Tier 4i

Compliant

Big Blue Air Pak Deluxe Model shown.

EPA Tier 4i

EPA Tier 4i

EPA Tier 4i

Compliant

Compliant

Compliant

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

500 A at 40 V (20 kW), 100% Duty Cycle
400 A at 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

*Deluxe model only. **Additional 7 in (178 mm) to top of exhaust. ***Additional 190 lb (86 kg) when fuel tank is full.

Compressor
Brand

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

TD2011L04w

Features

EPA Tier 4i compliant, turbocharged,
direct-injected, liquid-cooled (oil) engine.
Right-side service access with 500 hr intervals
for oil and filters.

Type

Four-cylinder,
industrial, liquid­cooled engine

Engine
Speeds

1850 Run
1250 Idle

HP

63.4

Fuel
Capacity

25 gal
(95 L)

Automatic Engine
Shutdowns

Low Oil Pressure,
High Coolant
Temperature,
Low Fuel Level

Oil
Capacity

11 qt
(10.4 L)

Engine

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: 69-1/2 in

(1765 mm)

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

Peak: 5500 watts
Continuous: 4000 watts, 34/17 A,

120/240 VAC, 60 Hz while welding

Additional Generator Power for
Deluxe Models (while NOT welding)

3-phase: 20 kW, 48 A, 240 VAC or
1-phase: 12 kW, 50 A, 120/240 VAC

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

Meets NEMA and IEC output ratings.

Certified by Canadian Standards Association to both the Canadian and U.S. Standards.

1

2

3

4
5

6

7

8

10
11

12
13

14

15

16
17

18
19

20
21

22

International Model

9

7

23

3

Performance Data

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 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.

3.00

2.75

2.50

2.25

2.00

1.75

1.50

1.25

US Gal./Hr.

1.00

0.75

0.50

0.25

0.00

67.5

DC VOLTS

22.5

AC VOLTS

FUEL CONSUMPTION CURVE

WELD AND AIR

WELD ONLY

IDLE

IDLE WITH AIR

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

DC WELD AMPERES AT 100% DUTY CYCLE

VOLT/AMP CURVE – DC STICK MODE

90

45

0

0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

VOLT/AMP CURVE – AC STICK MODE

100

80

60

40

20

0

0 100 200 300 400 500 600 700

AC AMPERES

300–Max
185–525
125–400

85–250
55–125

GENERATOR POWER CURVE OPTION

280

260

240

220

AC VOLTS

200

180

0 10203040506070

AC AMPERES

VOLT/AMP CURVE – DC TIG MODE

100

75

50

DC VOLTS

25

0

0 100 200 300 400 500 600

DC AMPERES

VOLT/AMP CURVE – AC TIG MODE

100

80

60

40

AC VOLTS

20

0

0 100 200 300 400 500 600

AC AMPERES

20 kW

3-PHASE

12 kW

1-PHASE

60–450
40–330
30–220
20–110

50

37.5

25

DC VOLTS

12.5

BATTERY CHARGE OUTPUT

0

0 100 200 300 400 500 600 700 800 900 1000

DC AMPS

VOLT/AMP CURVE – MIG MODE

100

75

50

DC VOLTS

25

0

0 250 500 750 1000

MAX

MIN

DC AMPERES

140

120

100

80

PSI

60

40

20

0

0102030

AIR SUPPLY CURVE

IDLE

40 50 60 70

CFM