Axcess S stems - ami-lovrekovic.hr · Optional Axcess-able software RMD ... available welding...

Axcess Power Systemsfor Semi-Automatic

Applications

ProcessesMulti-MIG®

Accu-Pulse® MIG (GMAW-P)- Accu-Curve™ MIG (GMAW-P)- Accu-Speed™ MIG (GMAW-P)

Pulsed MIG (GMAW-P)MIG (GMAW)Metal CoreCarbon Arc Gouging (CAC-A) canalso be activated (Axcess only)

FREE TRIAL! See page 2 for detailsRMD™ (GMAW-SCT) Optional

ManufacturingApplicationsConstruction EquipmentAutomotive ComponentsRecreational VehiclesFarm MachineryOffice FurnitureMining Machinery

QuickSpecs

Axcess® SystemsSoftware Driven Multi-MIG® Process Platform

Digital Semi-Automatic andRobotic Welding Systems

Issued February 2007 • Index No. AU/8.0

The Power of Blue®.

Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

Web Sitewww.MillerWelds.com

International HeadquartersPhone: 920-735-4505USA FAX: 920-735-4134Canadian FAX: 920-735-4169International FAX: 920-735-4125

Rated Output 300: 300 A at 32 VDC, 60% Duty Cycle(225 A at 29 VDC, 100% Duty Cycle)

450: 450 A at 44 VDC, 100% Duty Cycle675: 675 A at 44 VDC, 100% Duty Cycle

Voltage Range 10 – 44 V

Auxiliary Power 120 VAC, 10 A Duplex

Ship Weight 300: 116 lb (52.6 kg)450: 163 lb (72.9 kg)675: 208 lb (94.3 kg)

AA-40GB Wire Drive Motor Assembly with OCP(Over Current Protection) to protect against currentsurges. New design utilizes an improved sheetmetal enclosure including printed circuit board. Itfeatures a threaded gas connection and a direct-panel-mounted, quarter-turn motor control cableconnection that eliminates motion stress on themotor’s power and tachometer feedback wires.

Power source is warranted for 3 years, parts and labor.

Flexible, Expandable and UpgradeableMulti-MIG capable welding systems are precise,

digitally controlled and software-driven. For additional information visit MillerWelds.com/AMS.

Axcess digital control technology combined with inverter welding power source is designed to reduce complexity of a semi-automatic or robotic pulsed MIG system, simplify installation and provide superior welding performance.

“Axcess” the ability to accommodate welding data file exchange through downloadable upgradesand new hybrid welding processes using e-mail, orthe Web and a Palm™ handheld (PDA).

Axcess four-drive-roll wire drive feeder iscombined with operator interface leaving nocontrols back at the power source. Providespositive feeding for the appropriatepreprogrammed wire diameters from 50 –1400 IPM and operates from 40 VDCsupplied by Axcess power source.

Shown with Axcess feeders

Shown with AA-40GBwith OCP wire drivemotor assemblies

Auto-Axcess Power Systems forRobotic/Automation Applications

DESIGNED AND BUILT IN

AA-40GB motor connections.

Go to the online AxcessSystem Configurator atMillerWelds.com/AMS

Features and Benefits (Common to all Axcess Systems.)

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HARDWARE (Standard)

Miller’s patented technology allows for any input voltage hook-up (190 – 630 V) with no manual linking. Assures rock-solid, consistent output on fluctuating primary lines.

Wind Tunnel Technology™ Circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and improves reliability in harsh welding environments.

1/4-turn steel connectors Allow for faster installation of system and eliminates thread stripping.

Fan-On-Demand™ Cooling system operates only when needed. Reduces amount of airborne contaminants pulled through the machine.

115 VAC duplex receptacle Provides 10 amp circuit-breaker-protected auxiliary power regardless of primary power.

Dual removable lifting eyes For moving with overhead lifts. Removability allows for flat-top feeder or storage on top.

Forklift slots Slots cut into the frame for forklift transportation.

Matching footprints All models use common stacked power modules allowing small footprint.

Flexible feeding options Several different wire feeding and operator interface options are available and configurable to desired application.

9-pin Palm™ handheld (PDA) Separate ports provide Axcess with data transfer and optional program downloads.and 9-pin RS-232 serial communication port

SOFTWARE (Standard)

Multi-MIG® capability Includes common carbon steel, aluminum and stainless welding programs, including new patented Accu-Pulse®,standard or adaptive pulse, conventional MIG and metal core programs using the most popular wire diameters and gas combinations. Now with Accu-Curve™ and Accu-Speed ™.

Accu-Pulse® MIG process that delivers precise control of the arc even over tack welds and in tight corners. Provides optimum molten puddle control for out-of-position welding.

SureStart™ Provides consistent arc starts by electronically assuring a ball is not left on the wire when welding is stopped. This provides a predictable condition for the next arc start and combines this with precisely tuned arc starting routines.

Arc Control Control offers a simple way to tailor factory pulse weld programs by adjusting the arc plasma cone to accommodate a variety of welding applications without the need for any reprogramming or changing any hardware.

Arc Adjust Allows a simple method that controls arc length for pulse processes and wetting action for RMD.

Remote/trigger program select Allows changing weld programs to take advantage of up to 8 programs of Multi-MIG welding process capabilities.

Optional Axcess-able software RMD™ (Regulated Metal Deposition), Palm™ Axcess file management system, WaveWriter™ Palm pulse wave shaping.

p y

Process RMD™ RegulatedMetal Deposition (Optional) Standard Spray Pulsed Spray

Accu-Pulse®

Accu-Speed™

Accu-Curve™

StandardShort Circuit

Flat/Horizontal All Position Performance Thin Materials/Gap FillingWeld PuddleControl

Multi-MIG® Process Capability — Through Software-Based Programs“Axcess®” the ideal welding process for any weld joint at hand. Whether you need high travelspeed combined with high deposition rates orrequire gaps to be filled, any combination of theavailable welding processes can be “Axcess”-edeither at the start of a welding sequence or

anywhere in the weld while actually welding byusing trigger or remote program select.

For a given wire-feed speed, the chart belowshows from left (hottest) to right (coolest) all the possible arc mode transfer ranges of

“Axcess”-able MIG processes. This showscompatible spray gas combinations such as 90 Ar/10 CO2 (90% Argon and 10% CarbonDioxide) on steel using the same wire-feed speedand also gives an indication of puddle controlcharacteristics based on arc type selected.

Note: To achieve optimum performance, 4/0 welding power secondary cable is recommended and the supplied work-sense lead must be connected as close to arc as possible.

Learn More at MillerWelds.com/AMS

FREE Hour Trial of RMD™ with Every New Axcess or Auto-Axcess Power Supply888

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Featured Welding Process

Software-Based Welding Process OptionRMD™ (Regulated Metal Deposition)Field #195 252 (serial # must be provided)Field installation requires Palmhandheld.Note: Factory-installed software can be ordered as a combo-numberoption with power supply. See power source stock number listings on page 12.

The unique patented design ofRMD (Regulated Metal Deposition)is a precisely controlled short-circuit transfer. It is a method of detecting when the short is going to clear and then rapidly reacting tothis data changing the current levels. Features Proactive Dynamic Puddle Control.Note: Palm handheld required for field option installation — Field kit includes connection for Palm to connect to Axcess.

Benefits of RMD

Weld suited to thin materialsCan replace TIG process in someapplicationsGap fillingSpatter reductionProvides less heat into work pieceExcellent performance on stainless steelCan be combined with other Axcess®-related programsMinimize distortionUse larger diameter wire on thin materials

Accu-Pulse®

STANDARD pre-programmedwelding processes includepatented Accu-Pulse, 2 newAccu-Pulse programs called Accu-Curve™ and Accu-Speed™,conventional MIG and pulsed MIGoptimized for the most commonsteel, stainless steel, aluminumand metal-cored wires, using themost common wire diameters and gas combinations. Programsfor new processes and differentmaterials are planned andcurrently in development. In most cases, slightly different ratios of gas mixtures will perform wellusing a similar program and adjusting arc length or the appropriate arc control for the selectedprocess. Contact Miller for more information on less common materials and gas combinations.


Accu-Curve™

STANDARD on all Axcess models—Accu-Curveis a variation of the Accu-Pulse process. Thetransitions from peaks to background voltage are“curved”. The curved transitions provide a “softer”feel without sacrificing the tight arc lengths thatallow for better puddle control that have becomethe hallmark of the Accu-Pulse process.

Benefits of NEW! Accu-Curve™

“Softer” feel than Accu-PulseMaintains tight arc lengthsMaintains better puddle control

Accu-Speed™

STANDARD on all Axcess models—Accu-Speedis a variation of the Accu-Pulse process and was developed for the type of arcs needed inautomated welding applications. Accu-Speedhas a tighter driving arc that can be directed intothe joint, yet still remains stable at the highertravel speeds used in automated welding. Ingeneral, Accu-Speed has lower average voltageand amperage when compared to Accu-Pulse.

Note: Accu-Curve and Accu-Speed can be added to existing Axcess or Auto-Axcess systems for FREE by updating code online atMillerWelds.com/AMS/axcess. Requires Palmhandheld to transfer code from PC to Axcess.

Benefits of NEW! Accu-Speed™

Up to 20% greater travel speed than Accu-PulseLower average voltage/amperage thanAccu-PulseTight, driving arcRemains stable at higher travel speeds

Benefits of Accu-Pulse®

(Compared to conventional pulse)Shorter arc lengths possibleBetter puddle controlMore tolerant of contact tip to work variationLess audible noiseNo arc wandering in tight cornersNarrow arc plasma columnAllows weld to fill in at toes increasing travel speed and depositionMore tolerant of poor fit up and gaps (compared to standard pulse)Ideal for robot seam tracking applications

Accu-Pulse(CV Peak/Background)

Taught Peak Voltage

Taught Background Voltage

Voltage

Current

CC Ramps

Fixed current beginning points

CV Peak CV PeakCV Background Min Current Limit

CV Background

CurrentWave Form

RMD Ball Transfer

<- Wet -> Pinch Clear Blink Ball Background Pre-short

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Axcess® Control Panels

1. Power Switch2. Handheld RS-232 Port3. PC-Communication RS-232 Port

(Future use)

4. Network Feeder Connector5. 115 VAC, 10 A Duplex Receptacle6. Circuit Breakers7. DeviceNet Connector (Optional)

1. Voltage/Arc Adjust Display Meter2. Program Display3. Program # Select4. Process Setup Button5. Control Knob6. Trigger Receptacle7. On/Off Button8. Voltage Setup Button9. Wire Speed Setup Button

10. Wire Speed/Amperage Display Meter

11. Feeder Setup Button12. Jog/Purge Switch

Front Panel Rear Panel

Program

ProcessWire TypeGas Type

Volts Time Arc Adjust

WFS Amps Arc Ctl

Process Set Up Adjust Feeder Set Up

Trigger HoldTrigger ControlSequence

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7 in(178 mm)

13 in(330 mm)

Single AxcessFeeder and Remote OperatorInterface (ROI)

CapabilitiesDual Schedule — Toggle between two settingsusing a single wire.

4T — When trigger is released, output willoperate at different ranges.

Trigger Program Select (TPS) — Provides theability to “Axcess” any of the Multi-MIG®

processes or any of the eight active programs.

Trigger Dual Schedule (TDS) — When activatedallow selection between predetermined programpairs (e.g. 1,2 – 3,4 – 5,6 – 7,8).

Trigger Hold (TH) — When activated, allowsgun trigger release and continuous welding untiltrigger is pulled again.

Carbon Arc Gouging (CAC-A)—Can be activated.

SequencePreflow: 0.1– 5 secStart Power: 0.1– 5 secCrater: 0.1– 5 secPostflow: 0.1– 5 sec

Arc Adjust — Arc length (Trim)

Arc Control — Arc force or focus (SharpArc®)

Process Selection — Accu-Pulse®, Pulsed MIG,MIG, Metal Core, RMD™ (Optional)

4 Learn More at MillerWelds.com/AMS

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Auto-Axcess® Control Panels

1. Voltage/Arc Adjust Display Meter2. Program Display3. Program # Select4. Power Switch5. Process Setup Button6. Control Knob7. Wire Speed/Amperage Display Meter

8. Purge Pushbutton9. Handheld RS-232 Port

10. Jog Forward Pushbutton11. PC-Communication RS-232 Port

(Future use)12. Jog Retract Pushbutton13. Wire Feed/Amperage Select

14. Arc Control15. Peripheral Connector16. Robot Connection17. Motor Connector18. DeviceNet Connector

(Optional)19. 115 VAC, 10 A Duplex Receptacle

Front Panel

Back Panel

CapabilitiesAuto-CAL (Automatic Calibration) — Patentedsoftware-based feature exclusive to Auto-Axcess.Allows simple, quick and accurate wire feedspeed and voltage commands from most robotsusing analog signals. Auto-Axcess calibratesitself to deliver exact responses to commandsfrom robots. This allows Auto-Axcess to beused interchangeably with many brands ofrobots, and allows quick replacement ofcompetitive power supplies without the need tochange wire feed speeds.

Remote Program Select — Allows changingweld programs from the robot controller to takeadvantage of up to eight programs or Multi-MIG®

welding process capabilities.

Integrated 80 V Touch Sensor — To be usedwith external circuitry or peripheral equipmentwhen touch sensing.

Front Panel FeaturesWeld Process SelectionWire Size and TypeGas TypeWire Jog Forward ButtonWire Jog Reverse ButtonPurge ButtonDigital Display Meters: • Voltage / Arc Adjust (Trim)• Wire Feed Speed/AmperageProgram NumberArc Control(SharpArc® and Inductance)

Analog OutputsVoltageCurrent

Analog InputsVoltage/Arc Adjust (Trim)Wire Feed Speed

Digital OutputsArc OnWire StickWelder Ready

Digital InputsStartJog ForwardJog ReversePurgeProgram SelectE-Stop

Auto SetupRobot Specific

SequencePreflow: 0 – 9.9 secStart Power: 0 – 2.5 secVoltage: 10 – 44IPM: 50 –1400Crater: 0 – 2.5 secRetractPostflow: 0 – 9.9 sec

72-pin Harting connectorfor quick, easy connection tocommon robot controllers(ABB, Fanuc, and Motoman)with optional adapter cables.Analog robot controls.


AND

The Axcess platform is designed to provide multiple wire feeding configurations suited to the unique needs of modern manufacturing applications andindustries. It utilizes many common components to minimize both part and maintenance complexity. All motors operate on 40 VDC provided by theAxcess power supply and have a wire feed speed range of 50–1400 inches per minute. A common operator interface is used on all (see page 4).

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Axcess Semi-Automatic Power Source

Typical Axcess® Installations (Semi-Automatic Pulsed MIG or Conventional MIG)

Model

Axcess300

Axcess450

Axcess675*

Rated Output

300 A at 32 VDC,60% Duty Cycle(225 A at 29 VDC,100% Duty Cycle)

450 A at 44 VDC,100% Duty Cycle


VoltageRange

10 – 44 V

10 – 44 V

10 – 44 V

AmperageRange

5 – 400 A

5 – 600 A

5 – 900 A

Max. Open-Circuit Voltage

80 VDC

80 VDC

80 VDC

Dimensions

300 H: 23 in (584 mm)450 H: 31 in (787 mm)675 H: 39 in (991 mm)

W: 17 in (432 mm)D: 22-1/2 in (572 mm)

NetWeight

116 lb(52.6 kg)

163 lb(73.9 kg)

208 lb(94.3 kg)

Standard Installation

ROI Option InstallationAllows feeder motor drive to be placed away frompower supply and operatorinterface. Ideal for fixedautomation applications and updating or replacingequipment on booms orother applications whereseparate location of powersource, ROI, and wire drive motor is desirable.

A typical bench/sled feederinstallation. For use when the feeder is placed on thepower supply, a bench oran optional cart.

Model

AxcessBench/SledFeeder

GasValve

Included

Type ofInput Power

40 VDC (fromAxcess)

Connection to Power Source

DeviceNet InterconnectingFeeder Control Cable — 5, 10, 25, or 50 ft (Order separately)

Wire Feed Speed Range*

50 –1400 IPM (1.3–35.56 MPM)

Dual FeederDimensions

H: 15 in (381 mm)W: 19 in (483 mm)D: 34 in (863 mm)

Single Feeder Dimensions

H: 14-1/2 in (368 mm)W: 12-1/2 in (318 mm)D: 27 in (686 mm)

Wire DiameterRange

.035 – 3/32 in (0.9 –1.6 mm)

Ship Weight

Single Feeder49 lb (22 kg)Dual Feeder124 lb (56 kg)

*This is the wire feed speed range while using MIG. With pulsed MIG, the wire feed speed range may be more limited.

Amps Input at Rated Output, 50/60 Hz, 3-Phase208 V 230 V 400 V 460 V 575 V KVA KW

33 29.7 16.9 14.6 11.6 11.7 11.2

— 60 33.7 28.8 22.8 22.2 23.1

— 89.7 — 43.7 34.8 35.7 34.4

*Axcess 675 is not CSA approved.Certified to both the Canadian and U.S. Standards for welding equipment.

Wire Feeder OptionsAxcess Single Feeder #195 182Axcess Dual Feeder #195 325Feeder is designed specifically for Axcess. Providessingle-range control of 50–1400 inches per minute.Dual-wire model provides the same functionality assingle-wire version, but is ideal when two different wiretypes need to be available at the same time. Digitallycommunicates with Axcess power source via DeviceNetInterconnecting Feeder Control Cable.

Wire feeders do NOTinclude drive rolls orrequired DeviceNetInterconnectingFeeder Control Cable.These must beordered separately.

SingleFeeder

Dual Feeder

DeviceNet InterconnectingFeeder Control Cable5 ft (1.5 m) #195 24010 ft (3 m) #195 24125 ft (7.6 m) #195 24250 ft (15.2 m) #195 243

Motor Control Cable10 ft (3 m) #300 25920 ft (6.1 m) #300 09730 ft (9 m) #300 09650 ft (15.2 m) #300 098

Axcess Power Source ROI (Remote Operator Interface)

AA-40GB Wire Drive Motor Assembly(Drive rolls must be ordered separately.)

Gun (must be ordered

separately.)

DeviceNet InterconnectingFeeder Control Cable5 ft (1.5 m) #195 24010 ft (3 m) #195 24125 ft (7.6 m) #195 24250 ft (15.2 m) #195 243

Axcess Power Source Axcess Wire Feeder (Drive rolls must be ordered separately.)

Gun (must be ordered

separately.)


Feeder Base#195 369 (see page 10)

Boom RetrofitApplications

21-ft Trigger Control Cable #300 129

Flexible Mounting Options

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Model

AA-40GB

GasValve

Includedandenclosed

Type of InputPower

40 VDC (from Axcess)

Connection to ROI

Motor Control Cable—20, 30, or 50 ft (Order separately)


50 –1400 IPM (1.3 – 35.56 MPM)

AA-40GBDimensions


Wire DiameterRange

.035 – 3/32 in (0.9 –1.6 mm)

ShipWeight

23 lb (10.4 kg)


Model

ROI

Type of Input Power

Supplied from power source

Connection to Motor



DeviceNet InterconnectingFeeder Control Cable — 5, 10, 25, or 50 ft (Order separately)

Single ROI Dimensions


Dual ROI Dimensions


Ship Weight

Single ROI12 lb (5.4 kg)Dual ROI15 lb (6.8 kg)

ROI (Remote Operator Interface) Options

Wire Drive Motor Assembly Options (To be used with Remote Operator Interface.)

Single ROI #195 238Dual ROI #195 433The ROI allows the Axcess power supply, wiredrive motor assembly and operator interface (ROI)to be located in three separate places. This isdesirable for mounting to custom jibs, booms orother extended-reach applications. Since an ROIsystem can incorporate separate componentsproviding the most flexibility for custom appli-cations, it’s an ideal way to obtain the manybenefits of the Axcess while retaining an existingboom or other structural asset. The dual-wire ROIprovides the same functionality as the single,but controls two separate wire drive motorassemblies. Four programs are available per side.Note: For non-Miller boom and jib mounting, see ROI installation diagram on page 6 and select desiredcable lengths.

Auto ROI #195 239*(Contact Applications for assistance at 920-954-3814 prior to any new installation.)The Auto ROI is to be used with an Axcesspower supply with the E-Stop option. Providesfunctionality of the ROI, but replaces sequenceand trigger functions with two programmableinputs and outputs. To be used in simplededicated/fixed/hard automation applications.Features arc established output. Includes 30 ftcable for wiring to other external devices.*Requires Axcess power supply with E-Stop functionoption. E-Stop is not intended for continuousinterruption applications. Axcess systems requireapproximately 30 seconds to reboot or come backonline after recovering from an E-Stop condition.Note: For non-Miller boom and jib mounting, see ROI installation diagram on page 6 and select desiredcable lengths.

Axcess® ROI Swingarc™ Boom-Mounted Wire Feeders#195 484 12 ft (3.7 m) Single-Wire#195 434 12 ft (3.7 m) Dual-Wire#195 346 16 ft (4.9 m) Single-Wire#195 435 16 ft (4.9 m) Dual-WireSwingarc boom-mounted semiautomatic wirefeeders bring an extra dimension of flexibilityand efficiency to high-production MIG weldingstations. You get an effective solution thatmaximizes output, especially when dealing withlarge weldments and hard-to-reach places.

Dual Swingarc Retrofit Kit #300 032Kit is required when replacing motors on olderMiller Dual 60 Series Swingarc booms. Providesall of the Axcess benefits, but maintains existingdual-boom hardware.

21-ft Trigger Control Cable #300 129Required when retrofitting non-Miller boomswith an ROI option.

AA-40GB Wire Drive Motor Assembly#195 426 Left-Hand Drive#195 515 Right-Hand DriveThe AA-40GB Wire Drive Motor Assembly withOCP (Over Current Protection) is an improvedversion of the AA-40G. The motor control cable

now mounts directly to the gas box, reducingstrain on the tachometer wires. OCP providesanother layer of protection in the event a cable is damaged or shorted, reducing downtime and motor damage. Motors include a 50 ft volt-sense lead.

Wire drive motor assemblies do NOT include drive rolls or required Motor Control Cable. These must be ordered separately.Note: Left- and right-hand drives are determined by facing the wire feed gun outlet.

Pipe post NOT included. Must be ordered separately. • 4 ft Pipe Post with

18 in Base #149 838• 6 ft Pipe Post with

18 in Base #149 839

DeviceNet Interconnecting Cable NOT included (required, order separately).

MIG gun (required,order separately).

Single ROIDual ROI

ROI does NOT include AA-40GB Wire Drive Motor Assembly, Motor Control Cable or DeviceNet Interconnecting Feeder Control Cable. These must be ordered separately.


Auto ROI back panel showing connections for input and output signals.

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Auto-Axcess Power Source

Model

Auto-Axcess300

Auto-Axcess450

Auto-Axcess675*

Rated Output

300 A at 32 VDC,60% Duty Cycle(225 A at 29 VDC,100% Duty Cycle)



VoltageRange

10 – 44 V

10 – 44 V

10 – 44 V

AmperageRange

5 – 400 A

5 – 600 A

5 – 900 A

Max. Open-CircuitVoltage

80 VDC

80 VDC

80 VDC

Dimensions

300 H: 23 in (584 mm)450 H: 31 in (787 mm)675 H: 39 in (991 mm)

W: 17 in (432 mm)D: 22-1/2 in (572 mm)

NetWeight

116 lb(52.6 kg)

163 lb(73.9 kg)

208 lb(94.3 kg)

Amps Input at Rated Output, 50/60 Hz, 3-Phase208 V 230 V 400 V 460 V 575 V KVA KW

33 29.7 16.9 14.6 11.6 11.7 11.2

— 60 33.7 28.8 22.8 22.2 23.1

— 89.7 — 43.7 34.8 35.7 34.4

Typical Auto-Axcess® Installation (Robotic/Automation Pulsed MIG or Conventional MIG)

Motor Control Cable20 ft (6.1 m) #300 09730 ft (9 m) #300 09650 ft (15.2 m) #300 098Must be ordered separately.

Auto-AxcessPower Source

TorchMust be ordered

separately.

Motoman/Fanuc Motor Mount #300 013Motor mounts from other robot brands must be supplied

by robot manufacturer or system integrator.

Positive (+)Weld Cable

Must be ordered separately.

Negative (–) Weld CableMust be ordered separately.

Robot Cell Base

50 ft Work-Sense Cable Supplied with AA-40GB

Wire Drive Motor AssemblyShould be connected as close

to arc as possible for optimum performance.

AA-40GB Wire Drive Motor Assembly

*Auto-Axcess 675 is not CSA approved.Certified to both the Canadian and U.S. Standards for welding equipment.



Wire Drive Motor Assembly

AA-40GB Wire Drive Motor Assembly #195 426 Left-Hand Drive#195 515 Right-Hand DriveThe AA-40GB Wire Drive Motor Assembly withOCP (Over Current Protection) is an improvedversion of the AA-40G. The motor control cable

now mounts directly to the gas box, reducingstrain on the tachometer wires. OCP providesanother layer of protection in the event a cable is damaged or shorted, reducing downtime and motor damage. Motors include a 50 ft volt-sense lead.

Wire drive motor assemblies do NOT include drive rolls or required Motor Control Cable. These must be ordered separately.Note: Left- and right-hand drives are determined by facing the wire feed gun outlet.

The Auto-Axcess platform is designed to bring the benefits of digital control technology to manufacturers who currently use analog robot control. Whencombined with a Smart Cable (#300 012) and AA-40GB wire drive motor assembly the Auto-Axcess will automatically reconfigure itself to function as asemi-automatic, thereby providing for single asset management and simplicity. Contact Robot Manufacturers for fully-digital versions of the Axcesscompatible with specific robot controllers.

Model

AA-40GB

GasValve

Includedandenclosed

Type of InputPower

40 VDC (from Auto-Axcess)




50 –1400 IPM (1.3 – 35.56 MPM)

AA-40GBDimensions


Wire DiameterRange

.035 – 3/32 in (0.9 –1.6 mm)

ShipWeight

23 lb (10.4 kg)

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Palm OS® Based Software OptionsWaveWriter™ Wave Shaping (required Palm Handheld not included)

#195 250 (Includes Palm™ serial cable andexpansion card)

WaveWriter is our premium Palm softwarepackage for Axcess systems. For Palmhandhelds, it includes all of the Palm AxcessFile Management functions plus a simple,pulsed MIG wave-shaping program for themost demanding pulsed MIG applications.Customers can expect exceptional weldingperformance from any Axcess system fromthe programs for common wire and gascombinations — right out of the box. Forthose who need to adjust pulse parametersfor special situations or to achieve a specificresult, WaveWriter will allow anyone to altera factory program for a specific wire, gas or weld joint configuration. Many weldingengineers may find this tool useful indeveloping their own unique competitiveadvantage and having their own proprietaryweld programs.

With WaveWriter it is possible to changeparameters while welding and immediatelysee the effect of the change in the arc. Real-time feedback helps in understandingthe effect of changing the sometimesconfusing pulse wave form variables (such as pulse peak, pulse width,background, and rise and fall rates) which saves enormous expense and time in welding procedure development. Most ofthe essential variables required for process and procedure development are not onlyprecisely controllable and stored, but theupper and lower control limits can beestablished to assure shop floor control.

Palm™ Convenience Package (Axcess File Management and WaveWriter software not included)

#195 517 Includes a compatible Palm™ handheldloaded with Service Pak software and a Palm™ serialcable that connects the Palm and Axcess®. Note: Palm model may vary and Axcess File Management and WaveWriter software are sold separately.

Axcess® File Management (required Palm Handheld not included)

#195 249 Includes Palm™ serial cable and expansion card.Simply put, the new Miller (Palm™ OS-based) filemanagement software turns a standard handheld(PDA) into a data card and a remote pendant controlfor all Axcess systems. This is in addition to all otherfunctions a handheld is typically used for. By using ahandheld in this manner, we have built a powerful

intuitive interface on a common affordable, portable platform. This opens the door to functions andcapabilities not previously available from Miller or from the welding industry as a whole.

With Miller’s Axcess File Management installed on your Palm OS handheld you can:

There are 3 basic types of files:

1) Programs – Contain all the welding data that create an arc: volts, amps, wire feed rates, wire type,size, gas and appropriate arc control. They also contain all the time-based functions typically usedin welding: pre-flow, start conditions, ramps, crater fill, retract, and post-flow.

2) Configuration – Files contain Locks, Errors and Feeder information that include robot selectiontype (Robot Control – PS Wire and Gas, Shared Control – Arc On-Analog, and Power SourceControl – Arc On-No Analog). Configuration enables error messages, dual schedule, and remoteprogram select to be selected. It also allows for checking software revisions and arc/ cycle timedata. Using configuration you can set Auto-Thread™ torch length allowing for pushbutton feed ofan exact wire length.

3) Back-up – Back-up files allow a convenient and simple way to store all files from a welding powersource in a Palm handheld.

Each type can reside or be “Axcess”ed in any of 3 locations:

1) Welder – The welding power source holds the main library of welding programs.2) Handheld – The handheld acts as an interim storage device where files can be pulled from the

power source stored or modified.3) E-mail – Files can be stored for Email in this location.

Any of the files can be cut, copied, pasted, modified, UN-protected files can also be beamed throughIR port. Copyright-protected and Miller proprietary files cannot be transferred such as Palm Axcess File Management, WaveWriter™, and RMD™ welding process.


E-mail Axcess files anywhere worldwideConfigure any Axcess system as desiredConfigure multiple Axcess systems exactlythe same or any way you chooseSave and store Axcess filesTransfer Axcess files to computersTransfer Axcess files from machine to machineBackup Axcess files and programs Set-up and modify Axcess welding sequences

Adjust and store welding program Locks & Limits for restricting or limitingoperator “Axcess” to programsEnable Auto-Thread™ feature to program torch length into Axcess memory. When acombination of purge and jog (or jog andretract) are depressed, the Axcess feedingsystem delivers exact programmed length ofwire. Great for troubleshooting wire feedspeed and loading wire into the system.

DeviceNet Interconnecting Feeder Control Cables #195 240 5 ft (1.5 m)#195 241 10 ft (3 m)#195 242 25 ft (7.6 m)#195 243 50 ft (15.2 m)These specially designed EMI (ElectricalMagnetic Interference) protected and shieldedfeeder control cables are required, but notincluded with Axcess feeders or ROI. Determinelength needed and order separately.

Motor Control Cables #300 097 20 ft (6.1 m)#300 096 30 ft (9 m)#300 098 50 ft (15.2 m)Includes overmolded connections on high-flexcables for optimal service life.

Axcess® FeederBase and Spool Support#195 369Sheet metalconstruction.Allows mounting of AA-40GBmotor (if desired)

when using ROI option or when using an Auto-Axcess with Smart Cable adapter.

Hub and SpindleAssembly #072 094

Spindle Support#092 989

MIGRunner™ XL Cart #195 246Dimensions: 46-1/2 x W: 42 x D: 35 inWide cart with motorcycle-type handle grips.Holds two large gas cylinders and Coolmate™ 3(when power source is mounted with facetoward handles) for water-cooled torches. Powersupply can be mounted in several directionswhile the feeder can be mounted on the top tray.Fits Axcess 300 and 450 models only.Note: Dual feeder not recommended for this cart. Fordual feeders we recommend using a separate feedercart (not available).

Wire Reel Assembly#108 008

Spool Covers

#057 607

Reel Covers #058 256For 60 lb (27 kg) coil. Helps to protect the weldingwire from dust and other contaminants.Note: Reel and Spool Covers cannot be installed if the wire drive assembly is in a rotated position.

Turntable Assembly #146 236Allows rotation of the feeder as the operatorchanges work positions. Reduces strain andbending on the gun cable.

Hanging Bail (Electrically Isolated) #058 435Used for suspending feeder over work area.

Wire Straightener #141 580For .035 –.045 in (0.9 –1.1 mm) dia. wire.#141 581For 1/16 –1/8 in (1.6 – 3.2 mm) dia. wire.Helps reduce the cast in wire to improve wirefeeding performance and increase the servicelife of the gun liner and contact tip.

Dual Schedule SwitchesDSS-8 #079 693A 15 ft, two-position

trigger switch which attaches to the gun handleand is used in place of the standard trigger fordual scheduling.

Adapter Cord #157 364Required for use with DSS-8. 1ft, Y trigger cable that connects DSS switch and control boxto the gun.

DSS-9M #041 793A 15 ft, two-positionslide switch

which attaches to the gun handle and is used toselect the desired welding condition for dualschedule purposes. The gun trigger operates asa standard trigger.

Coolant SystemsFor more information, see the Miller CoolantSystems literature sheet, Index No. AY/7.2.

Coolmate™ 3#043 007 115 VAC#043 008 230 VACFor use with water-cooled torches rated up to600 amps. Unique paddle-wheel indicator,external filter and easy-fill spout.

Coolmate™ V3 #043 009 115 VACFor use with water-cooled torches rated up to500 amps. Vertical design conveniently mountsto Miller cylinder rack in place of one cylinder.

Coolmate™ 4 #042 288 115 VACFor use with water-cooled torches rated up to600 amps. Tough molded polyethylene casewith carrying handle.

Low Conductivity Coolant #043 810Sold in cases of four 1-gallon recyclable plasticbottles. Miller coolants contain a base ofethylene glycol and deionized water to protectagainst freezing to -37˚F (-38˚C) or boiling to227˚F (108˚C). Also contains a compound thatresists algae growth.

Genuine Miller Accessories

10 Learn More at MillerWelds.com/AMS

Shown with AA-40GB.

Coolmate 3 Coolmate 4

Coolmate V3

SpindleSupport

Hub andSpindleAssembly

Fanuc Internal Wiring Kit #300 229Includes 30 ft cable that connects to the Fanuccontroller, and 22 in connector for mounting thewire drive assembly on top of the robot arm.

Receptacle/Adapter Kits#194 793 ABB#194 791 Fanuc#194 790 Motoman#300 056 Panasonic#195 002 UniversalOne required per machine. For analogcommunication with robot controls via 72-pinHarting connector on Auto-Axcess. 1-ft length.

Smart Adapter #300 012Allows Auto-Axcess to be configured to functionas semi-automatic. To be used when there is adesire to have a common power supply and motorin both robotic and semi-automatic application.Easy asset management. 21-ft trigger controlcable is included.

Universal Connector for Analog Control #195 002Includes mating Harting connector with pins toallow custom configuration for robotic and fixedautomation applications.

Fanuc/Motoman Wire Drive Motor AssemblyMounting Bracket #300 013

Shell Connector #194 847For use by anyone wishing to interfaceperipherals, but not wanting to source theappropriate female amphenol connector.

Coolant FlowSwitch #195 461To ensure coolant is flowing in thesystem. Lack ofcoolant flow may

cause damage to water-cooled guns. Moduleallows wiring into the peripheral connector port. 50 ft (15.2 m) cable with connector andseparate shell connector for simple modificationto desired length in the field. It can be mountedon the Auto-Axcess or as desired elsewhere.1/4-turn quick connection.

Fixed or Hard Automation Accessories Oscillators and Motorized Cross SlidesRefer to Lit. Index No. AU/6.0.

Welding Guns — see www.bernardwelds.com

11

Genuine Miller Services and Accessories (For robotic/automation applications only.)

Consulting ServicesField Application Support #195 480Auto-Axcess systems may require factory-trained technical support depending on the complexity of the application and thelocal availability and capability of qualifiedwelding engineers or robotic experts. You should contact the factory if there are questions. Factory support is available at a flat rate of $1250.00 per day plusexpenses when planned and ordered more than 10 days in advance. Rates andavailability of our technical specialists withless than 10 day notice are considerablymore. Rates are based on a 10-hour dayincluding travel. One day minimum.

Service and TroubleshootingAnalog Robot Simulator #195 030Device simulates the analog commands of typical robots. it can be used as adiagnostic tool to determine power sourcefunctionality and isolate robot, power source or cable issues.


“U” cogged forextremely soft

“U” groove for wire or soft-soft wire or “V” knurled shelled cored

“V” groove soft-shelled for hard-shelled wires (i.e., hardWire size for hard wire cored wires cored wires facing types)

.035 in (0.9 mm) #151 026 #151 036 #151 052 —

.040 in (1.0 mm) #161 190 — — —

.045 in (1.1/1.2 mm) #151 027 #151 037* #151 053 #151 070

.052 in (1.3/1.4 mm) #151 028 #151 038 #151 054 #151 071

1/16 in (1.6 mm) #151 029 #151 039 #151 055 #151 072

.068/.072 in (1.8 mm) — — #151 056 —

5/64 in (2.0 mm) — #151 040 #151 057 #151 073

3/32 in (2.4 mm) — #151 041 #151 058 #151 074

7/64 in (2.8 mm) — #151 042 #151 059 #151 075

1/8 in (3.2 mm) — #151 043 #151 060 #151 076

Select drive roll kits from chart below according to type and wire size being used. Drive roll kits include 4 drive rolls, the necessary guides and feature ananti-wear sleeve for the inlet guide.

*Accommodates .045 and .047 (3/64 in) wire.

Wire size Inlet Guide Intermediate Guide.047 (3/64) in (1.2 mm)* #151 203 #151 204

1/16 in (1.6 mm) #151 205 #151 206

3/32 in (2.4 mm) #151 207 #151 208

Note: “U groove” drive rolls are recommended when feeding aluminum wire.*Pushing .047 (3/64) in (1.2 mm) wire is not recommended in torchesgreater than 10 ft in length.

Drive Roll Kits (Order from Miller Service Parts.)

Nylon Wire Guides for Feeding Aluminum WireWire size Inlet Guide Intermediate Guide.023 –.040 in (0.6 –1.0 mm) #150 993 #149 518

.045 –.052 in (1.1 –1.4 mm) #150 994 #149 519

1/16 – 5/64 in (1.6 – 2.0 mm) #150 995 #149 520

1/16 – 5/64 in (2.4 – 2.8 mm) #150 996 #149 521

1/8 in (3.2 mm) #150 997 #149 522

Wire Guides

Litho in USA

Distributed by:

Ordering InformationSemi-Automatic Equipment Options Stock No. Description Qty. Price

Axcess® 300 #907 150 Power source only#907 150-01-1 Power source with RMD™ software upgrade

Axcess® 450 #907 152 Power source only#907 152-01-1 Power source with RMD™ software upgrade

Axcess® 675 #907 154 Power sourceAxcess® 300 Packages #951 038 Power source, bench feeder and 5 ft cable

#951 039 Power source with RMD™ software upgrade, bench feeder and 5 ft cableAxcess® 450 Packages #951 031 Power source, bench feeder and 5 ft cable

#951 037 Power source with RMD™ software upgrade, bench feeder and 5 ft cableNote: Other power sources are available. Consult factory at 1-920-954-3813 for power sources with E-Stop option.

Wire Feeder Options (see page 6)Axcess® Single Feeder #195 182 Bench/skid feeder — order DeviceNet Interconnecting Feeder Control Cable separatelyAxcess® Dual Feeder #195 325 Bench/skid feeder — order DeviceNet Interconnecting Feeder Control Cable separately

ROI Options (see page 7)Single ROI #195 238 See page 6 for connection diagram and required cablesDual ROI #195 433 See page 6 for connection diagram and required cablesAuto ROI (see note above) #195 239 See page 6 for connection diagram and required cables.

Requires power source with E-Stop option — consult factory at 1-920-954-3813Axcess® ROI Swingarc™ Boom See page 7 for various modelsDual Swingarc™ Retrofit Kit #300 032 Required when replacing motors on older Dual 60 Series Swingarc booms

Wire Drive Assembly Opt. (see page 7)AA-40GB Wire Drive Motor Assembly New-style wire drive assembly. See page 6 for connection diagram and required cables

Control Cables (see page 10) See page 6 for connection diagram and required cables

Automatic Equipment Options*Auto-Axcess® 300 #907 151 190 – 630 V. Inverter power supply with robotic interface(Robotic receptacle kit sold separately) #907 151-01-1 190 – 630 V. Inverter power supply, robotic interface, and RMD software upgradeAuto-Axcess® 450 #907 153 190 – 630 V. Inverter power supply with robotic interface(Robotic receptacle kit sold separately) #907 153-01-1 190 – 630 V. Inverter power supply, robotic interface, and RMD software upgradeAuto-Axcess® 675 #907 155 190 – 630 V. Inverter power supply with robotic interface

Motor/Kit/Cable OptionsWire Drive Motor Assembly See page 8Motor Control Cable (see page 10) See page 8 for connection diagram and required cablesReceptacle/Adapter Kits See page 11. One required per machine, consult factory

Palm OS® Based Software OptionsPalm™ Convenience Package #195 517 Palm model may vary (File Management and WaveWriter software NOT included)Axcess® File Management #195 249 File management software (required Palm™ handheld NOT included)WaveWriter™ Wave Shaping #195 250 File management software with wave shaping (required Palm™ handheld NOT included)Software-Based Welding Process Opt.RMD™ (Regulated Metal Deposition) #195 252 Field (required Palm™ handheld NOT included)

AccessoriesAxcess® Feeder Base and Spool Support #195 369 Allows mounting of AA-40GB motor when using ROI optionHub and Spindle Assembly #072 094Spindle Support #092 989MIGRunner™ XL Cart #195 246 Holds two cylinders, cooler, machine and feederCoolant Systems See page 10Drive Roll Kit (Required) See page 11Inlet/Intermediate Guides See page 11

Smart Adapter #300 012 Robotic/automation. Allows automatic to function as semi-automaticUniversal Connector for Analog Control #195 002 Robotic/automation. Allows custom configurationField Application Support #195 480 Robotic/automation. One day minimum, not subject to discount. See page 11Analog Robot Simulator #195 030 Robotic/automation. See page 11

Date:

*The Axcess is a fully digital machine and utilizes DeviceNet protocol for internal system operation. Select robot manufacturers have created unique software for specific controllers which enablethem to communicate digitally with an Axcess power supply. Check with your robot supplier of choice to further understand if there are benefits created by them that can reduce complexity, addvalue or reduce your total cost of integration and operation. Welding Distributors: you may also inquire with the robot manufacturer about drop-ship programs they may offer for digital or analogversions of the Axcess platform.


ProcessesMIG (GMAW)Flux Cored (FCAW)

Industrial/Heavy Industrial ApplicationsLight FabricationAutomotive FurnitureAgriculturalTruck Body/Metal FabricationSmall Equipment Manufacturing

QuickSpecs

CP-302 MIG WeldingPower Source

Issued May 2007 • Index No. DC/13

Large analog volt andammeters for easy viewing.

Simple control panel withjust one control adjustment.

Lower panel cover protectsoutput connections from harshwelding environments.

115 VAC duplex receptacleprovides 15 amps of auxiliary power.

14-pin receptacle providesquick, direct connection towire feeders and accessories.

Presettable welding voltage withvoltmeter allows you to easily setweld output before welding.

Power efficient which givesexceptional value and return on your investment.


Welder is warranted for 3 years, parts and labor. Original mainpower rectified parts are warranted for 5 years.




Input Power 3-Phase Power

Rated Output 300 A at 32 V, 100% Duty Cycle390 A at 32 V, 60% Duty Cycle

Max. Open-Circuit Voltage 14–44

Weight 332 lb (151 kg)

Adjustable weld stabilizer(high-low inductance) providesthe flexibility to produce theoptimal arc characteristics. Usethe high stabilizer setting forstainless steel and low setting formild steel and aluminum.

Solid-state weld contactorprovides longevity to match the ultra-durable and reliablereputation of the CP series.

CP-302 MIGRunner™ comes completein one box. See page 4 for details.

2

1

4

5

6

3

VOLT/AMP CURVE

800

600500

400

1000

100

WEL

DING

AM

PS

DUTY CYCLE CHART

1510 20 50403025 60 100 500 100 300250200150 350 400 100

200

250

150

40

30

50

0

DC V

OLTS

20

10

300

CP-302

CP-302 MAX

CP-302 MIN

Performance Data

2

Control Panel

Rated Output

300 A at 32 V, 100% Duty Cycle390 A at 32 V, 60% Duty Cycle

Open-CircuitVoltage

14 – 44

Amps Input at Rated Output, Three-Phase, 60 Hz200 V 230 V 460 V 575 V KVA KW

38 33 16.5 13.0 13.1 12.3

1.1* .95* .48* .38* .38* .32*

Dimensions

H: 30 in (762 mm)including lift eyeW: 23 in (585 mm)D: 30-1/2 in (775 mm)including strain relief

Net Weight

332 lb (151 kg)

Specifications (Subject to change without notice.)

Certified to both the Canadian and U.S. Standards for welding equipment.

1. Ammeter 2. Voltmeter 3. Power Switch4. Pilot Light5. Preset Indicator Light6. Voltage Control

Conforms with NEMA EW 1, “Electric Arc Welding Power Sources”, Class I (100).*While idling.

3

Industrial MIG Kit #195 197Includes 15 ft (4.6 m), 2/0 power cable andwork lead with clamp, regulator/flow meterwith 15 ft (4.6 m) gas hose, 15 ft (4.6 m)MIG gun and consumable kit.

Standard Running Gear #042 886The large 10 in (254 mm) rear wheels and5 in (127 mm) front casters on this runninggear provide excellent mobility on the shopfloor, making it easier to move the powersource. Very easy to install. Handles doubleas weld cable holder.

Standard Cylinder Rack #042 887Holds two cylinders. Only installs onStandard Running Gear.

Wire Feeders

22A #193 066Lightweight, 24 VAC constant-speed semi-automatic wire feeder, best suited for smalldiameter wires. Accommodates up to a 60 lb (27.2 kg) spool of welding wire when using optional wire reel assembly.Comes with FREE Bernard® Q™-Gun!See Lit. Index No. M/11.0.

70 Series

Single Wire ModelS-74S #195 057Dual Wire ModelD-74S #195 060Heavy-duty, industrial, constant-speed 24 VAC semiautomatic wire feeders insingle and dual models, with availabledigital meters. Ideal for high-duty-cycleMIG welding (GMAW) and Flux Coredwelding (FCAW). Accommodates a widevariety of wire sizes and types. Comes withFREE Bernard® Q™-Gun! Dual wire feedermodel includes two FREE Q-Guns. See Lit.Index No. M/3.0.

Extension Cables for 14-Pin Plugs to 14-Pin Sockets#122 973 25 ft (7.6 m)#122 974 50 ft (15.2 m)#122 975 75 ft (22.8 m)

Spoolmatic® 30A #130 831A 1-lb, air-cooled spool gun that extendsthe weld process range by adding a handyportable system for small wire MIG. Rated200 A at 100% duty cycle. Includes 30 ft(9.1 m) cable assembly. (WC-24 #137 549for 14-pin.)

WC-24 Weld Control#137 549Packaged in a compact,lightweight, non-metallicenclosure, the WC-24easily mounts directly on the power source.

It’s designed for use with Miller CV powersources supplying 24 VAC and 14-pinreceptacles. The control includes a board-mounted potentiometer which can alter thedrive motor acceleration rate to optimizearc starting performance.


Litho in USA

Distributed by:

Equipment and Options Stock No. Description Qty. Price

CP-302 #903 786 200/230/460 V, 60 Hz#903 521 575 V, 60 Hz

CP-302 MIGRunner #907 050 200/230/460 V, 60 Hz. See above for package components

Wire Feeders22A #193 066 See Lit. Index No. M/11.070 Series #195 057 S-74S. See Lit. Index No. M/3.0

#195 060 D-74S. See Lit. Index No. M/3.0Extension Cables for #122 973 25 ft (7.6 m)14-Pin Plugs to 14-Pin Sockets #122 974 50 ft (15.2 m)

#122 975 75 ft (22.8 m)Spoolmatic® 30A #130 831 1-lb air-cooled spool gun, 200 A at 100% duty cycle, includes 30 ft (9.1 m) cable assemblyWC-24 Weld Control #137 549

GunsBernard® GunConsumables

AccessoriesIndustrial MIG Kit #195 197 Includes 15 ft (4.6 m), 2/0 power cable and work lead with clamp, regulator/flow meter

with 15 ft (4.6 m) gas hose, 15 ft (4.6 m) MIG gun and consumable kitStandard Running Gear #042 886Standard Cylinder Rack #042 887

Date: Total Quoted Price:

Ordering Information

CP-302 MIGRunner Components

CP-302 MIGRunner™

#907 050 200/230/460 V#907 073 575 V

Comes Complete With:CP-302 power source22A wire feederBernard® Q™-Gun 15 ft (4.6 m).035/.045 in contact tips.035/.045 in reversible drive rollsRegulator/flow gauge with gas hoseWork cable and power cordFactory-installed running gear/ cylinder rack

Delta-FabInput Power 3-Phase, 230/460/575 V

Rated Output375 A at 100% Duty Cycle 450 A at 60% Duty Cycle

Voltage 10 – 45 V


Industrial ApplicationsHeavy-to-Light Fabrication

ProcessesMIG (GMAW) with mild steel, flux cored,stainless steel, andaluminum wires

QuickSpecs

Delta-Fab System MIG WeldingPower Source

Issued January 2006 • Index No. DC/15




24A Wire FeederInput Power 24 VAC / 7 A

Electrode Wire Diameter Capacity .023– 3/32 in (0.08 – 2.4 mm)

Wire Speed 75 – 750 IPM (1.9 – 16.5 m/min)

Remote Voltage Control Standard


Large analog volt andammeters for easy viewing.

Solid-state weld contactor provideslongevity to match the ultra-durableand reliable reputation of the Delta-Fab.

Large output voltage range providesmore flexibility on a variety of wirediameters. Also aids operator withvoltage losses that occur whenoperating long distances from power source.

Adjustable material output studsprovide the flexibility to producethe optimal arc characteristics foraluminum, stainless steel and allother materials.

115 VAC duplex receptacleprovides 15 amps of auxiliary power.

Four-Drive-Roll feeding system withindependent tension control handlessmall and large diameter wires. (Driverolls and guides ordered separately.)

Remote voltage control is standard.Parameter adjustments can be madein weld cell or at a remote location.

Run-in standard on 24A for betterarc-starting performance on a varietyof wires.

14-pin select is easy to setup with no external switchesto put in the wrong position.

14-pin receptacle providesquick, direct connection towire feeders and accessories.


Welder is warranted for 3 years, parts and labor. Originalmain power rectified parts are warranted for 5 years.

Shown with Bernard®

Q-400 15 ft MIG gun.

1

2

3

4

Delta-FabCV Welding Power Source

High TempShutdown ON

OFF

MILLER ELECTRIC MFG. CO., APPLETON, WI.

MADE IN

1

2

4

3

56

2

Control Panels

Performance Data

1. Voltage Meter2. High Temperature Shutdown Light3. Amperage Meter4. Power Switch with Indicator Light

Note: Weld output studs are energized by controls on the wirefeeder.Turn off power before connecting remote device.

1. Voltage/Wire Speed Meter*2. Voltage/Wire Speed Switch*3. Remote Voltage Control Standard4. Wire Speed Control5. Jog/Purge Switch6. Trigger Hold Switch

*OptionalNote: Power switch is on rear panel.

Rated Welding Output

375 A at 35 VDC, 100% Duty Cycle

Voltage Range DC

10 – 45

Amps Input at Rated Load Output, 60 Hz, Three-Phase230 V 460 V 575 V KVA KW

69 34.5 27.5 27.5 17.54* 2* 1.6* 1.61* 0.46*

Dimensions

H: 30 in (762 mm)(including lift eye)W: 23 in (585 mm)D: 30-1/2 in (775 mm)(including strain relief)

Net Weight

374 lb (170 kg)

Delta-Fab Specifications (Subject to change without notice.)

24A Wire Feeder Specifications (Subject to change without notice.)

*While idling.

VOLT/AMP CURVE – DELTA-FAB

800

600

500

400

1000

100

% DUTY CYCLE

WEL

DING

AM

PS

DUTY CYCLE CHART – DELTA-FAB

1510 20 50403025 60 70 80 90 100

DC AMPS

1000 200 600500400300 700 800

200

250

150

40

30

50

60

0

DC V

OLTS

20

10

300

MAX

MIN

Input Power

24 VAC, 7 A, 60 Hz

Electrode Wire Diameter Capacity

.023– 3/32 in (0.08 – 2.4 mm)

Maximum Spool Size Capacity

60 lb (27.2 kg)

Wire Speed

75 – 750 IPM(1.9 – 16.5 m/min)

(Use with CVPower Sources.)

Conforms to European standards.


Dimensions

H: 11 in (279 mm)W: 10-3/4 in (273 mm)D: 23-1/2 in (597 mm)

Net Weight

40 lb (18 kg)

Standard Running Gear #042 886The large 10 in (254 mm) rear wheels and5 in (127 mm) front casters on this runninggear provide excellent mobility on the shopfloor, making it easier to move the powersource. Very easy to install. Handles doubleas weld cable holder.

Standard Cylinder Rack #042 887Holds two cylinders. Only installs on Standard Running Gear.

Turntable Assembly #146 236Allows rotation of the feeder as the operatorchanges work positions. Reduces strainand bending on the gun cable.

Wire Reel Assembly #108 008For 60 lb (27 kg) coil of wire.(Cannot use when handle is installed.)

Feeder Cart #043 698 FieldA low-profile creeper cart with high-qualityrubber casters, front swivel and rear rigid.

3


Genuine Miller OptionsDigital Meter #186 498 FieldDual-function, back-lit LCD digital meter with selector switch. The digital meterallows the wire feed speed to be preset inmeters per minute or inches per minute.The voltage function will only monitor anddisplay the arc voltage. The voltage displaycan also be calibrated if required.

Preflow/Postflow and Spot Control#186 496 Field Installs inside feeder under an easy accesshinged cover. Provides up to 5 seconds of spot weld time and has adjustable timers(0.25 to 5 sec.) for controlling gas flowprior to arc initiation and after completionof weld.

Drive Roll Kits Select drive roll kits from chart below according to type and wire size being used. Kit includes (4) drive rolls and inlet guide.

*Accommodates 3/64 in (.045 and .047 mm) wires.

“V” knurled for hard-shelled cored wiresWire size

.023/.025 in (0.6 mm)

.030 in (0.8 mm)

.035 in (0.9 mm)

.040 in (1.0 mm)

.045 in (1.1/1.2 mm)

.052 in (1.3/1.4 mm)1/16 in (1.6 mm).068/.072 in (1.8 mm)5/64 in (2.0 mm)3/32 in (2.4 mm)

#087 132#046 780#046 781#191 917#046 782#046 783#046 784

——

#044 750—

#046 785#046 786#046 787

—#046 788#046 789

——

#046 792—

#046 793#046 794#046 795#089 985#046 796#046 797

————

#083 319#083 320#046 800

—#046 801#046 802

“U” groove forsoft wire orsoft-shelledcored wires

“V” groovefor hard wire

“U” cogged for extremelysoft wire or soft-shelledcored wires (i.e., hardfacing types)

Nylon Wire Guides for Feeding Aluminum WireWire Size

.047 in (1.2 mm)1/16 in (1.6 mm)3/32 in (2.4 mm)

Inlet Guide

#151 203#151 205#151 207

Intermediate Guide

#058 837#058 853#058 841

Note: “U” groove drive rolls are recommended when feeding aluminum wire.

Turntable Assembly

Wire Reel Assembly

Carrying Handle

Feeder Cart

Carrying Handle #193 762For lifting and moving feeder.

Spool Cover #057 607For 12 in (304 mm) spool.

Hanging Bail #058 435Suspends feeder over the work area.

Reel Cover #058 256For 60 lb (27.2 kg) coil.

Spool Adapter #047 141For use with 14 lb (6.4 kg) spool of Lincoln self-shielding wire.

Extension Cords#122 973 25 ft (7.6 m)#122 974 50 ft (15 m)#122 975 75 ft (23 m)Used to extend interconnecting cords.

Distributed by:

Equipment and Options Stock No. Description Qty. Price

Delta-Fab System #951 022 375 A at 35 VDC, 100% Duty Cycle, 60Hz, Three-Phasewith 24A Four-drive-roll wire feeder

Drive Roll Kit See Drive Roll Kits table (page 3)

Digital Meter #186 498 Field

Preflow/Postflow and Spot Control #186 496 Field

Accessories

Standard Running Gear #042 886

Standard Cylinder Rack #042 887

Wire Reel Assembly #108 008 For 60 lb (27.2 kg) coil

Feeder Cart #043 698 Field

Carrying Handle #193 762

Turntable Assembly #146 236

Hanging Bail #058 435

Spool Cover #057 607 For 12 in ( 304 mm) spool

Reel Cover #058 256 For 60 lb (27.2 kg) coil

Spool Adapter #047 141 For 14 lb (6.4 kg) Lincoln spool

Extension Cords #122 973 25 ft (7.6 m)#122 974 50 ft (15 m)#122 975 75 ft (23 m)



Litho in USA

Genuine Miller Accessories (Continued)

Spool Cover

Hanging Bail

ProcessesMIG (GMAW)Flux Cored (FCAW) Air Carbon Arc (CAC-A)

Cutting and GougingSubmerged Arc (SAW)

Heavy Industrial ApplicationsHeavy Equipment ManufacturingTruck and Trailer ManufacturingShip and Boat BuildingTank/Pressure Vessel FabricationManufacture of Automotive EquipmentRailcar/Locomotive Fabrication and RepairFurniture ManufactureStructural Steel FabricationSheet Metal FabricationMaintenance

QuickSpecs

Deltaweld®

Series MIG WeldingPower Source

Issued May 2007 • Index No. DC/16.2

14-pin receptacle provides quick,direct connection to Miller 14-pinwire feeders and accessories.

Internal digital voltage control(DVC) enables operator to presetweld voltage before striking an arc.

Two positive output terminalsprovide high/low stabilizer selection.Allows operator to optimize arcperformance.

Superior arc welding performancewith MIG welding.

Power efficient for exceptional valueand return on your investment.

Fan-On-Demand™ operates onlywhen needed reducing noise, powerconsumption, and the amount ofairborne contaminants pulledthrough the machine.


Power source is warranted for 3 years, parts and labor.Original main power rectified parts are warranted for 5 years.




Input Power 302/402: 3-Phase Power452/602: 3-Phase Power652/852: 3-Phase Power

Rated Output 302/402: 300 A at 32 VDC, 100% Duty Cycle452/602: 450 A at 38 VDC, 100% Duty Cycle652/852: 650 A at 44 VDC, 100% Duty Cycle

Weight 302/402: 323 lb (147 kg)452/602: 384 lb (174 kg)652/852: 472 lb (214 kg)

115 V duplex receptacle provides 15 amps of auxiliary power.

Simple control panel provideseasy, efficient operation.

Digital voltmeter and ammeter areeasy to read, even at 30 ft (9.2 m).

Line voltage compensation ensuresconsistent weld performance bykeeping output power constant even ifprimary input power varies by ±10%.

Deltaweld 452/602

Power cord strain relief providedfor your convenience at installation.

Remote on/off capabilities allowoperator to turn power sourceon/off from a distance.

Remote voltage control allowsoperator to change voltage fromfeeder.

Thermal overload protection light indicatespower shutdown. Helps prevent machine damageif the duty cycle is exceeded or airflow is blocked.

PC board protection prevents thewire feeder power or other strayvoltages (less than 115 VAC) fromharming the power source PC board.

Enclosed circuit boards provideadditional protection fromcontaminants resulting in longerservice life.

6

1

4

5

2

3

DC AMPS

DC V

OLTS

VOLT/AMP CURVE CV

00

20

10

30

40

50

60

70

80

50 100 150 200 250 300

GMAWFCAW

MAX.

MED.

MIN.

% DUTY CYCLE

WEL

DING

AM

PS

DUTY CYCLE CHART

200

400

300

500

600

80 90 1007040 50 60

RATED OUTPUT

Performance Data

2

Control Panel

Deltaweld® 302/402 Specifications (Subject to change without notice.)

1. Voltage Adjustment Control2. Output Switch3. Remote Voltage Control Switch

4. Digital Meters5. Power Switch with Indicator Light6. High Temperature Shutdown Light

Rated Output


Voltage Range

10–32 V

RecommendedWelding Range

15–32 V


44 VDC

Amps Input at Rated Output, 50/60 Hz200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW

48 42 27 25 23 21 17 16.9 12.9

Dimensions

H: 30 in (762 mm)including lift eyeW: 23 in (585 mm)D: 30-1/2 in (775 mm)including strain relief

Net Weight

323 lb(147 kg)


Note: For input conductor and fuse size information consult the Owner’s Manual.

6

1

4

5

2

3

Control Panel



% DUTY CYCLE

WEL

DING

AM

PS

DUTY CYCLE CHART

200

400

300

600

800

80 90 1007040 50 60

RATED OUTPUT

DC AMPS

DC V

OLTS

VOLT/AMP CURVE CV

00

20

10

30

40

50

60

70

80

100 200 300 400 500

GMAWFCAW

MAX.

MED.

MIN.

Performance Data

3


Rated Output


Voltage Range

10–38 V


15–38 V


44 VDC

Amps Input at Rated Output, 50/60 Hz200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW

72 63 39 37 33 32 25 25.1 21.1

Dimensions

H: 30 in (762 mm)including lift eyeW: 23 in (585 mm)D: 38 in (966 mm)including strain relief

Net Weight

384 lb(174 kg)


50 Hz models with CE Specifications are manufactured according to the Standards IEC-974-1 and EN-60974-1.



4

6

1

4

5

2

3

DC AMPS

DC V

OLTS

VOLT/AMP CURVE CV

00

20

10

30

40

50

60

70

80

100 200 300 400 500 600 700

GMAWFCAW

MAX.

MED.

MIN.

% DUTY CYCLE

WEL

DING

AM

PS

DUTY CYCLE CHART

300

400

600

800

1000

50 60 70 80 90 10040

RATED OUTPUT

Performance Data

Control Panel




50 Hz models with CE Specifications are manufactured according to the Standards IEC-974-1 and EN-60974-1.

Rated Output


Voltage Range

10–44 V


15–44 V


33 VDC

Amps Input at Rated Output, 50/60 Hz230 V 380 V 400 V 440 V 460 V 575 V KVA KW

96 58 54 50 48 38 38.2 34.2

Dimensions

H: 30 in (762 mm)including lift eyeW: 23 in (585 mm)D: 38 in (966 mm)including strain relief

Net Weight

472 lb(214 kg)


5

Genuine Miller Options


Air Filter Kit #042 939 FieldReusable air filter helps protect internalcomponents from dust and dirt, reducingneed for maintenance and providingextended service life. Easily attaches anddetaches from front of the power source.

Ground Current Sensor #195 048 FieldDisables power source if weld current ispresent on primary ground.

Industrial MIG Kit #195 197Includes 15 ft (4.6 m), 2/0 power cable andwork lead with clamp, regulator/flow meterwith 15 ft (4.6 m) gas hose, 15 ft (4.6 m)MIG gun and consumable kit.

Remote On/Off Control #042 869Allows you to turn power source on or offfrom a distance of 20 ft (6 m). This isespecially useful if your power source islocated up in a mezzanine.

Polarity Control #042 871This dual-function control is designed foruse with dual wire feeders or any applicationwhere electrical isolation and/or polarityreversing of weld current is required. Bothfunctions can be used at the same time.

Process Control Selector #042 872Allows you to easily change weld processes.Also includes features of Polarity Control.

Standard Running Gear #042 886The large 10 in (254 mm) rear wheels and 5 in (127 mm) front casters on this runninggear provide excellent mobility on the shopfloor, making it easier to move the powersource around and over cables and cracks.Very easy to install. Handles double as weldcable holder.

Standard Cylinder Rack #042 887Holds two cylinders. Only installs onStandard Running Gear.

Water Coolant SystemsFor more information, see Miller CoolantSystems Lit. Index No. AY/7.2.

Coolmate™ 3#043 007 115 VAC#043 008 230 VACFor use with water-cooled torches rated up to 600 amps. Unique paddle-wheelindicator, external filter and easy fill spout.

Coolmate™ V3 #043 009 115 VACFor use with water-cooled torches rated upto 500 amps. Vertical design convenientlymounts to Miller cylinder rack in place ofone cylinder.

Coolmate™ 4 #042 288 115 VACFor use with water-cooled torches rated upto 600 amps. Tough molded polyethylenecase with carrying handle.

Coolant #043 810Sold in cases of four 1-gallon recyclableplastic bottles. Miller coolants contain abase of ethylene glycol and deionized waterto protect against freezing to -37˚F (-38˚C)or boiling to 227˚F (108˚C). Also contains a compound that resists algae growth.

Coolmate 3 Coolmate 4

Coolmate V3

6

Genuine Miller Accessories (Continued)

Wire Feeders

70 Series Single Wire ModelsS-74S #195 057 S-74D #195 058 S-74D #195 058-01-1 High SpeedS-74DX #195 059 S-74DX #195 059-01-1 High SpeedDual Wire ModelsD-74S #195 060 D-74D #195 061 D-74DX #195 062 Heavy-duty, industrial, constant-speed 24 VAC semiautomatic wire feeders insingle and dual models, with availabledigital meters. Ideal for high-duty-cycleMIG welding (GMAW) and Flux Coredwelding (FCAW). Accommodates a widevariety of wire sizes and types. Comes withFREE Bernard® Q™-Gun! Dual wire feedermodels include two FREE Q-Guns. See Lit.Index No. M/3.0.

22A #193 066Simple, reliable, 24 VAC constant-speedsemiautomatic wire feeder, best suited forsmall diameter wires. Features two gear-driven drive rolls for smooth, positive wirefeed. Accommodates up to 60 lb (27.2 kg)spool of welding wire when using optionalwire reel assembly. Comes with FREEBernard® Q™-Gun! See Lit. Index No. M/11.0.

24A #195 112Simple, reliable, 24 VAC constant-speedsemiautomatic wire feeder, best suited forsmall diameter wires. Remote voltage isstandard. Features four gear-driven driverolls for larger wire sizes. Accommodatesup to 60 lb (27.2 kg) spool of welding wirewhen using optional wire reel assembly.Comes with FREE Bernard® Q™-Gun! SeeLit. Index No. M/11.0.

XR™-Control #181 538Push-pull wire feed system offersunparalleled performance for aluminumMIG welding. See Lit. Index No. M/1.7.

Swingarc™ Boom-Mounted Wire Feeders Single and dual 24 VAC semiautomatic wirefeeders are available with 12 ft (3.7 m) and16 ft (4.9 m) booms. Ideal for long reachand complete maneuverability whenworking on large weldments, or in hard-to-reach areas. See Lit. Index No. M/13.11.

Extension Cables for 14-Pin Plugs to 14-Pin Sockets #122 973 25 ft (7.6 m)#122 974 50 ft (15.2 m)#122 975 75 ft (22.8 m)This extension cord makes a directconnection between the power source andthe accessory control or wire feeder. Nomessy splicing or adapting required.

7

Notes

50/60 Hz models with CE Specifications are manufactured according to the Standards IEC-974-1 and EN-60974-1.Conforms with NEMA EW 1 “Electric Arc Welding Power Source,” Class I (100).

**

* Certified to both the Canadian and U.S. Standards for welding equipment.

Litho in USA

Distributed by:

Ordering InformationEquipment and Options Stock No. Description Qty. Price

Power Source

Deltaweld® 302 #903 376* 200-208/230/460 V, 60 Hz#903 392* 230/460/575 V, 60 Hz

Deltaweld® 402 #907 285 380/400/440 V, 50 Hz w/CE

Deltaweld® 452 #903 377* 200-208/230/460 V, 60 Hz#903 394* 230/460/575 V, 60 Hz


Deltaweld® 652 #903 396* 230/460/575 V, 60 Hz


Air Filter Kit #042 939 Field

Ground Current Sensor #195 048 Field

Wire Feeders

70 Series See Lit. Index No. M/3.0

22A #193 066 See Lit. Index No. M/11.0


XR™-Control #181 538 See Lit. Index No. M/1.7

Swingarc™ Boom Feeders See Lit. Index No. M/13.0

Extension Cables #122 973 25 ft (7.6 m)#122 974 50 ft (15.2 m)#122 975 75 ft (22.8 m)

Miscellaneous

Industrial MIG Kit #195 197 Includes 15 ft (4.6 m), 2/0 power cable and work lead with clamp, regulator/flow meter with 15 ft (4.6 m) gas hose, 15 ft (4.6 m) MIG gun and consumables kit

Remote On/Off Control #042 869

Polarity Control #042 871

Process Control Selector #042 872

Standard Running Gear #042 886

Standard Cylinder Rack #042 887

Coolmate™ 3 #043 007 115 VAC#043 008 230 VAC

Coolmate™ V3 #043 009 115 VAC

Coolmate™ 4 #042 288 115 VAC

Coolant #043 810

Primary Power Cable

Secondary Welding Cables

Work Cable and Clamp


Invision™ 456P MIG Welding Power Source

Issued January 2005 • Index No. DC/20

Fan-On-Demand™ cooling systemoperates only when needed,reducing noise, energy use and theamount of contaminants pulledthrough machine.

Primary voltage display saves timeand assures operator that powersource is correctly set for availableinput voltage without having toremove side panels.

85% power efficiency means unitcosts less to operate.


115 VAC auxiliary power provides 10 A of circuit-breaker-protected power for water circulators, etc.

600 A maximum output (450 A at 100% duty cycle)meets the high output needs of demanding applications.

Optional remote on/off providesability to turn the power source onand off when power source islocated away from your work.

Wind Tunnel Technology™ protectselectrical components and PCboards from contamination.

Variable, electronic inductancecontrol helps to minimize spatter andoptimize weld-bead wetting action.

ProcessesMIG (GMAW)/Pulsed MIG (GMAW-P)*Flux Cored (FCAW) Air Carbon Arc Cutting and Gouging(CAC-A)

Input Power Requires 3-Phase Power

Output Power 10 – 38 V, 5 – 600 A

Weight Net: 118 lb (53.5 kg) Ship: 129 lb (58.5 kg)

Heavy Industrial ApplicationsConstructionShipbuildingRailroad ManufacturingFabricationRepair Shops





QuickSpecs

Line voltage compensation keepspower constant even if power inputvaries by ±10%. Ensures consistentweld performance.

Pulsed MIG capabilities withoptional Optima control reducesspatter and distortion, allows betterout-of-position puddle control, andprovides potential reduction of fumeparticle emission.

Lightweight, aerospace-gradealuminum case offers protection with the benefit of reduced weight.

Unique case design protects internalcomponents from dirt and dust. Toconnect power cord and/or set unitup for correct input power, removethe easy-to-handle panel (1/3 case).The remaining two-thirds of the casenever needs to be removed!.

Auto Remote Sense enables unit toautomatically use remote control ifconnected to remote control receptacle.

Remote control circuit protectionprevents damage from high frequencyand shorted control cables.

Large, dual digital meters display both volts and amps forquick and easy viewing by anoperator. Voltmeter is presettablefor ease of setting weld output. A hold function lets the operatorsview actual welding output when the arc is broken.

2

3

1

2

4

5

6

Performance Data

Control Panel

InputPower

Three-Phase

Rated Output



AmperageRange inCC Mode

5–600 A

VoltageRange inCV Mode

10–38 V


95 VDC

Amps Input at Rated Load Output, 60 Hz 230 V 400 V 460 V 575 V KVA KW

50.8 31 27.8 24.4 21.2 19.2

Weight

118 lb (53.5 kg)

Dimensions

H: 17 in (432 mm)W: 14-1/2 in (368 mm)D: 26 in (660 mm)



Additional FeaturesPrimary voltage display shows what primaryvoltage the power source is linked for withoutremoving the side panels. Saves time andassures you that the power source has beencorrectly linked for available input voltage.

Unique case design helps protect internalcomponents from dirt and dust. To connectinput power cord and/or set unit up for correctinput power, remove the easy-to-handle panel(1/3 case). The remaining two-thirds of thecase never needs to be removed!

Optional remote on/off provides ability to turnpower source on or off when it is located awayfrom your work.

1. Voltmeter2. Power On/Off Switch3. Inductance Control4. Remote On/Off Receptacle (Optional)5. Ammeter6. Voltage Adjustment Control

0

150

100

200

300

400

500

600

10 15 20 25 30 40 50 60 70 80 90 100

WEL

DAM

PS

% DUTY CYCLE

DUTY CYCLE CHART

3-PHASE OPERATION

CV VOLT/AMP CURVES

MAX.

MIN.

100

80

60

40

20

0

AMPERAGE

VOLT

AGE

0 100 200 300 400 500 600 700

Optima™ #043 389A multipurpose,microprocessor-based pulsecontrol for both synergicMIG (wire welding orGMAW) or manual MIGpulsing. Use this control withInvision 456 power sources

and any Miller wire feeder, includingautomatic feeders and spool guns. Includesa 25 ft (7.6 m) cord with 14-pin plug.

Extension Cords for Optima #043 725 25 ft (7.6 m)#043 726 50 ft (15.2 m)#043 727 75 ft (22.9 m)

WC-24 Weld Control#137 549Designed for use withMiller CV power sourcessupplying 24 VAC and14-pin receptacles. Foruse with Spoolmatic30A spool gun.

WC-115A Weld Control #137 546-01-1Operates on 115 VACand is designed forpower sources withouta 14-pin receptacle. For

use with Spoolmatic 30A spool gun. Includes10 ft (3 m) wall-type plug and power cord.

Process Selector Control #042 872Designed for use with dual wire feeders,applications where electrical isolation and/orpolarity reversing of weld current is required,and for welding process changes. Includes115 VAC/2 amp receptacle, two 14-pinreceptacles and a 10 ft (3 m) 14-pin cord.

RHC-14 Hand Control#129 340Miniature hand controlfor remote current andcontactor 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.

Extension Cords for Remote Controls and 24 VAC Wire Feeders#122 973 25 ft (7.6 m)#122 974 50 ft (15.2 m)#122 975 75 ft (22.8 m)14-pin plug to 14-pin socket.Note: Not for use with Optima or 60M Series.

Inverter RacksFour or Six-Arc Welding System

The Inverter Rackconveniently housesmultiple powersources for multiplewelders. Both 4-packand 6-pack models are available. Features include:

Provision to parallel power sources orcommon work connectionsTwo lifting eyes for transportationRugged skids for dragging or pushingCustomer can install up to a maximumof 4 Invision 456 power sources

For detailed information on customizedInverter Rack systems see Lit. Index No.DC/18.81.

Running Gear

MIGRunner™ XL Cart #195 246 Small footprint and easily maneuverable,with cylinder rack low enough that you donot have to lift bottles. Carries two 160 lb (72.6 kg) gas cylinders, or one gas cylinderand one coolant system.

Cylinder Cart #042 537Carries two 160 lb (72.6 kg) gas cylinders,or one gas cylinder and one coolant system.Feeder mounts to tray above power source.

Wire Feeders/Guns

SuitCase™ 8RC #194 938SuitCase™ 12RC #194 940Lightweight, portable wire feeder for avariety of wires up to .062 in. Holds up toan 8 in (8RC) or 12 in (12RC) spool ofwire. Operates using 14-pin controlreceptacle. See Lit. Index No. M/6.5.

XR-Control #181 538Push-pull wire feedsystem offers unparalleledperformance for aluminum

MIG welding. See Lit.Index No. M/1.7.

S-74 DX #195 059Wire feeder featuresprocess and weldcontrol and handlesa variety of wires upto 1/8 in. See Lit.Index No. M/3.0.

60M SeriesS-60M #131 794D-60M #131 796Semiautomaticpulsed-MIG andstandard CV-MIGfeeder equipped

with eight synergic pulse programs. Handles.023 to 1/8 in wires and up to 60 lb spool.Optional data cards for program storageand transfer. Pulse arc characteristics arefully customizable. See Lit. Index No. M/2.4.

Spoolmatic®

30A #130 831A 1-lb, air-cooled spoolgun that extendsthe weld process

range by adding a handy portable systemfor small wire MIG. Rated 200 A at 100%duty cycle. Includes 30 ft (9.1 m) cableassembly. (WC-24 #137 549 for 14 pin.)

3


Roughneck® C-Series MIG Guns See Lit. Index No. AY/17.0.

Ironmate™ Flux Cored Guns See Lit. Index No. AY/16.0.FC-1260#195 732 10 ft (3 m)#195 729 15 ft (4.6 m)FC-1260LM#194 912 10 ft (3 m)#194 911 15 ft (4.6 m)FC-1150#194 864 10 ft (3 m)#194 863 15 ft (4.6 m)

Water Coolant SystemsFor more information, see the Miller CoolantSystems literature sheet, Index No. AY/7.2.

Coolmate™ 3#043 007 115 VAC#043 008 230 VACFor use with water-cooled torches rated upto 600 amps. Unique paddle-wheelindicator, external filter and easy-fill spout.



Coolant #043 810Sold in cases of four 1-gallon recyclableplastic bottles. Miller coolants contain abase of ethylene glycol and deionized waterto protect against freezing to -37˚F (-38˚C)or boiling to 227˚F (108˚C). Also contains acompound that resists algae growth.

Genuine Miller Accessories (continued)


Litho in USA

Power Source and Options Stock No. Description Qty. Price

Invision® 456P #903 505 230/460 VAC, 60 Hz#903 505-01-1 230/460 VAC, 60 Hz with Remote On/Off#903 545 400 VAC, 50/60 Hz with CE#903 546 575 VAC

Accessories

Optima™ MIG Pulse Control #043 389 For CC/CV models only

Optima™ Extension Cords See page 3

WC-24 #137 549 For use with Spoolmatic 30A and power sources with 14-pin

WC-115A #137 546-01-1 For use with Spoolmatic 30A and power sources without 14-pin

Process Selector Control #042 872

Extension Cords (For 24 VAC wire See page 3. Not to be used with Optima or 60Mfeeders and remote controls)

Running Gear

MIGRunner™ XL Cart #195 246 For all models

XMT Cylinder Cart #042 537 For all models

Wire Feeders/Guns

SuitCase™ 8RC / 12RC #194 938 / #194 940 See Lit. Index No. M/6.5

XR-Control #181 538 See Lit. Index No. M/1.7

S-74 DX #195 059 See Lit. Index No. M/3.0

60M Series #131 794 / #131 796 S-60M / D-60M. See Lit. Index No. M/2.4

Spoolmatic® 30A Spool Gun #130 831 Includes 30 ft (9.1 m) cable assembly

Roughneck® C-Series MIG Guns See Lit. Index No. AY/17.0

Ironmate™ Flux Cored Guns See Lit. Index No. AY/16.0

Water Coolant Systems See above. See Lit. Index No. AY/7.2


Distributed by:

ProcessesMIG (GMAW)Pulsed MIG (GMAW-P)Stick (SMAW)Flux Cored (FCAW) Air Carbon Arc (CAC-A)Cutting and Gouging

Industrial ApplicationsMetal FabricationHeavy Manufacturing ConstructionLight Manufacturing

QuickSpecs

Invision™ 354MP/456MP MIG WeldingPower Source

Issued Aug. 2007 • Index No. DC/23

Dual digital meters forquick and easy viewingand large setup screento choose pulse weldingmode.

International-style welddisconnects provide high-qualityweld cable connections. (Twoconnectors supplied with eachunit. Invision 354MP only.)

Remote control of arc trim allows wirefeeder complete controlof arc parameters.

Pulsed spray transferhelps reduce spatter andfume levels.

Fan-On-Demand™

operates only whenneeded reducing bothnoise and powerconsumption.


Welder is warranted for 3 years, parts and labor. Original mainpower rectified parts are warranted for 5 years.




Input Power 354MP: 3-Phase or 1-Phase Power456MP: 3-Phase Power

Rated Output 354MP: 300 A at 32 V, 60% Duty Cycle (3-Phase)225 A at 29 V, 60% Duty Cycle (1-Phase)

456MP: 450 A at 38 V, 100% Duty Cycle (3-Phase)

Weight 354MP: 79.5 lb (36.1 kg) 456MP: 118 lb (53.5 kg)

Built-in pulsed MIGcapability which eliminatespendants and cables thatcould potentially getdamaged or lost.

Microprocessor-based technology allows processparameter storage to be retained between power down andpower up and also between program changes.

Wind Tunnel Technology™

protects electricalcomponents and PC boards from contam -ination, significantlyimproving reliability.

Invision 456MP onlyAuto Remote Sense enables unit toautomatically use remote control ifconnected to remote control receptacle.

Primary voltage display shows whatprimary voltage the power source isset for without removing the sidepanels. Saves time and assures youthat the power source has beencorrectly set for available input voltage.

Standard 10 amp, 115 VAC auxiliarypower receptacle.

Invision 354MP

Invision 456MP

Invision 354MP onlyAuto-Link® circuit auto matically linksthe power source to primary voltagebeing applied (208-230/460 VAC,single- or three-phase).

Protective cover for front controlpanel protects controls from damagein rough conditions.

Optional 10 amp, 115 VAC auxiliarypower available.

Inverter arc control technology provides greater puddlecontrol demanded especially by the pipe welding industry.

Lightweight, aerospace-grade aluminum caseoffers protection with thebenefit of reduced weight.

Invision 354MP MIGRunner™ industrial packagecomes complete in one box. See page 7 for details.

1

4

9

10

5

2

3

67

8

CV VOLT/AMP CURVE

MAX.

MIN.

100

80

60

40

20

0

AMPS

VOLT

S

0 100 200 300 400 500

SMAW-MAX.

SMAW-MIN.

100

80

60

40

20

0

AMPS

CC VOLT/AMP CURVE

VOLT

S

0

0% 25%50%

75%100%

100 200 300 400 500

500

400

300250225200

150

10010

% DUTY CYCLE

DUTY CYCLE CHART

WEL

DING

AM

PS

15 20 25 30 40 6050 70 80 90 100

3-PHASE OPERATION

1-PHASE OPERATION

Performance Data

2

Control Panel

Rated Output

Three-Phase

Single-Phase

Rated Output at60% Duty Cycle

300 A at 32 VDC

225 A at 29 VDC(Non-pulseapplications)


10 – 35 V


5 – 400 A


90 VDC

RMS Amps Input at Rated Load Output, 60 Hz3-Phase at NEMA Load Voltages and Class I Rating230 V 400 V 460 V 575 V KVA KW

30.5 17 18.9 15.2 12.2 11.6

47.4 — 24.5 — 11.3 7.6

Dimensions


Weight

Net: 76 lb (34.5 kg)Ship: 85 lb (38.6 kg)

Invision™ 354MP Specifications (Subject to change without notice.)

1. Power Switch 2. Voltmeter3. Ammeter/Trim Display4. Select Push Button5. Alphanumeric Display6. Ammeter Indicator Light7. Trim Indicator Light8. Output Adjust Control9. Increment Push Button

10. Decrement Push Button

1

23

4

5

6

7

8

9

10

SMAW-MAX.

100

80

60

40

20

0

CC VOLT/AMP CURVE

0 100 200 300 400 500 600 700

500600

400

300

200

150

10010

DUTY CYCLE CHART

15 20 25 30 40 6050 70 80 90 100

3-PHASE OPERATION

CV VOLT/AMP CURVE

MAX.

MIN.

100

80

60

40

20

00 100 200 300 400 500 600 700

SMAW

0%25%

50%75%

100%

AMPS AMPS% DUTY CYCLE

VOLT

S

VOLT

S

WEL

DING

AM

PS

Performance Data

Control Panel

Rated Output

Three-Phase

Rated Output at100% Duty Cycle

450 A at 38 VDC


10 – 38 V


5 – 600 AStick


95 VDC

RMS Amps Input at Rated Load Output, 60 Hz3-Phase at NEMA Load Voltages and Class I Rating230 V 400 V 460 V 575 V KVA KW

50.8 31 27.8 24.4 21.2 19.2

Dimensions


Weight

Net: 118 lb (53.5 kg)Ship: 129 lb (58.5 kg)

Invision™ 456MP Specifications (Subject to change without notice.)

1. Power Switch 2. Voltmeter3. Ammeter/Trim Display4. Select Push Button5. Alphanumeric Display

6. Ammeter Indicator Light7. Trim Indicator Light8. Output Adjust Control9. Increment Push Button

10. Decrement Push Button

3

Protective Cover#195 478Mildew and waterresistant, odor-freecover protects yourmachine’s finish. For300/350 A inverters:XMT, Maxstar,Invision and Dynasty.

MIGRunner™ Cart #195 445For 354MP only. Small footprint and easilymaneuverable, with cylinder rack lowenough that you do not have to lift bottles.Durable, heavy-duty ergo nomic handles aredesigned for comfort.

MIGRunner™ XL Cart #195 246 (For all models)Small footprint and easily maneuverable,with cylinder rack low enough that you donot have to lift bottles.

Invision™ Cylinder Cart #042 537Has adjustable handles and is slanted for con ve nient access to power source front panel con trols. Carries two 160 lb (72.6 kg) gas cylinders, or one gas cylinder and onecoolant system for TIG (GTAW) welding.Feeder mounted to tray above power source.

Universal Carrying Cart and Cylinder Rack#042 934Accommodates Invision™ 354MP only, plusgas cylinder up to 56 in (142.2 cm) highmea sur ing 6 to 9 in (15.2 to 22.8 cm) india meter. Also provides storage forauxiliary items such as elec trodes, helmets,gloves, etc.


4

Coolmate 3Coolmate 4

Coolmate V3

Coolmate™ 3#043 007 115 VAC#043 008 230 VACFor use with water-cooled torches rated up to 600 amps. Unique paddle-wheel indicator,external filter and easy-fill spout.



Low Conductivity Coolant #043 810Sold in cases of four 1-gallon recyclableplastic bottles. Miller coolants contain abase of ethylene glycol and deionized waterto protect against freezing to -37˚F (-38˚C)or boiling to 227˚F (108˚C). Also contains acompound that resists algae growth.

Water Coolant SystemsFor more information, see the Miller Coolant Systems literature sheet, Index No. AY/7.2.

5

Wire Feeders

Note: The Invision 354MP power source is equippedwith International-style connectors for secondaryconnections. (Power source is shipped with two 50-mm male International-style plugs for use with #4 to #1/0 AWG size cable.)

International-Style Connector Kit #042 418 50 mm Accepts #4 to #1/0 AWG cable size.Required if male plugs shipped with powersource must be replaced, if additional plugsare needed.#042 533 70 mmAccepts #1/0 or #2/0 AWG cable size.Required if #1/0 or #2/0 AWG size cable isto be used.

Kit includes one International-style maleplug which attaches to the work and/or weldcables and plugs into the International-stylerecep tacles on the power source.

Extension Kit for International-Style Cable Connectors#042 419 50 mm Accepts #4 to #1/0 AWG size cable.#042 534 70 mm Accepts #1/0 or #2/0 AWG size cable.

Used to adapt or extend weld and/or workcables. Kit includes one male International-style plug and one in-line femaleInternational-style receptacle.

International/Tweco®

Adapter #042 465A one-piece adapter whichhas an International-stylemale plug (to power

source) on one end and a female Twecoreceptacle (for weld cable connection) onother end.

International/Cam-LokAdapter #042 466A one-piece adapter whichhas an International-style

male plug (to power source) on one endand a Cam-Lok receptacle (for weld cableconnection) on other end.

International-Style Connectors (Will accept Dinse™ or other International connectors.)

SuitCase™ 8RC #194 938SuitCase™ 12RC #194 940Lightweight, portable wire feeder for avariety of wires up to .062 in. Holds up toan 8 in (8RC) or 12in (12RC) spool of wire.Operates using 14-pin control receptacle.See Lit. Index No. M/6.5.

70 SeriesS-74S #195 057S-74D #195 058Wire feeder featuresPosifeed™ wire driveassembly and

handles a variety of wires up to 1/8 in. See Lit. Index No. M/3.0.

S-74 DX #195 059Wire feeder features process and weldcontrol and handles a variety of wires up to 1/8 in. See Lit. Index No. M/3.0.

22A Wire Feeder #193 006Simple, Reliable, 24 VAC constant-speedsemiautomatic wire feeder, best suited forsmall diameter wires. Accommodates up to a 60 lb (27.2 kg) spool of welding wire when using optional wire reel assembly. See Lit. Index No. M/11.0.

XR Control #181 538Push-pull wire feed system offersunparalleled performance for aluminumMIG welding.See Lit. Index No. M/1.7.

Extension Cables for 14-Pin Plugs to 14-Pin Sockets#122 973 25 ft (7.6 m)#122 974 50 ft (15.2 m)#122 975 75 ft (22.8 m)

6

Typical Systems for Invision™ 354MP

Typical Systems for Invision™ 456MP

Aluminum SystemInvision 354MP #903 593

XR-Control Wire Feeder #181 538XR-A Edge 30 ft Gun #181 535XR-W Edge 30 ft Gun #181 532Note: Guns are available in other lengths.

Steel and Stainless Steel SystemInvision 354MP #903 593

SuitCase 12RC Feeder #194 940

Aluminum SystemInvision 456MP #903 725

XR-Control Wire Feeder #181 538XR-W Edge 30 ft Gun #181 532Note: Guns are available in other lengths.

Steel and Stainless Steel SystemInvision 456MP #903 725

S-74D Wire Feeder #195 058

7

Package Components

Invision™ 354MP MIGRunner™ #907 051

The Invision 354MP combines the advantages ofan inverter-based power source with built-inpulse features for pulsed MIG welding. Perfectlymatched with the full-featured S-74D wire feederand durable Roughneck® gun, accessories andrunning gear, this package is an outstandingindustrial-class welding system.

Comes Complete With:Invision 354MPS-74D wire feederRoughneck™ C-4015 gunConsumables.035 and .045 in drive roll kitRegulator/flow gauge with gas hose10 ft assembled work and positive weld cables10 ft factory-installed power cordFactory-installed running gear and cylinder rackBottom tray will hold optional Coolmate 3(sold separately)

Litho in USA

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Ordering InformationEquipment and Options Stock No. Description Qty. Price

Power Source

Invision™ 354MP #903 593 208-230/460 VAC with Auto-Link®

#903 593-01-1 208-230/460 VAC with Auto-Link® and Aux. Power#903 756 400 VAC with Aux. Power and CE#907 057 575 VAC

Invision™ 354MP MIGRunner #907 051 208-230/460 VAC with Auto-Link®. See page 7 for components

Invision™ 456MP #903 725 230/460 VAC#903 598 400 VAC#907 056 575 VAC

Accessories

MIGRunner™ Cart #195 445

MIGRunner™ Cart XL #195 246

Invision™ Cylinder Cart #042 537

Universal Cart and Cylinder Rack #042 934 For use with Invision™ 354MP only

Coolmate™ 3 #043 007 115 VAC#043 008 230 VAC

Coolmate™ V3 #043 009 115 VAC

Coolmate™ 4 #042 288 115 VAC

Coolant #043 810

Wire Feeders

SuitCase™ 12RC #194 940 See Lit. Index No. M/6.5

70 Series #195 057 S-74S. See Lit. Index No. M/3.0#195 058 S-74D. See Lit. Index No. M/3.0 #195 059 S-74DX. See Lit. Index No. M/3.0



XR-Edge™ Gun See Lit. Index No. M/1.7

XR-Pistol Gun See Lit. Index No. M/1.7

Extension Cords #122 973 25 ft (7.6 m)(For 24 VAC wire feeders and remote controls) #122 974 50 ft (15.2 m)

#122 975 75 ft (22.8m)

International-Style Connectors

International-Style Connector Kit #042 418 50 mm #042 533 70 mm

Extension Kit for International-Style #042 419 50 mm Cable Connectors #042 534 70 mm

International/Tweco® Adapter #042 465 A one-piece adapter with International-style male plug

International/Cam-Lok Adapter #042 466 A one-piece adapter with International-style male plug


Note: Invision 354MP will operate from 200/208 VAC, but will not compensate for low line fluctuations at this level.Meets NEMA rated output standards using 230/460 VAC primary only.

Invision™ 350 MPa System MIG Welding Power Source

Issued Nov. 2007 • Index No. DC/23.5

Lightweight, aerospace-grade aluminumcase offers protection with the benefit ofreduced weight.

SharpArc™ technology changes welding arccharacteristics in Pulsed MIG welding mode.

Auto-Line™ Power ManagementTechnology allows for any input voltagehook-up (208 – 575 V) with no manuallinking required, providing conveniencein any job setting. Ideal solution for dirtyor unreliable input power.

Easy setup for MIG and Pulsed MIGapplications.

Inverter arc control technology providesgreater puddle control for outstanding MIGweld performance.

Fan-On-Demand™ cooling systemoperates only when needed, reducingnoise, energy use and the amount ofcontaminants pulled through machine.

The Power of Blue®.Dynamic Pulsed MIG—highly-engineeredpulse programs default to give a tightproductive pulse arc. The operator can fine tune the arc if desired.

ProcessesInvision 350 MPaMIG (GMAW)/Pulsed MIG (GMAW-P)Flux Cored (FCAW) Air Carbon Arc Cutting and Gouging(CAC-A) (1/4 in carbons max.)

S-74 MPaMIG (GMAW)Flux Cored (FCAW) Pulsed MIG (GMAW-P)

Invision 350 MPaInput Power Requires 3- or 1-Phase Power, 50/60 HzRated Output 10 – 38 V, 5 – 425 AWeight Net: 80 lb (36.3 kg) Ship: 89.1 lb (40.4 kg)

S-74 MPaInput Power 24 VAC, 10 A, 50/60 HzElectrode Wire Dia. Capacity .023–5/64 in (0.6–2 mm)Wire Speed 50–780 IPM (1.3–19.8 m/min)Weight Net: 58 lb (26 kg)

Heavy Industrial ApplicationsInvision 350 MPaRailroad Truck/Trailer ManufacturingLight Gauge and TubeLawn and Garden EquipmentRecreational Vehicles

S-74 MPaHeavy/Light ManufacturingMetal Fabrication





Gun warranted for 90 days, parts and labor.

QuickSpecs

Line voltage compensation keeps weldingoutput constant even if input power variesby +/-10%. XMT 350 models further expandline voltage compensation on 460 VAC toan amazing +37%, -59%.

Large, dual digital meters are easy toview and are presettable to ease settingweld output.

Invision 350 MPa SystemAdd the new S-74 MPa feeder for apackage that gives you the benefit ofSynergic-Pulsed MIG. As you increase/decrease the wire feed speed, the pulseparameters increase/decrease matchingthe right amount of power output to the wire speed.

2


DUTY CYCLE CHART

DUTY CYCLE

30

WEL

DING

AM

PERE

S

200

150

10010 15 20 25

500

400

300

10040 50 60 70 9080

425

350

250

3-PHASE OPERATION

1-PHASE OPERATION

6 AWG POWER CORD

8 AWG POWER CORD

0

10

20

30

40

50

60

70

80

90

100

0 100 200 300 400 500

AMPS

VOLT

AGE

MAX

MIN

CV VOLT/AMP CURVE

Performance Data

InputPower

Three-Phase

Single-Phase

Rated Out putat 60% Duty Cycle

350 A at 34 VDC

300 A at 32 VDC


5–425 A

5–425 A


10–38 V

10–38 V


75 VDC

75 VDC

Amps Input at Rated Load Output, 60 Hz, 208 V 230 V 400 V 460 V 575 V KVA KW

40.4 36.1 20.6 17.8 14.1 14.2 13.6

60.8 54.6 29.7 24.5 19.9 11.7 11.2

Weight

80 lb(36.3 kg)

Dimensions



Additional FeaturesExceptional electrical efficiency. At 400 A,efficiency is 87.24%!

350 A of welding output at 60% duty cyclewith superior low-end performance.

Power factor of .95 enables smallerfuses/breakers and primary wiring. Primaryamperage draw at rated output is 25% less than the competition.

Ultra-tough, polycarbonate-blended cover for control panel protects front controls from damage.

3

1. Output ON Indicator Light2. Left Display3. Voltage Indicator4. Arc Length Indicator5. Wire Feeder Receptacle6. Adjustment Control7. Right Display

8. Setup Indicator9. Amperage Indicator

10. Setup Indicator Lights• Arc Control Indicator• Process Indicator• Wire/Gas Type Indicator• Setup Button

5

234

1

789

6

10

SetupOUTPUT ON

SETUP

Arc Control

Process

Wire/Gas

Control Panel

Additional FeaturesSharpArc™

Changes welding arc characteristics in Pulsed MIG (GMAW-P) welding mode.

If a gas is used other than what is listed on the Pulsed MIG welding program chart (below left), the SharpArc™ can beadjusted to help customize your arc to thegas being used.Lower SharpArc™ settings widen the arccone, increase puddle fluidity and flattensthe weld bead.

Auto Remote Sense™

Enables unit to automatically use remotecontrol if connected to remote controlreceptacle.

Dinse International-style weld disconnectsProvide high-quality weld cable connections.Dinse and Tweco connectors are available.When Dinse connectors are specified, twoconnectors are supplied with the unit.

Optional 115 VAC auxiliary power Provides 10 amps of circuit-breaker-protected power for water circulators, etc.

MPaMPa: M (MIG), P (Pulse), a (AdvancedArc Control). Advanced arc control enables an improved pulse welding arc.The operator has more control over puddleand bead characteristics using SharpArc™.In addition, the unit provides a more robustand stable arc at very low arc length, reducingheat input, and providing the ability to weldon a wider range of material thickness.

Synergic pulsing is available only with theS-74 MPa dedicated wire feeder.

What are some benefits of Synergic-Pulsed MIG?1. Easier to set up2. No more changing wire speed, and

then having to go back to reset thewelding output.

The Invision 350 MPa has built-in dynamic Pulsed MIG capabilities. See the table below for the widerange of Pulsed MIG (GMAW-P) welding applications the Invision 350 MPa can handle.

The Invision™ 350 MPa and S-74 MPa combine for a synergic system that simplifies andimproves MIG and Pulsed MIG welding applications for industrial manufacturing.

(0 setting) (50 setting)

Low Setting High Setting

Note: Setting has a subtle effect on arc that isexaggerated in graphic for visual emphasis.Steel

Metal Core

Stainless Steel

Aluminum

Nickel

Silicon Bronze

Copper Nickel

.035 STL

.045 STL

.035 MCOR

.045 MCOR

.052 MCOR

.035 SSTL

.045 SSTL

.035 AL4X (4000 Series) 3/64 AL4X (4000 Series) .035 AL4X (5000 Series) 3/64 AL4X (5000 Series)

.035 NI

.045 NI

.035 SIBR

.045 CUNI

Gas Types

ARGN CO2 (Argon/Carbon Dioxide)ARGN OXY (Argon/Oxygen)

ARGN CO2 (Argon/Carbon Dioxide)

TRI MIX (Tri-gas mixture)ARGN OXY (Argon/Oxygen)ARGN CO2 (Argon/Carbon Dioxide)

ARGN (Argon)

ARGN HE (Argon/Helium)

ARGN (Argon)

HE ARGN (Helium/Argon)

Built-In Pulsed MIG Programs

Wire Types

4

S-74 MPa Single Feeder Features

Dual tension control adds flexibil ityfor the operator to fine-tune thepressure on the wire independentlywhen feeding a variety of wires.

Tool-less rotatable drive assem bly allows operator to rotate the drivehousing, eliminating severe bends in thewire feed path which reduce gun linerlife. Also aids in feeding difficult wires.

64

S-74 MPa24V Wire Feeder

3

1

2

5

1. Voltage Display Meter2. Wire Speed Display Meter3. Wire Feed Speed Select4. Trigger Hold5. Voltage Select6. Jog/Purge

Input Power

24 VAC, 10 A, 50/60 Hz

Wire Speed

50–780 IPM (1.3–19.8 m/min)Optional High Speed Motor:90–1440 IPM (2.3–36.6 m/min)

Electrode Wire Diameter Capacity

.023–5/64 in (0.6–2 mm)

Net Weight

58 lb (26 kg)

Dimensions

H: 14 in (356 mm)W: 12 in (305 mm)D: 26-1/2 in (673 mm)

Specifications (Subject to change without notice.)(Use with CVPower Sources.)

Posifeed™ Wire Drive Assembly Features(Synergic Pulsed MIG when connected to the Invision 350 MPa)

24 VDC high-torque, permanent-magnet motor.Quick-change drive rolls.Quick-release, calibrated drive-roll pressure adjustment arm allows drive roll changewithout losing spring preload setting.Four sealed ball bearing all-gear-driven drive-roll carriers for smooth, positive andaccurate wire feed with long uninterrupted service life.Easy loading and threading of welding wire with out having to release the drive-rollpressure arm.Solid-state speed control and brake circuit eliminates the need for electrical/mechanical relays and increases service life.Uses Miller standard 1-5/8 in (41 mm) diameter drive rolls.Quick-connect for all Miller guns.Covered drive rolls — easy access, heavy-duty, molded composite cover over drive assembly.Floating positive drive systems provide trouble-free feeding on a variety of wires.

Control Panel

5

Invision™ 350 MPa System Components

Invision™ 350 MPa MIGRunner™ #907 398

Comes Complete With:Invision 350 MPa power sourceS-74 MPa wire feederBernard® Q™-GunConsumables.035/.045 in drive roll kitNEW! Industrial MIG 4/0 Kit with Dinse ConnectorMIGRunner Cart with cylinder rackBottom tray will hold optional Coolmate 3(sold separately)

Invision™ 350 MPa Push-Pull AluminumPackage #951 115

Comes Complete With:Invision 350 MPa power sourceXR™-Control Box25 ft (7.6 m) air-cooled XR-Aluma-Pro™ Gun

Invision™ 350 MPa Stationary Package #951 113

Comes Complete With:Invision 350 MPa power sourceS-74 MPa wire feederBernard® Q™-GunConsumables.035/.045 in drive roll kitNEW! Industrial MIG 4/0 Kit with Dinse Connector

For Your Aluminum Welding Applications

Industrial MIG 4/0 Kit with DinseConnector #300 405This useful pulse-ready MIG kit can bepurchased separately. Includes Smith®

flowmeter/regulator with 10 ft (3 m) gashose, 10 ft (3 m) 4/0 feeder weld cable withDinse connector on one end and a lug onthe other, 15 ft (4.6 m) work cable withDinse connector on one end and 600-amp C-clamp on the other.

Process Selector Control #042 872Designed for use with dual wire feeders,applications where electrical isolation and/orpolarity revers ing of weld current is required,and for welding process changes. Includes115 VAC/2 amp recepta cle, two 14-pinreceptacles and a 10 ft (3 m) 14-pin cord.

Running Gear

MIGRunner™ Cart#195 445Small footprint and easilymaneuverable,with cylinder rack low enoughthat you do nothave to lift bottles.

XMT Cylinder Cart#042 537Carries two 160 lb (72.6 kg) gascylinders, or onegas cylinder andone coolantsystem for TIG(GTAW) welding.Feeder mounts totray above powersource.

UniversalCarrying Cart andCylinder Rack#042 934 Holds powersource, and gascylinder up to 56 in(142.2 cm) highmea sur ing 6 to 9 in(15.2 to 22.8 cm)in dia meter.

Protective Cover

#195 478Mildew and water resistant, odor-freecover protects your machine’s finish. For 300/350 A inverters: Invision, XMT,Maxstar and Dynasty.

Wire Feeders/Guns

70 SeriesS-74 MPa #300 411*S-74S #195 057 S-74D #195 058S-74DX #195 059Wire feeder features Posifeed™ wire driveassembly and handles a variety of wires up to1/8 in. Comes with FREE Bernard® Q™-Gun.See Lit. Index No. M/3.0. *Designed exclusively for Invision 350 MPa forSynergic Pulsed MIG benefits.

XR™-Control #181 538Push-pull wire feedsystem offersunparalleled performancefor aluminum MIG

welding. See Lit.Index No. M/1.7.

XR™-Aluma-Pro™ Gun*#300 000 15 ft (4.6 m) air-cooled#300 001 25 ft (7.6 m) air-cooled#300 264 35 ft (10.6 m) air-cooled#300 003 15 ft (4.6 m) water-cooled#300 004 25 ft (7.6 m) water-cooled#300 265 35 ft (10.6 m) water-cooledThis easy-to-use and easy-to-maintaingooseneck-style MIG gun is designed forpush-pull wire feed systems (with requiredXR-Control). Available in air- or water-cooled versions. Trigger hold reducesoperator fatigue (feature available whenpaired with XR-Control). Gun design allowsfor better access into tight spots. See Lit.Index No. M/1.7.*XR-Control is required to operate this gun withthe Invision 350 MPa System.

6


22A #193 066Simple, reliable, 24 VAC constant-speedsemiautomatic wire feeder, best suited forsmall diameter wires. Accommodates up to60 lb (27.2 kg) spool of welding wire whenusing optional wire reel assembly. Comeswith FREE Bernard® Q™-Gun! See Lit. IndexNo. M/11.0.

24A #195 112Simple, reliable, 24 VAC constant-speedsemiautomatic wire feeder, best suited forsmall diameter wires. Remote voltage isstandard. Features four gear-driven driverolls for larger wire sizes. Accommodatesup to 60 lb (27.2 kg) spool of welding wirewhen using optional wire reel assembly.Comes with FREE Bernard® Q™-Gun! SeeLit. Index No. M/11.0.

Spoolmatic® 30A #130 831A 1-lb, air-cooled spool gun that extendsthe weld process range by adding a handyportable system for small wire MIG. Rated200 A at 100% duty cycle. Includes 30 ft(9.1 m) cable assembly. (WC-24 #137 549for 14 pin.)

WC-24 Weld Control#137 549Designed for use withMiller CV power sourcessupplying 24 VAC and14-pin recep tacles. Foruse with Spoolmatic30A spool gun.

Water Coolant SystemsFor more information, see the Miller CoolantSystems literature sheet, Index No. AY/7.2.

Coolmate™ 3#043 007 115 VAC#043 008 230 VACFor use with water-cooled torches rated upto 600 amps. Unique paddle-wheelindicator, external filter and easy-fill spout.



Coolant #043 810Sold in cases of four 1-gallon recyclableplastic bottles. Miller coolants contain abase of ethylene glycol and deionized waterto protect against freezing to -37˚F (-38˚C)or boiling to 227˚F (108˚C). Also contains acompound that resists algae growth.

International-Style ConnectorsNote: XMT 350 power sources are equipped withInternational-style connectors for secondaryconnections. (Power source is shipped with two 50-mm male International-style plugs for use with #1 or #2 AWG size cable.)

International/Tweco®

Adapter #042 465International/Cam-LokAdapter #042 466

One-piece adapter with International-stylemale plug (to power source) on one end andfemale receptacle (Tweco or Cam-Lok forweld cable connection) on other end.

International-Style Connector Kit #042 418 50 mm Accepts #4 or #1/0 AWG cable size. Requiredif male plugs shipped with power source mustbe replaced, or if additional plugs are needed.#042 533 70 mmAccepts #1/0 or #2/0 AWG cable size.Required if #1/0 or #2/0 AWG size cable is to be used.Kit includes one International-style maleplug which attaches to the work and/or weldcables and plugs into the International-stylerecep tacles on the power source.

Extension Kit for International-Style Cable Connectors#042 419 50 mm Accepts #4 or #1/0 AWG size cable.#042 534 70 mm Accepts #1/0 or #2/0 AWG size cable.Used to adapt or extend weld and/or workcables. Kit includes one male International-style plug and one in-line femaleInternational-style receptacle.

Genuine Miller Accessories (continued)

7


Litho in USA

Power Source and Options Stock No. Description Qty. Price

Invision™ 350 MPa #907 397 208 – 575 VAC with Auto-Line™

#907 397-01-1 208 – 575 VAC with Auto-Line™ and Auxiliary Power

Invision™ 350 MPa System See page 5 for different packages and components

Accessories

Industrial MIG 4/0 Kit with Dinse Connector #300 405 See page 6

WC-24 #137 549 For use with Spoolmatic® 30A and power sources with 14-pin

Process Selector Control #042 872

Extension Cords (For 24 VAC wire #043 690 25 ft (7.6 m)feeders and remote controls) #043 691 50 ft (15 m)

Running Gear

MIGRunner™ Cart #195 445

XMT Cylinder Cart #042 537

Universal Carrying Cart and Cylinder Rack #042 934

Protective Cover #195 478

Wire Feeders/Guns

70 Series #300 411 S-74 MPa. Designed exclusively for Invision 350 MPa for Synergic Pulsed MIG benefits

#195 057 S-74S. See Lit. Index No. M/3.0#195 058 S-74D. See Lit. Index No. M/3.0#195 059 S-74DX. See Lit. Index No. M/3.0




Spoolmatic® 30A Spool Gun #130 831 Includes 30 ft (9.1 m) cable assembly

XR-Aluma-Pro™ Gun #300 000 15 ft (4.6 m) air-cooled#300 001 25 ft (7.6 m) air-cooled#300 264 35 ft (10.6 m) air-cooled#300 003 15 ft (4.6 m) water-cooled#300 004 25 ft (7.6 m) water-cooled#300 265 35 ft (10.6 m) water-cooled

Water Coolant Systems See page 7. See Lit. Index No. AY/7.2

International-Style Connectors See page 7


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