Wirpo Katalogy
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Wirpo Katalogy
Miller zdroje CE
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It begins with a spark of inspiration That inspiration builds to an idea —and then, a plan.Work begins. Challenges are overcome. And soon, we’ve built somethingnew for ourselves and for our world.The wonder of your imagination. The power of your determination.The capabilities of Miller products. Together, we build.MillerWelds.com/webuildWhen imagination meets determination,we can do anything.with youPage 3
New from Blue13XMS®425 MPa15Continuum™Systems16Auto-Continuum™Systems18SuitCase®12RC31Dimension™65034XMT®350 FieldPro™System45Maxstar®800Dynasty®80045Maxstar®400Dynasty®40061External Cladding HeadShop with expert advice and attentionVisit your local Miller distributor for in-depth knowledge and one-on-oneassistance in product selection. MillerWelds.com/wheretobuyPage 4
MIG (GMAW)⋆•Easiest process to learn•High welding speeds possible•Provides better control on thinner metals•Cleaner welds possible with no slag•Same equipment can be used for flux-cored weldingPulsed MIG (GMAW-P)⋆•Flexibility and productivity — nearly all metals canbe welded in all positions•Larger diameter electrode wires for higherdeposition rates•Virtually no spatter•Welds thin to thick metalsFlux-cored (FCAW)⋆•Can work as well as stick on dirty or rusty material•Out-of-position welding•Deep penetration for welding thick sections•Increased metal deposition rateStick (SMAW)⋆⋆•Well suited for windy, outdoor conditions•More forgiving when welding on dirty or rusty metal1Pick the right process for the metalsto be welded.S SS Ni AL CBS SS Ni AL CBS SSFinding the welding equipment that’s right for you doesn’t have to be complicated. Follow the steps below.Help me choose4Metal typeSteel Aluminium TitaniumStainless Steel Cast Iron Magnesium AlloysNickel Alloys Copper/Brass All Electrically ConductiveProcess skill level⋆Low⋆⋆Moderate⋆⋆⋆HighSSSNiALCICBTiMgECTIG (GTAW)⋆⋆⋆AC DC•Provides highest quality and most precise welds•Highly aesthetic weld beads•Allows adjustment of heat input while welding byuse of a remote controlPulsed TIG (GTAW-P)⋆⋆⋆AC DC•More control on thin metals•Less heat distortion on thin metalsSubmerged Arc (SAW)⋆⋆•High deposition rates can enhance weld speedand production•Excellent mechanical properties for high-qualitycode and X-ray requirements•Improves welding operator comfort and appealAir Carbon Arc Cutting and Gouging (CAC-A)⋆⋆AC DC•Wide variety of metals•Removes discontinuities or inferior weldsS SS NiS SSALMgS SS Ni CB TiALMgS SS Ni CB TiCICB S SS AL CIPage 5
2Evaluate your needs: input power, outputpower, generator power and portability.5Light industrialProcesses•MIG (GMAW)•Flux-cored (FCAW)Comes complete with•Power cord with plug•Work cable with clamp•Running gear/bottle rack•0.8/1.0 mm drive rollMost popular accessories•Bernard™MIG gun Q2010TE3EEQMigMatic®175See literature DCM/13.0 UKManual mode allows for simple manual setting of parameters forwelding on a broad range of applications.Thermal overload protection shuts down the power source output ifthe main transformer or rectifier overheats.Industrial dual-gear-driven system features a no-tool, quick-changereversible drive roll (0.8/1.0 mm) and an easy-to-set tensionadjustment knob.Traditional tapped design and laminated inductor provide a stable,smooth arc for consistent weld quality.MIGGMAWStock Number(029015550)230 V, 50/60 HzRated Output150 A at 21 VDC,30% duty cycleIPRatingIP21SWeldingOutput Ranges30–150 A15–21 VWire FeedSpeed1.8–18 mpm(70–708 ipm)Amps Input at Rated Output230 V21Max. Open-Circuit Voltage34Wire Type and Diameter CapacitySolid steel 0.6– 0.8 mm (.023 –.030 in.)Aluminium 0.8–1.0 mm (.030–.040 in.)Flux-cored 0.6–0.8 mm (.023–.030 in.)DimensionsH: 561 mm (22.1 in.)W: 447 mm (17.6 in.)D: 769 mm (30.25 in.)NetWeight43.3 kg(95.5 lb.)Color-coded sections areidentified by a primaryprocess icon and title.For more product specifications, give the productname and literature number to your distributor,visit us on the Web at MillerWelds.com.Brief listing of most popularaccessories. Refer to pageslisted for more details.Colored bullets indicate output power classification.Power icons indicate power supplied or required (seedescriptions above). Listing of recommended processes.PageClassMIGPulsed MIGFlux-cored*ProductGuideWeldable WeldingPortability Metals Output Ranges Special Features Typical ApplicationsInstalled Steel, stainless 30–150 A, 15–21 V Thermal overload protection, fan-cooled, Light fabrication, hobby, auto body repairrunning gear Euro torch connectionSteel, stainless, 30–200 A, 15–21 V Adjustable run-in, burnback and spot timer, General fabrication, auto body repair,aluminium thermal overload protection trailer fabrication30–200 A, 15 –21 V Synergic interface for simple user setup,weld metersInstalled Steel, stainless, 30–250 A, 15– 24 V Adjustable run-in, burnback and spot timer, General fabrication, auto bodyrunning gear aluminium thermal overload protection trailer fabricationSMigMatic®175 7MigMatic®220 7MigMatic®220 DX 7MigMatic®250 7MigMatic®250 DX 7 1-Phase3Check out the Product Guides.4Go to product descriptions.(Specifications are subject to change without notice.)Unit requires single-phaseinput powerUnit requires three-phaseinput powerUnit supplies alternating currentweld outputUnit supplies direct currentweld outputUnit supplies alternating currentand direct current weld outputUnit supplies constant-currentweld outputUnit supplies constant-voltageweld outputUnit supplies constant-currentand constant-voltage weld outputPower iconsInput powerDoes your machine need to be self-powered, or will AC powerbe available at the location where it’s primarily used?•For locations where an electrical hookup is not practical,consider a diesel-powered engine-driven welder/generatorto supply welding and generator power.•For locations where AC power is available, you need toknow its type — and whether it’s a match for the machineyou’re considering:Single-phase powerCheck to see if the machine you’re considering requiressingle-phase power, and whether its voltage requirementsare met by the electrical service at the intended location.Three-phase powerCheck to see if the machine you’re considering requiresthree-phase power and whether its voltage requirementsare met by the electrical service at the intended location.Output powerLight industrial products are suitable for the hobbyist oroccasional light industrial user. They are designed to be easyto operate, are affordably priced and typically have a low dutycycle and lower-rated output.Industrial products are suitable for applications that do notrequire high-volume production. They typically have a 60 percentduty cycle and/or rated output of 300 amps. Industrial productsare an appropriate choice for professional welders.Heavy industrial products are suited to high-volumeproduction and/or welding of thicker materials. They typicallyhave a duty cycle of 60 to 100 percent and a rated output ofat least 300 amps. Heavy industrial products are designedwith the arc characteristics and product features professionalwelders demand for code-quality work.Note: Units listed in more than one classification share attributes of both.About duty cyclesDuty cycle is an indication of how long a power sourcecan continuously weld (at a specific amperage and voltage)in a 10-minute period of time before it needs to cool down.For example, a machine with a 60 percent duty cycle at300 amps and 32 volts of welding output can be used(at 300 amps and 32 volts) for 6 minutes out of a 10-minuteperiod. When comparing two similar-sized power supplies itis important to pay close attention to both the amperageand voltage values that determine the rated load.The Product Guides (at the start of each major section) brieflydescribe and compare power sources within that section.Generator powerOut in the field, you may need an engine-driven welder/generatorto supply AC power to run tools and lights, or supply 12-voltDC power to charge automotive batteries and jump-startvehicles. Miller®welder/generators are packed with power;larger units even offer option packages that add 10 to 20 kWof generator power.PortabilityCan you bring the work to the machine, or does the machineneed to go to the work? Check the Product Guide pages fortypes of portability:•Shoulder strap, handles, running gear, carts, etc.•Many engine-driven welding generators fit in the back of a truck,enabling them to be driven to wherever the welding is needed.Heavy-duty trailers are also available for engine drives.Page 6
6PageClassMIGPulsed MIGFlux-cored*ProductGuideWeldable WeldingPortability Metals Output Ranges Special Features Typical ApplicationsInstalled Steel, stainless 30–150 A, 15–21 V Thermal overload protection, fan-cooled, Light fabrication, hobby, auto body repairrunning gear Euro torch connectionSteel, stainless, 30–200 A, 15–21 V Adjustable run-in, burnback and spot timer, General fabrication, auto body repair,aluminium thermal overload protection trailer fabrication30–200 A, 15–21 V Synergic interface for simple user setup,weld metersInstalled Steel, stainless, 30–250 A, 15–24 V Adjustable run-in, burnback and spot timer, General fabrication, auto body repair,running gear aluminium thermal overload protection trailer fabricationSynergic interface for simple user setup,weld meters30–300 A, 15–28 V Industrial two-gear drive system, spot timer, General fabrication, trailer fabrication, constructiondigital meterSynergic interface for simple user setup,digital meter, run-in and burnback30–350 A, 15–32 V Industrial four-gear drive system, spot timer, General fabrication, trailer fabrication, constructiondigital meterSynergic interface for simple user setup,digital meter, run-in and burnbackMost metals 30–350 A, 15–32 V Fan-On-Demand,™dual digital meters, Structural steel, trailer manufacturing,30–450 A, 15–34 V115-volt aux power socket, step voltage control general fabricationOptional Aluminium 5–425 A, 10–38 V Profile Pulse,™lightweight feeder with Heavy industrial aluminium production/fabrication,running gear multiple gun options truck and shipbuilding15–600 A, 10–38 VMost metals 30–375 A, 10–32 V Fan-On-Demand,™dual digital meters, Structural steel, trailer manufacturing,30–575 A, 10–38 V115-volt aux power socket, tried and tested general fabrication30–825 A, 10–44 V5–425 A, 10–38 V Advanced pulse and double-pulsed inverter Heavy manufacturing and production,with simplified user interface aluminium fabrication5–425 A, 10–38 V Push/pull gun capability, optimised with Heavy manufacturing and production,74 MPa Plus wire feeder aluminium fabrication15–600 A, 10–38 VSteel, stainless 20–400 A, 10–44 V Advanced arc performance, Welding Intelligence™Mid-to-high volume manufacturing20–600 A, 10–44 VLift eye Steel, stainless 20–400 A, 10–44 V Available for EtherNet/IP,™DeviceNet and Fixed and flexible automation20–600 A, 10–44 Vanalogue protocolProduct KeyClass:Light industrialIndustrialHeavy industrial Capability:Designed for this processCapable of this processNew! or Improved! products appear in blue type. *If using self-shielded wire on a CC/CV machine, use CV weld output.See aluminium MIG solutions chart (page 10) and industrial MIG solutions chart (page 12) for additional information.MigMatic®175 7MigMatic®220 7MigMatic®220 DX 7MigMatic®250 7MigMatic®250 DX 7MigMatic®300 8MigMatic®300 DX 8MigMatic®380 8MigMatic®380 DX 8XPS 350 9XPS 450 9AlumaFeed™350 11Aluminium SystemAlumaFeed™450 11Aluminium SystemDeltaweld®402 13Deltaweld®602 13Deltaweld®852 13XMS®425 MPa 13Welding SystemInvision™352 14MPa Plus SystemInvision™450 14MPa Plus SystemContinuum™350 15Continuum™500 15Auto-Continuum™350 16Auto-Continuum™500 16 1-Phase3-PhaseAlso see Multiprocess section for machines that can MIG weld.MIGGMAWPage 7
Light industrialProcesses•MIG (GMAW)•Flux-cored (FCAW)Comes complete with•Power cord with plug•Work cable with clamp•Running gear/bottle rack•0.8/1.0 mm drive rollMost popular accessories•Bernard™MIG gun Q2010TE3EEQMigMatic®175 See literature DCM/13.0 UKManual mode allows for simple manual setting of parameters forwelding on a broad range of applications.Thermal overload protection shuts down the power source output ifthe main transformer or rectifier overheats.Industrial dual-gear-driven system features a no-tool, quick-changereversible drive roll (0.8/1.0 mm) and an easy-to-set tensionadjustment knob.Traditional tapped design and laminated inductor provide a stable,smooth arc for consistent weld quality.MIGGMAWStock Number(029015550)230 V, 50/60 HzRated Output150 A at 21 VDC,30% duty cycleIPRatingIP21SWeldingOutput Ranges30–150 A15–21 VWire FeedSpeed1.8–18 mpm(70–708 ipm)Amps Input at Rated Output230 V21Max. Open-Circuit Voltage34Wire Type and Diameter CapacitySolid steel 0.6–0.8 mm (.023–.030 in.)Aluminium 0.8–1.0 mm (.030–.040 in.)Flux-cored 0.6–0.8 mm (.023–.030 in.)DimensionsH: 561 mm (22.1 in.)W: 447 mm (17.6 in.)D: 769 mm (30.25 in.)NetWeight43.3 kg(95.5 lb.)Light industrial220/220DX250/250DXProcesses•MIG (GMAW)•Flux-cored (FCAW)Comes complete with•Power cord with plug•3 m work cable with clamp•Running gear/bottle rack•0.8/1.0 mm drive rollWeld Ready packages includeabove plus•Bernard™MIG gun Q2010TE3EEQMigMatic®220/220 DX and 250/250 DXSee literature DCM/9.0 UK (220/220 DX) and DCM/10.0 UK (250/250DX)Manual mode allows for simple manual setting ofparameters for welding on a broad range of applications.Thermal overload protection shuts down the powersource output if the main transformer or rectifieroverheats.Industrial dual-gear-driven system features no-tool,quick-change reversible drive roll (0.8/1.0 mm) andan easy-to-set tension adjustment knob.Professional wire drive motor withstands even themost demanding applications.Superior arc control technology provides the operatorwith state-of-the-art welding performance on a widevariety of materials.Traditional tapped design (10 steps) and laminatedinductor provide a stable, smooth arc for consistentweld quality.Adjustable run-in control allows the operator tooptimize arc starting with a variety of different wires.Adjustable burnback control reduces wire stubbing,arc flaring and prevents wire burnback to protectcontact tips.Spot weld timer provides consistent spot welds everytime. (Base models only.)Synergic user interface with digital display to simplifysetup and offer precise settings for welding a variety ofmaterials. (DX models only.)MigMatic 220 and 220DX shown.Model/Stock NumberMigMatic 220(029015520) 230 V, 50/60 Hz(029083116) Weld Ready packageMigMatic 220DX(029015521) 230 V, 50/60 Hz(029083117) Weld Ready packageMigMatic 250(029015524) 230/400 V, 50/60 Hz(029083115) Weld Ready packageMigMatic 250DX(029015525) 230/400 V, 50/60 Hz(029083118) Weld Ready packageRated Output220 A at 28 VDC,25% duty cycle240 A at 26 VDC,35% duty cycleIPRatingIP23SIP23SWeldingOutput Ranges30–200 A15–21 V30–250 A15–24 VWire FeedSpeed1.0–20 mpm(39–787 ipm)1.0–20 mpm(39–787 ipm)Amps Input at Rated Output230 V 400 V34 —27 16Max. Open-Circuit Voltage4043Wire Type and Diameter CapacitySolid steel 0.6–1.2 mm (.023–.047 in.)Stainless 0.8–1.0 mm (.030–.040 in.)Aluminium 0.8–1.2 mm (.030–.047 in.)Flux-cored 0.9–1.2 mm (.035–.047 in.)Solid steel 0.6–1.2 mm (.023–.047 in.)Stainless 0.8–1.0 mm (.030–.040 in.)Aluminium 0.8–1.2 mm (.030–.047 in.)Flux-cored 0.9–1.2 mm (.035–.047 in.)DimensionsH: 712 mm(28 in.)W: 480 mm(18.88 in.)D: 920 mm(36.19 in.)NetWeight66 kg(152 lb.)73 kg(161 lb.)7Page 8
IndustrialProcesses•MIG (GMAW)•Flux-cored (FCAW)Comes complete with•Power cord with plug•5 m work cable with clamp•Running gear/bottle rack•Two 0.6–0.8 mm drive rolls(300 models)Four 1.0–1.2 mm drive rolls(380 models)Weld Ready packages includeabove plus•Bernard™MIG gun Q3015TE3EEQMigMatic®300/300 DX and 380/380 DXSee literature DCM/11.0 UK (300/300 DX) and DCM/12.0 UK (380/380DX)MigMatic 380 and 380 DX shown.Model/Stock NumberMigMatic 300(029083119) 400 V, 50 Hz Weld Ready pkg(029015540) 400 V, 50 HzMigMatic 300 DX(029015541) 400 V, 50/60 Hz(029083120) 400 V, 50/60 Hz Weld Ready pkgMigMatic 380(029015547) 230/400 V, 50/60 Hz(029083121) 400 V, 50 Hz Weld Ready pkg(029015542) 400 V, 50 HzMigMatic 380 DX(029083122) 400 V, 50/60 Hz Weld Ready pkg(029015543) 400 V, 50/60 HzRatedOutput300 A at28 VDC,35% dutycycle350 A at29 VDC,35% dutycycleIPRatingIP22SIP22SWeldingOutputRanges30–300 A15–28 V30–350 A15–32 VWire Feed Speed1.3–26 mpm(51–1,024 ipm)1.3–26 mpm(51–1,024 ipm)Amps Input atRated Output230 V 400 V35 2040 23Max.Open-CircuitVoltage4343Wire Type and Diameter CapacitySolid steel 0.6–1.2 mm (.023–.047 in.)Stainless 0.8–1.0 mm (.030–.040 in.)Aluminium 0.8–1.2 mm (.030–.047 in.)Flux-cored 0.9–1.4 mm (.035–.055 in.)Solid steel 0.6–1.2 mm (.023–.047 in.)Stainless 0.8–1.0 mm (.030–.040 in.)Aluminium 0.8–1.2 mm (.030–.047 in.)Flux-cored 0.9–1.4 mm (.035–.055 in.)DimensionsH: 825 mm(32.5 in.)W: 471 mm(18.5 in.)D: 1,066 mm(42 in.)H: 825 mm(32.5 in.)W: 471 mm(18.5 in.)D: 1,066 mm(42 in.)NetWeight88 kg(194 lb.)102.6 kg(227 lb.)8MIG GMAWManual mode allows for simple manual setting ofparameters for welding on a broad range of applications.Thermal overload protection shuts down the powersource output if the main transformer or rectifieroverheats.Industrial dual-gear-driven system features no-tool,quick-change reversible drive rolls and an easy-to-settension adjustment knob.Professional wire drive motor withstands even themost demanding applications.Superior arc control technology provides the operatorwith state-of-the-art welding performance on a widevariety of materials.Traditional tapped design (20 steps) and laminatedinductor provide a stable, smooth arc for consistentweld quality.Adjustable run-in control allows the operator tooptimize arc starting with a variety of different wires.Adjustable burnback control reduces wire stubbing,arc flaring and prevents wire burnback to protectcontact tips.Spot weld timer provides consistent spot welds everytime. (Base models only.)Synergic user interface with digital display to simplifysetup and offer precise settings for welding a variety ofmaterials. (DX models only.)Page 9
IndustrialProcesses•MIG (GMAW)•Flux-cored (FCAW)Comes complete with•Industrial power cord•Work cable with clamp•Factory-installed running gearMost popular accessories•ST®-44 Series Wire Feeders (pg 20)029007406 Base model029007404 Digital model•ST®-24 Series Wire Feeders (pg 20)029007395 Base model029007397 Digital model•Cylinder Rack 058066064 (pg 63)•Cylinder/Cooler Rack 058066065(pg 63)•HydraCool®1 028042103 (pg 64)XPS Series See literature DCM/42.0 UKXPS 450 shown.ModelXPS 350XPS 450Stock Number(029015531) 400 V, 50 Hz(029015528) 400 V, 50 Hz with aux power,digital meters and Fan-On-Demand(029015535) 230/400 V, 50 Hz with aux power,digital meters and Fan-On-Demand(029015532) 400 V, 50 Hz with aux power(029015529) 400 V, 50 Hz with aux power,digital meters and Fan-On-DemandRated Output350 A at 32 VDC,45% duty cycle450 A at 37 VDC,45% duty cycleIPRatingIP22IP22WeldingOutput Ranges30–350 A15–32 V30–450 A15–34 VAmps Input at Rated Output, 50 Hz230 V 400 V— 2356 32Max. Open-Circuit Voltage3847DimensionsH: 930 mm (37 in.)W: 570 mm (22.5 in.)D: 860 mm (34 in.)Net Weight125 kg(275 lb.)153 kg(337 lb.)9Traditional tapped transformer power source.Simple and precise with 30 voltage steps (XPS 350) or40 voltage steps (XPS 450). Provides the operator witha superior range and arc performance for even the mostdemanding applications.Two inductance terminals and laminated inductorprovides a stable, smooth arc operators appreciate.Standard 14-pin connection to Miller wire feed unitsconnects to a variety of Miller wire feeders.Thermal overload protection shuts down the power sourceoutput if the main transformer or rectifier overheats.Optional 115-volt auxiliary power receptacles.Auxiliary power for water-cooling unit.Optional Fan-On-Demand™cooling system operates onlywhen needed, reducing noise, energy use and amount ofcontaminants pulled through machine.Optional dual digital meters with hold function displayclear, precise readings of arc voltage and amperage.MIGGMAWPage 10
Choose the Right Industrial Aluminium MIG SolutionFor additional aluminium MIG solutions see push-pull guns and controls on pages 26–27.Power SourceFeederInput VoltageRated OutputPrimary ConnectionAluminium Wire DiametersGun CapabilityMIG ModesProfile Pulse™Synergic Pulsed MIGMIGFeaturesBuilt-In Pulsed ProgramsPortabilityTrigger HoldTrigger Schedule SelectProgram LocksFlow MeterAlumaPower™350 MPa or 450 MPaSingle-wire XR-AlumaFeed — portable feeder can be carriedup to 30.5 meters from power sourceThree-phase350 MPa: 350 A at 60% duty cycle450 MPa: 450 A at 100% duty cycle350 MPa: Auto-Line™— Allows for any primary inputvoltage (230–575 V, three-phase, 50 or 60 Hz) with nomanual linking. Also adjusts for voltage spikes within theentire range.450 MPa: 400 V only, 50 or 60 Hz0.9–1.6 mm (.035–1/16 in.)XR-Aluma-Pro™or XR™-PistolYes — achieve a “stacked dime” appearance quickly andeasily without gun manipulationYes — “one-knob” control, only need to change wire feedspeed to weld different material thicknessesSpray transfer MIG — for aluminium wiresAluminiumLightweight, portable feeder with handle — can be carriedup to 30.5 meters from power sourceYes — reduces operator fatigue from holding triggerYes — allows operator to switch between two preset weldconditions by tapping the triggerYes — prevents unintended changes to the welding programweld parametersYes — allows flow to be set at feeder even when gas supplyis a long distance awayInvision 352 MPa or 450 MPaSingle- or dual-wire 74 MPa Plus — stationary feeders canbe mounted up to 30.5 meters from power sourceThree-phase352 MPa: 350 A at 60% duty cycle450 MPa: 450 A at 100% duty cycle352 MPa: Auto-Line™— Allows for any primary inputvoltage (230–575 V, three-phase, 50 or 60 Hz) with nomanual linking. Also adjusts for voltage spikes within theentire range.450 MPa: 400 V only, 50 or 60 Hz0.9–1.6 mm (.035–1/16 in.)XR-Aluma-Pro™Plus, XR™-Pistol Plus or standard MIG gunYes — achieve a “stacked dime” appearance quickly andeasily without gun manipulationYes — “one-knob” control, only need to change wire feedspeed to weld different material thicknessesConventional MIG — modes for aluminium, steel andother wiresAluminium, steel, stainless and othersStationary feeder — can be mounted up to 30.5 metersfrom power sourceYes — reduces operator fatigue from holding triggerYes — allows operator to switch between two preset weldconditions by tapping the triggerYes — prevents unintended changes to the welding programweld parameters—AlumaFeed®Synergic AluminiumWelding System(page 11)Invision™MPa Plus System(page 14)AlumaPower 450 MPa and XR-AlumaFeedwith XR-Aluma-Pro gun shown.Invision 352 MPa and D-74 MPa Plus feeder withXR-Aluma-Pro and Bernard BTB Gun 400 A guns shown.Dedicated heavy-industrial-fabrication solution foraluminium welding, with advanced features that can handlelarger weldments. Its lightweight push-pull feeder caneasily be carried up to 30.5 meters from the power source.Versatile, heavy-industrial advanced system for large,high-duty-cycle aluminium and steel weldments. Featurespush and/or push-pull bench feeder for easy switchoverbetween solid, aluminium and tubular wires.10MIG GMAWPage 11
Note: All systems come set up out of the box to run 1.2 mm wire. 1.6 mm consumables not included — order separately above.See aluminium solutions comparison chart on page 10.ModelAlumaPower 350 MPa(907420003)230–575 Vwith auxiliary powerAlumaPower 450 MPa(907526) 400 Vwith auxiliary powerXR-AlumaFeedWire Feeder14-pin compliant, butonly operates synergicallyw/MPa power sourcesWire Feed Speed1.3–22.9 mpm(50–900 ipm)Input Welding Circuit Rating400 A at 100% duty cycleSystem duty cycle is limitedto gun ratingInput Power24 VAC,5 A,50/60 HzMaximum Spool Size Capacity305 mm (12 in.)Wire Diameter Capacity0.9–1.6 mm (.035–1/16 in.)Requires wire kit (230708) for gun and drive roll kit(195591) for control box to run 1.6 mm (1/16 in.) wireDimensionsH: 406 mm (16 in.)W: 241 mm (9.5 in.)D: 540 mm (21.25 in.)Net Weight19.2 kg(42.5 lb.)WeldingOutput Ranges5–425 A10–38 V15–600 A10–38 VAmps Input at Rated Load Output, 60 Hz230 V 400 V 460 V 575 V36.1 20.6 17.8 14.1— 29.8 — —KW13.618.3KVA14.221.6Rated Output350 A at 34 VDC,60% duty cycle450 A at 36.5 VDC,100% duty cycleIPRatingIP23IP23DimensionsH: 432 mm (17 in.)W: 318 mm (12.5 in.)D: 610 mm (24 in.)H: 438 mm (17.25 in.)W: 368 mm (14.5 in.)D: 689 mm (27.125 in.)Max. Open-Circuit Voltage75 VDC90 VDCNet Weight36.3 kg(80 lb.)55.3 kg(122 lb.)Heavy industrialProcesses•Aluminium MIG (GMAW)•Aluminium pulsed MIG (GMAW-P)AlumaFeed System consists ofthe following (sold separately)•AlumaPower 350 MPa power source(907420003) OR 450 MPa powersource (907526)•XR-AlumaFeed feeder•XR-Aluma-Pro™OR XR™-Pistol Grippush-pull MIG gun•Coolmate™3 cooling system withcoolant (water-cooled systems only)•Universal trolleyMost popular accessories•XR™Push-Pull Guns (pg 26)•Universal Trolley 018035028 (pg 63)•MIG Kit for Universal Trolley058066129 (pg 63)•Coolmate™3 Mounting Brackets forUniversal Trolley 028066301 (pg 63)•Coolmate™3 043007 (pg 64)•Coolant 043810 (pg 64)•Extension Cables (pg 66)247831025 7.6 m (25 ft.)247831050 15 m (50 ft.)247831080 24.4 m (80 ft.)•1.6 mm (1/16 in.) Liner andWire Kit for Gun 230708•1.6 mm (1/16 in.) Drive Roll Kit forControl Box 195591AlumaFeed®Synergic Aluminium Welding SystemSee literature DC/34.0Dedicated aluminium system for the most advanced MIG and synergic pulsed MIG performance.11MIGGMAWALUMINIUMAlumaPower 350 MPa and XR-AlumaFeed withXR-Aluma-Pro gun air-cooled system shown.AlumaPower™350 model allowsfor any input voltage hookup(230–575 V, three-phase) with no manual linking,providing convenience in any job setting. Ideal solutionfor dirty or unreliable power. 450 model is 400 V only,three-phase.Built-in MIG and pulsed MIG programs automaticallyset the optimal parameters for a wide variety of wiresmaking it easy to set up and use.Synergic pulsed MIG. As wire speed increases/decreases,pulse parameters also increase/decrease to match theright amount of power needed, eliminating the need tomake additional adjustments.Synchronized, true push-pull wire feed system forprecise wire feeding and arc performance.Profile Pulse™provides TIGappearance with MIG simplicityand productivity. Achieve“stacked dimes” without gunmanipulation. Profile Pulse frequency can be changedto increase or decrease the spacing between the ripplepattern to achieve the desired weld appearance.Parameter and system locks enhance quality assuranceand protect weld consistency.Trigger schedule select allows operator to changebetween two sets of weld parameters.Fan-On-Demand™cooling system operates only whenneeded, reducing noise, energy use and amount ofcontaminants pulled through machine.Page 12
•Simple and easy to use•Digital meters on powersource provide accurateweld parameter indication•74D feeder adds voltagecontrol and digital meterson feeder for point-of-usecontrolSteels•Short arc•Spray—Optional Insight Core™380/400/440 V, 3-phase402: 0.6–1.6 mm602: 0.6–2.0 mm852: 0.8–2.4 mmYes•Multiprocess power source•Synergic pulsed anddouble-pulsed programs•USB functionality forincreased ease ofadding/saving weld programs•Integrated water cooler(optional)Steels and aluminium•Short arc•Spray•Pulsed MIG——Auto-Line™230–575 V,3-phase0.6–1.8 mmYes•More advanced system withoptimized weld programsfor steel and aluminium•Push-pull gun for aluminium(optional)Steels and aluminium•Short arc•Spray•Pulsed MIG•Profile Pulse™— providesTIG appearance with MIGproductivityDedicated aluminium modelsavailable (see AlumaFeed®System, page 11)Optional Insight Core™352: Auto-Line™230–575 V,3-phase450: 400 V, 3-phase352: 0.6–1.6 mm452: 0.6–2.0 mmYes•Next generation advancedwelding solution•Improves productivity throughweld quality, ease of use andsystem flexibilitySteels•Short arc•Accu-Pulse®— most popularfor full range of materialthicknesses•Versa-Pulse™— fast, low-heat,low-spatter for thin material;ideal for automation•RMD®— designed to fill gaps,and for thin material•High-deposition MIG —increased deposition rateson thicker materialsSemi-auto and automationpackages available(see pages 15 and 16)Standard Insight Core™and optionalInsight Centerpoint™Auto-Line™230–575 V,3-phase0.9–2.0 mmYesWeldableMetalsMIG ProcessesSpecial ModelsWeldingIntelligence™(see page 53)Input PowerRecommendedWire DiametersBernard™GunIncludedwith FeederDeltaweld®with74S/D Feeder(page 13)XMS®425 MPa withXMS®MPa Feeder(page 13)Invision™with74 MPa Plus Feeder(page 14)Continuum™System(page 15)BasicFeature Advanced MIGChoose the Right Industrial MIG SolutionMIG GMAW12Page 13
Model/Stock NumberXMS 425 MPa(029015507) 230–575 V, 50/60 Hz(029083123) Weld Ready packageXMS MPa Wire Feeder(029007427)Wire Feed Speed1.27–25.4 mpm(50–1,000 ipm)Input Power24 VAC, 7 A, 50/60 HzIP RatingIP23SMaximum Spool Size Capacity305 mm (12 in.)15 kg (33 lb.)Wire Diameter Capacity0.6–1.8 mm(.023–.068/.072 in.)DimensionsH: 425 mm (16.7 in.)W: 235 mm (9.3 in.)D: 700 mm (27.6 in.)Net Weight18 kg(40 lb.)WeldingOutput Ranges5–425 A10–38 VIP RatingIP23SAmps Input at Rated Load Output, 50/60 Hz230 V 400 V 460 V 575 V KVA KW36.1 20.6 17.8 14.1 14.2 13.6Rated Output350 A at 34 VDC,60% duty cycleDimensionsH: 597 mm (23.5 in.)W: 349 mm (13.7 in.)D: 560 mm (22 in.)Max. Open-Circuit Voltage75 VDCNet Weight52.5 kg(116 lb.)Industrial 402 modelHeavy industrial 602/852 modelsProcesses•MIG (GMAW)•Flux-cored (FCAW)•Air carbon arc gouging (CAC-A)(Deltaweld 452: 6 mm carbons)(Deltaweld 652: 10 mm carbons)Most popular accessories•70 Series Feeders (pg 20)•Standard Running Gear 042886(pg 63)•Standard Cylinder Rack 042887(pg 63)•Extension Cables (pg 66)242208025 7.6 m (25 ft.)242208050 15 m (50 ft.)242208080 24.4 m (80 ft.)Deltaweld®Series See literature DC/16.2Industry standard for heavy-industrial MIG welding. Designed for manufacturing operations,with 100 percent duty cycle for extended arc-on time.Line voltage compensation ensures consistent weld performanceeven when primary power varies.Fan-On-Demand™cooling system operates only when needed.Reduces contaminants drawn into the machine and excess noisein work areas.Digital meters are easy to read and display preset and actualvoltage and amperage.Remote control capability allows operators fine tuning capabilityat an extended distance.115-volt power for tools and coolant systems.Thermal overload protection light indicates power shutdown.Helps prevent machine damage if the duty cycle is exceeded orairflow is blocked.Material specific output studs provide the flexibility to producethe optimal arc characteristics for aluminium, stainless steel andall other materials.Model/Stock NumberDeltaweld 402(907357) 380/400/440 V, 50/60 HzDeltaweld 602(907358) 380/400/440 V, 50/60 HzDeltaweld 852(907359) 380/400/440 V, 50/60 HzRated Output300 A at 32 VDC,100% duty cycle450 A at 38 VDC,100% duty cycle650 A at 44 VDC,100% duty cycleIPRatingIP21IP21IP21WeldingOutput Ranges30–375 A10–32 V30–575 A10–38 V30–825 A10–44 VMax. Open-Circuit Voltage42 VDC48 VDC54 VDCAmps Input at Rated Output, 50/60 Hz380 V 400 V 440 V KVA KW27 25 23 16.9 12.939 37 33 25.1 21.158 54 50 38.2 34.2Dimensions(Includes lift eye and strain relief)H: 762 mm (30 in.)W: 585 mm (23 in.)402 D: 775 mm (30.5 in.)602/852 D: 966 mm (38 in.)Net Weight147 kg (323 lb.)174 kg (384 lb.)214 kg (472 lb.)IndustrialProcesses•Double-pulsed MIG (GMAW-DP)•Pulsed MIG (GMAW-P)•MIG (GMAW)•Flux-cored (FCAW)•Lift-Arc™TIG (GTAW)•Stick (SMAW)Power sourcecomes complete with•Industrial power cord•Work cable with clampWeld Ready package includesabove plus•XMS MPa wire feeder w/feeder swivel•Bernard™water-cooled torch•XMS MPa cooler with coolant•Universal trolley with handle kitMost popular accessories•Universal Trolley 018035028 (pg 63)•Handle Kit for Universal Trolley058066130 (pg 63)•XMS MPa Cooler 028042109•Coolant 043810 (pg 64)•Feeder Swivel 028066300•Interconnecting Cable Assembly(Water-Cooled) (pg 66)•Bernard™air-cooled MIG gunQ4015TE3EEQ•Bernard™water-cooled MIG gunE4215-45-5-445-QXMS®425 MPa Synergic Welding SystemSee literature DCM/17.5XMS 425 MPa Weld Ready water-cooled package shownincludes power source, feeder, cooler, trolley, feeder swivel,handle kit and Bernard™E 4215 MIG torch.Enhanced double-pulsed and pulsed MIG capabilitiesreduce spatter and distortion, improve bead shape andprovide better out-of-position weld puddle control.Simple user interface reduces the number of controlsetup combinations for all processes and programs(including double-pulsed and pulsed MIG capabilities)without minimizing features or welding performance.Large, dual digital meters are easily preset to thedesired weld output, and provide easy-to-view currentand voltage measurements during welding to ensureoptimal control of the weld bead.Integrated water-cooling system provides efficientcooling with low-flow shutdown for both MIG and TIGapplications.Inverter arc control technology provides class-leadingwelding performance on a variety of material, whileline voltage compensation (LVC™) maintains constantpower even when primary power input varies from+/- 10 percent.Multiprocess power source. MIG, synergic MIG,synergic pulsed and double-pulsed MIG, Lift-Arc™TIGand stick processes.13Deltaweld 602 shown with optional S-74D wire feeder andstandard running gear with cylinder rack.MIGGMAWPage 14
Heavy industrialProcesses•MIG (GMAW)•Flux-cored (FCAW)•Pulsed MIG (GMAW-P)•Air carbon arc gouging (CAC-A)(Invision 352: 6 mm carbons)(Invision 450: 8 mm carbons)Invision MPa System consists ofthe following (sold separately)•Invision 352 MPa power source(907431002) OR 450 MPa powersource (907524)•70 Series MPa Plus feeder•XR-Aluma-Pro™Plus OR XR™-Pistol Pluspush-pull MIG gun•Coolmate™3 cooling system withcoolant (water-cooled systems only)•Universal trolleyMost popular accessories•XR™Push-Pull Guns (pg 26)•Universal Trolley 018035028 (pg 63)•MIG Kit for Universal Trolley058066129 (pg 63)•Coolmate™3 Mounting Brackets forUniversal Trolley 028066301 (pg 63)•Coolmate™3 043007 (pg 64)•Coolant 043810 (pg 64)•Extension Cables (pg 66)247831025 7.6 m (25 ft.)247831050 15 m (50 ft.)247831080 24.4 m (80 ft.)•1.6 mm (1/16 in.) Liner andWire Kit for Gun 230708Invision™MPa Plus System See literature DC/23.6Invision 352 MPa with S-74 MPa Plus feeder shown.Note: See aluminium solutions comparison chart on page 10.Max. Open-Circuit Voltage75 VDC90 VDCKW13.618.3KVA14.221.6ModelInvision 352 MPa(907431002) 230–575 Vwith auxiliary powerInvision 450 MPa(907524) 400 Vwith auxiliary powerWeldingOutput Ranges5–425 A10–38 V15–600 A10–38 VAmps Input at Rated Load Output, 60 Hz230 V 400 V 460 V 575 V36.1 20.6 17.8 14.1— 29.8 — —DimensionsH: 432 mm (17 in.)W: 318 mm (12.5 in.)D: 610 mm (24 in.)H: 438 mm (17.25 in.)W: 368 mm (14.5 in.)D: 689 mm (27.125 in.)Net Weight36.3 kg(80 lb.)55.3 kg(122 lb.)Rated Output350 A at 34 VDC,60% duty cycle450 A at 36.5 VDC,100% duty cycleIP RatingIP23IP23Recommended Aluminium SolutionDedicated XR Plus guns work with MPaPlus feeders to coordinate wire feedspeed of the gun and the feeder. Thisprovides optimized aluminium feedingand welding performance. See page 26for stock numbers.14Invision 352 model allows for anyinput voltage hookup (230–575 V,three-phase) with no manual linking, providingconvenience in any job setting. Ideal solution for dirtyor unreliable power. 450 model is 400 V, three-phase.Built-in MIG and pulsed MIG programs auto maticallyset the optimal parameters for a wide variety of wiresmaking it easy to set up and use.Synergic pulsed MIG. As wire speed increases/decreases, pulse parameters also increase/decreaseto match the right amount of power needed,eliminating the need to make additional adjustments.Profile Pulse™provides TIGappearance with MIG simplicityand productivity. Achieve“stacked dimes” without gunmanipulation. Profile Pulse frequency can be changed toincrease or decrease the spacing between the ripplepattern to achieve the desired weld appearance.Easy to set up. Select wire diameter, wire type and gasbeing used, set your wire speed and strike an arc.Wind Tunnel Technology.™Air flow that protects internalcomponents, greatly improving reliability.Fan-On-Demand™cooling system operates only whenneeded, reducing noise, energy use and amount ofcontaminants pulled through machine.MIG and synergic pulsed MIG system with optimized weld programs for both steel and aluminium.MIG GMAWPage 15
Heavy industrialProcesses•Accu-Pulse®MIG (GMAW-P)•Versa-Pulse™•RMD®•MIG (GMAW)•High-deposition MIG (GMAW)•Flux-cored (FCAW)•Air carbon arc gouging (CAC-A)Weld Ready package includesthe following•Continuum power source•Continuum single-wire feeder•Bernard™water-cooled torch•Continuum cooler with coolant•Universal trolleyMost popular accessories•Bernard™MIG Guns (pg 23/24)•Bernard™water-cooled torchE4215-45-5-445-Q•Insight Centerpoint™Software (pg 55)•Continuum Running Gear/CylinderRack 301264 (pg 63)•Universal Trolley 018035028 (pg 63)•Continuum Integrated Cooler 301214Mounts to bottom of Continuumpower source. Does not requireexternal power.•Coolant 043810 (pg 64)•Continuum Control/Motor Cables263368003 0.9 m (3 ft.)263368015 4.6 m (15 ft.)263368020 6.1 m (20 ft.)263368025 7.6 m (25 ft.)263368050 15 m (50 ft.)263368080 24.4 m (80 ft.)263368100 30.5 m (100 ft.)Continuum™Systems See literature DCM/41.0 UKNext generation of advanced industrial welding solutions improves productivity throughweld quality, ease of use and system flexibility.15Max. Open-Circuit Voltage75 VDC75 VDCModel/Stock NumberContinuum 350(907645) 230–575 V(029083124) Weld Ready packageContinuum 500(907648) 230–575 V(029083125) Weld Ready packageWeldingOutput Ranges20–400 A10–44 V20–600 A10–44 VRated Output350 A at 31.5 VDC,100% duty cycle500 A at 39 VDC,100% duty cycleIP RatingIP23IP23Amps Input at Rated Output, 50/60 Hz, 3-Phase230 V 380 V 400 V 460 V 575 V KVA KW36.7 21.8 20.8 18.8 14.6 14.4 13.80–1* 0–1* 0–1* 0–1* 0–1* 0.8* 0.17*58.7 34.9 33.2 28.9 23.3 23.1 21.90–1* 0–1* 0–1* 0–1* 0–1* 0.8* 0.17*Dimensions(Includes lift eye)H: 691 mm (27.187 in.)W: 444 mm (17.5 in.)D: 714 mm (28.125 in.)Net Weight57.6 kg(127 lb.)67.1 kg(148 lb.)Maximum SpoolSize Capacity457 mm (18 in.),27 kg (60 lb.)Continuum Feeder(301195010) Single-wire model(301199010) Dual-wire modelInputPower50 VDCInput WeldingCircuit Rating500 A at100% duty cycleIP RatingIP23Wire Feed SpeedStandard:1.3–25.4 mpm(50–1,000 ipm)Wire Diameter Capacity0.9–2.0 mm(.035–5/64 in.)DimensionsH: 351 mm (13.812 in.)Single W: 414 mm (16.312 in.)Dual W: 432 mm (17 in.)D: 754 mm (29.687 in.)Net WeightSingle 19.5 kg (43 lb.)Dual 27.9 kg (61.5 lb.)Continuum 350 shown with Continuum single-wire feeder,Bernard BTB Gun 400 A and Continuum running gear/cylinderrack. Filler metal sold separately.More power — better reliabilityUp to 26 percent more welding output(than competitive models) for demandingindustrial applications.Power source designSmart and powerful digital design has the fastresponse needed to deliver the most stablewelding performance for better welding results.Flexible to meet current and future needs withintegrated expansion capabilities.Welding Intelligence.™Increase productivity,improve quality and manage costs with InsightCore™(standard) and Insight Centerpoint™(optional) welding information managementsystems (see pages 54 and 55).Feeder designTru-Feed™technology provides precise feedingoperation for stable arc performance.•Low-inertia motor provides faster responsefor the best arc starts with the least amountof spatter•Balanced-pressure drive-roll design andtensioners feed wire in its truest and straightestform for consistent feedability, resulting in betterwelding performanceNew user interface makes the system easy toset up and adjust with minimal training.Note: As the technological advances offered by Continuum extend beyond the capability of Axcess® systems, the two systems are not compatible.Continuum systems are designed to allow future upgradability, to expand with your operation’s needs.*While idling.Best ForDepositionGap FilingLow Heat InputOut-of-Position WeldsLow SpatterThick MetalsThin MetalsIncreased Travel SpeedStandardSprayADDAAAHigh-DepositionMIGADCAAAAccu-PulseABBAAABAVersa-PulseBBABBCAAShort CircuitDAABCDABRMDDAABBDACRatings A, B, C, and D are relative values.An “A” rating indicates a best fit betweenyour performance needs and process.A “blank” rating indicates that the processis not recommended for that application.Accu-Pulse is the most popular process formajority of industrial welding applications.Versa-Pulse is a fast, low-heat, low-spatterprocess designed for thin-material applications.RMD is a low-heat modified short-circuitprocess designed to fill gaps withthin-material applications.High-deposition MIG provides increaseddeposition rates over standard spray onthicker materials.COLDHOTContinuum ProcessesMIGGMAWPage 16
Visit Tregaskiss.com to configure a robotic gun for your welding application today.Maximizing throughput. Minimizing costs.Automated welding applications require flexible, repeatable solutions thatmaximize production uptime and throughput while minimizing costs.This is why industrial manufacturers rely on Tregaskiss and its proventrack record of delivering reliable and resilient robotic MIG welding gunsand peripherals. See page 25 for more information.Heavy industrialProcesses•Accu-Pulse®MIG (GMAW-P)•Versa-Pulse™•RMD®•MIG (GMAW)•High-deposition MIG (GMAW)•Flux-cored (FCAW)Most popular accessories•Insight Centerpoint™Software (pg 55)•Wire Drive Motor Mounting Brackets301276 ABB®1600301277 ABB®2600300483 FANUC®100 and 120 IC300013 FANUC®/KUKA®/Motoman®301282 KUKA®KR5 HW301275 KUKA®KR16 HW300375 Motoman®EA1400300376 Motoman®EA1900•Motor Control Cables263368025 7.6 m (25 ft.)263368050 15 m (50 ft.)263368080 24.4 m (80 ft.)263368100 30.5 m (100 ft.)•EtherNet/IP™Communication Cables300734 3 m (9.8 ft.)300735 5 m (16.4 ft.)300736 10 m (32.8 ft.)•DeviceNet Communication Cables300020 2.7 m (9 ft.)300021 6.1 m (20 ft.)•DeviceNet to Analog Adapter 301427Adapts DeviceNet to analogcommunication.Auto-Continuum™Systems See literature AUM/90.0 UKNext generation automation welding solution delivers advanced arc performance to improvethroughput and weld quality.Max. Open-Circuit Voltage75 VDC75 VDCModelAuto-Continuum 350Auto-Continuum 500Stock Number(907660) EtherNet/IP™(907660001) DeviceNet(907661) EtherNet/IP™(907660001) DeviceNetWeldingOutput Ranges20–400 A10–44 V20–600 A10–44 VRated Output350 A at 31.5 VDC,100% duty cycle500 A at 39 VDC,100% duty cycleIPRatingIP23IP23Amps Input at Rated Output, 50/60 Hz, 3-Phase230 V 380 V 400 V 460 V 575 V KVA KW36.7 21.8 20.8 18.8 14.6 14.4 13.80–1* 0–1* 0–1* 0–1* 0–1* 0.8* 0.17*58.7 34.9 33.2 28.9 23.3 23.1 21.90–1* 0–1* 0–1* 0–1* 0–1* 0.8* 0.17*Dimensions(Includes lift eye)H: 691 mm (27.187 in.)W: 444 mm (17.5 in.)D: 717 mm (28.22 in.)Net Weight59.4 kg(130 lb.)69 kg(150 lb.)Auto-Continuum Wire Drive Motor Assembly(301207) Left-hand drive(301208) Right-hand driveInput Power50 VDCInput Welding Circuit Rating500 A at 100% duty cycleIP RatingIP23Wire Feed SpeedStandard:1.3–25.4 mpm(50–1,000 ipm)Wire Diameter Capacity0.9–2.0 mm(.035–5/64 in.)DimensionsH: 222 mm (8.75 in.)W: 254 mm (10 in.)D: 254 mm (10 in.)Net Weight7.5 kg (16.5 lb.)Auto-Continuum500 shown withrobot arm (notincluded) andAuto-Continuumwire drive motorassembly.More power — better reliability. Up to 26 percentmore welding output (than competitive models) fordemanding industrial applications.Improve work environment and reduce spatter.Versa-Pulse and Accu-Pulse processes reduce fumegeneration, and by precisely controlling the weldingarc they also reduce spatter size and quantity. Fumegeneration can be reduced up to 50 percent overtraditional CV MIG.•Versa-Pulse is a fast, low-heat, low-spatter processfor high-speed automation on thin materials and isgreat for gap filling•Accu-Pulse is better for out-of-position welds,provides higher deposition rates and is designedfor thicker materials than Versa-PulseEasy communication from robot to power source.Designed for easy integration with fixed andflexible automation.Fleet standardization. Auto-Continuum can be usedfor both automation and hand-held applications.Welding Intelligence.™Increase productivity, improvequality and manage costs.•Insight Core™(standard) is a simplified, Internet-based welding information solution that reportscell productivity and weld parameter verification(see page 54)•Insight Centerpoint™(optional) is an advanced,real-time feedback solution to ensure consistentweld quality and actively detects a bad weld whenit happens, reducing rework costs and improvingquality (see page 55)Note: As the technological advances offered by Auto-Continuum extendbeyond the capability of Axcess® systems, the two systems are notcompatible. Continuum systems are designed to allow future upgradability,to expand with your operation’s needs.*While idling.Closeup of Auto-Continuumwire drive motor assembly(left-hand drive).16MIG GMAWPage 17
17ProductGuidePortableBenchSuitCase®X-TREME™188VS/12VSArcReach®SuitCase®188/12SuitCase®12RC 18I-24A/ST®-24 Series 20ST®-44 Series 2070 Series S/D — 20Singles and Duals70 Series MPa Plus — 20Singles and Duals70 Series 22Remote Configurations —Singles and DualsWire TypesFlux-cored Flux-coredDual-shld Self-shldHardAlum. CC/CVCC/CVCVCVCVCVCVCV CV** CV** ***Wire Diameter Capacity Special Features Typical Applications0.6–2.0 mm (.023–5/64 in.) 203 mm (8VS model) or 305 mm (12VS model) Construction, site fabrication,diameter spool capacity, lightweight, powered by field maintenancearc voltage0.6–2.0 mm (.023–5/64 in.) 203 mm (8 model) or 305 mm (12 model) Construction, site fabrication,diameter spool capacity, powered by arc voltage, field maintenanceremote voltage control without a control cord0.6–2.0 mm (.023–5/64 in.) Standard remote voltage control, powered by Field maintenance,14-pin control cord, 305 mm diameter site fabricationspool capacity0.6–2.0 mm (.023–5/64 in.) Adjustable run-in and burnback, optional meters, Heavy and light manufacturing,remote voltage control and coolant fittings fabricationfor ST-240.6–2.0 mm (.023–5/64 in.) Adjustable run-in and burnback, optional meters, Heavy and light manufacturing,remote voltage control and coolant fittings fabrication0.6–3.2 mm (.023–1/8 in.) Four drive roll, remote voltage control Heavy and light manufacturing,Low-speed motor recommended (optional field kit for “S” model, standard fabricationfor 2.4 mm and 3.2 mm wires on “D” model)0.6–2.0 mm (.023–5/64 in.) XR-Aluma-Pro™Plus or XR™-Pistol Plus guns for Manufacturing requiringfeeding soft wires multiple wire types0.6–2.0 mm (.023–5/64 in.) Control box, cables and wire drive motor Heavy and light manufacturing,assemblies for generic booms or fabricationfixed automationPageClassMIGPulsed MIG*Flux-cored**PortablePower SourceRequiredProduct KeyClass:Light industrialIndustrialHeavy industrial Capability:Designed for this processCapable of this processNew! or Improved! products appear in blue type.*Requires MPa inverter power source. **Certain self-shielded wires require CV output. Miller recommends a CV power source whenever possible.***74S and 74D models are capable of aluminium welding and 74 MPa Plus models are designed for aluminium welding.Also see MIG, MIG Guns and Multiprocess sections for wire feeding options.Wire FeedersPage 18
Portable SuitCase feeders that setthe standard for performance andprovide extreme reliability to standup to the demands of constructionand fabrication.Models include male Tweco®connector installed on weld cableand reversible dual size (1.2 and 1.6 mm) VK drive rolls.SuitCase 12RC/12RC EuroSuitCaseX-TREME 12VSArcReachSuitCase 12SuitCase®SeriesPortable FeedersX-TREME ArcReachFeature 8VS 12VS 8 12 12RCRemote voltage control(control cable required)Remote voltage controlwithout a cordDigital meters Impact-resistant case Gas purge Wire jog StandardOptionalSuitCase Series FeaturesSuitCase X-TREME 8VSshown with optional metersPORTABLE!Setting the standard for performanceHeavy-duty drive motor with tachometer control provides wire feed speedthat is accurate and consistent from the start of the weld to the finish andfrom one weld to the next. Consistent wire feed speed is very important withlarge-diameter cored wire, because small changes in wire feed speed makelarge changes in deposition rates.Front panel has trigger hold, wire jog, and gas purge for easy operatoraccess (except 12RC).Wide voltage range for small and large wires with no contactor chatter orarc outages.Ultra-low drag inlet guide pins make loadingthe wire easy and does not deform the wireon the way into the drive rolls improving wirefeeding performance.Scaled wire pressure knob provides easyadjustment and consistent pressure on thedrive rolls and wire.Digital meters with SunVision™technologycan display voltage, wire feed speed, and alsoamperage if desired. Meters can be seen clearlyeven in direct sunlight (optional on 8VS).Unique and durable caseImpact-resistant, flame-retardant case provides strength and durability,and protects components and welding wire from moisture, dust andother contaminants.Built-in slide rails allow you to drag the feeder into position for welding.Innovative feeder door design allows you to change wire while feeder isstanding upright or laying down.Case is available in two sizes (except 12RC).Extreme reliabilityPotted and trayed main printed circuit board for the harshest environmentsadds exceptional reliability. Board has full-trigger isolation so a shorted guntrigger will not affect feeder operation.Gun locking tab works with guns and Euro-adapterhaving corresponding locking grooves to preventgun from being pulled out if the feeder is draggedby the gun.Gas inlet recessed into back of case isprotected from incidental contact by the weldcable, ensuring consistent and contaminant-freeshielding gas delivery to the gun. Double-filteredgas valve helps keep dirt from clogging andaffecting gas flow.Wire Feeders PORTABLE18Page 19
Increase ProductivityNo time-consuming trips to the power source.Improve Weld QualityReduces costly “work arounds”.Improve Worker SafetyReduces operator hazards and injuries.Maximize EfficiencyReduces costly cord set up, maintenanceand repair.Learn more at MillerWelds.com/arcreachExclusive Miller®technology uses the weld cables tocommunicate changes in voltage settings. With anArcReach system, voltage and wire-feed-speed controlsare conveniently located at the operator’s fingertips —right at the point of use — not back at the power source.By eliminating control cables to the feeder, cabling isstreamlined and operators work at maximum efficiency.Increase, improveand maximizeSuitCase®12RC See literature WFM/60.0 UKStandard remote voltage control with a control cord. For applications where the feeder is within30.5 meters of the power source and control cords are acceptable.SuitCase®X-TREME™8VS and 12VS See literature M/6.42Voltage-sensing feeders designed to run off of arc voltage from almost any welding powersource. 8VS model is sized for a 203 mm spool of wire, can be carried to remote welding sitesand fits through a 356 mm manhole/manway. 12VS model is sized for an 203 or 305 mm spoolof wire. 305 mm spools are the most common in structural steel and fabrication.ArcReach®SuitCase®8 and 12 See literature M/6.55Remote control of the power source without a cord. With a SuitCase ArcReachfeeder and ArcReach power source you can change output voltage at the feeder, and save a tripto the power supply. No extra control cable to purchase, maintain, string or unstring — saving timeand money.Input PowerOperates onopen-circuit voltageand arc voltage:14–48 VDC /110 max. OCVOperates onopen-circuit voltageand arc voltage:14–48 VDC /110 max. OCV24 VAC, 10 A,50/60 HzInput WeldingCircuit Rating330 A at60% duty cycle425 A at60% duty cycle330 A at60% duty cycle425 A at60% duty cycle425 A at60% duty cycleIP RatingIP23IP23IP23IP23IP23Model/Stock NumberSuitCase X-TREME 8VS(300877)SuitCase X-TREME 12VS(300876)ArcReach SuitCase 8(301456)ArcReach SuitCase 12(301457)SuitCase 12RC(301121)(301121E) w/Euro gun connectionWire Type and Diameter CapacitySolid wire 0.6–1.4 mm (.023–.052 in.)Flux-cored 0.8–2.0 mm (.030–5/64 in.)Solid wire 0.6–1.4 mm (.023–.052 in.)Flux-cored 0.8–2.0 mm (.030–5/64 in.)Solid wire 0.6–1.4 mm (.023–.052 in.)Flux-cored 0.8–2.0 mm (.030–5/64 in.)Solid wire 0.6–1.4 mm (.023–.052 in.)Flux-cored 0.8–2.0 mm (.030–5/64 in.)Solid wire 0.6–1.4 mm (.023–.052 in.)Flux-cored 0.8–2.0 mm (.030–5/64 in.)Wire Feed Speed1.3–19.8 mpm(50–780 ipm)Actual range inCC mode isdependent on arcvoltage applied1.3–19.8 mpm(50–780 ipm)Actual range inCC mode isdependent on arcvoltage applied1.3–17.8 mpm(50–700 ipm)Maximum SpoolSize Capacity203 mm (8 in.),6.4 kg (14 lb.)305 mm (12 in.),20 kg (45 lb.)203 mm (8 in.),6.4 kg (14 lb.)305 mm (12 in.),20 kg (45 lb.)305 mm (12 in.),20 kg (45 lb.)DimensionsH: 324 mm (12.75 in.)W: 184 mm (7.25 in.)D: 457 mm (18 in.)H: 394 mm (15.5 in.)W: 229 mm (9 in.)D: 533 mm (21 in.)H: 324 mm (12.75 in.)W: 184 mm (7.25 in.)D: 457 mm (18 in.)H: 394 mm (15.5 in.)W: 229 mm (9 in.)D: 533 mm (21 in.)H: 394 mm (15.5 in.)W: 229 mm (9 in.)D: 533 mm (21 in.)NetWeight13 kg(28 lb.)15.9 kg(35 lb.)13 kg(28 lb.)15.9 kg(35 lb.)14.1 kg(31 lb.)ArcReachHeavy industrialUse with CC (except 12RC model) and CV,DC power sources.Processes•MIG (GMAW)•Flux-cored (FCAW)Suggested power sources•Dimension™Series (pg 31)•XMT®Series (pg 32–35)•Big Blue® Series (pg 57/58)Note: Full functionality of ArcReach is onlyavailable with ArcReach power sources.RC feeder requires power source with14-pin connector.Suggested guns•Bernard™Guns (pg 23/24)Most popular accessories•Extension Cables(12RC only, 1 required) (pg 66)•Flowmeter Kit 300343•Shielding Gas Filter 19518919Wire FeedersPORTABLEPage 20
Designed for manufacturing,our popular bench feedersare available in three series withmultiple models to fit your needs.ST Series models include 1.0/1.2 mm reversible drive rollsand 70 Series models include 1.2 mm drive rolls.Trigger hold allows the operator to make long welds without having to hold the triggercontinuously. Reduces operator fatigue.Miller®standard, quick-change drive rolls save time.Easy loading and threading of welding wire without having to release the drive rollpressure arm.Additional features for 70 Series feedersAvailable in dual-wire models which allows two different wire types to be available onone feeder, avoiding downtime from changing spools and drive rolls.Toolless rotatable drive assembly allows operator to rotate the drive housing, allowing astraight path for wire flow.Quick-release drive-roll pressure arm allows drive roll change without losing springpreload setting.High-torque permanent-magnet motor, sealed ball bearing gear drive and solid-statespeed and brake control are maintenance free for long life.D-74 MPa PlusST-44 DST-24I-24A and ST®SeriesIndustrial Bench Feeders70 SeriesHeavy-IndustrialBench FeedersST Series 70 SeriesFeature I-24A 24 44 74S 74D 74MPATrigger hold Adjustable run-in control Automatic run-in control Digital meters Remote voltage control Preflow/postflow Spot control Quick-connect coolant fittingsDual-wire models Rotatable drive assembly Accu-Mate™Dual schedule controlTrigger program selectTrigger dual scheduleSequence controlLocks and limitsWeld programs4Trigger schedule selectPush-pull capabilitySynergic pulsed MIGProfile Pulse™StandardOptionalI-24A, ST Series and 70 Series FeaturesIndustrial, four-roll gear-driven, cast aluminium drive system withheavy-duty motor. Provides exceptional feed performance, reliabilityand wire speeds ranging from 1.3–20 meters per minute.Scaled wire pressure knob.Adjustable run-in and burnback controls allow the operator to set theoptimum arc starts and stops, reducing wire stubbing, arc flaring or wireburning back. ST Series only.Euro-style or US-style torch connections ensure exceptional performanceand reliability for various style torches.Standard 14-pin connection. Connects to any Miller®CV power source witha 14-pin receptacle.Optional features for ST SeriesDual digital meters display clear, precise readings of arc voltage, wire feedspeed and/or amperage. Can be set to hold last reading.Remote voltage control enables precise remote operation of the weldingpower source arc voltage.Quick-connect coolant fittings provide easy hook up for water-cooledtorches, no tools required!I-24A, ST-24 and ST-44 See literature M/6.91x (I-24A), WFM/4.0 UK (ST-24) and WFM/51.2 UK (ST-44)S-74DSimple and cost-effective feeders for industrial manufacturing and fabricating.20Wire Feeders BENCHPage 21
ModelI-20 SeriesST-24 SeriesST-44 Series70 Series(Single-wiremodels)70 Series(Dual-wiremodels)Stock Number*I-24A (186493)ST-24 (029007395) Base modelST-24 (029007396) w/voltage controland coolant fittingsST-24 (029007397) w/meters,voltage control and coolant fittingsST-44 (029007406) Base modelST-44 D (029007404) w/meters,voltage control and coolant fittingsS-74S (300616002)S-74D (300617002)S-74 MPa Plus (300577)D-74D (300620002)D-74 MPa Plus (300578)Input Power24 VAC, 4 A,50/60 Hz24 VAC, 4 A,50/60 Hz24 VAC, 5 A,50/60 Hz24 VAC, 10 A,50/60 HzIPRatingIP21IP23IP23IP23Wire Type and Diameter Capacity0.6–2.0 mm (.023–5/64 in.)0.6–1.6 mm (.023–1/16 in.)0.6–2.0 mm (.023–5/64 in.)0.6–3.2 mm (.023–1/8 in.)Low-speed motor recommended for2.4 and 3.2 mm wires (factory option)MPa Plus modelHard wire 0.6–2.0 mm (.023–5/64 in.)Aluminium* 0.9–1.6 mm (.035–1/16 in.)Maximum SpoolSize Capacity305 mm (12 in.),15 kg (33 lb.)305 mm (12 in.),15 kg (33 lb.)305 mm (12 in.),15 kg (33 lb.)27 kg (60 lb.)coil with optionalwire reel assembly(108008)Wire FeedSpeed1.9–16.5 mpm(75–650 ipm)1.3–20 mpm(51–790 ipm)1.3–20 mpm(51–790 ipm)1.3–19.8 mpm(50–780 ipm)DimensionsH: 279 mm (11 in.)W: 273 mm (10.75 in.)D: 597 mm (23.5 in.)H: 279 mm (11 in.)W: 273 mm (10.75 in.)D: 597 mm (23.5 in.)H: 420 mm (16.5 in.)W: 220 mm (8.65 in.)D: 650 mm (25.5 in.)H: 356 mm. (14 in)W: 318 mm (12.5 in.)D: 711 mm (28 in.)H: 356 mm (14 in.)W: 533 mm (21 in.)D: 889 mm (35 in.)Net Weight12 kg (26 lb.)16.6 kg (36.5 lb.)ST-44 18 kg (40 lb.)ST-44 D 20 kg (44 lb.)26 kg (58 lb.)39.5 kg (87 lb.)Optional Push-Pull Gun (For MPa Plus feeders only)XR-Aluma-Pro Plus (Water-cooled)(300003001) 4.6 m (15 ft.)(300004001) 7.6 m (25 ft.)XR-Pistol Plus (Water-cooled)(300757) 7.6 m (25 ft.)(300758) 10.6 m (35 ft.)Welding Current Rating400 A at 100% duty cycleIP RatingIP23Wire Type and Diameter CapacityAluminium*0.8–1.6 mm (.030–1/16 in.)Wire Feed Speed1.8–23 mpm(70–900 ipm)DimensionsH: 127 mm (5 in.)W: 64 mm (2.5 in.)L: 432 mm (17 in.)H: 187 mm (7.375 in.)W: 48 mm (1.875 in.)L: 270 mm (10.625 in.)Net Weight1.3 kg (2.9 lb.)1.1 kg (2.4 lb.)*Requires wire kit (230708) to run 1.6 mm (1/16 in.) wire.74 MPa Plus See literature WFM/30.0 UKAdds features for weld control and programs, plus push-pull aluminium capabilities.Optimized with Invision™MPa or XMT®MPa power sources.74S and 74D See literature WFM/30.0 UKStandard, simple feeders for most heavy-industrial applications, with the 74D providingincreased accuracy and control of the most common weld parameters.Adjustable run-in control for improved arc starts.Dual schedule control allows the operator to switchbetween two preconfigured welding parameterswithout readjusting the machine, saving time andenhancing quality.Trigger schedule select saves time when switchingbetween two weld settings by simply tapping gun trigger.Trigger program select provides the ability to accessany of the four active programs.Sequence control gives the operator the ability toadjust all of the welding parameters: preflow, run-in,weld time, crater, burnback and postflow.Locks and limits for restricting or limiting operatoradjust ments, such as voltage and wire feed speedparameters.Four weld program memories allow operators torecall up to four previously used processes and theirweld settings.Accu-Mate™properly seats the MIG gun power pin forbest feeding performance.Push-pull capability provides consistent, versatileand dependable aluminium wire feeding overgreater distances.Recommendedaluminium solution.Dedicated XR Plus guns(gooseneck and pistol grip)work with MPa Plus feedersto coordinate wire feed speed ofthe gun and the feeder. This providesoptimized aluminium feeding and welding performance.See chart below for gun models and stock numbers.Additional features when used withInvision MPa or XMT MPa power sourcesSynergic pulsed MIG. As wire speed increases/decreases,pulse parameters also increase/decrease to match theright amount of power needed, eliminating the need tomake additional adjustments.Profile Pulse™providesTIG appearance with MIGsimplicity and productivity.Achieve “stacked dimes”without gun manipulation. Profile Pulse frequencycan be changed to increase or decrease the spacingbetween the ripple pattern to achieve the desiredweld appearance.Digital meters (74D models only) ensure accuracywhen presetting and reading actual voltage, amperageand wire feed speed.Remote voltage control (74D models only) allows youto set both voltage and wire feed speed at the feeder,saving time and increasing weld quality because optimalweld parameters are easy to set.Industrial I-24/ST SeriesHeavy industrial 70 SeriesUse with CV, DCpower sources.Processes•MIG (GMAW)•Flux-cored (FCAW)•Pulsed MIG (GMAW-P) with MPa Plusfeeder and optional MPa power sourceSuggested power sources•Deltaweld®Series (pg 13)•Invision™MPa Series (pg 14)•Dimension™Series (pg 31)•XMT®Series (pg 32–35)Suggested guns•Bernard™Guns (pg 23/24)•XR-Aluma-Pro™Plus and XR™-PistolPlus (see chart below)Most popular accessories•Wire Straightener (pg 66)•Hanging Bail 058435•Wire Reel Assembly 108008•Spool Covers057607 For I-24 and 70 Seriessingle-wire modelsand left side ofdual-wire models090389 For right side ofdual-wire models21Wire FeedersBENCHPage 22
Your welders select the Bernardgun handles, triggers and necksthat are the most comfortable andeffective for accessing their welds.Management enjoys the resultingincrease in productivity, longergun life, and a reduced partsinventory with consumablesdesigned to work across all of yourwelding guns.For more information see pages23/24, or contact your local weldingdistributor or Bernard directly.Visit BernardWelds.com to configure a hand-held gun for your welding application today.A Division of Miller Electric Mfg. Co.Engineered for Simplicity. Built for Durability.Heavy industrialUse with CV, DC power sources.Processes•MIG (GMAW)•Flux-cored (FCAW)•Pulsed MIG (GMAW-P) with MPa Pluscontrol box and optional MPa powersourceSuggested power sources/guns•Same as 70 SeriesMost popular accessories•Motor Control Cable (11 conductor)254935010 3 m (10 ft.)254935025 7.6 m (25 ft.)For push-only gun configurations.•MPa Plus Motor Control Cable(14 conductor)254864010 3 m (10 ft.)254864025 7.6 m (25 ft.)For MPa Plus configurations only —single-wire or left side of dual-wire.•Feeder Base 195369For use with spooled wire.70 Series Remote ConfigurationsSee literature WFM/30.0 UK22Remote wire feeder control box and wire drive assembly for non-Miller boom applications.Motor control cableStandard: 11 conductorMPa Plus: 14 conductorWire drive motor assembly300904 Standard left-hand drive300740001 MPa Plus left-hand driveMPa Plus drive can be used with push-only guns ORXR-Aluma-Pro™Plus and XR™-Pistol Plus push-pull guns.Gun NOT included.Must be ordered separately.S-74 MPaPlus shown.D-74Dshown.Single-wire control box300881 S-74S300882 S-74D300738 S-74 MPa PlusGun NOT included.Must be ordered separately.Wire drive motor assembly300904 Standard left-hand drive300740001 MPa Plus left-hand driveMPa Plus drive can be used with push-only guns ORXR-Aluma-Pro™Plus and XR™-Pistol Plus push-pull guns.Motor control cableStandard: 11 conductorMPa Plus: 14 conductorMotor control cable11 conductorPush-only wire drive motor assembly300741001 Standard right-hand drive300741 MPa Plus right-hand driveDual-wire control box300886 D-74S300887 D-74D300739 D-74 MPa PlusGun NOT included.Must be ordered separately.Note: MPa Plus wire drive motor assemblies and controlcables are only for use with MPa Plus control boxes.Wire FeedersPage 23
Heavy industrialProcesses•MIG (GMAW)•Flux-cored (FCAW)Suggested feeders•Continuum™Feeder (pg 15)•SuitCase®Series (pg 18)•I-24A, ST Series and 70 SeriesFeeders (pg 20)Most popular consumablesTOUGH LOCK Consumable SeriesDiffusers (amps)404-18-25 200, 300, 400 SD404-26-25 300, 400, 500, 600 HDCopper Nozzles (inches)401-4-62 5/8 ID, 1/8 Rec., SD401-6-62 5/8 ID, 1/8 Rec., HD401-5-62 5/8 ID, 1/4 Rec., HD401-5-75 3/4 ID, 1/8 rec., HDContact Tips (mm)403-14-35-25 0.9 SD403-20-35-25 0.9 HD403-14-45-25 1.2 SD403-20-45-25 1.2 HD403-20-52-25 1.4 HD403-20-116-25 1.6 HDCenterfire Consumable SeriesDiffusers (amps)DS-1 200, 300, smallD-1 400, 500, 600, largeBrass Nozzles (inches)NS-1218B 1/2 ID, 1/8 rec., smallCopper Nozzles (inches)NS-5818C 5/8 ID, 1/8 rec., smallN-5818C 5/8 ID, 1/8 rec., largeN-5814C 5/8 ID, 1/4 rec., largeN-3414C 3/4 ID, 1/4 rec., largeContact Tips (mm)T-035 0.9T-045 1.2T-052 1.4T-062 1.6To configure your BTB MIG gun from the following array of options visit BernardWelds.com/ConfigureMyGun•Compatible with two high-performance consumable lines — TOUGH LOCK™and Centerfire™(see page 24 for more information)•Compatible with Universal Conventional or front-loading QUICK LOAD™liners (see page 25 for more information)•Fixed or rotatable aluminium armored necks in various lengths and angles to optimize weld access•Choice of seven different handles with various trigger options for a comfortable, ergonomic fit•Internal cable connections are compression fit (instead of crimped) to optimize conductivity, reduce heat andincrease gun life•Optional ultra-heavy-duty steel monocoil cable provides extra reinforcement and high pinch/kink resistance•One year manufacturer’s warranty with lifetime warranty on rear strain reliefBTB Air-Cooled MIG Guns See Bernard literature SP-BTBOur rugged Bernard BTB (Best of the Best) MIG guns bring together all the best features andoptions from our former Q-Gun,™S-Gun™and T-Gun™MIG guns into a single, flexible gun series.ITW Welding offers rugged and reliable Bernard welding guns that have been customized tomatch the performance of many of its industrial wire feeders and power sources.Bernard™Semi-Automatic GunsFor more detailed information, visitBernardWelds.comB Series handle(small or large)O Series handle(small or large)T Series handle(small or large)ProductGuideSteel AluminiumBernard™BTB MIG Guns23Bernard™Clean Air™24Fume Extraction GunsBernard™Dura-Flux™Gun24with Fixed LinerBernard™Dura-Flux™Gun 24with Replaceable LinerXR-Aluma-Pro™Push-Pull Guns 26XR™-Pistol Push-Pull Guns 26XR™Controls 27Wire TypesFlux-cored Flux-coredDual-shld Self-shldHardAlum. CV** CV**CV**CV** Wire Diameter Capacity Available Cable Lengths Typical Applications0.6–3.2 mm (.023–1/8 in.) 2.4, 3, 3.7, 4.5, 6, or 7.6 m Heavy industrial steel fabrication0.6–3.2 mm (.023–1/8 in.) 2.4, 3, 3.7, 4.5, 6, or 7.6 m Heavy industrial steel fabrication1.6–2.4 mm (1/16–3/32 in.) 2.4, 3, 3.7, 4.5, 6, or 7.6 m Heavy industrial steel fabrication1.2–2.0 mm (.045–5/64 in.) 2.4, 3, 3.7, 4.5, 6, or 7.6 m Heavy industrial steel fabrication0.8–1.6 mm (.030–1/16 in.) 4.5, 7.6 or 10.6 m Heavy industrial aluminium fabrication0.8–1.6 mm (.030–1/16 in.) Pistol: 4.5 or 9 m Heavy industrial aluminium fabricationPistol-Pro: 4.5, 7.6 or 10.6 m0.8–1.6 mm (.030–1/16 in.) — Heavy industrial aluminium fabricationPageClassMIGPulsed MIG*Flux-cored**Product KeyClass:Light industrialIndustrialHeavy industrial Capability:Designed for this processCapable of this process*Requires MPa inverter power source. **Certain self-shielded wires require CV output. Miller recommends a CV power source whenever possible.23MIG GunsPage 24
Bernard Welding Consumables (cutaways shown)Most popular consumablesTOUGH LOCK Consumable SeriesDiffusers (amps)404-18-25 200, 300, 400 SD404-26-25 300, 400, 500, 600 HDCopper Nozzles (inches)401-4-62 5/8 ID, 1/8 Rec., SD401-6-62 5/8 ID, 1/8 Rec., HD401-5-62 5/8 ID, 1/4 Rec., HD401-5-75 3/4 ID, 1/8 rec., HDContact Tips (mm)403-14-35-25 0.9 SD403-20-35-25 0.9 HD403-14-45-25 1.2 SD403-20-45-25 1.2 HD403-20-52-25 1.4 HD403-20-116-25 1.6 HDCenterfire Consumable SeriesDiffusers (amps)DS-1 200, 300, smallD-1 400, 500, 600, largeBrass Nozzles (inches)NS-1218B 1/2 ID, 1/8 rec., smallCopper Nozzles (inches)NS-5818C 5/8 ID, 1/8 rec., smallN-5818C 5/8 ID, 1/8 rec., largeN-5814C 5/8 ID, 1/4 rec., largeN-3414C 3/4 ID, 1/4 rec., largeContact Tips (mm)T-035 0.9T-045 1.2T-052 1.4T-062 1.6Heavy industrialProcesses•MIG (GMAW)•Flux-cored (FCAW)Suggested feeders•Continuum™Feeder (pg 15)•SuitCase®Series (pg 18)•I-24A, ST Series and 70 SeriesFeeders (pg 20)24MIG Guns STEELDura-Flux™Self-ShieldedFlux-Cored Guns See Bernard literature SP-DFFor structural steel applications, bridge constructionand heavy equipment repair, Bernard offers two typesof 350-amp self-shielded flux-cored guns.Dura-Flux gun with replaceable power cable liner•Replaceable power cable liner allows quick and easy powercable maintenance•Quik Tip consumables provide excellent heat transfer andelectrical conductivityDura-Flux gun with fixed power cable liner•Ultra-heavy-duty steel monocoil power cable is highly resistantto kinking•Centerfire consumables are easy to use and high performing,providing better arc starts, less spatter and more consistent weldsFume Extraction MIG GunSee Bernard literature SP-CLA (Clean Air™gun)Maintaining a clean working environment is importantand Bernard understands the need for a reliable fumeextraction solution. Extract fumes at the weld beadusing our Clean Air fume extraction MIG gun.Clean Air™gun•Available in 300-, 400-, 500- and 600-amp models•Compatible with TOUGH LOCK and Centerfire consumables•Ergonomic, lightweight handle with rear swivel improves operatorcomfortIndustrial-duty fume extraction and flux-cored welding solutions built for the way you weld.Bernard™Semi-Automatic GunsClean AirReplaceablepower cable linerFixed powercable linerFor more detailed information, visitBernardWelds.comCenterfire™See Bernard literature SP-CFC•Drop-in contact tip (no tools required to replacetip or nozzle) means quick changeover andreduced downtime•Spatter shield within nozzle holds tip in place,protects diffuser and directs gas evenly withreduced turbulence•Diffuser mates securely with contact tip forbetter conductivityTOUGH LOCK™See Bernard literature SP-TLC•Dual-taper technology keeps consumableslocked from tip to neck for improved weldconsistency, positive electrical conductivityand maxi mized heat dissipation•Consumables run cooler, improvingperformance and extending lifePage 25
IndustrialProcess•MIG (GMAW)Compatible robots•Panasonic®•ABB®•COMAU®•FANUC®•Kawasaki®•KUKA™•Motoman®•OTC Daihen®•Reis™(CA3 only)Most popular accessories•TOUGH GUN I.C.E.™(IntegratedCooling Enhancer) Technology —adds water-cooling to air-cooled gunsfor a boost in duty cycle.•Neck Checking Fixture•Reamer Lubricator•TOUGH GUN TT3 ReamersTT3A AnalogTT3E EthernetTwo models available — TT3A (analog)and TT3E (Ethernet) model enhancedwith digital Ethernet communicationfor better integration. Reamers provideautomated spatter removal to helpextend the life of your robotic MIGguns and consumables, increasingboth production uptime andthroughput while benefiting yourbottom line. Designed to operatereliably in even the harshest weldingenvironments.•NEW! TOUGH GUN Reamer Stand —custom height, quick installation,easy on the budget.•TOUGH GARD Multi-Feed SystemMost popular consumables•TOUGH LOCK™Consumables(see Tregaskiss literature TLC/1.0)•QUICK LOAD™Liners (see Tregaskissliterature QLL/1.2)•QUICK LOAD Liner AutoLength™System(see Tregaskiss literature QLL/1.2)25MIG GunsTOUGH GUN CA3 MIG GunSee Tregaskiss literature SP-CA3Designed for welding applications where the gun runs externalto the robot arm.Available in 385-amp models at 100 percent duty cycle with mixed gases.Replaceable unicable reduces downtime through faster repair andextended service life.Cable guide minimizes stress on cable connection as the robot articulates.Re-engineered neck clamp improves durability and consistency ofclamping force.Easy maintenance with minimal downtime.TOUGH GUN TA3 MIG GunSee Tregaskiss literature SP-TA3Designed for welding applications where the gun runsinternally through the robot arm.Available in 350-amp models at 100 percent duty cycle with mixed gases.Available as a complete package from the power pin to the contact tip.Re-engineered neck clamp improves durability and consistency ofclamping force.Easy maintenance with minimal downtime.Tregaskiss™Robotic GunsAir-Cooled MIG GunsCompatible with most robotic welding systems, fully configurable TOUGH GUN™robotic MIGguns are engineered for accurate, reliable and repeatable performance that maximizesproduction uptime and throughput.QUICK LOAD™Liner AutoLength™SystemSee Tregaskiss literature QLL/1.2Pair your QUICK LOAD liner with an AutoLength pin toreap the benefits of the revolutionary QUICK LOADLiner AutoLength System. Minimize downtime, wirefeeding and quality issues commonly associated withshort liner length.•Reduces issues caused by short liners•Decreases burn-backs caused by misalignmentbetween the liner and contact tip•Accommodates liner movement during welding•Improves wire feeding by enhancing wire alignmentwith the contact tip•Spring-loaded module allows for up to 2.54 cm(1 in.) forgiveness if the liner is too shortQUICK LOAD™LinersSee Tregaskiss literature QLL/1.2This innovative front-loading liner is a two-piecesystem with the retainer installed inside thepower pin on first use.•Requires less than half the time and effort toreplace compared to conventional liner•Compatible with Tregaskiss TOUGH GUNrobotic and automatic air-cooled MIG guns,and Bernard™BTB MIG GunsAutoLength pin cutaway shown.Tregaskiss LinersFor more information or to configure your Tregaskissrobotic gun online, visitTregaskiss.com/ConfigureMyGunTOUGH GUN TT3Ereamer shown withTOUGH GUN CA3MIG gun.Page 26
Heavy industrialUse with CC/CV, DC power sources.Processes•MIG (GMAW) with aluminium wire(capable of other wires with optionalhardwire kits)•Pulsed MIG (GMAW-P) with optionalpulsing power sourceSuggested power sourcesThese power sources requireXR-AlumaFeed®(pg 11) ORXR™Control (pg 27)•AlumaPower™MPa (pg 11)•Invision™MPa (pg 14)•XMT®Series (pg 32–35)Most popular accessories•Hardwire Liner Kit 198377XR™Push-Pull GunsXR-Aluma-Pro and XR-Pistol guns work in conjunction with an XR Control or XR-AlumaFeedto provide the best solution for push-pull applications.XR-PistolXR-Pistol-ProModelXR-Aluma-Pro (Water-cooled)XR-Pistol (Air-cooled)XR-Pistol (Water-cooled)4.6 m (15 ft.)(300003)(198127)(198129)7.6 m (25 ft.)(300004)——9 m (30 ft.)—(198128)(198130)10.6 m (35 ft.)(300265)——Wire Type andDiameter CapacityAluminium**0.8–1.6 mm(.030–1/16 in.)Aluminium0.8–1.6 mm(.030–1/16 in.)Wire FeedSpeed*1.8– 23 mpm(70– 900 ipm)1.8– 22.2 mpm(70– 875 ipm)Welding Current Rating400 A at 100% duty cycle200 A at 100% duty cycle400 A at 100% duty cycleIPRatingIP23IP23IP23DimensionsH: 127 mm (5 in.)W: 64 mm (2.5 in.)L: 432 mm (17 in.)H: 187 mm (7.375 in.)W: 48 mm (1.875 in.)L: 270 mm (10.625 in.)Gun OnlyNet Weight1.3 kg (2.9 lb.)1 kg (2.2 lb.)1.1 kg (2.4 lb.)Cable Length*Dependent on control box used. **Requires wire kit (230708) to run 1.6 mm (1/16 in.) wire.XR-Aluma-ProXR-Aluma-Pro™See literature M/1.71Robust professional-grade gun has thehighest duty cycle rating in its class.Easy access to drive assembly and removabletoolless head tube reduce service time, by allowinga simple means of changing drive rolls and headtube — or performing routine maintenance withoutdisassembly of gun.XR™-Pistol See literature M/1.73Reliable, cost-effective gun forlight- to medium-industrial applications.XR™-Pistol-Pro See literature M/1.74Exceptional aluminium welding results forheavy-industrial applications.Most durable motor and drive design improvesfeedability and arc consistency while helping reducedowntime and maintenance costs.Easy access to drive assembly and removabletoolless head tube reduce service time, by allowinga simple means of changing drive rolls and headtube — or performing routine maintenance withoutdisassembly of gun.Threaded quick-change 360-degree rotatable head tubes are available in different bends and lengthsfor even those hard-to-reach welds. Over 30 different styles to fit your application and welder’s preference.Wire tension settings (except XR-Pistol). 4000- or 5000-specific tension settings ensure the very bestwire feeding performance and arc consistency.Heavy-duty construction. All internal components are designed to provide long lasting performance andfeeding precision.PORTABLE!26MIG Guns ALUMINIUMPage 27
XR™Control See literature M/1.7Standard aluminium wire feeding system for fabrication and manufacturing, consisting of acontrol box and push-pull gun. Beneficial for difficult-to-feed wire types.Feeding aluminium –choose the right gun solutionKnown as standard MIG guns, these guns are only usedfor occasional aluminium work.•Typically used with hard wire or flux-cored wires ingeneral manufacturing•For aluminium, guns should be limited to 3.7 meterlengths and configured with correct aluminium liner andconsumablesPreferred guns for industrial productionwork with thebest overall aluminium wire feedability.•Built for longevity•Great arc starts and performance•Higher amp ratings•Air- and water-cooled models•Work in conjunction with designated wire feedersXR-SSimple, cost-effective push-pull feeder forindustrial applications.True torque feed motor push-pull design providescontinuous push force to the wire while the gunmotor controls the speed at the gun. The motorswork together to provide accurate and positive wirefeed speed without wire shaving or deformation.Digital meters ensure accuracy when presettingand reading actual wire feed speed or voltage.Trigger hold for making long weldments withouthand fatigue.Adjustable wire run-in control allows arc start finetuning. Reduces wire stubbing or arc flaring whichcan result in contact tip burnback.XR-D (additional features)Adds basic programmable weldsequencing that allows adjustments forpreflow, postflow, start, and craterproviding higher quality welds.Includes both 0.9 mm and factory-installed 1.2 mm drive rolls.Order 1.6 mm control box drive roll kit (195591) separately.XR-DXR-SModel/Stock NumberXR-S (300601)XR-D (300687)Input Power24 VAC,50/60 or 100 HzIP RatingIP23Wire Feed Speed1.3–23 mpm(50–900 ipm)Wire Type and Diameter CapacityAluminium 0.8–1.6 mm (.030–1/16 in.)Requires drive roll kit (195591) to run1.6 mm (1/16 in.) wireMaximum Spool Size Capacity305 mm (12 in.)DimensionsH: 406 mm (16 in.)W: 235 mm (9.25 in.)D: 540 mm (21.25 in.)Net Weight19.2 kg(42.5 lb.)PORTABLE!Learn more at MillerWelds.com/aluminumUPGRADEPush-only Guns23–24 26Push-pull GunsHeavy industrialUse with CC/CV, DC power sources.Processes•MIG (GMAW) with aluminium andother soft alloy wires•Pulsed MIG (GMAW-P) with optionalpulsing power sourceSuggested guns•Push-pull guns (pg 26)Suggested power sources•AlumaPower™MPa (pg 11)•Invision™MPa (pg 14)•XMT®Series (pg 32–35)Most popular accessories•Extension Cables (pg 66)•Gas Flowmeter Kit 246127Visit MillerWelds.com or your distributorfor other Miller® options and accessories.27MIG GunsALUMINIUMPage 28
People like you use their talent and toolsto make our world a better place.Miller celebrates those who build dreams, security, industry, adventure,performance…everything that makes a positive difference in our lives.Together, we build with you.Page 29
Icon KeyMild SteelStainless SteelAluminium*Gauge(0.5–3.0 mm)Sheet(3.0–9.5 mm)Plate(9.5–25 mm)Plate(25+ mm)0.6 mm0.8 mm1.0 mm1.2 mm1.4 mm1.6 mm2.0 mm2.4 mmShort CircuitPulsed SprayStickTIGCAC-AMaterialMaterialThicknessWire SizeProcessMPi 220P XMT®XMT®Dimension™XMT®XMT®Dimension™Dimension™(1-Phase) 350 CC/CV 350 MPa 562 450 CC/CV 450 MPa 812 650(pg 30) (pg 32) (pg 32) (pg 31) (pg 32) (pg 32) (pg 31) (pg 31) ⋆⋆⋆ ⋆⋆⋆⋆ ⋆⋆⋆⋆ ⋆⋆ ⋆⋆⋆⋆ ⋆⋆⋆⋆ ⋆⋆ ⋆⋆⋆⋆⋆⋆ ⋆⋆⋆⋆ ⋆⋆⋆⋆⋆⋆ ⋆⋆⋆⋆ ⋆⋆⋆⋆ ⋆⋆ ⋆⋆⋆⋆ ⋆⋆⋆⋆ ⋆⋆ ⋆⋆⋆⋆⋆⋆ ⋆⋆⋆ ⋆⋆⋆ ⋆ ⋆⋆⋆ ⋆⋆⋆ ⋆ ⋆⋆⋆6 mm 6 mm 6 mm 8 mm 8 mm 10 mm 10 mmPower SourceWeldingPerformanceCapability:Designed forCapable of Process Quality:⋆Good⋆⋆Better⋆⋆⋆Best⋆⋆⋆⋆OptimizedNew! or Improved! products appear in blue type. *XR push-pull system recommended for best results.450 Amp 650 A200 A 350 Amp29MultiprocessPage 30
Design the perfect MIG guns for all your welds!Improve welding productivity by choosing the neck length and angle, handleshape and trigger style that allows welders to comfortably and efficiently reachall your welds.Plus, longer gun life and shared parts and consumables will help to simplifyinventory and minimize costs across our shop.For additional information, pleasecontact your local welding distributor.To request a catalog, please call orcomplete our online request form.BernardWelds.comEngineered for Simplicity.Built for Durability.A Division of Miller Electric Mfg. Co.IndustrialProcesses•MIG (GMAW)•Pulsed MIG (GMAW-P)•Flux-cored (FCAW)•Stick (SMAW)•TIG (GTAW)Weld Ready package includesthe following•Power source•Bernard™MIG gun Q2010TE3EEQ•Work cable with clampMost popular accessories•TIG Torch WP-17VS4BXEY3GL150 amps DC/100 amps AC,60% duty cycle•Bernard™MIG gun Q2010TE3EEQ200-amp gun with 3 m cableMPi 220P See literature DCM/9.5 UK30Synergic welding mode offers the simplicity of single knobcontrol. The machine will select the correct voltage and amperagebased on the wire feed speed (WFS) set by the operator.Note: Complete material library to select from for the targeted market segment.Large graphical display guides user through process andparameter setup with ease and high visibility.Durable cast aluminium feedhead incorporates dual-groovequick-change drive roll and spring-loaded tension arm withcalibrated tension knob, all designed to make setup easierand faster.Thermal overload protection shuts down unit and activatesover temperature light if airflow is blocked or duty cycle isexceeded. Automatically resets when fault is corrected andunit cools.Adjustable Hot Start™for stick arc starts. Adjust the optimalstart current for the application. The current automaticallyincreases the output amperage at the start of a weld.Built-in upslope/downslope function for TIG helps providebetter arc starts and reduces craters.Built-in run-in/crater/burnback function for MIG helpsprovide better arc starts and reduces craters.Adjustable preflow and postflow gives operator better controlof the gas parameters affecting weld zone.Selectable trigger configuration allows the operator to choosestandard or 2T trigger method.Stock Number(059016014)230 V, 50/60 Hz(029083114)Weld Ready packageRated Output180 A at 23.0 VDC, 35% duty cycle140 A at 21.0 VDC, 60% duty cycle110 A at 17.5 VDC, 100% duty cycle170 A at 26.8 VDC, 35% duty cycle130 A at 25.2 VDC, 60% duty cycle100 A at 24.0 VDC, 100% duty cycle180 A at 17.2 VDC, 35% duty cycle130 A at 15.2 VDC, 60% duty cycle100 A at 14.0 VDC, 100% duty cycleWelding ModeMIGStickTIGWelding Output Ranges2–200 A, 15–24 V5–200 A, 20.2–28 V5–200 A, 10–18 VIP RatingIP22SMax. Open-Circuit Voltage356565DimensionsH: 365 mm (14.4 in.)W: 237 mm (9.3 in.)D: 548 mm (21.6 in.)Net Weight16 kg (35 lb.)MultiprocessPage 31
Stock Number(907618) 380/460 V, 50/60 HzRated Output650 A at 44 VDC,100% duty cycleIP RatingIP23Welding OutputRangesCC mode: 20–815 ACV mode: 10–44 VSAW mode: 10–65 VMax. Open-Circuit Voltage87 VDCAmps Input at Rated Output, 50/60 Hz380 V 460 V KVA KW53.2 42.8 34 30.7Dimensions(Includes lift eye and strain relief)H: 716 mm (28.187 in.)W: 424 mm (16.687 in.)D: 803 mm (31.625 in.)Net Weight71.7 kg(158 lb.)Heavy industrialProcesses•MIG (GMAW)•Flux-cored (FCAW)•Stick (SMAW)•TIG (GTAW)•Air carbon arc cutting and gouging(CAC-A) (carbons — 562: 6 mm,812: 10 mm)Most popular accessories•SuitCase®X-TREME™Feeders (pg 18)•70 Series Feeders (pg 20)•Standard Running Gear 042886(pg 63)•Standard Cylinder Rack 042887(pg 63)•Extension Cables (pg 66)Dimension™562 and 812 See literature DC/19.2Multiprocess performance in a reliable package. Designed for heavy-industrial applications,with 100 percent duty cycle for extended arc-on time.Built-in arc control for stick welding allows operators moreflexibility when welding in tight areas where sticking electrodesis a problem.Line voltage compensation ensures consistent weldperformance even when primary power varies.Fan-On-Demand™cooling system operates only when needed.Reduces contaminants drawn into the machine and excessnoise in work areas.Digital meters are easy to read and display preset and actualvoltage and amperage.115-volt power for tools and coolant systems.31MultiprocessDimension 562 shown with 70 Series feeder, MIG gun,weld cable and work cable (components sold separately).Model/Stock NumberDimension 562(907360) 380/400/440 V, 50 HzDimension 812(907361) 380/400/440 V, 50 HzRated Output450 A at 36.5 VDC,100% duty cycle650 A at 44 VDC,100% duty cycleIP RatingIP23SIP23SWelding OutputRangesCC mode: 20–565 ACV mode: 10–38 VCC mode: 50–815 ACV mode: 10–65 VMax. Open-Circuit Voltage65 VDC43 VDC72 VDC67 VDCAmps Input at Rated Output, 60 Hz380 V 400 V 440 V KVA KW48 46 41 31.4 2252.5 51 46 35.3 22.377 73 66 50 34.8Dimensions(Includes lift eye and strain relief)H: 762 mm (30 in.)W: 585 mm (23 in.)D: 966 mm (38 in.)H: 762 mm (30 in.)W: 585 mm (23 in.)D: 966 mm (38 in.)Net Weight192 kg(424 lb.)247 kg(545 lb.)Heavy industrialProcesses•MIG (GMAW)•Flux-cored (FCAW)•Stick (SMAW)•TIG (GTAW)•Submerged arc (SAW)•Air carbon arc cutting and gouging(CAC-A) (rated 10 mm carbons)Most popular accessories•SuitCase X-TREME™Feeders (pg 18)•70 Series Feeders (pg 20)•Bernard™MIG Guns (pg 23/24)•Universal Trolley 018035028 (pg 63)•Dimension 650 Running Gear301307 (pg 63)•Extension Cables (pg 66)242208025 7.6 m (25 ft.)242208050 15 m (50 ft.)242208080 24.4 m (80 ft.)Dimension™650 See literature DCM/40.0 UKDeveloped for harsh environmental conditions and output requirements that range frompower-intensive to precise.All aluminium construction helps the machine resist corrosionfor long life.Exclusive protection input inductor protects machine’sperformance and reliability from “dirty” input power.Wind Tunnel Technology™protects internal components,greatly improving reliability.Fan-On-Demand™reduces power consumption andimproves reliability.High-quality performance in all welding processes, from thickto thin metals.Arc control available in the stick and wiremodes for easier finetuning of tough-to-weldmaterials and out-of-position applications.Reduced size and weight results in an easier-to-handlepackage that exceeds the welding performance of larger,heavier machines. Dimension 650 is 3.5 times lighter thanthe Dimension 812 and also uses 40 percent less floor space.High electrical efficiency and excellent power factormean that you can get more welding done using less power.Dimension 650 uses 32 percent fewer amps than theDimension 812.Page 32
350 Amp 450 AmpXMT 350 CC/CV XMT 350 MPa XMT 450 CC/CV XMT 450 MPa3-phase 3-phaseAuto-Line (230–575 V) 400 V350 A at 34 VDC 450 A at 38 VDC(3-phase input power at 60% duty cycle) (3-phase input power at 100% duty cycle)Rated: 6 mm Rated: 8 mm36.3 kg (80 lb.) 55.3 kg (122 lb.)Dinse 1/2 in. stud— Yes —YesYes YesYes Yes(pg 54) (pg 54)Input PowerPrimary Operating RangeWeld OutputCarbon Arc GougingNet WeightOutput ConnectorPulsed MIG14-pin CompliantInsight Core Capable(requires Insight Core14-pin module)Choose the Right XMTXMT®SeriesXMT 450Portability and excellent multiprocessarc performance make the XMT familythe most popular in the industry.With many models to choose fromthe XMT family has the right solutionfor your business.XMT 350ReliabilityWind Tunnel Technology.™Air flow that protects internal components, greatlyimproving reliability.Fan-On-Demand™cooling system operates only when needed, reducing noise,energy use and amount of contaminants pulled through machine.Welder friendly control panelProcess selector switch reduces the number of control setup combinationswithout reducing any features.Ultra-tough, polycarbonate-blended cover protects front controls from damage.Large, dual digital meters are easy to view and presettable to ease settingweld output.Output connector choicesDinse-style weld disconnects (350 models) provide high-quality weld cableconnections. Machines come with two Dinse connectors.Weld studs (450 models).14-pin receptacle provides a quick, direct connection to Miller® wire feeders.Capable of remote voltage control.Input power choices(350 models) allows for any input voltage hookup(230–575 V, three-phase) with no manual linking,providing convenience in any job setting. Ideal solution for dirty orunreliable input power.Standard hookup (450 models). 400 V only, three-phase.Advanced features for the professional welderAdaptive Hot Start™makes starting stick electrodes easy withoutcreating an inclusion.Infinite arc control available in the stick and wire modes for easierfine tuning of tough-to-weld materials and out-of-position applications.Lift-Arc™provides arc starting that minimizes contamination of theelectrode and without the use of high frequency.Welding Intelligence™system. XMT 14-pinmodels are Insight Core capable to monitorweld voltage, amperage, and arc-time and percentage.UPGRADEUPGRADEUPGRADEUPGRADE32MultiprocessPage 33
XMT®350 CC/CV and 450 CC/CVSee literature DCM/43.0 UK (350) and DC/18.94 (450)Flexibility and simplicity make this the mostpopular model. It has the core multiprocesscapabilities along with the flexibility of a14-pin for spool guns, feeders, and remotecontrols.Strong weld output for increased capabilities.More output for larger wires and stick electrodes.XMT®350 MPa and 450 MPaSee literature DCM/43.0 UK (350) and DC/18.94 (450)Built-in pulse programs for manufacturing and fabrication applications that have benefits forstandard steels, high-strength steels and aluminium.Pulse programs provide reduced heat affected zone,weld in all positions, great for thick-to-thin metal, goodgap filling ability and faster travel speeds and deposition.SharpArc®controls the arc in pulsed MIG mode andgives total control over the arc cone shape, puddlefluidity and bead profile.Synergic pulsed MIG.As you increase/decrease the wirefeed speed, the pulseparameters increase/decrease, matchingthe right amount ofpower output to matchthe wire speed,eliminating theneed to makeadditionaladjustments.Profile Pulse™providesTIG appearance withMIG simplicity andproductivity. Achieve“stacked dimes” without gun manipulation. Profile Pulsefrequency can be changed to increase or decrease thespacing between the ripple pattern to achieve thedesired weld appearance.Added capabilities with Insight Core.™When using anMPa Plus feeder, wire deposition is added to the InsightCore capabilities.Additional features when using a 70 Series MPa Plus feeder or XR-AlumaFeed®feeder.350 A450 AWeldingOutput Ranges5–425 A10–38 V15–600 A10–38 VModel/Stock NumberXMT 350 CC/CV(907161011) 230–575 V w/auxiliary power*XMT 350 MPa(907366011) 230–575 V w/auxiliary power*XMT 450 CC/CV(907525) 400 V w/auxiliary power*XMT 450 MPa(907468) 400 V w/auxiliary power*InputPower3-phase3-phaseAmps Input at Rated Load Output, 60 Hz230 V 400 V 460 V 575 V KVA KW36.1 20.6 17.8 14.1 14.2 13.6— 32.1 — — 22 18.9— 32.1 — — 22.2 19.2Max. Open-Circuit Voltage75 VDC90 VDCDimensionsH: 432 mm(17 in.)W: 318 mm(12.5 in.)D: 610 mm(24 in.)H: 438 mm(17.25 in.)W: 368 mm(14.5 in.)D: 689 mm(27.125 in.)NetWeight36.3 kg(80 lb.)43 kg(94.8 lb.)w/aux power55.3 kg(122 lb.)Rated Output350 A at 34 VDC,60% duty cycle450 A at 38 VDC,100% duty cycleIPRatingIP23IP23*Optional 115-volt auxiliary power provides 10 amps of circuit-breaker protected power for coolant systems, etc.**Duty cycle rating below achieved with 6-gauge input power cord (8-gauge cord supplied with unit).Heavy industrialProcesses•MIG (GMAW)•Pulsed MIG (GMAW-P)*•Stick (SMAW)•TIG (GTAW)•Flux-cored (FCAW)•Air carbon arc cutting and gouging(CAC-A) (carbons — 350: 6 mm,450: 8 mm)*Only XMT MPa models.Most popular accessories•XR-AlumaFeed®(pg 11)•SuitCase®X-TREME™Feeders (pg 18)•70 Series Feeders (pg 20)•XR™Control (pg 27)•Universal Trolley 018035028 (pg 63)•Coolmate™Coolant System (pg 64)•HydraCool™Coolant System (pg 64)•Coolant 043810 (pg 64)•Protective Cover (XMT 350 only)195478 (pg 65)•Gas Valve Kit195286 XMT 350300928 XMT 450Visit MillerWelds.com or your distributorfor other Miller® options and accessories.33MultiprocessPage 34
XMT®350 FieldPro™System See literature DC/18.96Remote control of the power sourcewithout a cord.More jobsite productivity and efficiency•Cable Length Compensation (CLC™) ensures that the voltage a weldoperator sets is the voltage they get by automatically adjusting voltagebased on weld cable lengthExceptional arc performance•Regulated Metal Deposition (RMD®) and pulsed MIG are fully supported,enabling operators to use these advanced processes in the field for faster,more-efficient welds•Common weld failures can be minimized with stick stops that are specificallyprogrammed to eliminate arc strikes outside of the heat-affected zoneMore operator control•Weld operators can Adjust While Welding (AWW™) to change weldparameters while the arc is on•Inadvertent parameter changes by other jobsite workers can be easilyavoided because connecting an ArcReach accessory from the power sourceautomatically locks out the power source’s panel controls•Return to a previous weld process faster because the power source isrestored to its previous settings once the ArcReach accessory is removed•Decrease the chance of an incorrect weld process being used becauseAuto-Process Select™automatically sets the power source to the correctweld process based on the polarity applied to the weld accessoryIncreased uptime•No more expenses related to maintaining or replacing easily damagedcontrol cords because the weld cables are used to communicate weldparameters between the wire feeder and power sourcePipeWorx 350 FieldPro shown with optionalFieldPro Remote, ArcReach Smart Feeder,ArcReach SuitCase 12 and ArcReachSuitCase 8 feeders.Remote control of the power sourcewithout a cord.Complete control at the weld joint•FieldPro Remote reduces weld defects by automatically setting correctpolarity for each welding process — without the need to manuallyswap cables•Eliminates the need to “get by” with less than optimal settings withoutcontrol cables, and allows for easy setup of a new weld process with thetouch of a button•Total remote control of welding processes and parameters improves safetyby limiting jobsite movement and reducing slip, trip and fall hazardsArc performance optimized for critical pipe welding•Industry-leading arc performance like the PipeWorx 400 welding system,but in a field-ready package•True multiprocess system provides conventional stick, TIG, flux-cored andMIG welding, as well as the advanced technologies of RMD®and pulsed MIG•Smart Feeder delivers excellent RMD and pulsed MIG welding 200 feet fromthe power source with no control cables. RMD and pulse processes helpreduce weld failures and eliminate backing gas on some stainless andchrome-moly applicationsNew durability standard for field construction•Designed and built to withstand the harshest field environmentsMultiprocess PIPE WELDING34PipeWorx 350 FieldPro™System See literature PWSM/6.5 UKXMT 350 FieldPro shown with optionalArcReach Smart Feeder, ArcReach SuitCase 12and ArcReach SuitCase 8 feeders.Simplicity-driven performance foryour pipe construction site.Page 35
Heavy industrialProcesses•Stick (SMAW)•DC TIG (GTAW)•MIG (GMAW)•Flux-cored (FCAW)•RMD•Pulsed MIG (GMAW-P)•Air carbon arc cutting and gouging(CAC-A)XMT 350 FieldPro systems(components sold separately)MIG/flux-cored system consists of•XMT 350 FieldPro power source•ArcReach SuitCase®8 or 12 feederwith drive rolls, work sense leadand clampRMD/pulse system consists of•XMT 350 FieldPro power source•ArcReach Smart Feeder with driverolls, work sense lead and clampPipeWorx 350 FieldPro systems(components sold separately)MIG/flux-cored system consists of•PipeWorx 350 FieldPro power source•ArcReach SuitCase®8 or 12 feederwith drive rolls, work sense leadand clampRMD/pulse system consists of•PipeWorx 350 FieldPro power source•ArcReach Smart Feeder with driverolls, work sense lead and clampStick/TIG system consists of•PipeWorx 350 FieldPro power source•FieldPro Remote with work sense leadand clamp (301176)Most popular accessories forboth FieldPro systems•Bernard™PipeWorx™250-15 MIG GunQ2015TF2DEL Euro connectionQ2015TF2DML Miller connection•Bernard™PipeWorx™300-15 MIG GunQ3015TF2DEL Euro connectionQ3015TF2DML Miller connection35RMD®(regulated metal deposition)•Higher quality root pass•Calm stable arc•Less spatter•More tolerant of hi-lo conditions•Reduced training requirements•Less chance of cold lap or lack of fusion reducing rework•Can eliminate the need for a hot pass•Can eliminate backing/purge gas in some stainlessapplicationsPulsed MIG•Less heat input than traditionalspray pulse transfer•Shorter arc length•Narrower arc cone•Improved fusion and fill at thetoes of the weld resulting in:- Faster travel speeds- Higher deposition rates•Less training time required because pulsed MIG:- Virtually eliminates arc wander- Is easier to control the puddle- Compensates for tip to work variations automatically•When used with RMD, it is possible to use one wireand one gas for all passesPipeWorx Memory Card, Accu-Power 300667Displays instantaneous power during welding to meet the newASME requirement for calculating heat input on complexwaveform processes (RMD and pulsed MIG).Pulsed MIG stainlessRMD carbon steelAdvanced Technologies of FieldPro Systems*Welding with the Smart Feeder requires the XMT 350 FieldPro or PipeWorx 350 FieldPro to be hooked up to three-phase power.Power Source/Stock NumberXMT 350 FieldPro(907730002) 230–575 VPipeWorx 350 FieldPro(907633) 230–575 VRated Output at60% Duty Cycle350 A at 34 VDC350 A at 34 VDCIPRatingIP23IP23Welding OutputRangesCC mode: 5–425 ACV mode: 10–38 VCC mode: 10–350 ACV mode: 10–44 VInput PowerThree-phaseThree-phaseMax. Open-Circuit Voltage75 VDC75 VDCAmps Input at Rated Output, 60 Hz230 V 380 V 400 V 460 V 575 V36.1 23.4 20.6 17.8 14.136.1 27.1 25.9 17.8 14.1KVA14.215.0KW13.614.4DimensionsH: 432 mm (17 in.)W: 318 mm (12.5 in.)D: 610 mm (24 in.)H: 432 mm (17 in.)W: 305 mm (12 in.)D: 559 mm (22 in.)NetWeight42.2 kg(93 lb.)45.4 kg(100 lb.)Wire FeederModel/Stock NumberArcReach SuitCase 8 (301456)ArcReach SuitCase 12 (301457)ArcReach Smart Feeder (301177)Wire Feed Speed1.3–19.8 mpm(50–780 ipm)dependent on arc voltage1.3–19.8 mpm(50–780 ipm)dependent on arc voltage1.3–12.7 mpm(50–500 ipm)dependent on arc voltageIPRatingIP23IP23IP23Input WeldingCircuit Rating330 A at60% duty cycle425 A at60% duty cycle275 A at60% duty cycleInput PowerOperates on open-circuitvoltage and arc voltage:14–48 VDC/110 max. OCVOperates on open-circuitvoltage and arc voltage:14–48 VDC/110 max. OCVOperates on open-circuitvoltage and arc voltage:14–48 VDC/110 max. OCV*Wire Diameter Type and CapacitySolid wire 0.6–1.4 mm (.023–.052 in.)Flux-cored 0.8–2.0 mm (.030–5/64 in.)Solid wire 0.6–1.4 mm (.023–.052 in.)Flux-cored 0.8–2.0 mm (.030–5/64 in.)0.9–1.1 mm (.035–.045 in.)Maximum SpoolSize Capacity203 mm (8 in.),6.4 kg (14 lb.)305 mm (12 in.),20 kg (45 lb.)305 mm (12 in.),15 kg (33 lb.)DimensionsH: 324 mm (12.75 in.)W: 184 mm (7.25 in.)D: 457 mm (18 in.)H: 394 mm (15.5 in.)W: 229 mm (9 in.)D: 533 mm (21 in.)H: 457 mm (18 in.)W: 330 mm (13 in.)D: 546 mm (21.5 in.)NetWeight13 kg(28 lb.)15.9 kg(35 lb.)23 kg(50 lb.)ArcReach technology uses the existing weld cable to communicate welding control information between thefeeder or remote and the power source. This technology eliminates the need for control cords, and their associatedproblems and costs. Learn more at MillerWelds.com/arcreachArcReachpower sourceArcReachfeeder orremoteHow ArcReach®WorksMultiprocessPIPE WELDINGPage 36
PipePro®XC Welding System See literature PWSM/5.0Power source featuresPipeWorx 400XC power source is able to performsimple stick (SMAW) welding to advanced RMD®welding. The arc performance and ease-of-use isoptimized to provide quality and productivity, whilesimplifying welding training.•Temperature — power source rating is based on50°C ambient•Moisture — meets IP23 standards. Horizontal controlboards are potted•Shock and vibration — the power source base isdesigned with shock mounts to reduce vibration whenmounted on tractors•Dust — Wind Tunnel Technology™circulates air overcomponents that require cooling (not electroniccircuitry). Fan-On-Demand™cooling system operatesonly when needed. This reduces the amount ofairborne contaminants in the machineEquipped with a memory card reader to provide newcapabilities into the future.•Stores weld parameters for all welding processes•Enables the use of custom programs for futureapplications•Provides range locks•Provides Accu-Power™(instantaneous power display)•Provides diagnostic information and operationalinformation in a text file formatFeeder featuresPipePro XC feeder is uniquely designed to operatewith the PipePro 400XC power source to perform theself-shielded flux-cored weld process for fill and cappass welding on pipelines. This economical solutionoptimizes the weld process using the Hobart Fabshieldfamily of self-shielded wires.PipePro XC RMD feeder provides the most versatilewelding solution when used with the PipePro 400XCpower source. It can provide MIG and RMD (solid wireand metal-cored wire), and flux-cored (self-shieldedor gas-shielded wires). All welding processes areoptimized for pipe welding.Gun featuresBernard PipePro Dura-Flux gun is uniquely designedto perform self-shielded flux-cored with the PipePro400XC system for onshore pipeline applications. Thegun features a dual schedule switch to enable two setsof welding parameters — wire feed speed and voltage.Bernard PipeWorx 250-15 gun is designed by weldersto reduce fatigue and improve visibility of the puddle onthe root pass.Bernard PipeWorx 300-15 gun provides a heavy-dutysolution to producing root, fill and cap welds on pipe.PipeWorx 400XC shown with optional PipePro XC Feeder with Bernard PipePro Dura-Flux gunand PipePro XC RMD Feeder with Bernard PipeWorx 250-15 gun.Designed specifically to meet the rugged demands of pipeline applications.System is optimized to provide excellent arc performance using the Hobart®Fabshield®family of self-shielded FCAW filler metals.Heavy IndustrialProcesses•Stick (SMAW)•MIG (GMAW)•Flux-cored (FCAW)•RMDMost popular accessories•Bernard™PipePro Dura-Flux™Gun301011 3 m (10 ft.)•Bernard™PipeWorx 250-15 MIG GunQ2015TF2DEL Euro connectionQ2015TF2DML Miller connection•Bernard™PipeWorx 300-15 MIG GunQ3015TF2DEL Euro connectionQ3015TF2DML Miller connection•Feeder Control Cable(one required per system)300845 10 m (32 ft.)300846 20 m (64 ft.)•RHC-14 Remote Control (pg 65)242211020 6 m (20 ft.)242211100 30.5 m (100 ft.)•Work Sense Lead300947 5 m (16 ft.)300461 7.6 m (25 ft.)300462 15.2 m (50 ft.)36Wireless Hand Control300430 (pg 66)Power Source/Stock NumberPipePro 400XC(907675) 380/400 VRated Output at100% Duty Cycle350 A at 34 VDC400 A at 34 VDCIPRatingIP23WeldingOutput Ranges40–350 A10–39 VWeldingMode/ProcessCC: StickCV: MIG/flux-coredMax. Open-Circuit Voltage80 VDCAmps Input at Rated Output, 50/60 Hz380 V 400 V23.5 22.727.1 25.7KVA380 V 400 V15.7 15.9KW380 V 400 V13.2 13.2DimensionsH: 375 mm(14.75 in.)W: 464 mm(18.25 in.)D: 686 mm(27 in.)NetWeight56.7 kg(125 lb.)Wire Feed Speed1.3–12.7 mpm(50–500 ipm)IP RatingIP23Input Welding Circuit Rating100 V, 500 A at100% duty cycleInput Power24 VAC, 9 AMaximum Spool Size Capacity15 kg (33 lb.)Wire Diameter Type and Capacity0.9–2.0 mm (.035–5/64 in.)DimensionsH: 438 mm (17.25 in.)W: 203 mm (8 in.)D: 508 mm (20 in.)Net Weight15.2 kg(33.5 lb.)Wire Feeder/Stock NumberPipePro XC (300794)SuitCase XC RMD(300844)Multiprocess PIPE WELDINGPage 37
Heavy industrialProcesses•Stick (SMAW)•DC TIG (GTAW)•MIG (GMAW)•Flux-cored (FCAW)•RMD•Pulsed MIG (GMAW-P)•Air carbon arc cutting and gouging(CAC-A)System consists of(components sold separately)•PipeWorx 400 power source withcable hangers (907534)•Dual feeder with drive rolls (300950)•Two 4.6 m (15 ft.) PipeWorx 300 guns(Q3015TF2DEL or Q3015TF2DML)•Running gear with gas cylinder rackand handles (300368)Most popular accessories•Bernard™PipeWorx 250-15 MIG GunQ2015TF2DEL Euro connectionQ2015TF2DML Miller connection•Bernard™PipeWorx 300-15 MIG GunQ3015TF2DEL Euro connectionQ3015TF2DML Miller connection•PipeWorx 400 Insight Module301304•Composite Cable Kit300454 7.6 m (25 ft.)300456 15.2 m (50 ft.)•PipeWorx Cooler 300370•Foot Control Bracket 300676•DSS-9 Dual Schedule Switch071833•RFCS-14 HD 194744 (pg 65)37RMD®(regulated metal deposition)•Higher quality root pass•Calm stable arc•Less spatter•More tolerant of hi-lo conditions•Reduced training requirements•Less chance of cold lap or lack of fusion reducing rework•Can eliminate the need for a hot pass•Can eliminate backing/purge gas in some stainlessapplicationsPulsed MIG•Less heat input than traditionalspray pulse transfer•Shorter arc length•Narrower arc cone•Improved fusion and fill at thetoes of the weld resulting in:- Faster travel speeds- Higher deposition rates•Less training time required because pulsed MIG:- Virtually eliminates arc wander- Is easier to control the puddle- Compensates for tip to work variations automatically•When used with RMD, it is possible to use one wireand one gas for all passesPipeWorx Memory Card, Accu-Power 300667Displays instantaneous power during welding to meet the newASME requirement for calculating heat input on complexwaveform processes (RMD and pulsed MIG).Pulsed MIG stainlessRMD carbon steelAdvanced Technologies of PipeWorx 400 Welding SystemPipeWorx 400 Welding System See literature PWS/2.0Simple process setup•The front panel was designed by welders for welders•Requires just a few basic steps to set up a new weldprocess, resulting in less training time and minimizingerrors from incorrect setups•Memory feature stores four programs for each selection:stick, DC TIG, and MIG (left and right side of feeder) —eliminates the need to remember parametersTrue multiprocess machine•Weld processes are optimized to deliver superior arcperformance and stability specifically for root, fill, andcap passes on pipe•RMD®and pulsed MIG increase quality and productivityQuick process changeover•Simply push a process selection button to choose awelding process•Eliminates setup time and reduces the risk of weldreworks due to incorrect cable connections•PipeWorx “Quick Select” technology automaticallyselects the welding process, the correct polarity,cable outputs, gas solenoid, and user-programmedwelding parametersSingle-system design•One machine designed to perform all of your pipewelding needs•Simplified and optimized specifically for pipe weldingPipeWorx 400 welding systemshown. All components aresold separately.Optimized for pipe fabrication shops.Power Source/Stock NumberPipeWorx 400(907534) 380/400 VRated Output at100% Duty Cycle400 A at 36 VDC350 A at 24 VDC400 A at 34 VDCIPRatingIP21WeldingOutput Ranges40–400 A10–350 A10–44 VWeldingMode/ProcessCC: StickCC/DC: TIGCV: MIG/flux-coredMax. Open-Circuit Voltage90 VDCAmps Input at Rated Output, 50/60 Hz380 V 400 V26.3 25.519 18.127.1 25.7KVA380 V 400 V17.6 17.812.4 12.518.0 18.0KW380 V 400 V16.5 16.59.7 9.815.5 15.6DimensionsH: 724 mm(28.5 in.)W: 495 mm(19.5 in.)D: 806 mm(31.75 in.)NetWeight102 kg(225 lb.)Wire Feeder/Stock NumberPipeWorx Feeder(300949) Single-wire model(300950) Dual-wire modelWire Feed Speed1.3–19.8 mpm(50–780 ipm)Input Welding Circuit Rating100 V, 750 A at 100% duty cycleIP RatingIP21Input Power24 VAC, 11 AWire Diameter Capacity0.9–1.6 mm(.035–.062 in.)Maximum Spool Size Capacity27 kg (60 lb.)DimensionsH: 356 mm (14 in.)W: 483 mm (19 in.)D: 737 mm (29 in.)Net WeightSingle30 kg (65 lb.)Dual41 kg (90 lb.)Wireless Hand Control300430 (pg 66)MultiprocessPIPE WELDINGPage 38
The ITW ORBITAL CUTTING & WELDINGdivision with its brands ORBITALUM TOOLS andE.H. WACHS provides global customers onesource for the finest in pipe & tube cutting,beveling and orbital welding products.powergenerationindustry«pharmaceutical,biotechnology& chemicalindustry«food & beverageindustry««heating,ventilation &air conditioningindustry«aerospaceindustry«semiconductorindustryApplications,e.g.Orbital cutting,beveling &welding machinesfor high-purityprocess piping,e.g.»pipe cutting &bevelingmachines«pipeendprepmachines»tube facingmachinesWORLDWIDE SALES & SERVICE:EUROPE, ASIA, AFRICA& MIDDLE EAST:Orbital um Tools GmbHJosef-Schuettler-Str. 1778224 Singen, GermanyTel. +49 (0) 77 3 1 - 792 0tools@orbitalum.comwww.orbitalum.comNORTH AMERICA:E.H. Wachs600 Knightsbridge ParkwayLincolnshire, IL 60069, USATel. +1 847 537 8800Toll Free 800 323 8185sales@ehwachs.comwww.ehwachs.comITW Orbital Cutting & WeldingMiller recommends«oil, gas &petrochemicalindustry«powergenerationindustry«off-shore«pipelinedistributionApplications,e.g.Portable weldprep machinetools forindustrialapplications,e.g.HDSFheavy duty splitframes - builtfor big jobs inthe field«EP 424ID mount endprep machines»LCSFlow clearancesplit frames«TRAV-L-CUTTERportable millingmachines»SDB / FFsmall diameterbevelers & flangefacers«orbital (TIG)welding powersources andorbital weldingheadsNEW DynaPrepMDSF splitframes forheavy duty formtooling & pipeweld preparation»»Page 39
ProductGuideSi 160/160 PFC39STi 160 40STi 203 40STR®400/400C 41STR®500/500C 41Blue Thunder®253 42Blue Thunder®