Editorial Contact:

Chuck Schroeder
Charleston|Orwig, Inc.
(262) 563-5056
cschroeder@comktg.com

MINES, RAILROADS BENEFIT FROM NEW BIG BLUE AIR PAK™; FEATURES SUPERIOR WELDER/GENERATOR/COMPRESSOR POWER

- Uses ultra-rugged Ingersoll-Rand compressor, reliable Big Blue design

- Gouge with 1/2-in. carbons, run larger air tools

- Deluxe model for AC welding, battery starting, 20 kW generator power

APPLETON, Wis., April 8, 2003 -
Miller Electric Mfg. Co. has introduced its new Big Blue Air Pak, the world’s most powerful, most reliable and best-performing welder/generator/air compressor. Its turbo-charged Deutz 2011 diesel engine produces 65 HP at 1800 RPM to create a welding output of 45 to 750 amps (600 amps/44 volts at 40 percent duty cycle) and an optional 20 kW of generator power. Under its hood, a belt-driven, rotary screw compressor from Ingersoll-Rand produces 100 PSI at 60 CFM (100 percent duty cycle).

With nearly twice the welding and air compressor power of the previous design and competitive units, the Big Blue Air Pak can easily air carbon arc gouge with a 1/2-in. diameter carbon at high altitudes.

“The Big Blue Air Pak has performed flawlessly in mines in the Andes Mountains at elevations exceeding 13,000 ft.,” said John Luck, product manager, Miller Electric Mfg. Co. “In remote locations such as mines or rail lines, users also demand reliability. That’s why this new unit marries the proven performance of our Big Blue design with a heavy-duty Ingersoll-Rand CE55 G1 compressor.”

Because it performs the duties of three separate machines a welder, generator and air compressor the Big Blue Air Pak reduces transportation costs and saves space on service and repair rigs. The machine is MSHA approved (Mine Safety Health Administration) for use in underground coal mines.

Compressor Performance

The new Big Blue Air Pak produces 100 PSI at 60 CFM. This is nearly a 50 percent improvement over competitive welder/generator/compressors (100 PSI at 35 CFM) and the old Miller Air Pak (90 PSI at 40 CFM).

“Customers asked us for better air performance because higher pressures remove more molten metal when gouging, run larger tools and improve tool operation,” said Luck. “In fact, this turbo-charged machine is so powerful that when not welding or using generator power it can produce 100 PSI at 40 CFM at idle speed. This reduces noise and lowers fuel use.”

Unlike other compressors and similar competitive units, the Big Blue Air Pak’s compressor does not automatically start when the engine starts.

“You tell this machine when you want compressed air,” said Luck. “An on/off switch on the front panel engages a clutch similar to the one used on your car’s air conditioner.” The clutch stays engaged until the operator pushes the switch to the off position or shuts down the engine. Once off, the clutch cannot be re-engaged for 10 to 15 seconds while the system bleeds off pressure. A self-adjusting belt-tensioner automatically maintains belt tension.

For better quality air, the compressor has its own air cleaner, and its air intake is located inside the machine’s case. An optional air dryer (desiccant) system similar to the one on semi-trailer air brakes prevents water from damaging tools. The air dryer can be remotely mounted. Operators of large service trucks often prefer to locate the engine drive in the truck bed and place air compressor connections under the truck for easier access.

Big Blue Welding Performance

“Anyone who has used a Big Blue 302, 402 or 502 will be familiar with the welding performance and controls of the new Big Blue Air Pak,” noted Luck. “Its Stick welding performance is excellent because it incorporates Arc-Drive active dig control.”

Arc-Drive Improvements

Arc-Drive improves arc starts and out-of-position performance with E7018 electrodes. E7018 electrodes the electrode type most commonly used for structural welds on boom arms, buckets and I-beams tend to stick during arc start. To compensate, many operators increase heat beyond the optimum range. Unfortunately, excess heat creates undercuts, plus the hot puddle could roll out of the joint. Arc-Drive minimizes these problems because its dig characteristics are initiated at the moment when the rod tends to stick. It lets operators keep a tight arc without the electrode sticking and maintains the heat at the optimum level.

The Big Blue Air Pak also produces a DC TIG arc that allows operators to weld as low as 20 amps for thin material. For MIG and flux cored welding, it has the voltage control (14 to 40 volts) and power (500 amps, 40 volts at 100 percent duty cycle) to weld with any wire used for fabrication, construction or repair.

The unit’s single control board is housed in “the vault,” a compartment that completely isolates it from dirt, moisture and corrosion. Since its 1998 introduction, machines with the vault have a 99.71 percent reliability rating on this component.

Standard or Deluxe Models

The standard Big Blue Air Pak features a DC, CC/CV welding output, 5,500 watts peak and 4,000 watts continuous generator power, automatic idle, engine gauges and compressor gauges.

The new deluxe model features an AC/DC polarity switch for AC TIG or Stick welding, 12- and 24-volt battery charger/jump starting capabilities and 20,000 watts of three-phase or 12,000 watts of single-phase generator power. Additional deluxe features include weld meters, battery lockout/tag out disconnect, intake manifold heater, oil pan heater and vandalism lockout.

The Big Blue Air Pak and compressor are covered by Miller’s True Blue three-year factory warranty; the engine is covered separately by Deutz for three years. To download a product spec sheet, visit Miller's website at www.MillerWelds.com. For more information or the Miller distributor nearest you, call 1-800-4-A-MILLER (800-426-4553), fax 877-327-8132, visit the website or write to Miller Electric Mfg. Co., P.O. Box 100, Lithonia, GA 30058.

With headquarters in Appleton, Wis., Miller Electric Mfg. Co. is a leading worldwide manufacturer of Miller and Hobart brand arc welding equipment and related systems for metalworking, construction, maintenance and other applications. Miller Electric is a wholly owned subsidiary of Illinois Tool Works Inc. (ITW), Glenview, Ill. ITW is a diversified multinational manufacturer of highly engineered components, assemblies and systems.