Miller Deltaweld Systems
The new standard in manufacturing, offering advanced MIG welding solutions for all skill levels.
Quick Specs
Heavy Industrial Manufacturing
- General manufacturing
- General fabrication
- Structural steel fabrication
- Transportation
- Sheet metal fabrication
- Light-gauge tube and sheet
Processes
- MIG (GMAW-P)
- Flux-cored (FCAW)
- Accu-Pulse® MIG (GMAW-P) (with Intellx™ Pro feeder)
- Air carbon arc (CAC-A)
- Rated: 3/8-inch carbons (500 model only)
Input Power
- 350: 208/230/460 V, 3-phase, 60 Hz
- 500: 208/230/460 V or 575 V, 3-phase, 60 Hz
Rated Output
- 350: 350 A at 60% duty cycle
- 500: 500 A at 100% duty cycle
Output Range
- 350: 20-400 A, 10-38 V
- 500: 30-650 A, 10-44 V
Make Your Move
The Deltaweld Systems provide a solution for welders of all skill levels, with pulsed MIG capabilities featuring the Intellx™ Pro integrated package.
Ready to weld
Reduce setup time and hassle with a weld-ready Deltaweld MIGRunner™ system.
Dedicated wire feeder options
- Intellx™ feeder: Features a new arc control for improved weld quality with minimal parameter adjustments.
- Intellx™ Pro feeder: Adds Accu-Pulse®, EZ-Set, steel weld programs, and memory buttons.
Legacy meets pulse
Accu-Pulse® offers a more forgiving arc that compensates for variations in operator technique, providing a wider operating window.
Easy to use
EZ-Set simplifies parameter setup based on material thickness, removing complexity.
The Deltaweld 350 MIGRunner™ with Intellx™ Pro feeder is shown. It features superior arc performance, is easy to set up and use, and offers an integrated package with Accu-Pulse™ and a 28% wider operating window.
Deltaweld Systems Features
The Deltaweld systems are designed for performance and reliability.
Intellx™ Pro single-wire feeder:
- Memory buttons for quick program recall.
- Display and controls for volts/arc length, wire feed speed, and EZ-Set (if selected).
- Arc control to fine tune the welding arc.
- LCD setup screen for easy selection of welding processes.
- Jog and purge button.
- Trigger hold, trigger select, preflow and postflow buttons.
Features of the Intellx™ Pro feeder:
- Balanced-pressure drive-roll design and tensioners ensure consistent feedability for better welding performance.
- Accu-Mate™ connection aligns the gun perfectly in the drive-roll carrier, preventing the gun from being pulled loose and providing consistent wire feeding.
- Drive rolls and guides are common with other Miller® industrial feeders.
- Toolless inlet guide and intermediate guide installation.
- Rotatable drive assembly allows for rotation, eliminating severe bends in the wire feed path, extending gun-liner life and aiding in feeding difficult wires.
- Quality-engineered cable management protects connections.
Deltaweld 500 features:
- Dedicated constant-current gouge mode (500 model only), rated for up to 3/8-inch carbons.
- Wind Tunnel Technology™: Internal airflow protects electrical components and PC boards from dirt, dust, and debris, greatly improving reliability.
- Fan-On-Demand™: Operates only when needed, reducing noise, power consumption, and airborne contaminants.
- ArcConnect™: A next-generation communication that utilizes high-speed signals to improve weld performance and allow point-of-use controls to be located at the feeder.
- Standard 115-volt auxiliary power provides 15 amps of circuit-breaker-protected power.
Intellx™ Feeder Features
Comparison of Intellx™ and Intellx™ Pro feeders:
| Feature | Intellx™ Feeder | Intellx™ Pro Feeder |
|---|---|---|
| Digital meters | ✔️ | ✔️ |
| Remote voltage | ✔️ | ✔️ |
| Wire feed speed | ✔️ | ✔️ |
| Arc control | ✔️ | ✔️ |
| Trigger hold | ✔️ | ✔️ |
| Wire jog and purge | ✔️ | ✔️ |
| Wire feed speed feedback | ✔️ | ✔️ |
| Four drive rolls | ✔️ | ✔️ |
| Rotatable drive | ✔️ | ✔️ |
| Up to 60 lb. spool | ✔️ | ✔️ |
| MIG process | ✔️ | ✔️ |
| Dual-wire models | ✔️ | ✔️ |
| EZ-Set MIG | ✔️ | |
| EZ-Set Accu-Pulse® | ✔️ | |
| Trigger select | ✔️ | |
| Preflow | ✔️ | |
| Postflow | ✔️ | |
| Memory slots (2) | ✔️ | |
| Out-of-box programs (steel only) | ✔️ |
Processes available include: MIG, EZ-Set MIG (Intellx Pro only), EZ-Set Accu-Pulse (Intellx Pro only).
Feeder programs (Intellx Pro only) available include: Steel, Stainless steel, Flux-cored, Metal-cored, Different wire sizes, Different gas types.
Single-wire feeder: Swivels for convenience and function, eliminating wear on gun and liner assembly. It moves with the MIG gun, allowing the operator to see the front of the feeder and which parameters are selected.
Dual-wire models: Allow two different wire types to be available on one feeder, avoiding downtime from changing spools and drive rolls.
Deltaweld Systems Processes
Take the performance of each process to the highest level.
Accu-Pulse®
- More forgiving arc compensates for variations in operator technique.
- Most adaptive arc on 16 gauge (1.6 mm) and thicker.
- Designed for all weld positions.
The Accu-Pulse process allows for precise control of the pulse arc, providing optimum molten puddle control and the power to increase wire feed speeds and deposition by 20 to 25 percent in many applications. Adjusting arc length or the appropriate arc control for the selected process can yield good results with various gas mixtures.
| Best For | Standard Spray | Accu-Pulse | Short Circuit |
|---|---|---|---|
| Deposition | A | A | D |
| Gap filling | D | B | A |
| Low heat input | D | B | A |
| Out-of-position welds | A | B | A |
| Low spatter | A | A | C |
| Thick metals | A | A | D |
| Thin metals | B | A | D |
| Increased travel speed | A | A | B |
Ratings A, B, C, and D are relative values. An “A” rating indicates a best fit between performance needs and process. A “blank” rating indicates the process is not recommended for that application.
Deltaweld Specifications
| Model | Mode | Amp/Volt Ranges | Rated Output | Amps Input at Rated Output, 60 Hz, 3-Phase | KVA | Dimensions (Includes lift eye) | Net Weight | ||||
|---|---|---|---|---|---|---|---|---|---|---|---|
| 208 V | 230 V | 460 V | 575 V | ||||||||
| Deltaweld 350 (GMAW) | 10-38 V | 300 A at 29 VDC, 100% duty cycle 350 A at 31.5 VDC, 60% duty cycle 425 A at 35.25 VDC, 30% duty cycle |
29.3 36.7 50.0 |
26.5 33.4 45.1 |
14.6 18.1 23.1 |
11.6 14.5 18.5 |
10.0 12.5 16.9 |
H: 22.36 in. (568 mm) W: 15.35 in. (390 mm) D: 29.15 in. (740 mm) |
115 lb. (52.2 kg) | ||
| Deltaweld 500 (GMAW) | 10-44 V | 500 A at 39 VDC, 100% duty cycle 575 A at 42.75 VDC, 60% duty cycle 650 A at 44 VDC, 25% duty cycle |
64.2 80.2 94.2 |
58.1 73.5 84.9 |
30.4 38.0 43.9 |
24.8 30.4 34.9 |
24.2 (24.7*) 30.3 (30.2*) 35.0 (34.8*) |
21.7 (21.7*) 27.2 (27.2*) 31.6 (31.7*) |
H: 22.36 in. (568 mm) W: 15.35 in. (390 mm) D: 31.65 in. (804 mm) |
145 lb. (65.8 kg) | |
| Gouge (CAC-A) | 30-650 A | 500 A at 40 VDC, 100% duty cycle 575 A at 43 VDC, 60% duty cycle 650 A at 44 VDC, 25% duty cycle |
65.4 81.0 94.2 |
59.6 73.5 84.9 |
31.1 38.0 43.9 |
25.3 30.3 34.9 |
24.8 (25.2*) 30.2 (30.1*) 35.0 (34.8*) |
22.2 (22.3*) 27.3 (27.4*) 31.6 (31.7*) |
|||
*KVA and KW for 575-volt model.
SP Certified by Canadian Standards Association to both the Canadian and U.S. Standards. ✔
Intellx™ Feeder Specifications
| Input Power | Welding Power Source | Input Welding Circuit Rating | Wire Feed Speed | Wire Diameter Capacity | Maximum Spool Size Capacity | Dimensions | Net Weight |
|---|---|---|---|---|---|---|---|
| 50 VDC | Deltaweld 350 or 500 | 600 A at 113 VDC, 60% duty cycle | 50-780 ipm (1.3-19.8 m/min.) | .023-5/64 in. (0.6-2.0 mm) | 18 in. (457 mm) 60 lb. (27 kg) |
Single-wire: H: 16.25 in. (413 mm) W: 12.38 in. (314 mm) D: 27.88 in. (708 mm) Dual-wire: H: 14 in. (356 mm) W: 18 in. (457 mm) D: 34.5 in. (876 mm) |
Single-wire: 44.8 lb. (20.3 kg) Dual-wire: 77 lb. (34.9 kg) |
SP Certified by Canadian Standards Association to both the Canadian and U.S. Standards. ✔
Deltaweld® Performance Data
Deltaweld 350 Duty Cycle Chart
A chart showing welding amperes versus % duty cycle for the Deltaweld 350.
Deltaweld 500 Duty Cycle Chart
A chart showing welding amperes versus % duty cycle for the Deltaweld 500.
Genuine Miller® Accessories
Enhance your Deltaweld system with genuine Miller accessories.
- Running Gear 301523: Features small footprint, dual-cylinder rack, chains for gas cylinders, ergonomic handle design, lockable front casters, two torch holders, and storage area.
- Cart Accessory Kit 301528: Single-wire feeder kit for use with running gear 301523. Includes flowmeter regulator, gas hose, feeder weld cable, work cable with C-clamp, and ArcConnect control/motor cable.
- Stationary Handle Kit 301529: Allows easy movement and portability of the power source.
- Feeder Swivel Kit 301533: For single- and dual-wire feeders. Allows feeder to mount to the top of Deltaweld. Only single-wire feeder can swivel.
- Hanging Bail 058435: Used for suspending feeder over work area.
- ArcConnect Control/Motor Cables: Available in various lengths (9 ft. to 100 ft.) to connect power source directly to feeder or remote operator interface.
- Work Sense Leads (volt sense): Provides accurate voltage feedback on the wire feeder display and compensates for voltage drop from weld cables. Available in 25 ft. and 50 ft. lengths.
Drive Roll Kits and Guides
Select drive roll kits based on wire type and size. Kits include four drive rolls, necessary guides, and an anti-wear sleeve for the inlet guide.
| Wire Size | "V" groove for hard wire | "U" groove for soft wire or cored wires | "V" knurled for hard-shelled cored wires | "U" cogged for extremely soft wire or soft-shelled cored wires (i.e., hard facing types) | "V" groove |
|---|---|---|---|---|---|
| .023/.025 in. (0.6 mm) | 087132 | ||||
| .030 in. (0.8 mm) | 046780 | 044750 | 046792 | ||
| .035 in. (0.9 mm) | 046781 | 044750 | 046792 | ||
| .035 and .045 in. (0.9 and 1.2 mm) | 227061* | ||||
| .040 in. (1.0 mm) | 191917 | ||||
| .045 in. (1.1/1.2 mm) | 046782 | 046785 | 046793 | 083319 | |
| .052 in. (1.3/1.4 mm) | 046783 | 046786 | 046794 | ||
| 1/16 in. (1.6 mm) | 046784 | 046787 | 046795 | 046800 | |
| .068/.072 in. (1.8 mm) | 046788 | 046796 | |||
| 5/64 in. (2.0 mm) | 046788 | 046796 | 046801 |
*Included with Intellx feeders. Drive roll is dual-size reversible with one .035-inch and one .045-inch groove.
Wire Guides
| Wire Size | Inlet Guide | Intermediate Guide |
|---|---|---|
| .023-.040 in. (0.6-1.0 mm) | 221030 | 056206 |
| .045-.052 in. (1.2-1.3 mm) | 221030 | 056207 |
| 1/16-5/64 in. (1.6-2.0 mm) | 221030 | 056209 |
| 5/64-1/8 in. (2.0-3.2 mm) | 229919 | 056211 |
Typical Deltaweld Systems Installations
Illustrations showing different installation configurations for Deltaweld systems.
Standard installation
- Deltaweld power source
- ArcConnect control/motor cable (one required)
- Intellx™ or Intellx™ Pro feeder with Bernard® BTB MIG gun (single-wire)
- Dual-wire feeder with Bernard® BTB MIG guns
Remote wire drive installation
Ideal for fixed automation and boom applications where the wire drive motor is installed/controlled remotely.
- Deltaweld power source
- ArcConnect control/motor cable*
- Intellx™ or Intellx™ Pro remote operator interface (ROI)
- Intellx™ or Intellx™ Pro single-wire remote wire drive with Bernard® BTB MIG gun
- Intellx™ or Intellx™ Pro dual-wire remote wire drive with Bernard® BTB MIG guns
*Remote wire drive installations require two total control/motor cables.
Swingarc™ boom-mounted installation
Accommodates a wide variety of semi-automatic applications, including large weldments and hard-to-reach areas.
- Deltaweld power source
- ArcConnect control/motor cable
- Pipe post and optional Swingpak™ base
- Optional single/dual spool carrier
- Intellx™ Pro single- or dual-wire Swingarc with Bernard® BTB MIG gun(s)
*Required pipe post (bolts to floor or Swingpak base) and optional Swingpak base and single/dual spool carrier must be ordered separately. See page 8.
Ordering Information
Information for ordering Deltaweld MIGRunner™ Systems and components.
Most popular models
| Deltaweld® MIGRunner™ System | Stock No. | Description | Qty. | Price |
|---|---|---|---|---|
| 350 MIGRunner With Single-Wire Intellx™ |
951792 | Includes Deltaweld 350 power source (907747), single- or dual-wire bench feeder with Bernard® BTB Gun 300 A (two with dual-wire feeders) and 035/.045 in. V-grooved drive rolls, factory-installed running gear with cable holder, gun holders, and chains for gas cylinders, cart accessory kit for single- or dual-wire feeder (see page 6), and quick-setup guide and video. | ||
| With Single-Wire Intellx Pro | 951777 | Includes Deltaweld 350 power source (907747), single- or dual-wire bench feeder with Bernard® BTB Gun 300 A (two with dual-wire feeders) and 035/.045 in. V-grooved drive rolls, factory-installed running gear with cable holder, gun holders, and chains for gas cylinders, cart accessory kit for single- or dual-wire feeder (see page 6), and quick-setup guide and video. | ||
| With Dual-Wire Intellx | 951817 | Includes Deltaweld 350 power source (907747), single- or dual-wire bench feeder with Bernard® BTB Gun 300 A (two with dual-wire feeders) and 035/.045 in. V-grooved drive rolls, factory-installed running gear with cable holder, gun holders, and chains for gas cylinders, cart accessory kit for single- or dual-wire feeder (see page 6), and quick-setup guide and video. | ||
| With Dual-Wire Intellx Pro | 951818 | Includes Deltaweld 350 power source (907747), single- or dual-wire bench feeder with Bernard® BTB Gun 300 A (two with dual-wire feeders) and 035/.045 in. V-grooved drive rolls, factory-installed running gear with cable holder, gun holders, and chains for gas cylinders, cart accessory kit for single- or dual-wire feeder (see page 6), and quick-setup guide and video. | ||
| 500 MIGRunner With Single-Wire Intellx |
951814 | Includes Deltaweld 500 power source (907785), single- or dual-wire bench feeder with Bernard® BTB Gun 400 A (two with dual-wire feeders) and 035/.045 in. V-grooved drive rolls, factory-installed running gear with cable holder, gun holders, and chains for gas cylinders, cart accessory kit for single- or dual-wire feeder (see page 6), and quick-setup guide and video. | ||
| With Single-Wire Intellx Pro | 951808 | Includes Deltaweld 500 power source (907785), single- or dual-wire bench feeder with Bernard® BTB Gun 400 A (two with dual-wire feeders) and 035/.045 in. V-grooved drive rolls, factory-installed running gear with cable holder, gun holders, and chains for gas cylinders, cart accessory kit for single- or dual-wire feeder (see page 6), and quick-setup guide and video. | ||
| With Dual-Wire Intellx | 951819 | Includes Deltaweld 500 power source (907785), single- or dual-wire bench feeder with Bernard® BTB Gun 400 A (two with dual-wire feeders) and 035/.045 in. V-grooved drive rolls, factory-installed running gear with cable holder, gun holders, and chains for gas cylinders, cart accessory kit for single- or dual-wire feeder (see page 6), and quick-setup guide and video. | ||
| With Dual-Wire Intellx Pro | 951820 | Includes Deltaweld 500 power source (907785), single- or dual-wire bench feeder with Bernard® BTB Gun 400 A (two with dual-wire feeders) and 035/.045 in. V-grooved drive rolls, factory-installed running gear with cable holder, gun holders, and chains for gas cylinders, cart accessory kit for single- or dual-wire feeder (see page 6), and quick-setup guide and video. | ||
| With Single-Wire Intellx Pro | 951824 | Same as above, but with Deltaweld 500 (575 V) power source (907786) |
Configure a Custom Deltaweld System (See corresponding item numbers in Typical Deltaweld Systems Installations on page 7.)
Power Source
| Deltaweld® 350 | Deltaweld® 500 | |
|---|---|---|
| Stock No. | 907747 907747001 |
907785 907785001 907786 907786001 |
| Description | 208/230/460 V power source with ArcConnect 208/230/460 V power source with ArcConnect, meters and 14-pin receptacle |
208/230/460 V power source with ArcConnect and meters 208/230/460 V power source with ArcConnect, meters and 14-pin receptacle 575 V power source with ArcConnect and meters 575 V power source with ArcConnect, meters and 14-pin receptacle |
Cables and Leads
- ArcConnect Control/Motor Cables: See page 6 for available lengths.
- Work Sense Leads (volt sense): See page 6 for available lengths.
Feeder, ROI and Swingarc
| Intellx Bench-Style Wire Feeders | Intellx Pro Bench-Style Wire Feeders | |
|---|---|---|
| Stock No. | 951783 951815 |
951784 951816 |
| Description | Single-wire feeder with Bernard BTB Gun 300 A and .035/.045 in. V-groove drive rolls Dual-wire feeder with two Bernard BTB Gun 300 A and .035/.045 in. V-groove drive rolls |
Single-wire feeder with Bernard BTB Gun 300 A and .035/.045 in. V-groove drive rolls Dual-wire feeder with two Bernard BTB Gun 300 A and .035/.045 in. V-groove drive rolls |
| Intellx Remote Operator Interface (ROI) | 301548 (Control box for single-wire drive assembly) 301551 (Control box for dual-wire drive assembly) |
|
| Intellx Pro Remote Operator Interface (ROI) | 301552 (Control box for single-wire drive assembly) 301553 (Control box for dual-wire drive assembly) |
|
| Intellx Remote Wire Drive | 301554 (Single-wire drive assembly) 301555 (Dual-wire drive assembly) |
|
| Bernard BTB Gun | Q3015AE8XMC (300 A, 15 ft. (4.6 m) with Centerfire™ consumables) Q4015AE8EMC (400 A, 15 ft. (4.6 m) with Centerfire™ consumables) |
|
| Intellx Pro Swingarc™ Wire Feeders | 951804 (12 ft. single-wire model with Bernard BTB Gun 400 A and .035/.045 in. V-groove drive rolls) 951806 (16 ft. single-wire model with Bernard BTB Gun 400 A and .035/.045 in. V-groove drive rolls) 951805 (12 ft. dual-wire model with two Bernard BTB Gun 400 A and .035/.045 in. V-groove drive rolls) |
|
| Pipe Post | 149838 (4 ft. pipe post. Required for mounting Swingarc booms) 149839 (6 ft. pipe post. Required for mounting Swingarc booms) |
|
| Swingpak™ Base | 183997 (Optional mounting platform for pipe post) | |
| Single/Dual Spool Carrier | 300353 (Optional spool carrier for 4 ft. pipe post) 300352 (Optional spool carrier for 6 ft. pipe post) |
|
| Boom Retrofit Kits | 301470 (Single boom. Retrofits Deltaweld onto 70 Series Swingarc™) 301471 (Dual boom. Retrofits Deltaweld onto 70 Series Swingarc™) |
Accessories
- See page 6
Distributed by: Miller Electric Mfg. LLC
©2020 Miller Electric Mfg. LLC
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