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Miller Trailblazer Engine-Driven Welder/Generators Reduce Fuel Use, Sound

Thu October 25, 2012 - National Edition
Construction Equipment Guide

The Trailblazer 325 EFI with Excel power reduces fuel use by as much as 35 percent, extends runtimes by as much as 50 percent, is up to 68 percent quieter, and is up to 5 in. (127 cm) shorter and 108 lbs. (49 kg) lighter than previous models, according to
The Trailblazer 325 EFI with Excel power reduces fuel use by as much as 35 percent, extends runtimes by as much as 50 percent, is up to 68 percent quieter, and is up to 5 in. (127 cm) shorter and 108 lbs. (49 kg) lighter than previous models, according to

Miller Electric Mfg. Co. has introduced the new Trailblazer series of engine-driven welder/generators — the Trailblazer 275 and Trailblazer 325. Built for general construction, structural steel, maintenance and repair, mobile fabrication, and farm and ranch applications, the new Trailblazer welder/generators offer a number of technologies designed to reduce fuel use by as much as 35 percent, extend runtimes by 50 percent, reduce noise by 68 percent, and provide a smaller and lighter footprint for ease of mobility and more space on work trucks, according to the manufacturer.

Two technologies anchor these new welder/generators: Smart-Cor technology and Auto-Speed technology. Smart-Cor technology provides independent weld and generator power, ensuring no interaction between the welding arc and job site tools such as grinders and chop saws. Welder/generators without this capability can cause fluctuations in the welding arc when a load is simultaneously applied to the generator, creating an erratic arc.

Auto-Speed technology automatically adjusts the engine speed to run at lower speeds determined by the load applied to the machine. Whereas other comparable welder/generators operate at 3,600 rpm at all times, the new Trailblazer series varies its output based on demand. For instance, welding with a 1/8-in. Stick electrode can be accomplished at idle speeds of 2,400 rpm. This lowers fuel use and cost, and helps reduce noise in the work area rather than having a machine constantly running at full speed.

“We designed these machines to be the most fuel efficient gas engine-driven welder/generators produced in this size class without sacrificing any power and performance,” said Chris Wierschke, product manager, Miller. “These advances, along with design changes to the way the machine is built, allow for extremely quiet operation and a noticeably smaller and lighter layout. We’ve also built a number of recommended optional technologies into the Trailblazers that make these machines extremely fuel efficient while driving down total operating costs over time.”

Excel Power, EFI Add to Fuel Efficiency

In addition to auto-speed technology, there are two recommended options on both the Trailblazer 275 and 325 that improve fuel efficiency: Excel power and electronic fuel injection (EFI). Excel power is a new technology from Miller that allows users to run most job site tools at idle speed (2,400 rpm) — saving fuel and reducing noise. In traditional welder/generators, the machine immediately ramps up to 3,600 rpm when a generator load is applied. With Excel power, users get 2,400 watts of pure 120-volt, 60-hertz generator power (completely separate from the machine’s standard generator power). This provides powerful and clean generator power, and allows users to run tools and low-amperage welding arcs simultaneously at idle speed.

EFI optimizes the air/fuel ratio for reduced fuel consumption, longer runtimes, fewer emissions and superior performance compared to carbureted models. It provides more reliable starting performance in cold climates, requires no choke, and is less prone to fuel deterioration due to infrequent use. When added together, these technologies allow for runtimes up to approximately 19.5 hours on a single 12-gallon tank of gas, and annual fuel savings up to $1,600 (based on typical usage), according to the manufacturer.

“I can run this machine about 20 hours on one tank of gas,” said Chad Hummel, superintendent, Coastal Steel. “I believe it’s about 30 to 40 percent better on gas than other machines. You might get 12 hours out of [other machines], but they either run on low idle or high idle — it’s all the way or nothing.”

Strong Multiprocess Welding Capabilities and Generator Power

The new Trailblazer series welder/generators provide Stick, MIG, Flux-Cored and DC TIG welding performance. The machine offers carbon arc gouging performance, and the generator is able to power Spectrum plasma cutters for additional cutting and gouging flexibility. The new Trailblazers also feature wave filter technology and a 10-degree skewed motor that provides “clean” generator power for running job site tools with sensitive electronics such as plastic fusion welders, bore welders and appliances.

Each Trailblazer welder/generator also has been fully optimized for truck integration. The shorter and lighter design (up to 5 in. [127 cm] shorter and 108 lbs. [49 kg] lighter) allows more room for other tools and equipment, and reduces the wear and strain of a heavier machine on the truck’s chassis. Daily maintenance also has been made easier with front panel displays to help users keep track of service intervals, as well as the intuitive placement of service points. Each machine is tested and rated for use at 104 F, making it suitable for work in all climates and conditions.

The Trailblazer 275 and Trailblazer 325 offer 275 amps and 325 amps of welding power at 100 percent duty cycle, respectively, in all welding processes, as well as 12,000 watts peak/10,500 watts continuous generator power. The new Trailblazer models represent an improvement in arc quality and offer new features designed to improve total weld quality and performance, according to the manufacturer.

For more information, call 800/4-A-Miller or visit

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