SubArc Digital Series

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1 Digital Series Issued Sept. 01 Index No. ADM/10.0 UK Submerged Arc Welding Power Source Quick Specs Heavy Industrial Applications Railcar Shipbuilding Heavy Fabrication Pipe Manufacturing Pressure Vessel Processes Submerged Arc (SAW) Electroslag (ESW) Air Carbon Arc (CAC-A) Input Power Requires -Phase Power Rated Output DC 60/800: 60 A at V, 100% Duty Cycle DC 1000/10: 1000 A at V, 100% Duty Cycle AC/DC 1000/10: 1000 A at V, 100% Duty Cycle Net Weight DC 660/800: 7 kg ( lb.) DC 1000/10: 9 kg (6 lb.) AC/DC 1000/10: 0 kg (1 lb.) Miller Digital Series Choice of three power sources, two interface controls and a range of wire drive motors and accessories. Digital process control technology. Highly reliable thyristor power regulation. Newly designed digital control and communication electronics improve weld performance and simplify the integration of the equipment in more advanced applications. Intuitive setup and operation. The Digital Series Interface controls recognize the power source and wire drive connected, and automatically configure the system for proper operation. The intuitive interface provides the operator the necessary controls to set process parameters and control output. The power sources feature simplified parallel and tandem setups. Improved flux delivery system. The new Flux Hopper utilizes a flux valve mechanism that assures continuous delivery of flux to the arc. The unique valve design helps prevent jamming of the solenoid actuator due to dust and debris. A sight glass on the front of the flux hopper allows the weld operator to visually monitor the remaining flux in the hopper. DC 60/800 Digital Easy to integrate. The new power sources are easy to integrate by using a standard Modbus connection. Different levels of integration are possible, from simple remote operation to more complex automated systems. DC 1000/10 Digital AC/DC 1000/10 Digital Two DC power source models and one AC/DC power source model. Power sources have sufficient power capacity to cover applications from traditional DC single-arc to multi-wire tandem welding. In Electroslag welding or other high-current demand, two or more power sources can easily be paralleled (both DC and AC/DC machines). Low-voltage accessory operation and improved environmental protection. The new Digital Series accessories are powered with VAC control voltage from the power source. All power sources, interface controls and wire drives are IP- rated. All power sources include thermal overload protection, line voltage compensation and Fan-On-Demand. Power source is warranted for years, parts and labor. Original main power rectifier parts are warranted for years. ITW Welding Italy S.r.l. Via Privata Iseo 6/e 0098 San Guiliano M.se Milano Italy TEL.: FAX: itw@itw-welding.it International Headquarters Miller Electric Mfg. Co. An Illinois Tool Works Company 16 W. Spencer Street Appleton, WI 91 USA TEL.: FAX: MillerWelds.com

2 DC Digital DC 60/800 Digital and DC 1000/10 Digital cover most single- and twin-wire applications. These traditional transformer/rectifier power sources combine high efficiency with the highest reliability, providing best-in-class welding performance and repeatability. DC Digital Specifications (Subject to change without notice.) Model Amperage/ Voltage Ranges Rated Output IP Rating Amps Input at Rated Load Output, 0/60 Hz 0 V 80 V 00 V 0 V 60 V 7 V KVA KW Max. Open- Circuit Voltage** Dimensions Net Weight DC 60/800 Digital DC 1000/10 Digital 0 81 A in CC mode 0 V in Subarc mode A in CC mode 0 V in Subarc mode 60 A at V, 100% duty cycle 1000 A at V, 100% duty cycle IP IP * 1.9* 1.8* 1.6* 1.9* 1.* 1.* 0.76* *.*.0*.*.9*.*.* 0.* 7 VDC 66 VDC H: 69 mm (7. in.) (including lift eye) W: 6 mm (. in.) D: 9 mm (7. in.) (not including strain relief) 7 kg ( lb.) 9 kg (6 lb.) *While idling. **Open-circuit voltages in CV mode are factory set at values less than indicated for CC. DC 60 Digital and DC 1000 Digital models are certified by Canadian Standards Association to both the Canadian and U.S. Standards. All DC Digital models are manufactured and certified in accordance with IEC , -10. DC Digital Control Panel Process Selector Switch. Output Indicator Light. Output Switch (Contactor). Amperage/Voltage Adjustment Control. Fault Indicator 6. Power Switch

3 AC/DC Digital AC/DC 1000/10 Digital. AC welding output enables the AC/DC to be used in tandem arc welding systems with a DC lead arc and AC trailing arc, or with AC / AC arc combinations. Multiple arcs increase deposition rate, resulting in shorter welding cycles. All AC balance control modes can be set directly on the digital interface. The intuitive interface includes two DC modes and 1 best-practice AC balance settings. In multiple-arc configurations, the system automatically adjusts the phase shifting between power sources thereby eliminating arc interaction. There is no need to employ a laptop PC for complex wave shaping. AC/DC Digital Specifications (Subject to change without notice.) Model Amperage/ Voltage Ranges Rated Output IP Rating RMS Amps Input at Rated Output, -Phase at NEMA Load Voltages and Class 1 Rating 80 V 00 V 60 V (0 Hz) (0 Hz) (60 Hz) KVA KW Max. Open- Circuit Voltage Dimensions Net Weight AC/DC 1000/10 Digital A in CC mode 0 V in Subarc mode 1000 A at V, 100% duty cycle 10 A at V, 60% duty cycle IP *.0*.0*.7* 0.9* *.0*.0*.7* 0.9* 71 VDC H: 109 mm ( in.) (including lift eye) W: 699 mm (7. in.) D: 107 mm (7. in.) (not including strain relief) 0 kg (1 lb.) *While idling. AC/DC 1000 Digital model is certified by Canadian Standards Association to both the Canadian and U.S. Standards. Both AC/DC Digital models are manufactured and certified in accordance with IEC , -10. AC/DC Digital Control Panel 1 1. Output Indicator Light. Output Switch (Contactor). Amperage/Voltage Adjustment Control. Fault Indicator. Power Switch

4 Interface Interface Analog Internal terminal strip is able to integrate with positioners, sidebeams, turning rolls and other peripheral equipment. Interface Digital Interface Specifications (Subject to change without notice.) Model Type of Input from Welding Power Source Welding Power Source Type Weld Voltage and Amperage Capacity Dimensions Net Weight Interface Analog Interface Digital Single-phase VAC, A, 0/60 Hz Single-phase VAC, A, 0/60 Hz Constant current (CC), constant voltage (CV), DC with remote contactor and output control capabilities Constant voltage (CV), AC or DC, with remote contactor and output control capabilities 0 60 V A 0 60 V A H: 178 mm (7 in.) W: 86 mm (11. in.) D: 9 mm (11. in.) 8. kg (18 lb.) Certified by Canadian Standards Association to both the Canadian and U.S. Standards. Manufactured according to the Standard IEC , -, -10. Interface Control Panels VOLTS 60 0 AMPERES Interface Analog 1. Jog Speed. Preflux Time 0 10 Seconds. Run-In Speed. CC/CV Switch (Located on Right Side of Access Panel). Crater/Burnback Output 6. Crater Speed 7. Crater Time 0 Seconds 8. Burnback Time 0 Seconds 9. Postflow Time 0 10 Seconds 10. Voltage Meter 11. Power Switch 1. Output Control Knob 1. Start Button 1. Stop Button 1. Amperage Meter 16.Wire Feed Speed Control Knob 17. Indicator Light 18. Wire Inch Up 19. Wire Inch Down 1. Program Display. Program Push Button. Adjust Control. Sequence Push Button. Upper Display 6. Upper Display Push Button 7. Lower Display 8. Lower Display Push Button Interface Digital 9. Flux Push Button 10. Setup Push Button 11. Start Button 1. Power Switch 1. Stop Button 1. Wire Inch Up 1. Wire Inch Down

5 Interface Setup FH In the new setup the positive sense lead is integrated in the wire feeder motor cable and control cable. A customer supplied negative sense lead is required for optimal performance. DC or AC/DC Power Source + Control Cable Interface Analog or Digital VS +VS WF Work Modbus Operation Easy Method High-Level Method Modbus Communication Integrator- Supplied Interface All other items in system: positioner, rolls,etc. FH Modbus Communication Integrator- Supplied Interface All items in the system including integrator-supplied feed motor, etc. DC or AC/DC Power Source + Control Cable Interface Analog or Digital VS +VS WF Work DC or AC/DC Power Source + +VS VS Work Easy method of integrating standard components while controlling them over Modbus communication. Using the standard Interface, wire feed motor and flux hopper, the integrator can remotely adjust settings and operation of the Interface. Documentation is available. High-level method where the integrator uses only the digital power sources and controls them over Modbus communication. Benefits from Miller technology-driven arc performance while integrating into a custom-made welding solution. System Parallel and Tandem Configurations Parallel Connections Tandem Connections DC or AC/DC Controlling Unit DC or AC/DC Following Unit(s) DC or AC/DC Lead Unit AC Trail Unit(s) RC (Blue) RC1 RC (White) RC (Blue) RC1 RC (White) RC (Blue) RC1 RC (White) RC (Blue) RC1 RC (White) To Electrode White To Work To Work To RC1 on Next Unit To AC or DC Output Electrode #1 To Work White To AC Output Electrode # Blue To Work To RC on Next AC Unit Parallel setup. Only like power sources can be paralleled. Paralleling of two machines to increase maximum welding current is done by connecting the paralleling cable from RC on the first unit to RC1 on the second unit. This works for both DC as well as AC/DC machines. Daisy chaining multiple machines to achieve higher output is done in the same way. No special tools needed... plug and play. Tandem setup. To use two or more AC arcs, the arc must be phase shifted to prevent arc to arc interaction. This is done by connecting the tandem cable from RC on the first unit to RC on the second unit. This automatically sets the optimum phase shift for AC welding. No special tools needed... plug and play.

6 Wire Drive Assemblies Strip Drive 100 Digital Low Voltage #00 99 #00 90* With mounting bracket Heavy-duty, right-angle wire drive assembly designed for automated strip clad applications. Wire Drive 00 Digital Low Voltage #00 98* Standard speed # Standard speed, for use with Tractor Wire Drive 780 Digital Low Voltage #00 91* High speed Right-angle wire drive assembly. *Includes adapter plate allowing mounting to 6.-, 108-, and 118-mm (.-,.-, and.6-inch) bolt-hole patterns. Wire Drive Assembly Specifications (Subject to change without notice.) Model Wire Feed Speed Range Wire Diameter Range Rating Type of Input Power Input Power Cord Weight Strip Drive 100 Digital Low Voltage m/min. (10 69 IPM) N/A (Strip cladding applications) 1/ HP, 1 RPM 8 VDC 1. m ( ft.) 9.1 kg (0 lb.) Wire Drive 00 Digital Low Voltage m/min. (0 00 IPM)..6 mm (/ 7/ in.) 1/ HP, 8 RPM 8 VDC 1. m ( ft.) 1 kg ( lb.) Wire Drive 00 Digital Low Voltage for Tractor Wire Drive 780 Digital Low Voltage m/min. (0 780 IPM) 1.6. mm (1/16 1/8 in.) 1/ HP, 1 RPM 8 VDC 1. m ( ft.) 1 kg ( lb.) Accessories Drive Rolls V Knurled drive rolls for use with hard-shelled cored wires. # mm (1/16 in.) # mm (/6 in.) # mm (/ in.) # mm (7/6 in.) #1 96. mm (1/8 in.) # mm (/ in.) # mm (/16 in.) # mm (7/ in.) Cables Control Cables # m (0 ft.) # m (0 ft.) # m (80 ft.) # m (100 ft.) # m (10 ft.) # m (00 ft.) Cable between Interface and power source. Motor Extension Cables # 010 m (10 ft.) # m ( ft.) # m (6 ft.) Cable between Interface and drive motor. Flux Hopper Extension Cables # m (10 ft.) # m ( ft.) # m (6 ft.) Cable between Interface and flux hopper. Parallel Cable # m (1 ft.) Tandem Cable # m (1 ft.) 6

7 Accessories Submerged Arc Torches OBT 600 # amp, 100-percent-duty-cycle torch with concentric flux flow nozzle. Used with mm (1/16 7/ in.) wire. OBT 600 Torch Body Extensions # mm (1 in.) # mm ( in.) # mm ( in.) # mm (6 in.) OBT 100 # amp, 100-percent-duty-cycle torch with concentric flux flow nozzle. Used with mm (1/16 7/ in.) wire. OBT 100 features a replaceable breakaway adapter to prevent costly damage. OBT 100 Torch Body Extension #0 981 Extension length is 1.9 mm (8. in.). Overall length with extension is 8.6 mm (9 in.). OBT Torch Contact Tips OBT 600 OBT 100 Wire Size # # mm (1/16 in.) # # mm (/6 in.) #19 70 #19 1. mm (/ in.) #19 70 # mm (7/6 in.) #19 70 #19 1. mm (1/8 in.) #19 70 # mm (/ in.) # # mm (/16 in.) # # mm (7/ in.) 100-Amp Single-Wire Torches #01 11 Short, 88 mm (11. in.) Used with mm (1/16 / in.) wires. 100-Amp Single-Wire Torch Contact Tips # mm (1/16 in.) # mm (/6 in.) #6 87. mm (/ in.) #6 9. mm (1/8 in.) #6 9.0 mm (/ in.) 100-Amp Twin-Wire Torches #01 1 Short, 88 mm (11. in.) #01 1 Long, 7 mm (16.8 in.) Used with 1.. mm (/6 / in.) wires. 100-Amp Twin-Wire Torch Contact Tips # mm (/6 in.) # mm (1/16 in.) # mm (/6 in.) #6 88. mm (/ in.) Internal and External Cladding Heads Our range of external Strip Cladding Heads are designed for both Electroslag and Submerged Arc strip cladding. Strip size can vary from 0 to 10 mm (1-/16 to -/ in.). The internal Strip Cladding Heads are designed for Submerged Arc strip cladding. Strip size, 0 mm (1-/16 in.). Contact Miller for a full overview of welding torches and cladding heads. Flux Hopper Digital Low Voltage #00 9 Flux hopper with automatic flux valve will carry 11. kg ( lb.) of flux. Sized to allow hookup of any flux-hoppermounted recovery system. Slag screen is provided. Includes. m (11-ft.) power cord. Single-Wire Straightener #199 7 For use with Wire Drive 00 Digital Low Voltage or 780 Digital Low Voltage. For mm (1/16 7/ in.) wires. Twin-Wire Straightener # Single adjustment #01 16 Double/separate adjustment For Twin-Wire Torches only. Wire Reel # For 7-kg (60 lb.) coil of wire. Requires Spool Support Assembly (#119 8). Spool Support Assembly #119 8 For 7-kg (60 lb.) wire reel. Light-Duty Cross Slide #19 11 Allows 1. mm (6 in.) of travel adjustment. Two units can be stacked to provide vertical and horizontal movement. Not recommended for tandem. Heavy-Duty Cross Slide #00 8.-mm (1 in.) diameter, precision, hardened and ground guide rods provide a perfect path for the sealed linear bushings, and smooth accurate movement of the weld head. Allows for 1. mm (6 in.) of travel adjustment and load capacity of 90.7 kg (00 lb.). Recommended for tandem. Contact Miller for a full overview of powered or manual slides. Tractor #00 9 Tractor only #91 61 Analog Weld Control Package #91 61 Digital Weld Control Package tractor packages include Tractor with remote start/stop control and guide rolls, Interface weld controller (analog or digital), Wire Drive 00 for Tractor, 11.-kg ( lb.) capacity flux hopper with valve, 7-kg (60 lb.) wire reel, OBT 600 torch and wire straightener See Lit. No. AD/7. for more information. 7

8 Ordering Information Equipment and Options Stock No. Description Qty. Price DC 60 Digital # /60/7 V, 60 Hz DC 800 Digital (0 Hz) # /00/0 V, 0 Hz, CE DC 1000 Digital # /60/7 V, 60 Hz DC 10 Digital (0 Hz) # /00/0 V, 0 Hz, CE AC/DC 1000 Digital # V, 60 Hz # V, 60 Hz with 7 V to 60 V step-down transformer AC/DC 10 Digital (0 Hz) # /00 V, 0 Hz, CE Controls Interface Analog #00 97 CC/CV, DC analog control Interface Digital #00 96 CV, AC/DC digital control Drive Motors Strip Drive 100 Digital Low Voltage #00 99 Heavy-duty, right-angle drive motor for automated strip clad applications #00 90 Same as above with mounting bracket Wire Drive 00 Digital Low Voltage #00 98 Standard-speed, right-angle drive assembly. Maximum speed 10 mpm (00 IPM) # Same as above for use with Tractor Wire Drive 780 Digital Low Voltage #00 91 High-speed, right-angle drive assembly. Maximum speed 19.8 mpm (780 IPM) Drive Rolls See page 6 Torches OBT 600 # amp, 100% duty cycle, air cooled OBT 600 Torch Body Extensions # mm (1 in.) # mm ( in.) # mm ( in.) # mm (6 in.) OBT 100 # amp, 100% duty cycle, air cooled OBT 100 Torch Body Extension # mm (9 in.) 100-Amp Single-Wire Torches #01 11 Short, 88 mm (11. in.), 100 amp 100-Amp Twin-Wire Torches #01 1 Short, 88 mm (11. in.), 100 amp #01 1 Long, 7 mm (16.8 in.), 100 amp Contact Tips Internal and External Cladding Heads Accessories See page 7 for contact tips for all torches Contact Miller Control Cables See page 6 Motor Extension Cables See page 6 Flux Hopper Extension Cables See page 6 Parallel Cable # m (1 ft.) Tandem Cable # m (1 ft.) Flux Hopper Digital Low Voltage # kg ( lb.) flux capacity Single-Wire Straightener #199 7 For Wire Drive 00 Digital Low Voltage or 780 Digital Low Voltage Twin-Wire Straightener # Single adjustment for Twin-Wire Torches only #01 16 Double/separate adjustment for Twin-Wire Torches only Wire Reel # For 7-kg (60 lb.) coil, requires Spool Support Assembly (#119 8) Spool Support Assembly #119 8 Support for 7-kg (60 lb.) reels Light-Duty Cross Slide #19 11 Provides 1.-mm (6 in.) travel adjustment, load capacity of 68 kg (10 lb.) Heavy-Duty Cross Slide #00 8 Provides 1.-mm (6 in.) travel adjustment, load capacity of 90.7 kg (00 lb.) Tractor See page 7 Date: Total Quoted Price: Distributed by: 01 Miller Electric Mfg. Co.

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