Digital Series Issued Oct. 016 Index No. AD/7. 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 cutting and gouging (CAC-A) Input Power Requires -phase power Rated Output DC 60/800: 60 A at V, 100% duty cycle DC 1000/10: 1,000 A at V, 100% duty cycle AC/DC: 1,000 A at V, 100% duty cycle 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. Easier 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 easy-tounderstand interface provides the operator with the necessary controls to set process parameters and control output. The power sources feature simplified parallel and tandem setups just plug the cable into the appropriate connectors. DC 60/800 Digital Easy to integrate. Our 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 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 the case of electroslag welding or other high-current demand, two or more power sources can easily be paralleled (both DC and AC/DC machines). Improved flux delivery system. Our new flux hopper utilizes a flux valve mechanism that assures continuous delivery of flux to the arc. The unique valve design provides a barrier between the flux and actuation device to help prevent jamming of the solenoid actuator due to dust and debris. A sight glass is provided on the front of the flux hopper allowing the weld operator to visually monitor the remaining flux in the hopper. 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 providing a high level of protection for harsh environments. All power sources also feature thermal overload protection, line voltage compensation and Fan-On-Demand. Power source is warranted for three years, parts and labor. Original main power rectifier parts are warranted for five years. Miller Electric Mfg. Co. An ITW Welding Company 16 West Spencer Street P.O. Box 1079 Appleton, WI 91-1079 USA Equipment Sales US and Canada Phone: 866-91-970 FAX: 800-67-1 International Phone: 90-7- International FAX: 90-7-1 MillerWelds.com
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. They also feature state-of-the-art digital-control electronics to provide 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 Amps Input at Rated Load Output, 60 Hz Load Output, 0 Hz 0 V 60 V 7 V 80 V 00 V 0 V KVA KW Maximum Open-Circuit Voltage DC** Dimensions Net Weight DC 60 Digital DC 800 Digital DC 1000 Digital DC 10 Digital 0 81 A in CC mode 0 V in sub arc mode 100 1,0 A in CC mode 0 V in sub arc mode 60 A at V, 100% duty cycle 81 A at V, 60% duty cycle 1,000 A at V, 100% duty cycle 1,0 A at V, 60% duty cycle IP IP 16 6 0. 0.8.8* 1.9* 1.* 1.* 0.76* 9 90 8 1.9* 1.8* 1.6* 180 90 7 7.8*.9*.*.* 0.* 1 18 117.*.0*.* 7 Vpk 68 Vpk H: 0 in. (76 mm) (including lift eye) W: in. (8 mm) D: 8 in. (96 mm) (not including strain relief) 9 lb. (69 kg) 60 lb. (7 kg) 68 lb. (09 kg) 681 lb. (09 kg) *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-6097-1, -10. DC Digital Control Panel 1 6 1. Process Selector Switch. Output Indicator Light. Output Switch (Contactor). Amperage/Voltage Adjustment Control. Fault Indicator 6. Power Switch
AC/DC Digital AC/DC Digital and AC/DC 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. Using multiple arcs increases deposition rate, resulting in shorter welding cycles for very thick weldments without compromising quality. All AC balance control modes can be set on the Interface Digital. The easy-to-understand 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 before operation. AC/DC Digital Specifications (Subject to change without notice.) Model Amperage/ Voltage Ranges Rated Output IP Rating Amps Input at Rated Load Output 60 V 80 V 00 V (60 Hz) (0 Hz) (0 Hz) KVA KW Maximum Open-Circuit Voltage DC Dimensions Net Weight AC/DC Digital AC/DC 10 Digital 00 1,0 A in CC mode 0 V in sub arc mode 1,000 A at V, 100% duty cycle 1,0 A at V, 60% duty cycle IP 1 98.0*.7* 0.9* 179 176 1 67.0*.0*.7* 0.9* 9 Vpk H: in. (1,09 mm) (including lift eye) W: 8 in. (711 mm) D: 8 in. (1,19 mm) (not including strain relief) 1,187 lb. (8 kg) 1,60 lb. (7 kg) *While idling. AC/DC Digital 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-6097-1, -10. AC/DC Digital Control Panel 1 1. Output Indicator Light. Output Switch (Contactor). Amperage/Voltage Adjustment Control. Fault Indicator. Power Switch
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 Input Power from Welding Power Source Welding Power Source Type Weld Voltage and Amperage Capacity Dimensions Net Weight Interface Analog Interface Digital VAC, single-phase A, 0/60 Hz VAC, single-phase 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 0 1,00 A 0 60 V 0 1,00 A H: 11. in. (9 mm) W: 1 in. (0 mm) D: 7 in. (178 mm) 1.8 lb. (7. kg) Certified by Canadian Standards Association to both the Canadian and U.S. Standards. Manufactured according to the Standard IEC-6097-1, -, -10. Interface Control Panels 1 0 0 0 600 900 10 0 00 100 0 VOLTS 60 0 AMPERES 100 10 1 1 6 7 8 11 1 16 9 10 6 7 8 9 1 1 17 18 19 11 1 1 1 1 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
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, an integrator can remotely adjust settings and operation of the interface. A separate document with interfacing information is available. High-level method where the integrator solely uses the digital power sources and controls them over Modbus communication. Benefits from Miller technology-driven arc performance while integrating into a custommade welding solution. System Parallel and Tandem Setups 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 Parallel setup. Only like power sources can be paralleled. Paralleling of two machines to increase maximum welding current is simply 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 gain higher output is done in the same way. No special tools, laptop or software needed... plug and play. To AC or DC Output Electrode #1 To Work White To AC Output Electrode # Blue To Work To RC on Next AC Unit Tandem setup. To use two or more AC arcs, the arc must be phase shifted to prevent arc to arc interaction. This is simply 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, laptop or software needed... plug and play.
Wire Drive Assemblies Strip Drive 100 Digital Low Voltage 0090 Heavy-duty, right-angle wire drive assembly with mounting bracket. Designed for automated strip clad applications. Wire Drive 00 Digital Low Voltage 0098 0098001 For use with tractor Standard-speed, right-angle wire drive assemblies. Wire Drive 780 Digital Low Voltage 0091 High-speed, right-angle wire drive assembly. Wire Drive Assembly Specifications (Subject to change without notice.) Model Input Power Input Power Cord Rating Wire Feed Speed Wire Diameter Capacity Net Weight Strip Drive 100 Digital Low Voltage 8 VDC ft. (1. m) 1/ hp, 1 rpm 10 1 ipm (0.. m/min.) N/A (strip cladding applications) 0 lb. (9.1 kg) Wire Drive 00 Digital Low Voltage 8 VDC ft. (1. m) 1/ hp, 8 rpm 0 00 ipm (0.8 10. m/min.) / /16 in. (..8 mm) 6 lb. (11.8 kg) Wire Drive 00 Digital Low Voltage for Tractor Wire Drive 780 Digital Low Voltage 8 VDC ft. (1. m) 1/ hp, 1 rpm 0 780 ipm (1. 19.8 m/min.) 1/16 1/8 in. (1.6. mm) 6 lb. (11.8 kg) Accessories Drive Rolls 19 1/16 in. (1.6 mm) 1960 /6 in. (.0 mm) 1961 / in. (. mm) 196 7/6 in. (.8 mm) 196 1/8 in. (. mm) 19700 / in. (.0 mm) 19701 /16 in. (.8 mm) Cables Control Cables 60600 0 ft. (9.1 m) 60600 0 ft. (1. m) 606060 60 ft. (18. m) 606080 80 ft. (. m) 606100 100 ft. (0. m) 60610 10 ft. (6.6 m) 60600 00 ft. (61.0 m) Cable between Interface and power source. Flux Hopper Extension Cables 606010 10 ft. ( m) 6060 ft. (7.6 m) 60606 6 ft. (19.8 m) Cable between Interface and flux hopper. Parallel Cable 607701 1 ft. (.6 m) Motor Extension Cables 00 ft. (1. m) 010 10 ft. ( m) 0 ft. (7.6 m) 06 6 ft. (19.8 m) Cable between Interface and drive motor. Tandem Cable 6087801 1 ft. (.6 m) Insight Core to Digital Series Adapter 019 6
Accessories Submerged Arc Torches OBT 600 09 600-amp 100-percent-duty-cycle torch with concentric flux flow nozzle. Can be used with 1/16 /16 inch (1.6.8 mm) wire. OBT 600 Torch Body Extensions 0967 1 in. (. mm) 0969 in. (0.8 mm) 097 in. (101.6 mm) 097 6 in. (1. mm) OBT 100 0900 1,00-amp 100-percent-duty-cycle torch with concentric flux flow nozzle. Can be used with 1/16 /16 inch (1.6.8 mm) wire. OBT 100 features a replaceable breakaway adapter end to prevent costly damage should torch run into an obstruction. OBT 100 Torch Body Extension 0981 Overall length with extension is 9 inches (8.6 mm). Actual length of extension is 8. inches (1.9 mm). OBT Torch Contact Tips OBT 600 OBT 100 Wire Size 19700 1911 1/16 in. (1.6 mm) 19701 19906 /6 in. (.0 mm) 1970 191 / in. (. mm) 1970 00771 7/6 in. (.8 mm) 1970 191 1/8 in. (. mm) 1970 191 / in. (.0 mm) 1916 /16 in. (.8 mm) 1,00-Amp Single-Wire Torch 0111 Short, 11. in. (88 mm). 1,00-amp torch for 1/16 / in. (1.6.0 mm) wires. 1,00-Amp Single-Wire Torch Contact Tips 690 1/16 in. (1.6 mm) 691 /6 in. (.0 mm) 687 / in. (. mm) 69 1/8 in. (. mm) 69 / in. (.0 mm) 1,00-Amp Twin-Wire Torches 011 Short, 11. in. (88 mm) 011 Long, 16.8 in. (7 mm) 1,00-amp torches for /6 / inch (1.. mm) wires. 1,00-Amp Twin-Wire Torch Contact Tips 69 /6 in. (1. mm) 696 1/16 in. (1.6 mm) 697 /6 in. (.0 mm) 688 / in. (. mm) 0 90 mm External Cladding Head 01167,000-amp 100%-dutycycle water-cooled external cladding head for submerged arc and electroslag cladding. For use with 0 90 mm strip. See literature AY/.0 for more information Flux Hopper Digital Low Voltage 009 -pound-capacity flux hopper with automatic flux valve. The opening is sized to allow hook-up of any flux-hopper-mounted recovery system. Includes slag screen and 11-foot (. m) power cord. Single-Wire Straightener 1997 For use with Wire Drive 00 Digital Low Voltage or 780 Digital Low Voltage. For 1/16 /16 inch (1.6.8 mm) wires. Twin-Wire Straightener 01160 Single adjustment 0116 Double/separate adjustment For twin-wire torches only. Wire Reel 108008 For 60-pound (7 kg) coil of wire. Requires Spool Support Assembly (1198). Spool Support Assembly 1198 For 60-pound (7 kg) wire reel. Tandem Bracket 011 Single Mounting Bracket 011 Mounting Hinge 0116 Manual Slide 0117 Manual slide for smooth and accurate movement of the welding head. Slide allows for 7.87 inch (00 mm) travel adjustment with load capacity of 0 pounds (100 kg) at 1.6 feet (00 mm). Not recommended for tandem. Tractor 009 Tractor only 9161 Analog weld control package 9161 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, -pound (11. kg) capacity flux hopper with valve, 60-pound (7 kg) wire reel, OBT 600 torch and wire straightener. See literature AD/7. for more information. Welding Intelligence 1-pin Insight Core Module 0107 Insight Core is a simplified, internetbased industrial welding information management solution that monitors and reports welding activity for basic productivity and quality metrics. Requires Insight Core to Digital Series Adapter (019). See Insight Core brochure 66011 for more information. ArcAgent Auto 016 See literature WI/1.0 for more information. 7
Ordering Information Equipment and Options Stock No. Description Qty. Price DC 60 Digital 9076 0/60/7 V, 60 Hz DC 800 Digital (0 Hz) CE 9076 80/00/0 V, 0 Hz DC 1000 Digital 9076 0/60/7 V, 60 Hz DC 10 Digital (0 Hz) CE 9076 80/00/0 V, 0 Hz AC/DC Digital 90760 60 V, 60 Hz AC/DC 10 Digital (0 Hz) CE 90761 80/00 V, 0 Hz Controls 91618 7 V, 60 Hz with 7 V to 60 V step-down transformer Interface Analog 0097 CC/CV, DC analog control Interface Digital 0096 CV, AC/DC digital control Drive Motors Strip Drive 100 Digital Low Voltage 0090 Heavy-duty, right-angle wire drive assembly with mounting bracket Wire Drive 00 Digital Low Voltage 0098 Standard-speed, right-angle drive assembly. Maximum speed 00 ipm (10 mpm) 0098 001 Same as above for use with Tractor Wire Drive 780 Digital Low Voltage 0091 High-speed, right-angle drive assembly. Maximum speed 780 ipm (19.8 mpm) Drive Rolls See page 6 Torches OBT 600 09 600 amp, 100% duty cycle, air cooled OBT 600 Torch Body Extensions See page 7 OBT 100 0900 1,00 amp, 100% duty cycle, air cooled OBT 100 Torch Body Extension 0981 9 in. (8.6 mm) 1,00-Amp Single-Wire Torch 0111 Short, 11. in. (88 mm), 1,00 amp 1,00-Amp Twin-Wire Torches 011 Short, 11. in. (88 mm), 1,00 amp 011 Long, 16.8 in. (7 mm), 1,00 amp Contact Tips See page 7 for contact tips for all torches 0 90 mm External Cladding Head 01167,000-amp, 100%-duty-cycle, water-cooled. For use with 0 to 90 mm strip. Accessories Control Cables See page 6 Motor Extension Cables See page 6 Flux Hopper Extension Cables See page 6 Parallel Cable 607701 1 ft. (.6 m) Tandem Cable 6087801 1 ft. (.6 m) Flux Hopper Digital Low Voltage 009 lb. (11 kg) flux capacity Single-Wire Straightener 1997 For Wire Drive 00 Digital Low Voltage or 780 Digital Low Voltage Twin-Wire Straightener 01160 Single adjustment for twin-wire torches only 0116 Double/separate adjustment for twin-wire torches only Wire Reel 108008 For 60 lb. (7 kg) coil, requires Spool Support Assembly (1198) Spool Support Assembly 1198 Support for 60 lb. reels Single Mounting Bracket 011 Tandem Bracket 011 Mounting Hinge 0116 Single Manual Slide 0117 7.87 in. (00 mm) travel adjustment Tractor See page 7 1-pin Insight Core Module 0107 Requires Insight Core to Digital Series Adapter (019) ArcAgent Auto 016 See literature WI/1.0 for more information Date: Total Quoted Price: Distributed by: 016 Miller Electric Mfg. Co.