Series Issued Feb. 0 Index No. AD/. 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 0/800: 0 A at V, 00% duty cycle DC 000/0:,000 A at V, 00% duty cycle AC/DC:,000 A at V, 00% duty cycle Series Choice of three power sources, three interface controls and a range of wire drive motors and accessories. process control technology. Highly reliable thyristor power regulation. control and communication electronics improve weld performance and simplify the integration of the equipment in more advanced applications. Easier setup and operation. The 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 0/800 Easy to integrate. Our 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 000/0 AC/DC 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 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 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 West Spencer Street P.O. Box 09 Appleton, WI 9-09 USA Equipment Sales US and Canada Phone: 8-9-90 FAX: 800-- International Phone: 90-- International FAX: 90-- MillerWelds.com
DC DC 0/800 and DC 000/0 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 Specifications (Subject to change without notice.) Model Amperage/ Voltage Ranges Rated Output IP Rating Amps Input at Rated Amps Input at Rated Load Output, 0 Hz Load Output, 0 Hz 0 V 0 V V 80 V 00 V 0 V KVA KW Maximum Open-Circuit Voltage DC** Dimensions Net Weight DC 0 DC 800 DC 000 DC 0 0 8 A in CC mode 0 V in sub arc mode 00,0 A in CC mode 0 V in sub arc mode 0 A at V, 00% duty cycle 8 A at V, 0% duty cycle,000 A at V, 00% duty cycle,0 A at V, 0% duty cycle IP IP 0. 0.8.8*.9*.*.* 0.* 9 90 8.9*.8*.* 80 90.8*.9*.*.* 0.* 8.*.0*.* Vpk 8 Vpk H: 0 in. ( mm) (including lift eye) W: in. (8 mm) D: 8 in. (9 mm) (not including strain relief) 9 lb. (9 kg) 0 lb. ( kg) 8 lb. (09 kg) 8 lb. (09 kg) *While idling. **Open-circuit voltages in CV mode are factory set at values less than indicated for CC. DC 0 and DC 000 models are certified by Canadian Standards Association to both the Canadian and U.S. Standards. All DC models are manufactured and certified in accordance with IEC-09-, -0. DC Control Panel. Process Selector Switch. Output Indicator Light. Output Switch (Contactor). Amperage/Voltage Adjustment Control. Fault Indicator. Power Switch
AC/DC AC/DC and AC/DC 0. 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 or the Remote Pendant. These easy-to-understand interfaces include two DC modes and 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 Specifications (Subject to change without notice.) Model Amperage/ Voltage Ranges Rated Output IP Rating Amps Input at Rated Load Output 0 V 80 V 00 V (0 Hz) (0 Hz) (0 Hz) KVA KW Maximum Open-Circuit Voltage DC Dimensions Net Weight AC/DC AC/DC 0 00,0 A in CC mode 0 V in sub arc mode,000 A at V, 00% duty cycle,0 A at V, 0% duty cycle IP 98.0*.* 0.9* 9.0*.0*.* 0.9* 9 Vpk H: in. (,09 mm) (including lift eye) W: 8 in. ( mm) D: 8 in. (,9 mm) (not including strain relief),8 lb. (8 kg),0 lb. ( kg) *While idling. AC/DC is certified by Canadian Standards Association to both the Canadian and U.S. Standards. Both AC/DC models are manufactured and certified in accordance with IEC-09-, -0. AC/DC Control Panel. Output Indicator Light. Output Switch (Contactor). Amperage/Voltage Adjustment Control. Fault Indicator. Power Switch
Interface Interface Internal terminal strip is able to integrate with positioners, sidebeams, turning rolls and other peripheral equipment. Interface Analog 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 Interface Analog VAC, single-phase, A, 0/0 Hz VAC, single-phase, A, 0/0 Hz Constant voltage (CV), AC or DC, with remote contactor and output control capabilities Constant current (CC), constant voltage (CV), DC with remote contactor and output control capabilities 0 00 V 0,00 A 0 0 V 0,00 A H:. in. (9 mm) W: in. (0 mm) D: in. (8 mm).8 lb. (. kg) Certified by Canadian Standards Association to both the Canadian and U.S. Standards. Manufactured according to the Standard IEC-09-, -, -0. Interface Control Panels 8 0 9 0 8 9 8 9 Interface Analog. Program Display. Program Push Button. Adjust Control. Sequence Push Button. Upper Display. Upper Display Push Button. Lower Display 8. Lower Display Push Button Interface 9. Flux Push Button 0. Setup Push Button. Start Button. Power Switch. Stop Button. Wire Inch Up. Wire Inch Down. Jog Speed. Preflux Time 0 0 Seconds. Run-In Speed. CC/CV Switch (Located on Right Side of Access Panel). Crater/Burnback Output. Crater Speed. Crater Time 0 Seconds 8. Burnback Time 0 Seconds 9. Postflow Time 0 0 Seconds 0. Voltage Meter. Power Switch. Output Control Knob. Start Button. Stop Button. Amperage Meter.Wire Feed Speed Control Knob. Indicator Light 8. Wire Inch Up 9. Wire Inch Down
Remote Operator Interface Motor Control Internal terminal strip inside Motor Control is able to integrate with positioners, sidebeams, turning rolls and other peripheral equipment. Remote Pendant Remote Operator 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 Motor Control Remote Pendant VAC, single-phase, A, 0/0 Hz VDC, A Constant voltage (CV), AC or DC, with remote contactor and output control capabilities 0 00 V 0,00 A H:. in. (9 mm) W: in. (0 mm) D: in. (8 mm) H: in. (9 mm) W: 0. in. (0 mm) D:. in. (80 mm).8 lb. (. kg) lb. (. kg) Certified by Canadian Standards Association to both the Canadian and U.S. Standards. Manufactured according to the Standard IEC-09-, -, -0. Remote Operator Interface Control Panels 8 9 0 Motor Control Remote Pendant. Power Switch. Program Display. Program Push Button. Adjust Control. Sequence Push Button. Upper Display. Upper Display Push Button. Lower Display 8. Lower Display Push Button 9. Flux Push Button 0. Setup Push Button. Start Button. Stop Button. Wire Inch Up. Wire Inch Down
Interface and Remote Operator Interface Setups Interface 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 or Analog VS +VS Remote Operator Interface Setup Wire drive Flux hopper Work Remote Pendant DC or AC/DC power source + Motor Control VS +VS Wire drive Flux hopper Work Modbus Setups Easy Method High-Level Method Modbus communication DC or AC/DC power source + Control cable Integratorsupplied interface Interface or Analog VS All other items in system: positioner, rolls,etc. +VS Wire drive Flux hopper Work Modbus communication DC or AC/DC power source + Integratorsupplied interface VS All items in the system including integrator-supplied feed motor, etc. +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 DC or AC/DC controlling unit DC or AC/DC following unit(s) 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 RC 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. RC (Blue) RC RC (White) RC (Blue) RC RC (White) To work To work To electrode White To RC on next unit Tandem Connections DC or AC/DC lead unit AC trail unit(s) 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. RC (Blue) RC RC (White) RC (Blue) RC RC (White) To AC or DC output electrode # To work To AC output electrode # To work White Blue To RC on next AC unit
Wire Drive Assemblies Strip Drive 00 Low Voltage 0090 Heavy-duty, right-angle wire drive assembly with mounting bracket. Designed for automated strip clad applications. Wire Drive 00 Low Voltage 0098 Standard-speed, right-angle wire drive assembly. Wire Drive 80 Low Voltage 009 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 00 Low Voltage 8 VDC ft. (. m) / hp, rpm 0 9 ipm (0.. m/min.) N/A (strip cladding applications) 9 lb. ( kg) Wire Drive 00 Low Voltage 8 VDC ft. (. m) / hp, 8 rpm 0 00 ipm (0.8 0. m/min.) / / in. (..8 mm) lb. (.8 kg) Wire Drive 80 Low Voltage 8 VDC ft. (. m) / hp, rpm 0 80 ipm (. 9.8 m/min.) / /8 in. (.. mm) lb. (.8 kg) 8
Accessories Drive Rolls 9 / in. (. mm) 90 / in. (.0 mm) 9 / in. (. mm) 9 / in. (.8 mm) 9 /8 in. (. mm) 900 / in. (.0 mm) 90 / in. (.8 mm) Cables Control Cables 000 0 ft. (9. m) 000 0 ft. (. m) 000 0 ft. (8. m) 0080 80 ft. (. m) 000 00 ft. (0. m) 00 0 ft. (. m) 000 00 ft. (.0 m) Cable between Interface or Motor Control and power source. Submerged Arc Torches Parallel Cable 00 ft. (. m) Tandem Cable 0880 ft. (. m) OBT 00 09 00 amps at 00 percent duty cycle. For / / inch (..0 mm) wire. Torch has concentric flux flow nozzle. OBT 00 Torch Body Extensions 09 in. (. mm) 099 in. (0.8 mm) 09 in. (0. mm) 09 in. (. mm) 00-Amp Single-Wire Torch 0 Short,. in. (88 mm).,00 amps at 00 percent duty cycle. For / / in. (..0 mm) wires. 00-Amp Single-Wire Torch Contact Tips 90 / in. (. mm) 9 / in. (.0 mm) 8 / in. (. mm) 9 /8 in. (. mm) 9 / in. (.0 mm) Flux Hopper Extension Cables 000 0 ft. ( m) 00 ft. (. m) 00 ft. (9.8 m) Cable between Interface or Motor Control and flux hopper. Motor Extension Cables 00 ft. (. m) 00 0 ft. ( m) 0 ft. (. m) 0 ft. (9.8 m) Cable between Interface or Motor Control and drive motor. Continuum Motor/Control Cables 80 ft. (. m) 800 0 ft. (. m) 80 ft. (. m) 800 0 ft. (. m) 8080 80 ft. (. m) 800 00 ft. (0. m) Cable between Motor Control and Remote Pendant. OBT 00 0900,00 amps at 00 percent duty cycle. For / / inch (..8 mm) wire. Torch has concentric flux flow nozzle and features a replaceable breakaway adapter end to prevent costly damage should torch run into an obstruction. OBT 00 Torch Body Extension 098 Overall length with extension is 9 inches (8. mm). Actual length of extension is 8. inches (.9 mm). OBT Torch Contact Tips OBT 00 OBT 00 Wire Size 900 9 / in. (. mm) 90 990 / in. (.0 mm) 90 9 / in. (. mm) 90 00 / in. (.8 mm) 90 9 /8 in. (. mm) 90 9 / in. (.0 mm) 9 / in. (.8 mm) 00-Amp Twin-Wire Torches 0 Short,. in. (88 mm) 0 Long,.8 in. ( mm),00 amps at 00 percent duty cycle. For / / inch (.. mm) wires. 00-Amp Twin-Wire Torch Contact Tips 9 / in. (. mm) 9 / in. (. mm) 9 / in. (.0 mm) 88 / in. (. mm) 0 90 mm External Cladding Head 0,000 amps at 00 percent duty cycle. For 0 90 mm strip. Water-cooled external cladding head is for use with submerged arc and electroslag cladding. See literature AY/.0 for more information. 9
Accessories (continued) Single-Wire Straightener 99 For use with OBT 00, OBT 00 and 00-amp single-wire torches. For / / inch (..8 mm) wires. Twin-Wire Straightener 00 Single adjustment 0 Double/separate adjustment For 00-amp twin-wire torches only. Single Mounting Bracket 0 Single mounting bracket configures single-arc welding head to mount to manual slide. Flux Hopper Low Voltage 009 -pound-capacity flux hopper with automatic flux valve. The opening is sized to allow hook-up of any flux-hoppermounted recovery system. Includes slag screen and -foot (. m) power cable. Wire Reel 08008 For 0-pound ( kg) coil of wire. Requires Spool Support Assembly (98). Tandem Mounting Bracket 0 Tandem mounting bracket is a predesigned welding head configuration for tandem applications. Independent adjustments of lead and trail torches adapt to most applications. Mounting Hinge 0 Mounting hinge allows welding head to swivel 90 degrees with minimal effort. Ideal for changing from longitudinal to circumferential welds. Portable Welding System 9 With DC 0 9 With DC 000 9 With AC/DC Portable Welding System is a ready-toweld submerged arc system for pressure vessel, pipe and welding that requires positioning equipment which can adapt to your application. See literature AD/. for more information. Welding Intelligence Spool Support Assembly 98 For 0-pound ( kg) wire reel. Manual Slide 0 Manual slide for smooth and accurate movement of the welding head. Slide allows for.8 inch (00 mm) travel adjustment with load capacity of 0 pounds (00 kg) at. feet (00 mm). Not recommended for tandem. Tractor 009 Tractor only 9 weld control package 9 Analog weld control package tractor packages include tractor with remote start/stop control and guide rolls, Interface weld controller (digital or analog), Wire Drive 00 for tractor, -pound (. kg) capacity flux hopper with valve, 0-pound ( kg) wire reel, OBT 00 torch and wire straightener. See literature AD/. for more information. -pin Insight Core Module 00 Insight Core is a simplified, internet-based industrial welding information management solution that monitors and reports welding activity for basic productivity and quality metrics. Requires Insight Core to Series Adapter (09). See Insight Core brochure (0) for more information. Insight Core to Series Adapter 09 ArcAgent Auto 0 See literature WI/.0 for more information. 0
Typical Installations ( Interface and Remote Operator Interface Setups.) Continuum motor cable control cable (to power source) b a control cable Electrode cable Must be ordered separately. Volt-sense cable Must be ordered separately. Work cable Must be ordered separately. Power Source See page for available models. Interface (choose one) a b Interface OR Analog See page. Requires a control cable to connect power source to interface. See page 9 for available cable lengths. Remote Operator Interface See page. Consists of Motor Control and Remote Pendant. Requires a Continuum motor cable and a control cable. See page 9 for available cable lengths. Drive Motor See page for available models. Includes -foot (. m) motor control cable. See page 9 for optional cable extension lengths and required drive rolls. Torch (choose one) a b c Single-Wire See page 9 for single-wire torches, optional body extensions and required contact tips. See page 0 for optional wire straightener. Twin-Wire See page 9 for twin-wire torches and required contact tips. See page 0 for optional wire straightener. External Cladding Head (for use Strip Drive 00 Low Voltage drive motor) See page 9. Flux Hopper See page 0. Includes -foot (. m) flux hopper cable. See page 9 for optional cable extension lengths. Reel/Spool Assembly See page 0. Wire reel requires spool support assembly. Manual Slide See page 0.
Ordering Information Equipment and Options Stock No. Description Qty. Price a b a b c Power Source DC 0 90 0/0/ V, 0 Hz DC 800 (0 Hz) CE 90 80/00/0 V, 0 Hz DC 000 90 0/0/ V, 0 Hz DC 0 (0 Hz) CE 90 80/00/0 V, 0 Hz AC/DC 900 0 V, 0 Hz 98 V, 0 Hz with V to 0 V step-down transformer AC/DC 0 (0 Hz) CE 90 80/00 V, 0 Hz Interface Controls and Cables Interface 009 CV, AC/DC digital control Interface Analog 009 CC/CV, DC analog control Control Cables See page 9 Motor Control 0 Motor control for Remote Pendant Remote Pendant 0 CV, AC/DC digital control, requires 0 and Continuum motor/control cable Continuum Motor/Control Cables See page 9 Control Cables See page 9 Drive Motors, Extension Cables and Rolls Strip Drive 00 Low Voltage 0090 Heavy-duty, right-angle wire drive assembly for strip cladding Wire Drive 00 Low Voltage 0098 Standard-speed right-angle drive assembly Wire Drive 80 Low Voltage 009 High-speed right-angle drive assembly Motor Extension Cables (if needed) See page 9 Drive Rolls See page 9 Single-Wire Torches, Straighteners and Tips OBT 00 09 00 amps, 00% duty cycle, air cooled OBT 00 0900,00 amps, 00% duty cycle, air cooled OBT Torch Body Extensions (if needed) See page 9 00-Amp Single-Wire Torch 0 Short,. in. (88 mm),,00 amps, 00% duty cycle Single-Wire Straightener 99 For single-wire torches Contact Tips See page 9 Twin-Wire Torches, Straighteners and Tips 00-Amp Twin-Wire Torches 0 Short,. in. (88 mm),,00 amps, 00% duty cycle 0 Long,.8 in. ( mm),,00 amps, 00% duty cycle Twin-Wire Straightener 00 Single adjustment for twin-wire torches only 0 Double/separate adjustment for twin-wire torches only Contact Tips See page 9 Cladding Head 0 90 mm External Cladding Head 0,000 amps, 00% duty cycle, water-cooled Flux Hopper and Cables Flux Hopper Low Voltage 009 lb. ( kg) flux capacity Flux Hopper Extension Cables (if needed) See page 9 Reel/Spool Assembly Wire Reel 08008 For 0 lb. ( kg) coil, requires 98 Spool Support Assembly 98 Slides Single Manual Slide 0.8 in. (00 mm) travel adjustment Accessories Parallel/Tandem Cables See page 9 Brackets/Hinge See page 0 Tractor/ Portable Welding System See page 0 Welding Intelligence See page 0 Date: Total Quoted Price: Distributed by: 0 Miller Electric Mfg. Co.