Miller KF962846 is a Process Selector Control for SMAW, GTAW, GMAW, and FCAW Welding Processes. Rated at 100 Volts, 650 Amperes with a duty cycle of 30%. It electrically isolates weld current at electrodes allowing for changing processes without changing cable connections. The device also features Remote 14 Receptacles for remote control and a 115 Volt Receptacle for connecting a high-frequency unit. Additionally, it has a Process Selector Switch for selecting the correct welding process and a Duty Cycle indicator to prevent overheating.
OWNERS
MANUAL
November
1995
FORM:
OM-177
028A
Process
Selector
Control
(Per
NSPR
10663)
1.
Specifications
Effective
With
Serial
No.
KF962846
Process
Selector
Control
For
SMAW,
GTAW,
GMAW,
And
FCAW
Welding
Processes
.
~
ST-800
202-A
Rated
At
100
Volts,
650
Amperes
At
30%
Duty
Cycle
Electrically
Isolates
Weld
Current
At
Electrodes
Allows
Changing
Process
Without
Changing
Cable
Connections
2.
Safety
Symbol
Definitions
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
in
the
adjoining
symbols.
shock
from
wiring.
Keep
al
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
For
WELDING
SAFETY
and
EMF
information,
read
wire
feeder
and
welding
power
source
manuals.
I
.-.
I
Beware
of
electric
shock
from
welding
electrode
or
wiring.
Touching
the
electrode
while
in
contact
with
the
work
or
ground
can
cause
electric
shock.
Always
wear
dry
gloves.
Keep
all
panels
and
covers
closed.
Welding
processes
cause
flying
pieces
of
metal
and
slag.
Wear
safety
glasses
with
side
shields.
parts
can
cause
burns.
Welding
makes
parts
very
hot
iem
cool
before
touching.
3.
Location
And
Mounting
'
1995
MILLER
Electric
Mig.
Co.
4.
Weld
Cable
Connections
Remote
Contactor
A
24
volts
ac.
B
Contact
closure
to
A
completes
24
volts
ac
contactor
control
circuit.
I
115
volts
ac.
J
Contact
closure
to
I
completes
115
volts
ac
contactor
control
circuit.
G
Circuit
common
for
24
and
115
volts
ac
circuits.
D
Remote
control
circuit
common.
E
0
to
+10
volts
dc
input
command
signal
from
remote
control.
NOTE
~
See
welding
power
source
Owners
Manual
for
weld
cable
and
connection
location
information.
See
wire
feeder
Owners
Manual
for
connection
location
information
as
applicable.
See
High-Frequency
unit
Owners
Manual
for
connection
location
in
formation
as
applicable.
5.
Remote
14
Receptacles
Information
Socket*
Socket
Information
C
Remote
AmperageNoltage
Control
*The
remaining
sockets
are
not
used.
Command
reference;
+10
volts
dc
output
to
remote
control.
K
Chassis
common.
OM-177
028
Page
2
w
6.
Welding
Power
Source
Remote
14
Receptacle
And
115
Volt
Receptacle
Connections
1
Remote
Control
Plug
Connect
to
the
welding
power
source
Remote
14
receptacle.
2
115
Volt
Receptacle
Connect
115
volt
plug
from
HF-252D-1
high
frequency
unit.
NOTE:
Do
not
make
any
other
con
nections
to
this
receptacle.
A
Pin
K
in
welding
power
source
must
be
grounded.
See
welding
power
source
circuit
diagram
to
be
sure.
ST-800
201-A
/
Ret.
800
101
7.
Operation
1
Process
Selector
Switch
Make
connections
according
to
Section
4.
Place
switch
in
correct
position
for
application.
For
OTAW
DC
Electrode
Negative
(DCEN).
use
Process
2
position.
For
GMAW
or
SMAW
DC
Electrode
Positive
(DCEP),
use
Process
1
position.
A
Arcing
can
damage
switch.
Do
not
change
Process
Selector
switch
position
while
welding.
A
Using
unit
with
switch
between
positions
can
dam
age
switch.
Place
switch
lever
fully
left
or
right.
ST-BOO
202-A
I
Ret.
ST-162
505-A
PROCESS
2
/
PROCESS
I
DO
NOT
SWITCH
UNDER
LOAD
PROCESS
SELECTOR
CONTROL
WELDING
CIRCUIT
RA11NG
100V
650
AMPS
8.
Duty
Cycle
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load
without
overheating.
A
30%
Duty
Cycle
at
650
Amperes.
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
3 Minutes
Welding
7
Minutes
Resting
OM-177
028
Page
3
9.
Routine
Maintenance
Trouble
Remedy
Switch
does
not
work.
Check
connections
and
Process
Selector
switch
position
for
desired
application.
If
switch
still
does
not
work,
contact
nearest
Factory
Authorized
Service
Agent.
10.
Troubleshooting
OM-177
028
Page
4
11.
Electrical
Diagram
11
~
fi~,3~LS1
s1~GIo
W23
QIJV
PR~EESS
I
I
2C~
A(.)
o-~--~~
c(wo~)
Figure
11-1.
Circuit
Diagram
11
A10
23
23
Cr07
acw
77
~
ow/aK
42
HAIr
G
0
Pt-cl
A
<
ow
~
<
~
<
IJV~
~A~4A~U
o
<
CRU~j1r
008.QA
POWER
(
CC5~4AIO
(o-.tiv~
S3J~CE
-
~4vAr/Tl~vAr
tT)~IJ
cR2
i
E)~
~
2
PC,
cR1
~
______
cR1
~i
.~
-____
____
cR1
~)i
fi
6
e~R~'
<115VAC
MI)aK
73
8
<cOATACTLR
(0~IASSR
DAOJO
aL/
IIIIII_
12
42
c
2
<A
RC3O-11
RC31-5
<
B
RC3O-tt
R031-4
l
PO30-9
RC31-3
<a
PO30-8
RC31-2
~
PO30-5
RC3111
~-<
PC30-4
RC31-1O
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RC3112
D
'
-5
0
-~
77
0R2
0
24
73
0R3
27
77
72
0
)
cR
R3
C
D(
Rd
A
B
SB-177
083-B
OM-177
028
Page
5
0
0
I)
0)
/_
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N)
N)
F)
Q
-c
-I
F.)
(n
I-
U)
T1
(0
C
-&
1%)
-I
0
0
3
CD
-I.
m
C,,
CD
3
a.
(0
0)
0)
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C.)
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ci)
01
Description
Quantity
Figure
12-1.
Complete
Assembly
LABEL,
warning
general
precautionary
1
WRAPPER
1
DOOR,
rear
1
CONNECTION,
cable
clamp
.075
1
CABLE,
interconnection
lOft
.600
in
1
TERMINAL,
pwr
output
neutral
(consisting
of)
5
SCREW,
.500-13
x
1.500
hexhd
sti
1
TERMINAL
BOARD,
neutral
1
BUSBAR,termbd
1
NUT,
.500-13
x
.31
high
sti
1
NUT,
.500-13
x
.44
high
sti
1
SWITCH,
selector
1
SWITCH,
mag
blwt
lim
1OA
125/25OVDC
SPDT
1
CAPACITOR,
cer
disc
1
BRACKET
mtg
switch
1
PLATE,
control
1
RECEPTACLE,
str
grd
2P3W
15A
125V
1
RECEPTACLE
w/SOCKETS,
(consisting
of)
2
CONNECTOR,
circ
skt
14-l8ga
2
RELAY,
end
24VAC
DPDT
20A/1
2OVAC
8
pin
2
CASE
SECTION,
front/bottom/rear
1
NAMEPLATE,
(order
by
model
and
serial
number)
1
010
650
..
PIN,
spring
CS
.125
x
1.000
1
019663
..
MOUNT,
nprn
15/160D
4
019 603
..
KNOB,
ball
1
091
597
..
HANDLE,
switch
1
140772
..
RELAY,encI24VAC4PDT5A/llOVACl4pin
1
116
005
..
BLOCK,
term
20A
7
pole
1
108
023
..
LINK,
jumper
term
blk
1OA
2
097
132
..
STAND-OFF~
6-32
x
.375
Ig
.250
hex
brs
4
166
064
..
CIRCUIT
CARD
ASSEMBLY,
receptacle
bypass
1
130
203
..
CONNECTOR,
rect
mini
.045
l2skt
2
row
(consisting
of)
2
113
746
.
..
CONNECTOR,
rect
mini
O4Sskt
18-24CA
12
098
471
..
BUS
BAR,
interconnecting
(1/8
x
1-1/4
x
3-3/8)
1
098 468
..
BUS
BAR,
interconnecting
(1/8
x
1
x
2-1/8)
2
098 466
..
BUS
BAR,
interconnecting
(1/8
x
1
x
2-5/8)
1
098 465
..
BUS
BAR,
interconnecting
(1/8
x
1
x
3-1/4)
2
098
469
..
BUS
BAR,
interconnecting
(1/8
x
1
x
3-3/4)
1
098
467
..
BUS
BAR,
interconnecting
(1/8
x
1
x
4-1/2)
4
059 805
..
TUBING,
cop
.540
OD
x
.123
wall
x
.312
Ig
3
059 804
..
TUBING,
cop
.540
OD
x
.123
waIl
x
.437
Ig
2
049
633
..
TUBING,
cop
.540
OD
x
.123
wall
x
.500
Ig
3
049
611
..
TUBING,
cop
.540
OD
x
.123
wall
x
.687
Ig
2
145
898
..
BRACKET
mtg
PR/IC
rear
1
145
900
..
BRACKET~
mtg
PR/IC
front
1
+When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
Part
No.
Mkgs.
No.
1
134327
2
+159588
3
159587
4
010916
5
1630780010663
iT
099255
601
976
039
040
039
044
601
880
601879
12
Si
117914
13
S2
603946
14
Cl
....
1367360010663
15
117913
16
177568
17
RC3
134837
18
RC1,
2
143
976
152486
19
CR2,3
072817
20
1595890010633
CR1
PCi
PLG3O,31
OM-177
028
Page
7
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Miller PROCESS SELECTOR CONTROL Owner's manual
