OWNER’S MANUAL
FORM: OM-817
September 1999
164 065E
Process Selector Control
1.
Specifications
Process Selector Control For SMAW, GTAW, GMAW, And FCAW Welding Processes
Rated At 100 Volts, 650 Amperes At 30% Duty Cycle
Electrically Isolates Weld Current At Electrodes
Allows Changing Process Without Changing Cable Connections
ST-800 202-A
2.
Safety Symbol Definitions
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Symbole graphique d’avertissement! Attention! Cette procédure comporte des risques possibles! Les dangers
éventuels sont représentés par les symboles graphiques
joints.
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.
L’installation, l’exploitation et l’entretien de cet appareil
doivent être confiés uniquement à des personnes
qualifiées et convenablement formées. S’adresser à un
distributeur si l’on ne comprend pas les directives. Pour
des renseignements ayant trait à la SÉCURITÉ lors du
soudage et aux champs électromagnétiques, consulter
les manuels traitant les dévidoirs et les sources de
courant pour le soudage.
Beware of electric shock from wiring.
Attention! Risque d’électrocution due au contact avec des
fils.
Hot parts can cause severe burns. Do not touch hot parts
bare handed––allow cooling period.
Des pièces chaudes peuvent provoquer des brÛlures
graves. Ne pas toucher des parties chaudes à mains
nues––prévoir une période de refroidissement.
Wear safety glasses with side shields.
Porter des lunettes de sécurité avec protections
latérales.
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.
Attention à l’électrocution due au contact avec les fils
électriques et l’électrode de soudage. Toucher l’électrode
en étant en contact avec la masse ou la terre peut causer
une électrocution. Toujours porter des gants secs. Garder
les panneaux et capots fermés.
1998 MILLER Electric Mfg. Co.
3.
Location And Mounting
1
2
2
2
1
3
Welding Power Source
Process Selector Control
Place control as shown.
3
Brackets (Optional)
4
Intellitig Unit
Use brackets as shown when attaching control to a D-60 model wire
feeder or Intellitig unit.
4
Tools Needed:
ST-800 214-A / ST-800 215-A
OM-817 Page 2
4.
Weld Cable Connections
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off welding power source, and disconnect input power before making any input or output weld cable connections.
swarn12.1* 2/93
NOTE
1
See welding power source Owner’s Manual for weld cable and connection location
information. See wire feeder Owner’s Manual for connection location information
as applicable. See High-Frequency unit Owner’s Manual for connection location
information as applicable.
2
3
4
1
Electrode 1
2
Electrode 2
3
A Terminal
4
B Terminal
5
C Terminal
5
E #2
FROM ELECTRODE 2
B
(–)
C
FROM WORK
FROM
POWER
(+)
S1
SOURCE
A
FROM ELECTRODE 1
Tools Needed:
E #1
13/16 in
Ref. ST-099 082-C / Ref. ST-098 115-B
Figure 4-1. One Electrode Positive (+) And One Electrode Negative (–) Connection
OM-817 Page 3
1
1
2
3
4
5
Electrode 1
2
Bus Bar
3
Electrode 2
4
A Terminal
5
B Terminal
6
C Terminal
6
CONNECT BUS BAR
E #1 TO E #2
E #2
B
(–)
FROM
POWER
FROM WORK
C
SOURCE
(+)
S1
A
FROM ELECTRODE
E #1
Tools Needed:
13/16 in
Ref. ST-099 082-C / Ref. ST-098 115-B
Figure 4-2. One Electrode Either Polarity Connection
1
2
3
4
5
1
Electrode 1
2
Electrode 2
3
A Terminal
4
Bus Bar
5
B Terminal
6
C Terminal
6
E #2
FROM ELECTRODE 2
B
FROM
(+)
POWER
SOURCE
C
S1
FROM ELECTRODE 1
A
CONNECT BUS BAR
A TO B
E #1
CONNECT WORK TO POWER SOURCE ( – )
Tools Needed:
13/16 in
Ref. ST-099 082-C / Ref. ST-098 115-B
Figure 4-3. Two Electrodes Same Polarity Connection (Electrode Positive Shown)
OM-817 Page 4
1
2
3
4
1
Electrode 1
2
Electrode 2
3
A Terminal
4
B Terminal
5
C Terminal
5
E #2
FROM ELECTRODE 2
B
MAX. IND.
C
FROM
POWER
MIN. IND.
S1
SOURCE
A
FROM ELECTRODE 1
E #1
CONNECT WORK TO POWER SOURCE ( – )
Tools Needed:
13/16 in
Ref. ST-099 082-C / Ref. ST-098 115-B
Figure 4-4. One Electrode CV And One Electrode CC Connection
(For Welding Power Source With CV And CC Terminals)
5.
Remote 14 Receptacles Information
Socket*
Remote Contactor
A
B
K
J
I
C L N
D M
E
Remote
Amperage/Voltage
Control
Socket Information
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.
C
Command reference; +10 volts dc output to remote control.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from remote control.
K
Chassis common.
H
Voltage feedback; +1 volt dc per 10 output (arc) volts.
L
Not used.
M
Mode select.
N
Remote inductance control.
F
Current feedback; +1 volt dc per 100 amperes.
H
G
F
Remote Output Control
OM-817 Page 5
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 the 115 volt plug from high
frequency unit to this receptacle.
3
1
3
2
Circuit Breaker CB1–Protects
unit from overload.
Y Pin K in welding power
source must be grounded.
See welding power source
circuit diagram to be sure.
ST-800 201-B / Ref. 800 101
7.
Operation
1
Process Selector Switch
Make connections according to
Section 4. Place switch in correct
position for application. For GTAW
DC Electrode Negative (DCEN),
use Process 2 position. For GMAW
or SMAW DC Electrode Positive
(DCEP), use Process 1 position.
1
Y Arcing can damage switch.
Do not change Process Selector
switch position while welding.
Y Using unit with switch
between positions can damage switch.
Place switch lever fully left or right.
ST-800 202-A / Ref. ST-162 505-B
8.
Duty Cycle
Duty Cycle is percentage of 10 minutes
that unit can weld at rated load without
overheating.
Y 30% Duty Cycle at 650 Amperes. Exceeding duty cycle can damage unit
and void warranty.
OM-817 Page 6
3 Minutes Welding
7 Minutes Resting
9.
Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Repair Or
Replace
Cracked
Cables
Replace
Unreadable
Labels
Clean
And
Tighten
Weld
Terminals
6 Months
OR
Blow Out
Or
Vacuum
Inside
During Heavy
Service,
Clean Monthly
When Necessary
Use a high temperature grease such as MILLER Part No. 156 738 to grease the switch mechanism.
10. Troubleshooting
Trouble
Switch does not work.
Remedy
Check connections and Process Selector switch position for desired application. If switch still does
not work, contact nearest Factory Authorized Service Agent.
OM-817 Page 7
11. Electrical Diagram
SB-191 353
Figure 11-1. Circuit Diagram
OM-817 Page 8
12. Parts List
2
3
1
5
6
4
7
8
19
9
17
18
16
15
14
13
12
20
11
10
ST-801 362-B
Figure 12-1. Complete Assembly
OM-817 Page 9
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Complete Assembly
. . . 1 . . . . . . . . . . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . +159 588 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . . . . 159 587 . . DOOR, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . . . . . . 099 255 . . TERMINAL, pwr output neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . 5 . . . . . . . . . . . . . . . . . . . . . . 010 916 . . CONNECTION, cable clamp .075 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . . . . . 190 156 . . CABLE, extension 11ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . . . . . . . . 191 351 . . PLATE, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . PC1 . . . . . . . . . . . 197 769 . . CIRCUIT CARD ASSY, Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . . . . . 097 132 . . STAND-OFF, no 6 x 32, .31 hex .20h stl p . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . . . . . . . . . . . . . . . . . . . 117 913 . . BRACKET, mtg switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . S1 . . . . . . . . . . . 117 914 . . SWITCH, selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . LS1 . . . . . . . . . . . 603 946 . . SWITCH, mag blwt lim 10A 125/250VDC SPDT . . . . . . . . . . . . 1
. . . 13 . . . . . . RC3 . . . . . . . . . . . 134 837 . . RECEPTACLE, str grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . . . . . . . 190 153 . . CASE SECTION, front/bottom/rear . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . . . . . . . 019 663 . . MOUNT, nprn 15/16 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . . . . . . . . . . 010 650 . . PIN, spring CS .125 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . . . . . . . . 019 603 . . KNOB, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . . . . . . . . 091 597 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 lg . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 059 804 . . TUBING, cop .540 OD x .123 wall x .437 lg . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 049 633 . . TUBING, cop .540 OD x .123 wall x .500 lg . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 049 611 . . TUBING, cop .540 OD x .123 wall x .687 lg . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 898 . . BRACKET, mtg PR/IC rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 900 . . BRACKET, mtg PR/IC front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . CB1 . . . . . . . . . . . 083 431 . . CIRCUIT BREAKER, 5 AMP, 250 VAC . . . . . . . . . . . . . . . . . . . . 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.
OM-817 Page 10
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