Miller Electric CV-2 Owner`s manual

July 1993 Form: OM-880B

Effective With Serial No. JJ490601

OWNER’S

MANUAL

CV-2 Control Option

Constant Voltage Control

For Big 30, 30A, 40, And 50 Diesels, And Big 40G Models

For SMAW, GMAW, FCAW, And GTAW Welding

100% Duty Cycle At Welding Generator Rated Load

Adapter And Extension Cords May Be Needed

Read and follow these instructions and all safety blocks carefully.

Have only trained and qualified persons install, operate, or service this unit.

cover 6/93 – ST-111 216-A

Call your distributor if you do not understand the directions.

Give this manual to the operator.

For help, call your distributor or: MILLER Electric Mfg. Co., P.O. Box 1079,

Appleton, WI 54912 414-734-9821

PRINTED IN USA

From Miller to You

Thank you and congratulations on choosing Miller. Now

you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy.

With Miller you can count on years of reliable service with proper maintenance. And if for

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System

Standard.

some reason the unit needs repair, there’s a

Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Working as hard as you do

– every power source from

Miller is backed by the most hassle-free warranty in the business.

Miller offers a Technical

Manual which provides more detailed service and parts information for your unit. To obtain a Technical

Manual, contact your local distributor. Your distributor can also supply you with

Welding Process Manuals such as SMAW, GTAW,

GMAW, and GMAW-P.

Miller Electric manufactures a full line of welders and welding related equipment.

For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

TABLE OF CONTENTS

Section No.

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1.

General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2.

Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SPECIFICATIONS

Page No.

1

1

2-1.

Volt-Ampere Curves

2-2.

Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION OR RELOCATION

3-1.

CV-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2.

Remote-5 Receptacle Information And Connections . . . . . . . . . . . . . .

3-3.

Remote-14 Receptacle Information And Connections . . . . . . . . . . . . .

SECTION 4 – OPERATOR CONTROLS

4-1.

Constant Voltage (CV)/Constant Current (CC) Switch

4-2.

Current Control Switch

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3.

Output/Contactor Switch

4-4.

AC/DC Selector Switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5.

Circuit Breaker For Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

12

13

13

13

3

8

8

SECTION 5 – SEQUENCE OF OPERATION

5-1.

Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW)

5-2.

Shielded Metal Arc Welding (SMAW)

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3.

Gas Tungsten Arc Welding (GTAW)

5-4.

Shutting Down

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

15

15

16

SECTION 6 – MAINTENANCE & TROUBLESHOOTING

3

3

6-1.

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2.

Resetting Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3.

Circuit Board PC3 Or PC4 Replacement Procedure . . . . . . . . . . . . . .

6-4.

Tungsten Electrode

6-5.

Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

17

17

18

20

SECTION 7 – ELECTRICAL DIAGRAM

Diagram 7-1. Circuit Diagram For CV-2

Diagram 7-2. Wiring Diagram

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

22

SECTION 8 – PARTS LIST

Figure 8-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

LIST OF CHARTS AND TABLES

Table 2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chart 2-1. DC Volt-Ampere Curves (CV Mode) . . . . . . . . . . . . . . . . . . . . . . . . .

Chart 2-2. AC Volt-Ampere Curves (Single-Phase, CC Mode) . . . . . . . . . . . .

Table 6-1. Maintenance Schedule

Table 6-2. Tungsten Electrode Size

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

19

21

1

2

2

OM-880B – 7/93

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1.

GENERAL INFORMATION AND SAFETY

A. General

Information presented in this manual and on various labels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment.

The nameplate of this unit uses international symbols for labeling the front panel controls. The symbols also appear at the appropriate section in the text.

B. Safety

The installation, operation, maintenance, and troubleshooting of arc welding equipment requires practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with this manual and all applicable codes such as, but not limited to, those listed at the end of Arc Welding Safety Precautions in the welding generator Owner’s Manual.

1-2.

SAFETY ALERT SYMBOL AND SIGNAL

WORDS

The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instructions.

This safety alert symbol is used with the signal words WARNING and CAUTION to call attention to the safety statements.

WARNING statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life.

CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment.

IMPORTANT statements identify special instructions necessary for the most efficient operation of this equipment.

SECTION 2 – SPECIFICATIONS

Table 2-1. Specifications

Model

Rated Output

At 100%

Duty Cycle*

DC

Load

Voltage

Range

In CV

Mode

AC

Open-

Voltage

Range

In CC

Mode*

AC

Amperage

Range

In CC Mode*

BIG 30

DIESEL

And

BIG 30A

DIESEL

BIG 40

DIESEL

And

BIG 40G

BIG 50

DIESEL

200 Amperes

At 28 Volts

300 Amperes

At 32 Volts

300 Amperes

At 32 Volts

10-35 40-70

45-325

Amperes

45-475

Amperes

50-495

Amperes

*See Owner’s Manual For DC Specifications In CC Mode

Max. Open-Circuit

Volts*

DC

CV Mode

AC

CC Mode

40 70

Weight

Net Ship

42 lbs.

(19 kg)

47 lbs.

(21 kg)

OM-880 Page 1

Chart 2-1. DC Volt-Ampere Curves

(CV Mode)

A. BIG 30 DIESEL And BIG 30A DIESEL Models

Chart 2-2. AC Volt-Ampere Curves

(Single-Phase, CC Mode)

A. BIG 30 DIESEL And BIG 30A DIESEL Models

B. BIG 40 DIESEL And BIG 40G Models

SB-111 680-B

B. BIG 40 DIESEL And BIG 40G Models

SB-111 309-A

C. BIG 50 DIESEL Models

SB-111 679-A

C. BIG 50 DIESEL Models

SB-111 313-B

SB-111 317-A

OM-880 Page 2

SB-111 678-A

2-1.

VOLT-AMPERE CURVES (Charts 2-1 And

2-2)

The volt-ampere curves show the output voltage and amperage of the welding generator available at any point from the minimum to maximum of each coarse amperage range. With the use of the volt-ampere curves it is possible to determine what the weld amperage will be at a particular arc voltage. The volt-ampere curves show the minimum and maximum curves of each coarse amperage range.

2-2.

DESCRIPTION

This Constant Voltage control panel is designed for use with the BIG 30 DIESEL, BIG 30A DIESEL, BIG 40 DIE-

SEL, BIG 40G, and BIG 50 DIESEL welding generator models.

The CV-2 expands capabilities of the welding generator to include constant voltage dc and single–phase ac weld output selections. A switch is provided for making the ac selection or for changing the dc polarity. In addition, the

5-socket and 14-socket Amphenol receptacles on this panel provide a junction point with the unit internal circuitry for connecting equipment used in Shielded Metal

Arc (SMAW), Gas Metal Arc (GMAW), Flux Cored Arc

(FCAW), and Gas Tungsten Arc (GTAW) Welding processes.

A 1 ft. (254 mm) adapter cord with 2-prong and 3-socket plugs to a 14-pin Amphenol plug is required to provide

CV-2 connection capability to wire feed equipment using an interconnecting cord with 2-socket and 3-prong twistlock plugs. Other adapter cords and extension cords with different plug combinations can be obtained for connecting various welding system devices and controls to the CV-2 receptacles.

SECTION 3 – INSTALLATION OR RELOCATION

IMPORTANT: If CV-2 was factory installed, proceed di- rectly to Section 3-2.

3-1.

CV-2 INSTALLATION

WARNING: ELECTRIC SHOCK can kill.

•

Do not touch live electrical parts.

•

Stop engine, and disconnect negative (–) battery cable from battery before inspecting, maintaining, or servicing.

MOVING PARTS can cause serious injury.

•

Keep away from moving parts such as fans, belts, and rotors.

HOT ENGINE PARTS can cause severe burns.

•

Wear protective gloves and clothing when working on a hot engine.

•

Allow unit to cool down, if applicable, before beginning installation.

Installation to be performed only by qualified persons.

A. Preparing Unit For Installation

IMPORTANT: On all welding generator models except

BIG 30A DIESEL, it is necessary to move the top cover back approximately 1 ft. (0.3 m) away from the front panel to gain access to components.

1.

Remove all necessary top cover securing hardware and components.

2.

Raise both side doors and tie together across the cover.

3.

Loosen the clamp securing the air cleaner hose to the engine intake manifold and remove the hose from the manifold.

4.

For BIG 40 DIESEL, BIG 40G, and BIG 50 DIE-

SEL models: Loosen the clamp securing the muffler to the exhaust pipe, and remove the muffler from the unit.

5.

Raise and slide cover with side doors approximately 1 ft. (0.3 m) back over radiator.

CAUTION: METAL FILINGS AND/OR

TOOL CONTACT WITH INTERNAL COM-

PONENTS can damage unit.

•

Cover internal components.

•

Clean unit, and remove internal covering material before resuming operation.

6.

On all welding generator models except BIG 30A

DIESEL install key chain onto CV-2 panel as follows: a.

Drill out the pop rivet securing the key chain to the lower front panel.

b.

Install and secure key with key chain onto CV-2 panel at the prepunched hole location (see Figure 4-1: hardware not supplied).

7.

Remove and discard lower front panel from unit; retain securing hardware.

8.

If applicable, disconnect electrode holder and work clamp cables from weld output terminals.

OM-880 Page 3

Transformer T2

Installed Onto

Base Mounting

Strip

Right Front Cover

Of Unit

BIG 30 DIESEL

And BIG 30A DIESEL

Transformer T2 Installation

Figure 3-1. Location For Transformer T2 Installation

B. Transformer And Lower Panel Installation

1.

Locate and install supplied transformer T2 onto the welding generator as follows: a.

For BIG 30 DIESEL and BIG 30A DIESEL models: Install T2 onto the right front portion of the base mounting strip at the prepunched hole locations (see Figure 3-1). Secure T2 with the four supplied 1/4-20 x 3/4 in. screws, flat washers, lockwashers, and nuts on BIG 30 DIESEL, but do not use flat washers and nuts on BIG 30A

DIESEL.

b.


SEL models: Install the supplied mounting bracket onto T2, and secure bracket with the four supplied 1/4-20 x 3/4 in. screws, lock washers, and flat washer. Mount T2 with bracket onto fuel tank and reactor Z1 support angles (see

Figure 3-5) with T2 located below right front corner of fuel tank. Secure mounting bracket to support angles with the three supplied 1/4-20 x

1/2 in. self-tapping screws.

IMPORTANT: To ease CV-2 electrical connections, re- move weld output terminal mounting bracket from left front upright Also, before securing CV-2 panel after installation, check for clearance between lugs of preinstalled cables on the AC/DC Selector switch terminals and any welding generator components. Reposition lugs at switch terminals as necessary to prevent contact between parts.

2.

Install and secure the supplied CV-2 panel onto the welding generator with the hardware removed in Step 7 of Section A.

OM-880 Page 4

ST-145 421

C. Electrical Connections

1.

Disconnect cable 30 from rear of Negative weld output terminal.

2.

Install a 6 in. (152 mm) long piece of supplied insulated tubing onto cable 30 disconnected in

Step 1.

IMPORTANT: If unit is equipped with dc meters, con- nect negative (black) voltmeter lead at the connection point where cables 30 join together. Be sure that the voltmeter lead is installed last on top of the two cable terminal lugs.

3.

Reconnect cable 30 to switch S1 cable 30 and secure with a supplied 1/4-20 x 1/2 in. flange screw and nut (see Figure 3-2).

4.

Slide the installed tubing over connections, and secure with two supplied nylon cable ties (see

Figure 3-2).

5.

Disconnect cable 19 from rear of Positive weld output terminal.

6.

Install the remaining 6 in. (152 mm) long piece of insulated tubing onto cable 19 disconnected in

Step 5.

7.

Reconnect cable 19 to switch S1 cable 19, and secure with a supplied 1/4-20 x 1/2 in. flange screw and nut (see Figure 3-2).

8.

Slide the installed tubing over connection, and secure with two supplied nylon cable ties (see

Figure 3-2).

9.

Connect cable 28 from switch S1 to rear of Negative weld output terminal (see Figure 3-2).

Cable 30 From Negative

Weld Output Terminal

And Black Voltmeter Lead,

If Applicable

Cable 19 From Positive


Rear View (Inside)

Of Lower Front Panel

Cable 28

Cable 30

Left Front Upright When

Viewed From Front

Of Control Panel

Electrode (Negative)


Weld Output

Terminal Assembly

Work (Positive)

Weld Output

Terminal

Bimetal Jumper

Bar-Copper Side

Of Bar Against

Terminal Surface

Cable Lug Connection

With Tubing And Ties

Selector

Switch S1

Cable 19

Figure 3-2. Selector Switch S1 DC Connections

WARNING: ELECTRIC SHOCK can kill; BI-

METAL JUMPER BAR CONTACT WITH IN-

TERNAL COMPONENTS can cause personal injury and equipment damage.

•


•

Do not allow bimetal jumper bar to touch metal surfaces or internal components other than the intended connection.

Route bimetal jumper bar so it is not touching other surfaces or components between connection points during operation.

IMPORTANT: Be sure that copper side of bimetal jumper bar is in contact with copper surface of output terminal when making connections.

10.

Connect bimetal jumper bar from switch S1 to rear of Positive weld output terminal (see Figure

3-2).

11.

For BIG 30 DIESEL and BIG 30A DIESEL models, connect cables 17 and 27 from CV-2 Selector switch S1 as follows: a.

Locate and install supplied cables 17 and 27 on existing cables 17 and 27 on S1. Be sure that the lugs on the nonconnected ends of the supplied cables have the larger diameter hole. Secure the cable lug connections using the supplied 1/4-20 x 3/4 in. screws, flat washers (4), and nuts.

b.

Slide a 6 in. (152 mm) long piece of supplied insulated tubing over each connection. Secure insulated tubing with the supplied nylon cable ties.

SB-112 688-A c.

Route cables over top of stator barrel and to right side of unit. Connect cables from S1 to rectifier SR3 with existing cables 17 and 27 below right rear corner of the fuel tank (see Figure

3-3).

12.


SEL models, connect cables 17 and 27 from

CV-2 Selector switch S1 as follows: a.

Route cables from S1 up to range switch S3.

b.

Connect S1 cables with existing cables 17 and

27 at appropriate terminals on S3 (see Figure

3-3).

13.

Connect lead 100 from installed transformer T2 to terminal D on CV-2 terminal strip 3T (see Parts

List view for CV-2 component locations).

14.

Connect lead 205 from T2 to piggyback connector on existing lead 205 at CV/CC switch S12 on

CV-2 panel (see Parts List view for CV-2 component locations).

15.

Connect lead 206 from T2 to the unused terminal at circuit breaker CB6 on CV-2 panel (see Parts

List view for CV- component locations).

16.

Locate leads 623, 625, 628, 632, and 634 hanging from Current Regulator box on rear of front panel. Cut and remove nylon cable ties holding leads together (see Figure 3-4).

17.

Disconnect leads 628 and 634 at insulated friction terminals, and connect these leads to the matching leads from the CV-2 panel (see Figure

3-4).

OM-880 Page 5

Rectifier SR3:

Connect CV-2 Leads

17 And 27 With

Existing Leads

On SR3

FRONT FRONT

Nameplate

Range Switch S3:

Connect CV-2 Leads

17 And 27 With

Existing Leads On SR3

BIG 30 DIESEL And BIG 30A DIESEL

Rectifier SR3

BIG 40 DIESEL, BIG 40G, And BIG 50 DIESEL

Rear View Of Range Switch

ST-145 422 / ST-145 423

Figure 3-3. Selector Switch S1 AC Connections

Current

Regulator

Box

Lead 628

Lead 634

Lead 632

Lead 623

Lead 625

Leads From

CV-2 Control

Lead 623

Lead 632

Lead 634

Lead 628

OM-880 Page 6

Figure 3-4. Lead Connections From CV-2 To Current Regulator Circuitry

SC-111 077-A

18.

Disconnect leads 623 and 625 at insulated friction terminals, and connect these leads to the matching leads from the CV-2 panel (see Figure

3-4).

19.

Connect lead 632 from Current Regulator box to lead 632 from CV-2 panel (see Figure 3-4).

20.

Connect lead 49 from CV-2 panel to terminal at

AUTO IDLE switch S4 on BIG 30 DIESEL, BIG

40 DIESEL, BIG 40G, and BIG 50 DIESEL models or to terminal at Engine Control switch S1 on

BIG 30A DIESEL models where existing lead 49 is connected as follows: a.

Disconnect existing lead 49 from S4 or S1.

b.

Reconnect lead 49 (from Step a) to piggyback connector on lead 49 from CV-2 panel.

c.

Install piggyback connector onto S4 or S1 terminal where lead 49 was removed in Step a.

21.

Connect lead 42 from CV-2 panel to the rear of the equipment grounding terminal located in the lower right portion of the front control panel on the welding generator.

IMPORTANT: Be sure that all existing leads remain connected to the equipment grounding terminal when connecting lead 42 from CV-2 panel.

22.

Connect leads 110 from CV-2 panel circuit breaker CB5 as follows:

For welding generators not equipped with auxiliary power circuit breaker CB3, proceed as follows; a.

Locate and disconnect the friction terminal connection between leads 110 and 112 near the rear of the 120V duplex receptacle.

b.

Connect the insulated male friction terminal on

CB5 lead 110 to female friction terminal on end of lead 110 disconnected in Step a.

c.

Connect remaining CB5 lead 110 to lead 112 disconnected in Step a.

For welding generators equipped with auxiliary power circuit breaker CB3, proceed as follows: a.

Disconnect existing lead 110 from CB3.

b.

Connect the insulated male friction terminal on

CB5 lead 110 to female friction terminal on end of lead 110 disconnected in Step a.

c.

Connect remaining CB5 lead 110 to CB3 terminal where lead 110 was disconnect in Step a.

23.

Connect the two leads 100 from terminal strip 3T on CV-2 panel to lead 100 at the 120V duplex receptacle as follows: a.

Locate and disconnect the friction terminal connection on lead 100 near the rear of the 120V duplex receptacle.

b.

Connect the insulated female friction terminal on 3T lead 100 with the male friction terminal on the end of lead 100 separated in Step a.

c.

Connect the remaining male friction terminal on

3T lead 100 with the female friction terminal on the end of the remaining lead 100 separated in

Step a.

24.

Tape or tie leads from CV-2 components to existing wiring harness to maintain lead dress and to avoid contact with hot or moving parts.

OM-880 Page 7

Welding

Generator Frame

LEFT

Install Switch Guard Onto

Lower Front Portion Of

Base Just Below New

Lower Front Panel

Big 40 Diesel, Big 40G, And

Big 50 Diesel Transformer

Mounting Bracket

Transformer

T2

Switch Guard

(Angle Bracket)

RIGHT

FRONT

Use Switch Guard

As Template To

Mark Hole Locations

Figure 3-5. Location For Switch Guard Installation

D. Switch Guard Installation (Figure 3-5)

IMPORTANT: Switch guard installation is only neces- sary on welding generators without this bracket installed from the factory.

1.

Locate the supplied switch guard (angle bracket), and using the guard as a template, mark the two mounting hole locations onto lower front portion of the welding generator base as shown in Figure

3-5.

CAUTION: METAL FILINGS AND/OR

TOOL CONTACT WITH INTERNAL COM-

PONENTS can damage unit.

•

Cover internal components.

•

Clean unit, and remove internal covering material before resuming operation.

2.

Drill 9/32 in. (7 mm) diameter hole at each marked location.

3.

Install and secure the switch guard with the two supplied 5/16-18 x 3/4 in. self-forming screws.

E. Final Procedure

1.

Reinstall weld output terminal bracket onto left front upright.

IMPORTANT: To ease reinstalling of the weld output terminal bracket, position cables 19 and 30 below the bottom edge of the bracket so that the cables are routed along the left side of the stator barrel. Also, check the bimetal jumper bar connection at the rear of the weld output terminal after reinstalling the bracket; tighten the bimetal jumper bar securing hardware if necessary.

OM-880 Page 8

SB-112 332-A

2.

Affix supplied ELECTRODE label over NEGA-

TIVE designation for weld output terminal.

3.

Affix supplied WORK label over POSITIVE designation for weld output terminal.

4.

Connect weld cables to weld output terminals as follows: Electrode holder cable to weld output terminal labeled ELECTRODE, and work clamp cable to weld output terminal labeled WORK.

IMPORTANT: Once weld cables are connected to the unit, the Selector Switch position provides the desired

DC polarity or AC to the weld output terminals.

5.

On all welding generator models except BIG 30A

DIESEL, reinstall components as follows: a.

Reinstall and secure top cover.

b.

Reinstall and secure the air cleaner hose onto the engine intake manifold.

6.

On BIG 40 DIESEL, BIG 40G, and BIG 50 DIE-

SEL models: Reinstall and secure the muffler onto the exhaust pipe.

7.

Close and secure both side doors.

3-2.

REMOTE-5 RECEPTACLE INFORMATION

AND CONNECTIONS (Figure 3-6 And 4-1)

REMOTE-5

The 5-socket REMOTE-5 receptacle RC3 provides a junction point for connecting a Remote Contactor and/or

Amperage or Voltage Control to the control circuitry of

the welding power source. To connect the Remote Contactor and/or Amperage or Voltage Control to the RE-

MOTE-5 receptacle, align keyway, insert plug from the

Remote Control, and rotate threaded collar fully clockwise.

A

B

E

D

C

S-0005

Figure 3-6. Front View Of 5-Socket Amphenol Receptacle With Socket Designations

Receptacle RC3 socket connections to the welding power source control circuitry are as follows:

Socket A: Contactor control switch connection.

Socket B: Contactor control switch connection.

Socket C: Amperage or voltage control connection

(maximum side).

Socket D: Amperage or voltage control connection

(minimum side).

Socket E: Amperage or voltage control connection

(wiper contact).

IMPORTANT: Use only one CV-2 receptacle at a time for remote current and/or voltage control or welding generator may not work properly.

3-3.

REMOTE-14 RECEPTACLE INFORMATION

AND CONNECTIONS (Figures 3-7 And 4-1)

REMOTE-14

The 14-socket REMOTE-14 receptacle RC4 provides a junction point for connecting a Remote Amperage/Voltage Control and/or a Remote Contactor Control or a wire feeder providing switch closure for contactor control to the control circuitry of the welding generator. To make connections, align keyway, insert plug fully into receptacle, and rotate threaded collar clockwise.

B

A

K

C

L

D M

N

E

J

I

F

G

H

S-0004

Figure 3-7. Front View Of 14-Socket Amphenol

Receptacle With Socket Designations

The command signals required and the output signals available at the sockets of receptacle RC4 by means of the welding generator control circuitry are as follows:

Socket A: Up to 10 amperes of 24 volts ac 60 Hz with respect to socket G (circuit common), protected by circuit breaker CB6.

Socket B: Weld contactor control for 24 volts ac wire feeders providing contact closure to socket

A.

Socket C: 0 to +10 volts dc with respect to Socket D; reference voltage for output command signal depends on the AMPERAGE & VOLT-

AGE ADJUSTMENT control setting on the unit.

Socket D: Control circuit common for remote control device.

Socket E: Output command signal to wiper of remote control potentiometer, 0 volts equals machine minimum; +10 volts equals machine maximum.

Socket F: Not used.

Socket G: 24 and 120 volts ac circuit common.

Socket H: Not used.

Socket I: Up to 10 amperes of 120 volts ac 60 Hz with respect to socket G (circuit common), protected by circuit breaker CB5.

Socket J: Weld contactor control for 120 volts ac wire feeders providing contact closure to socket

I.

Socket K: Machine chassis.

Socket L: Not used.

Socket M: Not used.

Socket N: Not used.

IMPORTANT: Use only one CV-2 receptacle at a time for remote current and/or voltage control or welding generator may not work properly.

OM-880 Page 9

Work

Electrode Holder

Welding

Generator

Optional Remote

Contactor And

Amperage Control

Connection To

CV-2 5-Socket

Amphenol

Receptacle RC3

SA-112 730

Figure 3-8. Connection Diagram For Remote Control Using 5-Socket Amphenol Receptacle RC3

Electrode Cable

Work

Connection To CV-2

14-Socket Amphenol

Receptacle RC4

Welding

Generator

Spoolmatic 3

Gun/Feeder

Gas Supply With

Flowmeter And

Regulator

SA-112 732

Gas Hose

Figure 3-9. Connection Diagram For Spoolmatic 3 Using 14-Socket Amphenol Receptacle RC4

Work

Wire Drive

Assembly

3 ft. (914 mm)

Long Pigtail

With Amphenol

Electrode Cable

Welding

Gun

S-32 Type Wire Feeder

With 12VDC Optional

Shielding Gas Valve,

Remote Contactor,

And Voltage Control



Receptacle RC4 - Use

14-Pin To 14-Pin

Interconnecting Cord

Welding

Generator

Gas Hose

Figure 3-10. Connection Diagram For S-32P Type Wire Feeders Using

14-Socket Amphenol Receptacle RC4

Gas Supply With

Flowmeter And

Regulator

SA-112 735

OM-880 Page 10

Work

Wire Drive

Assembly

Electrode Cable

Welding

Gun

Welding

Generator

Porta-Mig Model

Wire Feeder






Gas Hose

Figure 3-11. Connection Diagram For Porta-Mig Type Wire Feeders Using


Gas Supply With

Flowmeter And

Regulator

SA-112 734

Work

Electrode Cable

115 VAC Input Cord

Connected To Unit

Duplex Receptacle RC1

Torch/Gun

HF-251 Model

High-Frequency

Unit

Welding

Generator

Connection To CV-2 5-Socket

Amphenol Receptacle RC3 –

Use 5-Pin To 5-Pin


Remote Contactor

Amperage Control

With 20 ft. (6 m)

Long Cord

Work

Gas Hose

Figure 3-12. Connection Diagram For HF-251 Model High-Frequency Unit Using


Wire Drive

Assembly


Supplied With Feeder

Electrode Cable

Gas Supply With

Flowmeter And

Regulator

SA-112 733-A

Welding

Gun 50 Series Model

Wire Feeder

Welding

Generator




14-Pin To 2-Prong

And 3-Socket Twistlock

Receptacle Adapter Cord

Gas Hose

Gas Supply With

Flowmeter And

Regulator

SA-112 731

Figure 3-13. Connection Diagram For 50 Series Type Wire Feeders Using Adapter Cord

For Connection To 14-Socket Amphenol Receptacle RC4

OM-880 Page 11

Work

Wire Drive

Assembly

Electrode Cable

Welding

Gun

50 Series

Wire Feeder

Welding

Generator






Gas Hose

Gas Supply With

Flowmeter And

Regulator

SA-112 734

Figure 3-14. Connection Diagram For 50 Series Wire Feeder Using 14-Socket Amphenol Receptacle RC4

OM-880 Page 12

Prepunched Hole

For Securing

Key Chain

Remote-5

Receptacle RC3

Receptacle

Dust Cups

AC/DC Selector

Switch S1

CV-2 Control

Panel

SECTION 4 – OPERATOR CONTROLS

Circuit

Breaker CB5 Remote-14

Receptacle RC4

Circuit Breaker CB6

Output/Contactor

Switch S10

Current Control

Switch S11

Constant Voltage (CV)/

Constant Current(CC)

Switch S12

SC-111 216-A

Figure 4-1. CV-2 Panel Components

4-1.

CONSTANT VOLTAGE (CV)/CONSTANT

CURRENT (CC) SWITCH (Figure 4-1)

CC

CV

Placing this switch in the CC position causes the welding generator to provide weld output for processes requiring a constant current output.

Placing this switch in the CV position causes the welding generator to provide weld output for processes requiring a constant voltage output.

IMPORTANT: When using the CV mode, place the AM-

PERE RANGES switch on the welding generator in the maximum amperage range position.

4-2.

CURRENT CONTROL SWITCH (Figure 4-1)

PANEL

A

V

CURRENT

CONTROL

REMOTE


•


•

Do not touch weld output terminals when contactor is energized.

•

Do not touch welding wire or electrode and work clamp at the same time.

If remote current or voltage control is desired, make connections to either the REMOTE-5 or REMOTE-14 receptacle as instructed in Section 3-2 or 3-3. Place the

CURRENT CONTROL switch in the REMOTE position.

OM-880 Page 13

When a Remote Current or Voltage Control is being used, the remote control functions as a fine amperage or voltage adjustment for the AMPERAGE & VOLTAGE adjustment control setting of the welding generator. For example: If the AMPERAGE & VOLTAGE adjustment control on the welding generator is set at midrange, the

Remote Current or Voltage Control will provide (from minimum to maximum adjustment) fine amperage or voltage adjustment of one half of the welding generator output for the amperage range selected on the AM-

PERE RANGES switch. For complete remote control of the output, rotate the front panel AMPERAGE & VOLT-

AGE control to the maximum position.

If remote current or voltage control is not desired, place the CURRENT CONTROL switch in the PANEL position. Only the front panel controls will then adjust the output.

4-4.

AC/DC SELECTOR SWITCH (Figure 4-1)

(–)

ELECTRODE POS.

ELECTRODE

NEG.

(+)

AC

4-3.

OUTPUT/CONTACTOR SWITCH (Figure 4-1)

ON

OUTPUT/

CONTACTOR

REMOTE


•


•

Do not touch weld output terminals when contactor is energized.

•

Do not touch welding wire or electrode holder and work clamp at the same time.

When the OUTPUT/CONTACTOR switch is in the ON position, open-circuit voltage is present at the weld output terminals for as long as the engine is running.

If remote contactor control is desired, make connections to either the REMOTE-5 or REMOTE-14 receptacle as instructed in Section 3-2 or 3-3. Place the OUT-

PUT/CONTACTOR switch in the REMOTE position.

Open-circuit voltage is present at the weld output terminals when the Remote Contactor Control switch is closed.

If remote contactor control is not desired, place the

OUTPUT/CONTACTOR switch in the ON position.

Open-circuit voltage will be available at the weld output terminals whenever the engine is running.

OM-880 Page 14


•

Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

•

Use AC output ONLY if required for the welding process.

•

If AC output is required, use remote output control.

•

Read and follow Safety Precautions at beginning of welding generator Owner’s Manual.

CAUTION: ARCING can damage switch contacts.

•

Do not change the position of the AC/DC Selector switch while welding or under load.

Arcing causes the contacts to become pitted and eventually inoperative.

The Selector switch allows the operator to select DC

ELECTRODE NEGATIVE (–), DC ELECTRODE POSI-

TIVE (+), or AC without changing weld output connections.

4-5.

CIRCUIT BREAKER FOR CONTROL CIR-

CUITRY (Figure 4-1)

CIRCUIT

BREAKER

Two circuit breakers, CB5 and CB6, are provided on the

CV-2 panel. Circuit breaker CB5 protects the primary of transformer T2 and the unit wiring from overload and damage. If CB5 opens, there would be no 115 volts ac or

24 volts ac output and the wire feeder would stop. Circuit breaker CB6 protects transformer T2 and the unit wiring from overload and damage. If CB6 opens, there would be no 24 volts ac output and the wire feeder would stop if it was using 24 vac. For circuit breaker resetting and additional information, see Section 6-2.

SECTION 5 – SEQUENCE OF OPERATION

WARNING: ELECTRIC SHOCK can kill;

MOVING PARTS can cause serious injury;

IMPROPER AIRFLOW AND EXPOSURE TO

ENVIRONMENT can damage internal parts.

•


•

Stop engine, and disconnect negative (–) battery cable from battery before inspecting or servicing.

•


•

Keep all covers and panels in place while operating.

Warranty is void if the welding generator is operated with any portion of the outer enclosure removed.

ARC RAYS can burn eyes and skin; NOISE can damage hearing.

•

Wear correct eye, ear, and body protection.

FUMES AND GASES can seriously harm your health.

•

Ventilate to keep from breathing fumes and gases.

•

If ventilation is inadequate, use approved breathing device.

•

Use in open, well ventilated areas, or vent exhaust out of doors.

WELDING WIRE can cause puncture wounds.

•

Do not point gun toward any part of the body, any conductive surface, or other personnel.

HOT METAL, SPATTER, SLAG, AND

EXHAUST can cause fire and burns.

•

Watch for fire.

•

Keep a fire extinguisher nearby, and know how to use it.

•

Allow work and equipment to cool before handling.

ENGINE FUEL can cause fire or explosion.

•

Stop engine before checking or adding fuel.

•

Do not spill fuel; if spilled, wipe up.

•

Do not refuel if engine is hot or running.

•

Do not refuel near sparks or open flame.

•

Do not smoke while refueling.

•

Do not fill tank to top; allow room for expansion.

MAGNETIC FIELDS FROM HIGH CUR-

RENTS can affect pacemaker operation.

•

Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.

See Arc Welding Safety Precautions in the welding generator Owner’s Manual for basic welding safety information.

5-1.

GAS METAL ARC (GMAW) AND FLUX

CORED ARC WELDING (FCAW)

WARNING: Read and follow safety information at beginning of entire Section 5 before proceeding.

1.

Be sure that the welding generator has been prepared as instructed in its Owner’s Manual.

2.

Install and connect CV-2 according to Section 3, if applicable.

3.

Install and connect wire feeder to the appropriate

CV-2 REMOTE-5 or REMOTE-14 receptacle according to Section 3 and wire feed equipment

Owner’s Manual.

4.

Select and obtain proper welding wire, and thread as instructed in wire feeder Owner’s Manual.

5.

If shielding gas is required, make all the necessary connections.

6.

Wear dry insulating gloves and clothing.

7.

Connect work clamp to clean, bare metal at workpiece.

8.

Rotate the AMPERE RANGES switch and AM-

PERAGE AND VOLTAGE ADJUSTMENT control to the desired position (see welding generator

Owner’s Manual).

IMPORTANT: When using the CV mode, place the AM-

PERE RANGES switch on the welding generator in the maximum position, and use the AMPERAGE AND

VOLTAGE ADJUSTMENT control to select the desired voltage. If remote voltage control is used, the minimum to maximum voltage range selection at the remote control will be a percentage of the AMPERAGE AND VOLT-

AGE ADJUSTMENT control setting (see Section 4-2).

When using the CC mode, place the AMPERE

RANGES switch and the AMPERAGE AND VOLTAGE

ADJUSTMENT control on the welding generator in the desired positions. If remote amperage control is used, the minimum to maximum amperage range selection at the remote control will be a percentage of the AMPER-

AGE AND VOLTAGE ADJUSTMENT control setting

(see Section 4-2). GMAW normally uses the CV mode;

FCAW may use either CV or CC depending on the selected welding wire.

9.

Place the CV-2 CV/CC switch in the proper position as determined by the selected welding process (see Section 4-1).

OM-880 Page 15

10.

If remote contactor control is not used, place the

CV-2 OUTPUT/CONTACTOR switch in the ON position. If remote contactor control is to be used, place the OUTPUT/CONTACTOR switch in the

REMOTE position (see Section 4-3).

11.

If remote amperage or voltage control is not used, place the CV-2 CURRENT CONTROL switch in the PANEL position. If remote amperage or voltage control is to be used, place the

CURRENT CONTROL switch in the REMOTE position (see Section 4-2).

12.

Place the AC/DC Selector switch in the proper position as determined by the selected welding process (see Section 4-4).


•


•


•


•


13.

Turn on shielding gas supply at the source, if applicable.

14.

Start the engine as instructed in the welding generator Owner’s Manual.

15.

Place the AUTO IDLE control switch in the OFF position or the Engine Control switch in the RUN position (see welding generator Owner’s Manual).

IMPORTANT: Power requirements by CV-2 compo- nents will cause the welding generator engine to operate at weld rpm continuously in the CV mode if the AUTO

IDLE control switch is placed in the ON position or the

Engine Control switch is placed in the AUTO IDLE position. Placing the AUTO IDLE control switch in the OFF position or the Engine Control switch in the RUN position will prevent mistaking unit operation as a malfunction in the Auto Idle circuitry.

16.

Wear welding helmet with proper filter lens according to ANSI Z49.1.

17.

Begin welding.

5-2.

SHIELDED METAL ARC WELDING (SMAW)


1.


2.


OM-880 Page 16

3.


4.

Select and obtain proper electrode.

5.


6.



Owner’s Manual).

7.

Place the CV-2 CV/CC switch in the CC position

(see Section 4-1).

8.

If remote amperage control is not used, place the

CV-2 CURRENT CONTROL switch in the

PANEL position. If remote amperage control is to be used, place the CURRENT CONTROL switch in the REMOTE position (see Section 4-2).

9.

Place the AC/DC Selector switch in the desired position (see Section 4-4).


•


•


•


•


10.

Place the CV-2 OUTPUT/CONTACTOR switch in the ON position (see Section 4-3).

11.

Start the engine as instructed in the welding generator Owner’s Manual.

12.

Place the AUTO IDLE control switch or Engine

Control switch in the desired position (see welding generator Owner’s Manual).

13.

Insert electrode into holder.

14.


15.

Begin welding.

5-3.

GAS TUNGSTEN ARC WELDING (GTAW)


1.


2.


3.

Install torch/gun according to the manufacturer’s

Owner’s Manual.

4.

Make all necessary shielding gas and water (if applicable) connections.

5.

If high frequency is desired, install and connect the high frequency unit according the the equipment Owner’s Manual.

6.

Select and obtain proper tungsten electrode (see

Table 6-2).

7.

Prepare tungsten electrode according to Section

6-4, and insert into torch.

8.


9.


10.



Owner’s Manual).

11.

Place the CV-2 CV/CC switch in the CC mode

(see Section 4-1).

12.

Connect a Remote Contactor Control to the appropriate CV-2 REMOTE-5 or REMOTE-14 receptacle, and place the OUTPUT/CONTACTOR switch in the REMOTE position (see Sections

3-2, 3-3, and 4-3).

13.

If remote amperage control is not used, place the

CV-2 CURRENT CONTROL switch in the

PANEL position. If remote amperage control is to be used, place the CURRENT CONTROL switch in the REMOTE position (see Section 4-2).

14.

Place the AC/DC Selector switch in the desired position (see Section 4-4).


•


•


•


•


15.

Turn on the high frequency equipment, if applicable.

16.

Turn on shielding gas supply and water (if applicable) at the source.

17.

Start the engine as instructed in the welding generator Owners Manual.

18.

Place the AUTO IDLE control switch in the OFF position or the Engine Control switch in the RUN position (see welding generator Owner’s Manual).

IMPORTANT: Power requirements by CV-2 compo- nents will cause the welding generator engine to operate at weld rpm continuously in the CV mode if the AUTO

IDLE control switch is placed in the ON position or the

Engine Control switch is placed in the AUTO IDLE position. Placing the AUTO IDLE control switch in the OFF position or the Engine Control switch in the RUN position will prevent mistaking unit operation as a malfunction in the Auto Idle circuitry.

19.


20.

Begin welding.

5-4.

SHUTTING DOWN

1.

Stop welding.

2.

Turn off or disconnect all auxiliary equipment.

3.

Remove all weld and power loads from the unit.

4.

Allow the engine to idle for a few minutes to permit the internal engine temperature to equalize.

Increase the idling time if the engine has been operating for an extended period or at full load.

5.

Stop the engine.

6.

Turn off the shielding gas and water/coolant supply if applicable.

WARNING: HIGH CONCENTRATION OF

SHIELDING GAS can harm health or kill.

•

Shut off gas supply when not in use.

OM-880 Page 17

SECTION 6 – MAINTENANCE & TROUBLESHOOTING

6-1.

ROUTINE MAINTENANCE

IMPORTANT: Every six months inspect the labels on this unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced when necessary. See the Parts List for part numbers of precautionary labels.


•


•



•



•


Maintenance to be performed only by qualified persons.

Table 6-1. Maintenance Schedule

Frequency* Maintenance

Every Month Units in heavy service environments:

Check labels, cables, and wiring; clean internal parts (see Section

6-1A and Section 6-1B).

Every 3 Months Check cables and wiring (see

Section 6-1A.

Every 6 Months Check all labels (see IMPORTANT block, Section 6-1). Clean internal parts (see Section 6-1B).

*Frequency of service is based on units operated at

40 hours per week. Increase frequency of maintenance if usage exceeds 40 hours per week.

A. Cables And Wiring

WARNING: Read and follow safety information at beginning of entire Section 6-1 before proceeding.

Check wiring, cable, and bimetal jumper bar connections for tightness and flaws. Ensure that all connections are clean and tight. Check the insulation for breaks or other signs of damage. Repair or replace cables or wiring as necessary. Check for any contact by bimetal jumper bar to surfaces or components other than the intended connections. Move bimetal jumper bar to pre-

OM-880 Page 18 vent contact with other surfaces or components between connection points.

B. Internal Cleaning

WARNING: Read and follow safety information at beginning of entire Section 6-1 before proceeding.

Keep the unit clean by blowing out the inside with clean, dry, compressed air. Clean any dirty connections.

Check and tighten any loose connections.

6-2.

RESETTING CIRCUIT BREAKERS (Figure

4-1)

The circuit breakers are automatic-trip type and are not manually operable. When the circuit breaker button is in, the circuit breaker is functional. When the button is out, the breaker is open and not functional.

If a circuit breaker trips when equipment use begins, a fault is probable present in the equipment. If a breaker trips after prolonged equipment use, an overload condition is probably present. Should a breaker trip, proceed as follows:


•


•

Stop engine, and disconnect equipment from deenergized receptacle before repairing a fault or overload.

1.

Locate and repair fault or reduce receptacle load.

2.

Reconnect equipment to receptacle and start engine.

3.

Reset circuit breaker (depress button); it may be necessary to allow a cooling period before the breaker can be reset.

4.

Resume operation.

6-3.

CIRCUIT BOARD PC3 OR PC4 REPLACE-

MENT PROCEDURE (Figure 6-1)


•


•



•


If a printed circuit board is at fault for a problem with the unit, replace the board using the following procedure.

Do not attempt board repair. Contact the nearest Factory Authorized Service Station/Service Distributor for correct replacement part.

Standoff Support (3)

Contactor Control

Board PC3

Wiring Harness Plug

Voltage Control

Board PC4

Wiring Harness Plug

Standoff

Support (4)

SC-112 013-A

Figure 6-1. Circuit Board Locations And Components

CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit boards.

•

Put on properly grounded wrist strap

BEFORE handling circuit boards.

•

Transport circuit boards in proper staticshielding carriers or packages.

•

Perform work only at a static-safe work area.

INCORRECT INSTALLATION or misaligned plugs can damage circuit board.

•

Be sure that plugs are properly installed and aligned.

EXCESSIVE PRESSURE can break circuit board.

•

Use only minimal pressure and gentle movement when disconnecting or connecting board plugs and removing or installing board.

IMPORTANT: All directions, such as left or right, are with respect to the serviceperson facing the front panel.

1.

Open necessary side door as follows: left side for

Contactor Control board PC3, or right side for

Voltage Control board PC4.

2.

Disconnect wiring harness plug from board receptacle (see Figure 6-1), and remove board from standoff supports.

3.

Reconnect wiring harness plug to new board receptacle; be sure plug snaps firmly in place.

4.

Install and secure new board onto standoff supports on lower front panel.

5.

Close side door.

6.

Resume operation.

6-4.

TUNGSTEN ELECTRODE (Table 6-2, And

Figures 6-2 And 6-3)

Use Table 6-2 to select the correct size and type tungsten electrode. Prepare the tungsten electrode using the following guidelines. A properly prepared tungsten electrode is essential in obtaining a satisfactory weld.

A. For AC or DC Electrode Positive Welding (Figure 6-2)

Ball the end of tungsten electrodes used for ac or dc electrode positive welding before beginning the welding operation. Weld amperage causes the tungsten electrode to form the balled end. The diameter of the end should not exceed the diameter of the tungsten electrode by more than 1-1/2 times. For example, the end of a 1/8 in. (3.2 mm) diameter tungsten electrode should not exceed a 3/16 in. (4.8 mm) diameter end.

OM-880 Page 19

Table 6-2. Tungsten Electrode Size

Electrode Diameter Amperage Range - Polarity - Gas Type

Pure Tungsten

(Green Band)

DC-Argon Electrode

Negative/Straight Polarity

DC-Argon Electrode

Positive/Reverse Polarity

AC-Argon Using

High Frequency

AC-Argon Balanced

Wave Using High Freq.

.010”

.020”

.040”

1/16”

3/32”

1/8”

5/32”

3/16”

1/4”

2% Thorium Alloyed

Tungsten

(Red Band)

Up to 15

5-20

15-80

70-150

125-225

225-360

360-450

450-720

720-950

*

*

*

10-20

15-30

25-40

40-55

55-80

80-125

Up to 15

5-20

10-60

50-100

100-160

150-210

200-275

250-350

325-450

Up to 10

10-20

20-30

30-80

60-130

100-180

160-240

190-300

250-400

.010”

.020”

.040”

1/16”

3/32”

1/8”

5/32”

3/16”

1/4”

Up to 25

15-40

25-85

50-160

135-235

250-400

400-500

500-750

750-1000

*

*

*

10-20

15-30

25-40

40-55

55-80

80-125

Up to 20

15-35

20-80

50-150

130-250

225-360

300-450

400-500

600-800

Up to 15

5-20

20-60

60-120

100-180

160-250

200-320

290-390

340-525

Zirconium Alloyed

Tungsten

(Brown Band)

.010”

.020”

.040”

1/16”

3/32”

1/8”

5/32”

3/16”

1/4”

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

Up to 20

15-35

20-80

50-150

130-250

225-360

300-450

400-550

600-800

Up to 15

5-20

20-60

60-120

100-180

160-250

200-320

290-390

340-525

*NOT RECOMMENDED

The figures listed are intended as a guide and are a composite of recommendations from American Welding

Society (AWS) and electrode manufacturers.

S-0009/8-88

B. For DC Electrode Negative Welding (Figures 6-2

And 6-3)

1-1/2 Times

Electrode

Diameter

2-1/2 Times

Electrode

Diameter

CAUTION: HOT FLYING METAL PARTICLES can injure personnel, start fires, and damage equipment; TUNGSTEN CONTAMINA-

TION can lower weld quality.

•

Shape tungsten electrode only on grinder with proper guards in safe location wearing proper face, hand, and body protection.

•

Do not use same wheel for any other job or the tungsten will become contaminated.

AC And DC

Electrode Positive

DC Electrode

Negative

S-0161

Figure 6-2. Properly Prepared Tungsten

Electrodes

OM-880 Page 20

TUNGSTEN PREPARATION: IDEAL

Stable Arc

Straight Ground

TUNGSTEN PREPARATION: WRONG

Arc Wander

Point

Flat

(The Dia. Of This

Flat Governs

Amperage Capacity)

Radial Ground

S-0162

Figure 6-3. Tungsten Preparation

Shape tungsten electrodes on a fine grit, hard abrasive wheel used only for tungsten shaping. Grind tungsten electrodes so that grinding marks run lengthwise with the electrode. These procedures reduce the possibility of the tungsten electrode transferring foreign matter into the weld and help reduce arc wander.

Grind the end of the tungsten electrode to a taper for a distance of 2 to 2–1/2 electrode diameters in length. For example, the ground surface for a 1/8 in. (3.2 mm) diameter tungsten electrode should be 1/4 to 5/16 in. (6.4

to 8.0 mm) long.

For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process.

6-5.

TROUBLESHOOTING


•


•



•



•


MAGNETIC FIELDS FROM HIGH CUR-

RENTS can affect pacemaker operation.

•

Wearers should consult with their doctor before going near arc welding, gouging, or spot welding operations.

Troubleshooting of internal parts to be performed only by qualified persons.

IMPORTANT: Before beginning any troubleshooting procedures, check and be sure that all connections are correct and secure and that all switches are in the proper position.

OM-880 Page 21

Table 6-3. Troubleshooting

TROUBLE

Wire feeder inoperative.

PROBABLE

Circuit breaker CB5 or CB6 open.

REMEDY

Reset CB5 or CB6 according to

Section 6-2.

Place S10 in the REMOTE position

(see Section 4-3).

No remote control of conOUTPUT/CONTACTOR switch S10 tactor; open-circuit voltage in the ON position.

present all the time when engine is running.

No contactor control; no CV-2 not correctly installed if done as weld output; no opencircuit voltage.

a field kit.

Incorrect or poor connections to

REMOTE-5 receptacle RC3 or

REMOTE-14 receptacle RC4.

Remote Contactor Control device.

Review Section 3 and check all connections.

Check and secure connections (see

Sections 3-2 and 3-3).

Contactor control circuit board PC3.

Improper current or voltRemote current and/or voltage control age level adjustment with device connected at both receptacles.

remote control device.

Check and repair or replace remote device as necessary.

Replace PC3 according to Section 6-3.

Use only one CV-2 receptacle for remote current or voltage control.

No control of voltage; CV-2 not correctly installed if done as a Review Section 3 and check all maximum or very low or field kit (cables 19 and 30 from rectifier connections, especially cables 19 and no open-circuit voltage present.

SR3 reversed to Selector Switch cables). 30.

Incorrect or poor connections to

REMOTE-5 receptacle RC3 or

Check and secure connections (see

Sections 3-2 and 3-3).

REMOTE-14 receptacle RC4.

CV/CC switch S12 in CC position.

Remote Voltage Control device.

Place S12 in the CV position (see

Section 4-1).

Check and repair or replace remote device as necessary.

Voltage control circuit board PC4.

Replace PC4 according to Section 6-3.

OM-880 Page 22

SECTION 7 – ELECTRICAL DIAGRAM

Circuit Diagram No. SB-110 336-B

Diagram 7-1. Circuit Diagram For CV-2

Diagram 7-2. Wiring Diagram For CV-2

Ref. D-111 326-N

OM-880 Page 23

OM-880 Page 24

SECTION 8 – PARTS LIST

1

19

2

3 4

5

6

7

8

7

9

10

11

12

18 17

16

15

14

13

Figure 8-1. Main Assembly

SD-111 208-B

OM-880 Page 25

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 8-1. Main Assembly

. .

. .

1

2

. . . . . S1 . . . . . .

. . . . . . . . . . . . .

112 003

+110 641

. .

. .

SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PANEL, front - lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 3 . . . . . . . . . . . . . . . 110 375 . . STAND-OFF SUPPORT

. . 5 . . . . C8,9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 4 . . . . PC3 . . . . . .

. . . . . . . . . . . . . . . . . . . .

110 035

110 160

. .

. .

CIRCUIT CARD, contactor ctl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR, rect 6skt plug Amp 640250-6 . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

. . 6 . . . . RC3 . . . . .

. . . . . . . . . . . . . . . . . . .

129 764

035 523

. .

. .

CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR, circ 5skt rcpt MS-3102A-16S-8S

039 273 . . CONNECTOR, circ 5 pin plug MS-3106-16S-8P

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . 7 . . .

. . 8 . . . .

CB5,6

RC4

. . . .

. . . . .

. . . . . . . . . . . . . . . . . . .

039 685 . . CONNECTOR, circ clamp str rlf sz 16-16S Amphenol 97-3057-8

083 432

086 022

. .

. .

CIRCUIT BREAKER, man reset 1 pole 10A 250V

CONNECTOR, circ 14skt rcpt MS-3102A-20-27S

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

094 481 . . CONNECTOR, circ 14 pin sz 20 plug MS-3106A-20-27P-934

. . . . . . . . . . . . . . . . . . .

. . 9 . . . S10,11 . . . .

073 296 . . CONNECTOR, clamp str rlf sz 20-22 Amphenol 97-3057-12-6

011 609 . . SWITCH, tgl SPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 10 . . . S12 . . . . . . 011 611 . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

1

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . 11 . . . . 3T . . . . .

. . . . .

. . . . . . . . . .

PC4

T2

. . . . .

. . . . . . . . . . . . . . . . . . .

. .

. .

. .

. .

. .

. .

. .

12

13

14

15

16

17

18

19

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

035 131

035 129

038 772

010 647

111 785

108 864

111 051 . . TRANSFORMER, KVA 115-24

110 996

110 909 . . ANGLE, mtg panel

601 954 . . SCREW, cap - hex hd 1/4-20 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 159

602 241

. .

. .

SCREW, self - forming hex washer hd 5/16-18 x 3/4

WASHER, flat-SAE 1/4

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 207

601 865

020 265

046 507

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

CONNECTOR, blk 30A 45 deg

CONNECTOR, blk 20A 90 deg

BLOCK, term 20A 6 pole

021 385 . . BOOT, tgl switch lever

PIN, spring 5/32 x 1-1/4

HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAP, dust connector

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRACKET, mtg - transformer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WASHER, lock - split 1/4

NUT, hex - full 1/4-20

CABLE TIE, 0-1-3/4

BUS BAR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

123 375

048 104

. .

. .

CIRCUIT CARD, voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR, rect 7 skt plug Amp 640250-7 . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . 134 792 . .

NAMEPLATE, (order by model and serial number)

LABEL, warning general precautionary

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . 039 885 . . CAP, dust connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

6

1

2

1

1

1

1

1

1

3

6

6

4

1

6

2

8

1

1

1

1

1

1

070 582 . . TUBING, No 13 (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 154 . . SCREW, self - forming hex washer hd 1/4-20 x 1/2 . . . . . . . . . . . . . . . . . .

2ft

6

7

1

1

1

1

1

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-880 Page 26

Warranty Questions?

Call

1-800-4-A-MILLER for your local

Miller distributor.

Your distributor also gives you ...

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions?

Contact your distributor.

The expertise of the distributor and Miller is there to help you, every step of the way.

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an

International distributor.

1.

5 Years Parts – 3 Years Labor

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2.

3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Supplies

* Intellitig

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3.

1 Year — Parts and Labor

* DS-2 Wire Feeder

* Motor Driven Guns (w/exception of Spoolmate

185 & Spoolmate 250)

* Process Controllers

* Positioners and Controllers

* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources

* Water Coolant Systems

* HF Units

* Grids

* Maxstar 140

* Spot Welders

* Load Banks

* Miller Cyclomatic Equipment

* Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAF

Models)

* Field Options

(NOTE: Field options are covered under True

Blue

 for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

4.

6 Months — Batteries

5.

90 Days — Parts

* MIG Guns/TIG Torches

* Induction Heating Coils and Blankets

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches

* Remote Controls

* Accessory Kits

* Replacement Parts (No labor)

* Spoolmate 185 & Spoolmate 250

* Canvas Covers

Miller’s True Blue



Limited Warranty shall not apply to:

1.

Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

2.

Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3.

Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE

AND USE BY COMMERCIAL/INDUSTRIAL USERS AND

PERSONS TRAINED AND EXPERIENCED IN THE USE

AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Miller authorized service facility as determined by

Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR

ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION,

OPERATION OF LAW, CUSTOM OF TRADE OR COURSE

OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL

EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND

DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited

Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

miller_warr 7/00

Owner’s Record

Please complete and retain with your personal records.

Serial/Style Number Model Name

Purchase Date

Distributor

Address

City

State

(Date which equipment was delivered to original customer.)

Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com

to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information and Parts)

Circuit Diagrams

Welding Process Handbooks

File a claim for loss or damage during shipment.

Contact the Delivering Carrier for:

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

PRINTED IN USA



2000 Miller Electric Mfg. Co. 6/00

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters –

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066 www.MillerWelds.com

Miller Electric CV-2 Owner`s manual

July 1993 Form: OM-880B

Effective With Serial No. JJ490601

OWNER’S

MANUAL

CV-2 Control Option

From Miller to You

Thank you and congratulations on choosing Miller. Now

distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS

SECTION 2 – SPECIFICATIONS

SECTION 3 – INSTALLATION OR RELOCATION

REMOTE-5

REMOTE-14

SECTION 4 – OPERATOR CONTROLS

CC

CV

PANEL

CURRENT

CONTROL

REMOTE

ELECTRODE POS.

ELECTRODE

NEG.

AC

ON

OUTPUT/

CONTACTOR

REMOTE

CIRCUIT

BREAKER

SECTION 5 – SEQUENCE OF OPERATION

SECTION 6 – MAINTENANCE & TROUBLESHOOTING

SECTION 7 – ELECTRICAL DIAGRAM

SECTION 8 – PARTS LIST

Call

1-800-4-A-MILLER for your local

Miller distributor.

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

Owner’s Record

Please complete and retain with your personal records.

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com

to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Related manuals

Miller

CV-2

Miller

CV-2

Miller

RCMP-3A

Miller

CV-3

Miller

CV-3

Miller

CV-3

Miller

CV-3

Miller

CV-3

Miller

CV-3

Miller

CV-3

Miller

Big 40 CX

Miller

BIG BLUE 500 X (PERKINS)