Miller CV-1 User manual

Miller CV-1 User manual
September 1986 FORM: OM-879
Read and understand the entire . .
contents of both this manual and the power source Effective With Style No. JG-36
manual used with this unit, with special emphasis
on the safety material throughout both manuals,
before installing, operating, or maintaining this MODEL
equipment. This unit and these instructions are for
use only by persons trained and experienced in the CV-1
safe operation of welding equipment. Do not allow CONSTANT VOLTAGE
untrained persons to install, operate, or maintain CONTROL KIT
this unit. Contact your distributor if you do not fully
understand these instructions.
OWNER’S
MANUAL
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST, P.O. Box 1073
APPLETON, Wi 54912 USA
ADDITIONAL COPY PRICE 30 CENTS
NWSA CODE NO. 4579
PRINTED IN U.S.A.
LIMITED WAR RANTY
EFFECTIVE: OCTOBER 1, 1986
LIMITED WARRANTY - Subject to the terms and condi-
tions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin
warrants to its Distributor/Dealer that all new and unused
Equipment furnished by Miller is free from defect in workman-
ship and matertal as of the time and place of delivery by Miller.
No warranty is made by Miller with respect to engines, trade
accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any . All
engines are warranted by their manufacturer for one year from
date of original purchase, except Tecumseh engines which
have a two year warranty.
Except as specified below, Miller's warranty does not apply
to components having normal useful life of less than one {1}
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzies and nozzle insulators where failure does
not result from defect in workmanship or material.
Miller shall be required to honor warranty claims on war-
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delive-; Li Equip-
ment to the original. user:
1. Arc welders, power sources, robots, and components . 1 year
2. Load banks ............ ea 1 year
3. Original main power rectifiers ....,............ 3 years
(labor - 1 year only)
4. All welding guns, feeder/guns and plasma torches .. . 90 days
5. Allother Millermatic Feeders ................... 1 year
6. Replacement or repair parts, exclusive of labor .. 60 days
7. Batteries ............. 2... aran. 6 months
provided that Miller is notified in writing within thirty (30) days
of the date of such failure.
As a matter of general policy only, Miller may honor claims
submitted by the original user within the foregoing periods.
This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
In the case of Miller's breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore 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.Q.B., Factory, at
Appleton, Wisconsin, or F.O.B., at a MILLER authorized service
facility, therefore, no compensation for transportation costs of
any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the warranty
claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA-
TION AS TO PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPFRATION OF LAW,
CUSTOM QF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY ОВ ОЕ
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX-
CLUDED AND DISCLAIMED BY MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLERS WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLER'S WARRANTIES TO, ANY CONSUMER.
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EZ SECTION 1 - INTRODUCTION PN
DC
Load
Rated CV Voltage
Output Range Max.
At 100% For {Open-Circult .
Duty CV Volts For Weight y
Model Cycle* Output | CV Output” Net Ship
Eo 200 Amperes
DIESEL At 28 Volts DC
BIG
40 300 Amperes 10-35 40 1.7 lbs. | 2.7 lbs.
DIESEL At 32 Volts DC (0.8 kg) | (1.2 kg)
E 350 Amperes
DIESEL At 34 Volts DC
*See Welding Generator Owner's Manual For DC Specifications With
CC Output
Figure 1 - 1. Specifications
A à in.
{102 mm}
6-1/2 in,
(165 mm)*
4-1/2 in.
(114 mm)
9/32 in, (7 mm)
Dia. 2 Holes
*Add approximately 3/4 in. (19 mm) for controls
TA-111 219
Figure 1 - 2. Dimensions
OM-879 Page 1
1-1. VOLT-AMPERE CURVES (Figure 1-3)
A
50
40 E 100% RHEOSTAT
un
= 30
2 BIG 30 DIESEL Models
Я 20
0% RHEOSTAT
10
0 50 100 150 200 250 300 350 400
50
40 - 100% RHEQSTAT
ны 30 F
2 BIG 40 DIESEL Models
>
Sh
0% RHEOSTAT
10 E
e | ] | | |
D 100 200 300 400 500 500
DC AMPERES B-111 679
50
40 100% AHEOSTAT
Ww _
я 30
o BIG 50 DIESEL Models
eb
0% RHEOSTAT
10 +
| | 1 I do
0 100 200 300 400 500 600
DC AMPERES B-111 678
Figure 1 - 3. DC Volt-Ampere Curves (CV Output)
The volt-ampere curves show the output voltage and
amperage capabilities of the welding generator available
at any point from the minimum to maximum of each
coarse amperage range.
OM-879 Page 2
With the use of the volt-ampere curves it is possible to
determine what the weld amperage will be at a par-
ticular arc voltage. The volt-ampere curves show the
minimum and maximum curves of each coarse
amperage range.
1-2. GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various
labels, tags, and plates on the unit pertains to equip-
ment design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equip-
ment.
The nameplate of this unit uses international symbols
for labeling the controls. The symbols also appear at the
appropriate section in the text,
B. Safety
The installation, operation, maintenance, and
troubleshooting of arc welding equipment require prac-
tices 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 ap-
plicable codes such as, but not limited to, those listed at
the end of Section 1 - Safety Rules For Operation Of
Arc Welding Power Source.
Safety instructions specifically pertaining to this unit ap-
pear throughout this manual highlighted by the signal
words RIDE and RNA which identify
different levels of hazard.
КОДЕ statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of fife.
statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
A third signal word, Ei e]: IU highlights instruc-
tions which need special emphasis to obtain the most
efficient operation of this equipment.
1-3. RECEIVING-HANDLING - Before installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill
of lading will be furnished by the manufacturer on re-
quest if occasion to file claim arises.
When requesting information concerning this equip-
ment, it is essential that Mode] Description and Style
Numbers of the equipment be supplied.
1-4. DESCRIPTION - This Constant Voltage Con-
trol Kit is designed for use with the BIG 30, 40, and 50
DIESEL welding generator models.
The CV-1 changes welding generator output to cons-
tant voltage dc for the Gas Metal Arc (GMAW) and Flux
Cored Arc (FCAW) Welding processes. A REMOTE
CONTROL receptacle on the CV-1 provides a junction
point for connecting a Remote Contactor and/or
Remote Voltage Control to the internal circuitry of the
welding generator. This unit can also be installed when
the welding generator is equipped with an optional
polarity switch.
eL 7he welding generator must be equip-
ped with the optional Remote Contactor and Current
Control receptacle and switches to install the CV-1 kit.
Es SECTION 2 - INSTALLATION uuu DT
2-1. LOCATION - The Constant Voltage Control Kit
is designed for installation on the welding generator as
shown in Figure 2-1.
Welding Generator
LEFT
FRONT
Location For CV-1 Installation - Use Top Left Screw Securing
Lower Front Panel For Mounting CV-1 Onto The Welding
Generator With Receptacle And Switch Facing Down Toward
The Unit Base
Ref. TC-109 655
Figure 2 - 1. CV-1 Installation Onto Welding Generator
The mounting location allows room by the REMOTE
CONTROL receptacle and switch on the CV-1 for mak-
ing desired connections and for selecting the proper
switch position. The service life and efficiency of this
control are reduced when subjected to high levels of
dust, dirt, moisture, corrosive vapors, and extreme
heat.
2-2. INSTALLATION
GENERATOR (Figure 2-1}
ONTO WELDING
RIZLLIDICE ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Shut down the engine and disconnect negative (-)
battery cable from battery before beginning this
installation.
MOVING PARTS can cause serious injury.
e Keep clear of moving parts, ie., fans, belts,
rotors, etc.
HOT SURFACES can cause severe burns.
e Wear protective gloves and clothing when work-
ing near hot parts.
e Allow unit to cool down, if applicable, before
beginning installation.
1. Open and secure the left side access door.
Те EEE То ease CV-1 electrical connections,
remove weld output terminal mounting bracket from
left front upright.
2. Install CV-1 control onto welding generator as in-
structed on Figure 2-1.
3. Connect Amphenol plug PLG7 from CV-1 con-
trol to Remote Control receptacle RC3 on
welding generator. Align keyway, insert plug in-
to receptacle, and rotate threaded collar fully
clockwise.
4. Route white and black leads with attached ring
terminals from CV-1 control through weld cable
bracket on left front upright and up to the weld
output terminals or to polarity switch terminals,
if applicable.
5. Make lead connections to rear of weld output
terminals or Polarity switch terminals, If ap-
plicable, as follows:
UNEXPECTED MAXIMUM OUTPUT
WITHOUT CONTROL can cause personal injury
and equipment damage.
® Always connect largest lead first onto a terminal.
® (Connect any remaining leads onto a terminal ac-
cording to size; largest first, smaller last.
e This control is polarity sensitive and requires cor-
rect lead connections for proper polarity.
After a period of time, incorrect connection procedures
can cause the loss of the feedback signal.
a. Remove hardware securing lead 30 (large
cable) to rear of Negative (-) weld output ter-
minal or Polarity switch terminal.
b. Connect black lead from CV-1 with existing
lead 30 to rear of Negative (-) weld output
OM-879 Page 3
terminal or Polarity switch terminal, and
secure with hardware removed in Step a
{see Figure 2-2).
c. Remove hardware securing lead 19 (large
cable} to rear of Positive { +) weld output
terminal or Polarity switch terminal.
d. Connect white lead from CV-1 with existing
lead 19 to rear of Positive (+) weld output
terminal or Polarity switch terminal, and
secure with hardware removed in Step c
(see Figure 2-2).
6. Tapeor tie cord with white and black leads to ex-
isting wiring harness to maintain lead dress and
to avoid contact with hot or moving parts.
7. Reinstall weld output terminal bracket onto ieft
front upright.
8. Close and secure left side door.
Welding Generator Gas Hose
CV-1
Control
Work
Cable
With Clamp
Electrode
Cable To о
Wire
Feeder
Optional ==——
RHC-23
Remote
Contactor
And
Voltage
Control
wording
Gun
Nut
Lock Washer
Cv-1
Output Flat Washer
Lead
{White
Or Black)
Ring Lead 19 Or 30
Terminal Lug Location
Location
Terminal Bolt Or
Stud For
Lead Connections
Ref. TA-109 093
Figure 2 - 2. Location Of CV-1 Output Leads
With Existing Unit Leads
Gas Supply
With Flowmeter
And Regulator
— $-32P Model
Wire Feeder
With 12YDC Optional
Shielding Gas Valve
Ts Voltage Sensing
Lead With Clamp
Figure 2 - 3. Welding Generator With CV-1 And Wire Feed System
OM-879 Page 4
Welding Generator
Work Wire Drive Electrode CV-1 CV-1 Output
Assembly Cable Cord To
Weld Output
\ Terminais
|
NA
и Y
Welding
Gun |
À О
4
32 Type Wire
Feeder With 12YDC
Optional Shielding
Gas Valve
Optional RHC-23
Remote Contactor
And Voltage Control
CV-1 Input NA Gas Supply With
Cord With
Flowmeter And
Gas Hose 5-Pin Regulator
Amphenol
Plug TA-112 729
Figure 2 - 4. Connection Diagram
2 - 3. CV-1 REMOTE CONTROL RECEPTACLE
REMOTE CONTROL
Although the term CONTACTOR is
used on the welding generator nameplate and
throughout this manual, output is not switched on or
off by a physical contactor; rather, the output is con-
trolled by opening and closing the windings of the
revolving field thereby functioning as a contactor.
The CV-1 REMOTE CONTROL receptacle provides a
junction point for connecting a Remote Contactor
and/or a Remote Voltage Control to the internal cir-
cuitry of the welding generator. To connect the Remote
Contactor and/or Voltage Control to the CV-1 REMOTE
CONTROL receptacle, align keyway, insert the five-pin
plug from the Remote Control into the receptacle, and
rotate threaded collar fully clockwise.
2 - 4. WIRE FEEDER CONNECTION (Figures 2-3
And 2-4)
RZGINDIOE ELECTRIC SHOCK can Kill.
® Do not touch live electrical parts.
® Do not touch the weld output terminals when the
contactor is energized.
e Do not touch electrode wire and work clamp at
the same time,
When the CONTACTOR CONTROL switch on the
welding generator is in the OFF position, open-circuit
voltage is present at the weld output terminals for as
long as the engine is running.
The $-32P, S, SL, or SC model wire feeders with the
12VDC optional shielding gas valve connect directly to
the weld output terminals on the welding generator.
Remote contactor and/or voltage control may be added
by connecting the device to the 5-socket CV-1
REMOTE CONTROL receptacie.
És SECTION 3 - OPERATION AN
5-Pin Plug
PLG7 - Connects
To Remote Control
Receptacle RC3
On Welding Generator
CV-1 TO
Figure 3 - 1. Component Locations
Remote Control
Receptacle RCH
With Dust Cap
Remote Control
Switch $12
Mounting Hole (2)
Output Cord - Leads
Connected To Weld
Output Terminals On
Welding Generator
TA-111 219
OM-879 Page 5
When the CV-1 is installed, the CUR-
RENT CONTROL switch on the welding generator func-
ons as a Constant Voltage (CV)/Constant Current
(CC) switch. Place the CURRENT CONTROL switch in
the ON position for adjusting welding generator output
in the CV mode. Rotate the amperage Range switch on
the welding generator to the maximum position, and
use the AMPERAGE & VOLTAGE ADJUSTMENT con-
trol to select an open-circuit voftage between the
minimum and maximum range of the CV-1 circuitry.
Place the AUTO IDLE switch on the welding generator
/n the OFF position for CV mode operation.
Placing the CURRENT CONTROL switch in the OFF
position will provide CC mode operation (see welding
generator Owner's Manual) and makes the CV-1 control
inoperative,
3-1. REMOTE CONTROL SWITCH {Figure 3-1)
ON
A
Zly
OFF
- KILL ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
. Do not touch the weld output terminals when the
contactor is energized.
e Do not touch electrode wire and work clamp at
the same time,
If remote voltage control is desired, make connections
to the CV-1 REMOTE CONTROL receptacle as in-
structed in Section 2-3, Place the CV-1 REMOTE CON-
TROL switch and welding generator CURRENT CON-
TROL switch in the ÓN position.
When a Remote Voltage Control is being used, the
remote control functions as a fine voltage adjustment
for the AMPERAGE € VOLTAGE ADJUSTMENT con-
trol setting on the welding generator. For example, If
the AMPERAGE & VOLTAGE ADJUSTMENT control
on the welding generator is set at mid-range, the
Remote Voltage Control will provide (from minimum to
maximum adjustment) fine voltage adjustment of one
half of the welding generator open-circuit voltage out-
put.
If remote voltage control is not desired, place the CV-1
REMOTE CONTROL switch in the QFF position. Only
the AMPERAGE & VOLTAGE ADJUSTMENT control
on the welding generator will provide adjustment of
open-circuit voltage output.
3-2. REMOTE CONTACTOR CONTROL (Figure
3-1)
LILLIE ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
. Do not touch the weld output terminals when the
contactor is energized.
® Do not touch electrode wire and work clamp at
the same time.
When the CONTACTOR CONTROL switch on the
welding generator is in the OFF 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 connec-
tions to the CV-1 REMOTE CONTROL receptacie as in-
structed in Section 2-3. Place the CONTACTOR CON-
TROL switch in the ON 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
CONTACTOR CONTROL switch in the OFF position.
Open-circuit voltage will be available at the weld output
terminals whenever the engine is running.
—_———— SECTION 4 - MAINTENANCE & TROUBLESHOOTING ———
4 - 1. MAINTENANCE
EZLN ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Shut down engine and disconnect negative (-)
battery cable before inspecting, maintaining, or
Servicing.
MOVING PARTS can cause severe injury.
e Keep clear of moving parts, Le., fans, belts,
rotors, etc.
Maintenance to be performed only by qualified persons.
Usage and operating conditions will determine the fre-
quency and type of maintenance. Inspect equipment
avery six months as follows:
1. Remove grease and grime from components;
remove moisture from electrical parts and cords.
OM-879 Pax B
2. Inspect cords for damage to or breaks in the in-
sulating jacket, particulariy at the plug. Repair
the cordís) as necessary.
4-2. TROUBLESHOOTING
EXZCULNLTEE ELECTRIC SHOCK can kill.
e [Do not touch live electrical parts.
e Shut down the engine and disconnect negative (-)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause severe injury.
e Keep clear of moving parts, ie., fans, belts,
rotors, etc.
Troubleshooting to be performed only by qualified per-
SONS.
If trouble develops with the CV-1 control operation, per-
form checking procedures as follows:
1.
TO RES
Check positions of all switches. Place switches in
the proper position.
3. Check all interconnecting cords for damage. Per-
form continuity check if necessary, and replace
any damaged cords. Do not attempt to make or
repair any connections inside the CV-1 box.
If the trouble is not remedied after performing these
Check all plugs, cords, and leads for proper con- procedures, the nearest Factory Authorized Service
nections. If connections are incorrect or loose, Station should be contacted. In ail cases of equipment
make proper connections or tighten as malfunction, the manufacturers recommendations
necessary. should be strictly followed.
en — — 7
<a x BE |
Toy ``
OPTIONAL
5 <M Be 7 y
< ee |
c << , =< |
REMOTE
p< #0 30 El CURRENT |
CONTROL
Е GRN. ON 307 Die |
Te,
PLG7 OFF À Sia res + — — — — — — — +
ua #7. > + TO CKT. #19
S N
, ® 5 | £ BLA —# - TO .CKT. #30
— AA A A-A—A—A
G F E со В А
PCH
A-G ON RC6
Circuit Diagram No. A-110 599
Figure 4 - 1. Circuit Diagram
. E
REF. IN G REG. OUT
D
F
WELD NEG. A
WELD PDS. В
+24 Y, INPUT С
Circuit Diagram No. A-110 650
Figure 4 - 2. Circuit Diagram For Voltage Regulator Circuit Board PCH
OM-879 Page 7
OM-879 P:
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Dia. Part
Mkgs. No. Quantity
Complete Assembly For CV-1
PCH 110 588 CIRCUIT CARD, voltage control (consisting of) ........ ..................... 1
A1 096 275 IC, linear 324 . . LL LL A VA AA a A a a a LL aa ae LL 2200 1
C1,6 083 898 .CAPACITOR, ceramic 0.22 uf 50 volts de aa a aa 11240 2
C2 000 347 . CAPACITOR, tantalum 0.33 uf3bvolts. ........ 2. adrede 1
C3 000 340 .CAPACITOR, ceramic 0.01 uf 50 voltsS ii Lan 1
С4,5 080 507 . CAPACITOR, tantalum 22 uf 15 volts ea 2
D1 074 240 .DIODE, zener 8.2 volts 1 watt ............ AL La a La da a LL 1
D2 026 202 . DIODE, 1 amp 400 volts SP....111111 10 LL LL LL a a a La a da ae 10440 1
Ri 009 172 . POTENTIOMETER, cermet 25 turn 0.5 watt 50K ohm................ 1
R2,3,14,15 039 335 , RESISTOR, carbon film 0.25 watt 47K ohm ii... 4
R4 049 015 . RESISTOR, carbon fim0.2b watt 10 megohm ............... ........... … 1
R5 052 152 .POTENTIOMETER, cermet 25 turn 0.5 watt 1 meg ohm .............. 1
R6,7 000 885 .RESISTOR, carbon film 0.25 watt 10K ohm .......... eee ade, 2
R8,10,12,14 044789 . RESISTOR, carbon film 0.25 watt 100K ohm ............ i, 4
R9,13 039 336 . RESISTOR, carbon film 0.25 watt 220K ohm ............... eee. 2
RCT 110 323 . TERMINAL, header 7 pin ............Ñ.. aaa aaened aia 1
U1 110 325 .IC, interface 7662 . ..... a aaa aanaddeeredrooró 1
VR1 047 272 IC, linear 78112 LL a A LV a A ae A La da AA NA AR RAA 1
110 450 CABLE, control (consisting of) .............. 2 La aa a da de 1
PLG7 039 273 PLUG, 6 pin MS-3106A-16S-T1P . .. LL LL Le LL LL LA 1
039 685 CLAMP, cable . a aarona en ararenyecoenoo, 1
052 246 . CABLE, power5/clorderby ft) ...... enero ee. 3ft
RCH 035 523 RECEPTACLE, 5 socket MS-3102A-16S-8S$............... 2... dara. 1
S12 011 609 SWITCH, toggle SPDT 15 amp 125 volts i i. 1
049 455 CORD, No. 182/c ftorder by ft) .......... aereo 4ft
070 654 BUSHING, strain-relief .300 1D ............ ii 2
108 864 CAP, dustconnector........... NE naeradercaó, 1
110375 STAND-OFF SUPPORT, circuit card... aaa aara. 4
110 397 CASE SECTION, bottom/sides ............. ei 1
110 398 CASE SECTION, front/top/rear .............. ei o, 1
605 576 TUBING, 3/8 (order by ft) .........1111 LL LL LL LL LL LL Lan 1ft
021 385 BOOT, toggle-switch lever 1
1
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
+8
NAMEPLATE (order by model no)
« + 4 ® gg x 4 ®m Fr 4 ¥ 4 кие чи нц а 4 WE FW goa w ow Em & I 1 pg mw a =m mB xg
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