Miller Electric CV-2 User 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.
Call your distributor if you do not understand
the directions.
cover 6/93 – ST-111 216-A PRINTED IN USA
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
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
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
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.
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. T o obtain a Technical
Manual, contact your local
distributor. Y our distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMA W-P.
TABLE OF CONTENTS
Section No. Page No.
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. General Information And Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Safety Alert Symbol And Signal Words 1. . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS
2-1. Volt-Ampere Curves 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION OR RELOCATION
3-1. CV-2 Installation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Remote-5 Receptacle Information And Connections 8. . . . . . . . . . . . . .
3-3. Remote-14 Receptacle Information And Connections 8. . . . . . . . . . . . .
SECTION 4 – OPERATOR CONTROLS
4-1. Constant Voltage (CV)/Constant Current (CC) Switch 12. . . . . . . . . . . . .
4-2. Current Control Switch 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Output/Contactor Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. AC/DC Selector Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Circuit Breaker For Control Circuitry 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – SEQUENCE OF OPERATION
5-1. Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW) 14. . . . .
5-2. Shielded Metal Arc Welding (SMAW) 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Gas Tungsten Arc Welding (GTAW) 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Shutting Down 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Resetting Circuit Breakers 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Circuit Board PC3 Or PC4 Replacement Procedure 17. . . . . . . . . . . . . .
6-4. Tungsten Electrode 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Troubleshooting 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – ELECTRICAL DIAGRAM
Diagram 7-1. Circuit Diagram For CV-2 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 7-2. Wiring Diagram 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – PARTS LIST
Figure 8-1. Main Assembly 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF CHARTS AND TABLES
Table 2-1. Specifications 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 2-1. DC Volt-Ampere Curves (CV Mode) 2. . . . . . . . . . . . . . . . . . . . . . . . .
Chart 2-2. AC Volt-Ampere Curves (Single-Phase, CC Mode) 2. . . . . . . . . . . .
Table 6-1. Maintenance Schedule 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6-2. Tungsten Electrode Size 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6-3. Troubleshooting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 ef fective 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.
SECTION 2 – SPECIFICATIONS
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.
Table 2-1. Specifications
DC
Model
BIG 30
DIESEL
And
BIG 30A
DIESEL
BIG 40
DIESEL
And
BIG 40G
BIG 50
DIESEL
*See Owner’s Manual For DC Specifications In CC Mode
Rated Output
At 100%
Duty Cycle*
200 Amperes
At 28 Volts
300 Amperes
At 32 Volts
300 Amperes
At 32 Volts
Load
Voltage
Range
In CV
Mode
10-35 40-70
AC
Open-
Voltage
Range
In CC
Mode*
Amperage
In CC Mode*
Amperes
Amperes
Amperes
AC
Range
45-325
45-475
50-495
Max. Open-Circuit
Volts*
DC
CV ModeACCC 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)
Chart 2-2. AC Volt-Ampere Curves
(Single-Phase, CC Mode)
A. BIG 30 DIESEL And BIG 30A DIESEL Models
SB-111 680-B
B. BIG 40 DIESEL And BIG 40G Models
A. BIG 30 DIESEL And BIG 30A DIESEL Models
SB-111 309-A
B. BIG 40 DIESEL And BIG 40G Models
C. BIG 50 DIESEL Models
OM-880 Page 2
SB-111 679-A
SB-111 678-A
SB-111 313-B
C. BIG 50 DIESEL Models
SB-111 317-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 DIESEL, BIG 40G, and BIG 50 DIESEL welding generator
models.
SECTION 3 – INSTALLATION OR RELOCATION
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.
IMPORTANT: If CV -2 was factory installed, proceed directly 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.
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 DIESEL 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 COMPONENTS 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.
2. Raise both side doors and tie together across the
cover.
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
ST-145 421
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 mod-
els: 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. For BIG 40 DIESEL, BIG 40G, and BIG 50 DIE-
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, remove 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
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, connect 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 se cure 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
Weld Output Terminal
Cable Lug Connection
With Tubing And Ties
Rear View (Inside)
Of Lower Front Panel
Cable 28
Cable 30
Cable 19Selector
Switch S1
Figure 3-2. Selector Switch S1 DC Connections
Left Front Upright When
Viewed From Front
Of Control Panel
Electrode (Negative)
Weld Ou t p u t Terminal
Weld Output
Terminal Assembly
Work (Positive)
Weld Output
Terminal
Bimetal Jumper
Bar-Copper Side
Of Bar Against
Terminal Surface
SB-112 688-A
WARNING: ELECTRIC SHOCK can kill; BIMETAL JUMPER BAR CONTACT WITH INTERNAL COMPONENTS can cause personal injury and equipment damage.
• Do not touch live electrical parts.
• 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.
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. For BIG 40 DIESEL, BIG 40G, and BIG 50 DIESEL 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).
b. Slide a 6 in. (152 mm) long piece of supplied i n-
sulated tubing over each connection. Secure insulated tubing with the supplied nylon cable
ties.
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
Range Switch S3:
Connect CV-2 Leads
17 And 27 With
Existing Leads On SR3
Nameplate
BIG 30 DIESEL And BIG 30A DIESEL
Rectifier SR3
Figure 3-3. Selector Switch S1 AC Connections
Regulator
Current
Box
BIG 40 DIESEL, BIG 40G, And BIG 50 DIESEL
Rear View Of Range Switch
ST-145 422 / ST-145 423
Lead 628
Lead 634
Lead 632
Lead 623
Lead 625
Lead 623
Lead 632
Leads From
CV-2 Control
OM-880 Page 6
Lead 634
Lead 628
SC-111 077-A
Figure 3-4. Lead Connections From CV-2 To Current Regulator Circuitry
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