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
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 ter-
minal 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 con-
nection 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 termi-
nal 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 con-
nection 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
LEFT
Welding
Generator Frame
Install Switch Guard Onto
Lower Front Portion Of
Base Just Below New
Lower Front Panel
Switch Guard
(Angle Bracket)
FRONT
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 COMPONENTS 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.
Big 40 Diesel, Big 40G, And
Big 50 Diesel Transformer
Mounting Bracket
Transformer
T2
RIGHT
Use Switch Guard
As Template To
Mark Hole Locations
2. Affix supplied ELECTRODE label over NEGATIVE designation for weld output terminal.
3. Affix supplied WORK label over POSITIVE designation for weld output terminal.
4. Connect weld cables t o w e l d o u t p u t te r m i n a l s a s
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 DIESEL 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)
SB-112 332-A
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
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 REMOTE-5 receptacle, align keyway, insert plug from the
Remote Control, and rotate threaded collar fully clockwise.
AJ
K
B
L
NH
C
M
D
F
E
I
G
E
AD
BC
S-0005
Figure 3-6. Front View Of 5-Socket Amphenol Re-
ceptacle 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.
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 & VOLTAGE 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.
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.
Socket I: Up to 1 0 amperes of 120 volts ac 60 Hz with
respect to socket G (circuit common), pro-
tected 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
Optional Remote
Contactor And
Amperage Control
Connection To
CV-2 5-Socket
Amphenol
Receptacle RC3
Welding
Generator
Figure 3-8. Connection Diagram For Remote Control Using 5-Socket Amphenol Receptacle RC3
Electrode Cable
Work
Welding
Generator
Gas Supply With
Flowmeter And
Regulator
Spoolmatic 3
Gun/Feeder
Gas Hose
Connection To CV-2
14-Socket Amphenol
Receptacle RC4
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
SA-112 730
SA-112 732
Welding
Gun
OM-880 Page 10
S-32 Type Wire Feeder
With 12VDC Optional
Shielding Gas Valve,
Remote Contactor,
And Voltage Control
Connection To CV-2
14-Socket Amphenol
Receptacle RC4 - Use
14-Pin To 14-Pin
Interconnecting Cord
Figure 3-10. Connection Diagram For S-32P Type Wire Feeders Using
14-Socket Amphenol Receptacle RC4
Welding
Generator
Gas Supply With
Flowmeter And
RegulatorGas Hose
SA-112 735
Work
Wire Drive
Assembly
Electrode Cable
Welding
Gun
Work
Torch/Gun
Porta-Mig Model
Wire Feeder
Connection To CV-2
14-Socket Amphenol
Receptacle RC4 - Use
14-Pin To 14-Pin
Interconnecting Cord
Gas Hose
Figure 3-11. Connection Diagram For Porta-Mig Type Wire Feeders Using
14-Socket Amphenol Receptacle RC4
115 VAC Input Cord
Connected To Unit
Duplex Receptacle RC1
HF-251 Model
High-Frequency
Unit
Electrode Cable
Connection To CV-2 5-Socket
Amphenol Receptacle RC3 –
Use 5-Pin To 5-Pin
Interconnecting Cord
Welding
Generator
Gas Supply With
Flowmeter And
Regulator
SA-112 734
Welding
Generator
Remote Contactor
Amperage Control
With 20 ft. (6 m)
Long Cord
Work
Welding
Gun
Figure 3-13. Connection Diagram For 50 Series Type Wire Feeders Using Adapter Cord
Gas Hose
Figure 3-12. Connection Diagram For HF-251 Model High-Frequency Unit Using
5-Socket Amphenol Receptacle RC3
Wire Drive
Assembly
50 Series Model
Wire Feeder
Interconnecting Cord
Supplied With Feeder
Connection To CV-2
14-Socket Amphenol
Receptacle RC4 - Use
14-Pin To 2-Prong
And 3-Socket Twistlock
Receptacle Adapter Cord
Electrode Cable
Generator
For Connection To 14-Socket Amphenol Receptacle RC4
Gas Supply With
Flowmeter And
Regulator
SA-112 733-A
Welding
Gas Supply With
Flowmeter And
RegulatorGas Hose
SA-112 731
OM-880 Page 11
Work
Wire Drive
Assembly
Electrode Cable
Welding
Gun
50 Series
Wire Feeder
Connection To CV-2
14-Socket Amphenol
Receptacle RC4 - Use
14-Pin To 14-Pin
Interconnecting Cord
Gas Hose
Welding
Generator
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
SECTION 4 – OPERATOR CONTROLS
Prepunched Hole
For Securing
Key Chain
Remote-5
Receptacle RC3
Receptacle
Dust Cups
AC/DC Selector
Switch S1
CV-2 Control
Panel
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 AMPERE 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
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• 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 & VOLT AGE
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 AMPERE RANGES switch. For complete remote control of
the output, rotate the front panel AMPERAGE & VOLTAGE 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
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• 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.
WARNING: ELECTRIC SHOCK can kill.
• 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 weld-
ing process.
• If AC output is required, use remote output
control.
• Read and follow Safety Precautions at be-
ginning of welding generator Owner’s Manual.
CAUTION: ARCING can damage switch
contacts.
• Do not change the position of the AC/DC Se-
lector 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 POSITIVE (+), or AC without changing weld output connections.
4-5. CIRCUIT BREAKER FOR CONTROL CIR-
CUITRY (Figure 4-1)
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 OUTPUT/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
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.
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (–)
battery cable from battery before inspecting
or servicing.
• Keep away from moving parts such as fans,
belts, and rotors.
• 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 CURRENTS 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 AMPERAGE AND VOLTAGE ADJUSTMENT control to the desired position (see welding generator
Owner’s Manual).
IMPORTANT: When using the CV mode, place the AMPERE 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 VOLTAGE 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 AMPERAGE 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).
WARNING: ELECTRIC SHOCK can kill.
• 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 weld-
ing process.
• If AC output is required, use remote output
control.
• Read and follow Safety Precautions at be-
ginning of welding generator Owner’s Manual.
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 components 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.
3. Wear dry insulating gloves and clothing.
4. Select and obtain proper electrode.
5. Connect work clamp to clean, bare metal at workpiece.
6. Rotate the AMPERE RANGES switch and AMPERAGE AND VOLTAGE ADJUSTMENT control to the desired position (see welding generator
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).
WARNING: ELECTRIC SHOCK can kill.
• 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 weld-
ing process.
• If AC output is required, use remote output
control.
• Read and follow Safety Precautions at be-
ginning of welding generator Owner’s Manual.
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. Wear welding helmet with proper filter lens according to ANSI Z49.1.
15. Begin welding.
16. Wear welding helmet with proper filter lens according to ANSI Z49.1.
17. Begin welding.
5-2. SHIELDED METAL ARC WELDING (SMAW)
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.
OM-880 Page 16
5-3. GAS TUNGSTEN ARC WELDING (GTAW)
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 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. Wear dry insulating gloves and clothing.
9. Connect work clamp to clean, bare metal at workpiece.
10. Rotate the AMPERE RANGES switch and AMPERAGE AND VOLTAGE ADJUSTMENT control to the desired position (see welding generator
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/CONTACT OR
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).
WARNING: ELECTRIC SHOCK can kill.
• 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 weld-
ing process.
• If AC output is required, use remote output
control.
• Read and follow Safety Precautions at be-
ginning of welding generator Owner’s Manual.
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 components 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. Wear welding helmet with proper filter lens according to ANSI Z49.1.
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.
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.
Maintenance to be performed only by qualified
persons.
Table 6-1. Maintenance Schedule
Frequency* Maintenance
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:
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine, and disconnect equipment from
deenergized receptacle before repairing a
fault or overload.
Every Month Units in heavy service environ-
Every 3 Months
Every 6 Months
*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
ments:
Check labels, cables, and wiring;
clean internal parts (see Section
6-1A and Section 6-1B).
Check cables and wiring (see
Section 6-1A.
Check all labels (see IMPORTANT
block, Section 6-1). Clean internal
parts (see Section 6-1B).
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)
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.
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
Standoff
Support (4)
Figure 6-1. Circuit Board Locations And Components
Voltage Control
Board PC4
Wiring Harness Plug
SC-112 013-A
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap
BEFORE handling circuit boards.
• Transport circuit boards in proper static-
shielding 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 move-
ment 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 (Fig-
ure 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
Pure Tungsten
(Green Band)
.010”
.020”
.040”
1/16”
3/32”
1/8”
5/32”
3/16”
1/4”
2% Thorium Alloyed
Tungsten
(Red Band)
.010”
.020”
.040”
1/16”
3/32”
1/8”
5/32”
3/16”
1/4”
DC-Argon Electrode
Negative/Straight Polarity
Up to 15
5-20
15-80
70-150
125-225
225-360
360-450
450-720
720-950
Up to 25
15-40
25-85
50-160
135-235
250-400
400-500
500-750
750-1000
Amperage Range - Polarity - Gas Type
DC-Argon Electrode
Positive/Reverse Polarity
*
*
*
10-20
15-30
25-40
40-55
55-80
80-125
*
*
*
10-20
15-30
25-40
40-55
55-80
80-125
AC-Argon Using
High Frequency
Up to 15
5-20
10-60
50-100
100-160
150-210
200-275
250-350
325-450
Up to 20
15-35
20-80
50-150
130-250
225-360
300-450
400-500
600-800
AC-Argon Balanced
Wave Using High Freq.
Up to 10
10-20
20-30
30-80
60-130
100-180
160-240
190-300
250-400
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)
CAUTION: HOT FLYING METAL PARTICLES
1-1/2 Times
Electrode
Diameter
2-1/2 Times
Electrode
Diameter
can injure personnel, start fires, and damage equipment; TUNGSTEN CONTAMINATION 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
OM-880 Page 20
Figure 6-2. Properly Prepared Tungsten
Electrodes
TUNGSTEN PREPARATION: IDEAL
Stable Arc
Straight Ground
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.
Flat
(The Dia. Of This
Flat Governs
Amperage Capacity)
TUNGSTEN PREPARATION: WRONG
Arc Wander
Point
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
6-5. TROUBLESHOOTING
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (–) bat-
tery 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.
MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.
• Wearers should consult with their doctor be-
fore 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 PROBABLE REMEDY
Wire feeder inoperative. Circuit breaker CB5 or CB6 open. Reset CB5 or CB6 according to
Section 6-2.
No remote control of con- OUTPUT/CONTACTOR switch S10 Place S10 in the REMOTE position
tactor; open-circuit voltage in the ON position. (see Section 4-3).
present all the time when
engine is running.
No contactor control; no CV-2 not correctly installed if done as Review Section 3 and check all
weld output; no open- a field kit. connections.
circuit voltage.
Incorrect or poor connections to Check and secure connections (see
REMOTE-5 receptacle RC3 or Sections 3-2 and 3-3).
REMOTE-14 receptacle RC4.
Remote Contactor Control device. Check and repair or replace remote
device as necessary.
Contactor control circuit board PC3. Replace PC3 according to Section 6-3.
Improper current or volt- Remote current and/or voltage control Use only one CV-2 receptacle for
age level adjustment with device connected at both receptacles. remote current or voltage control.
remote control device.
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 SR3 reversed to Selector Switch cables). 30.
present.
Incorrect or poor connections to Check and secure connections (see
REMOTE-5 receptacle RC3 or Sections 3-2 and 3-3).
REMOTE-14 receptacle RC4.
CV/CC switch S12 in CC position. Place S12 in the CV position (see
Section 4-1).
Remote Voltage Control device. 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
Diagram 7-1. Circuit Diagram For CV-2
Circuit Diagram No. SB-110 336-B
Diagram 7-2. Wiring Diagram For CV-2
Ref. D-111 326-N
OM-880 Page 23
SECTION 8 – PARTS LIST
OM-880 Page 24
34
2
1
5
7
6
8
7
9
10
19
11
12
1718
16
15
14
13
SD-111 208-B
Figure 8-1. Main Assembly
OM-880 Page 25
Item
No.
Dia.
Mkgs.
Part
No.
Description Quantity
Figure 8-1. Main Assembly
1 S1 112 003 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 +110 641 PANEL, front - lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 110 375 STAND-OFF SUPPORT 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 PC3 110 035 CIRCUIT CARD, contactor ctl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110 160 CONNECTOR, rect 6skt plug Amp 640250-6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 C8,9 129 764 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 RC3 035 523 CONNECTOR, circ 5skt rcpt MS-3102A-16S-8S 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
039 273 CONNECTOR, circ 5 pin plug MS-3106-16S-8P. . . . . . . . . . . . . . . . . . . . .
039 685 CONNECTOR, circ clamp str rlf sz 16-16S Amphenol 97-3057-8. . . . . . . . . . . . . . . . . . . . .
7 CB5,6 083 432 CIRCUIT BREAKER, man reset 1 pole 10A 250V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 RC4 086 022 CONNECTOR, circ 14skt rcpt MS-3102A-20-27S 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
094 481 CONNECTOR, circ 14 pin sz 20 plug MS-3106A-20-27P-934. . . . . . . . . . . . . . . . . . . . .
073 296 CONNECTOR, clamp str rlf sz 20-22 Amphenol 97-3057-12-6. . . . . . . . . . . . . . . . . . . . .
9 S10,11 011 609 SWITCH, tgl SPDT 15A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 S12 011 611 SWITCH, tgl DPDT 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
035 131 CONNECTOR, blk 30A 45 deg 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
035 129 CONNECTOR, blk 20A 90 deg 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 3T 038 772 BLOCK, term 20A 6 pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 PC4 123 375 CIRCUIT CARD, voltage regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
048 104 CONNECTOR, rect 7 skt plug Amp 640250-7 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 021 385 BOOT, tgl switch lever 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 134 792 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 039 885 CAP, dust connector 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 010 647 PIN, spring 5/32 x 1-1/4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 111 785 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 108 864 CAP, dust connector 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T2 111 051 TRANSFORMER, KVA 115-24 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110 996 BRACKET, mtg - transformer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110 909 ANGLE, mtg panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
070 582 TUBING, No 13 (order by ft) 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 154 SCREW, self - forming hex washer hd 1/4-20 x 1/2 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 954 SCREW, cap - hex hd 1/4-20 x 3/4 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 159 SCREW, self - forming hex washer hd 5/16-18 x 3/4 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 241 WASHER, flat-SAE 1/4 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 207 WASHER, lock - split 1/4 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 865 NUT, hex - full 1/4-20 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
020 265 CABLE TIE, 0-1-3/4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
046 507 BUS BAR 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.
Y our distributor also gives
you ...
Service
Y ou 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
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
guarantees or warranties expressed or implied.
* 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 bas e d u p o n a c tual 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. I N N O 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.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State 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
Miller Electric Mfg. Co.
An Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters –USA
USA Phone: 920-735-4505 Auto-Att ended
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
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
File a claim for loss or damage during
shipment.
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