Miller KB058480 Owner's manual

Miller
Brand
Miller
Model
KB058480
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Millerfi
November
1991
FORM:
OM-2801B
Effecti
ye
With
Serial
No.
KB058480
MODEL:
CV-3
CONSTANT
VOLTAGE
CONTROL
OPTION
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd..
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
PRINTED
IN
U.S.A.
Ui
LIMITED
WARRANTY
EFFECTIVE:
AUGUST
6,
1990
u
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
deIi~iery
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
warrantied
by
their
manufacturer
for
two
years
from
date
of
original
purchase,
except
Deutz
engines
which
have
a
one
year,
2000
hour
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
tha~
come
in
contact
with
the
welding
wire
including
nozzles
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
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns.
feeder/guns
and
torches
.
.
.
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
7.
Batteries
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.
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)
replace
ment
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
MILLER
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
F.O.B.,
Factory
at
Appleton.
Wisconsin.
or
F.O.B.
at
a
MILLER
authorized
service
facility,
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
REPRE
SENTATION
AS
TO
PERFORMANCE.
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS~
PROVISION,
MIGHT
ARISE
BY
IMPLICATION.
OPERATION
OF
LAW.
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
F!TNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
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.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO.
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
I
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMEN
DMENT
TO
SECTION
8
PARTS
LIST
Amend
Parts
List
as
follows:
Dia.
Part
Mkgs.
No.
Replaced
With
Description
Quantity
23-5
...
RC3
...
086022
...
143976..
RECEPTACLE
w/SOCKETS,
(Effw/KC211335)
(consisting
of)
1
079 534
TERMINAL,
female
lskt
18-14
wire
14
134
734
HOUSING,
term
plug
plstc
l4cont
shell
sz
20
Amp
213571
-2
134
731
.
TERMINAL,
male
1
pin
18-14
wire
Amp
213603-1
079 739
..
CLAMP,
cable
strain
relief
sz
17
Amp
206322-2
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
C
a
OM.28016
-
11,91
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
claims
for
loss
or
damage
with
the
delivering
carrier.
mation
is
located
on
the
rating
label
or
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model
__________________________________
ers
Transportation
Department.
Serial
or
Style
No.
____________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
______________________
Number.
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
1
2-2.
Description
1
SECTION
3INSTALLATION
3-1.
CV-3
And
Remote
Control
Installation
2
3-2.
CV-3
Installation
g
3-3.
Remote
14
Receptacle
Information
And
Connections
10
3-4.
Terminal
Strip
3T
11
Diagram
3-1.
Connection
Diagram
For
Remote
Control
12
Diagram
3-2.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
Spoolmatic
3
Gun/Feeder
12
Diagram
3-3.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
S-32P
Series
Wire
Feeders
12
Diagram
3-4.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
Porta-Mig
Model
Wire
Feeders
13
Diagram
3-5.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
50
Series
Wire
Feeders
13
SECTION
4OPERATOR
CONTROLS
4-1.
AmperageNoltage
Switch
13
4-2.
Output
(Contactor)
Switch
14
4-3.
Constant
Voltage
(CV)/Constant
Current
(CC)
Switch
14
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
Gas
Metal
Arc
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
15
5-2.
Shielded
Metal
Arc
Welding
(SMAW)
15
5-3.
Shutting
Down
16
Section
No.
Page
No.
SECTION
6
MAINTENANCE
AND
TROUBLESHOOTING
6-1.
Routine
Maintenance
16
6-2.
Overload
Protection
16
6-3.
Circuit
Board
Handling
Precautions
16
6-4.
Troubleshooting
17
SECTION
7
ELECTRICAL
DIAGRAMS
Diagram
7-1.
Circuit
Diagram
For
BIG
30A
DIESEL
Models
With
CV-3
Option
18
Diagram
7-2.
Circuit
Diagram
For
BIG
40
DIESEL
Models
With
CV-3
Option
19
Diagram
7-3.
Circuit
Diagram
For
BIG
40G
Models
With
CV-3
Option
.
.
20
Diagram
7-4.
Circuit
Diagram
For
BIG
50
DIESEL
Models
With
CV-3
Option
21
SECTION
8
PARTS
LIST
Figure
8-1.
CV-3
Module
22
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
CV
Mode
Specifications
1
Chart
2-1.
DC
Volt-Ampere
Curves
(CV
Mode)
2
Table
6-1.
Troubleshooting
17
SECTION
1
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
labels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equipment.
The
nameplate
of
this
unit
uses
international
symbols
for
labeling
the
front
panel
controls.
The
symbols
also
appear
at
the
appropriate
section
in
the
text.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
Sons
in
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Generator
in
the
welding
generator
Owners
Manual.
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
identify
different
levels
of
hazard
and
special
instructions.
a
a
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
attention
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
serious
personal
injury
or
loss
of
life.
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equipment.
SECTION
2
SPECIFICATIONS
Table
2-1.
CV
Mode
Specifications
Model
Rated
Output
At
100%
Duty
Cycle*
Load
Voltage
Range
Maximum
Open-Circuit
Volts*
(OCV)
BIG
30A
DIESEL
200
Amperes
At
28
Volts
10-35
40
BIG
40
DIESELAnd
BIG
40G
300
Amperes
At
32
Volts
.
BIG
50
DIESEL
300
Amperes
At
32
Volts
*See
Owners
Manual
for
specifications
in
CC
mode.
2-1.
VOLT-AMPERE
CURVES
(Chart
2-1)
The
volt-ampere
curves
show
the
voltage
and
amperage
output
capabilities
of
the
welding
generator.
Curves
of
other
settings
fall
between
the
curves
shown.
2-2.
DESCRIPTION
This
Constant
Voltage
control
kit
is
designed
for
use
with
the
BIG
30A
DIESEL,
BIG
40
DIESEL,
BIG
40G,
and
BIG
50
DIESEL
welding
generator
models.
The
CV-3
changes
welding
generator
output
to
constant
voltage
dc
for
the
Gas
Metal
Arc
(GMAW),
Flux
Cored
Arc
(FCAW),
and
Shielded
Metal
Arc
(SMAW)
Welding
pro
cesses.
OM-2801
Page
1
C,,
0
>
C.)
Cl,
0
>
0
SB-ill
660-B
SB-Ill
679-A
IMPORTANT:
If
installing
CV-3
into
a
unit
that
already
contains
the
Remote
Control
option,
follow
the
instruc
tions
in
Section
3-2.
If
CV-3
was
factory
installed,
pro
ceed
directly
to
Section
3-3.
3-1.
CV-3
AND
REMOTE
CONTROL
INSTALLA
TION
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Stop
engine,
and
disconnect
negative
()
bat
teiy
cable
from
battery
before
inspecting
or
in
stalling.
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.
A.
BIG
30A
DIESEL
Models
50
40
30
-J
20
10
0
Chart
2-1.
DC
Volt-Ampere
Curves
(CV
Mode)
B.
BIG
40
DIESEL
And
BIG
40G
Models
50
40
30
20
10
0
0
50
100
150
200
250
DC
AMPERES
300 350
400
o
100
200
300
400
DC
AMPERES
500
600
C.
BIG
50
DIESEL
Models
50
40
30
20
10
0
o
ioo
200
300
400
500
DC
AMPERES
600
700
SB-ill
676-A
SECTION
3INSTALLATION
OM-2801
Page
2
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BE
FORE
handling
Circuit
boards.
Transport
circuit
boards
in
proper
static
shie(ding
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:
In
order
to
use
the
CV-3
option,
the
weld
ing
generator
must
include
the
Remote
Control
option.
This
subsection
covers
the
installation
of
the
compo
nents
for
both
the
CV-3
option
and
the
Remote
Control
option.
CV-3
components
consist
of
CV
board
PC2
and
CC/CV
switch
S9.
Remote
Control
components
consist
of
resistor
board
R2,
REMOTE
14
receptacle
RC3,
AM
PERA
GE/VOLTAGE
Control
switch
S4,
OUTPUT
(CONTACTOR)
switch
S5,
and
circuit
breakers
CB3
and
CB4.
IMPORTANT:
Unless
otherwise
specified,
all
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
fac
ing
the
welding
generator
front
panel.
Retain
all
hard-
ware
removed
during
this
procedure
for
reinstallation
unless
specifically
told
otherwise.
IMPORTANT:
In
some
cases,
more
than
one
lead
is
identified
with
the
same
number.
A
lead
that
is
provided
as
part
of
the
field
installation
kit
and
arrives
not
connected
to
anything
is
called
a
loose
lead,
even
after
a
connection
has
been
made
at
one
end.
A
lead
that
already
has
a
connection
made
at
one
end
when
these
procedures
are
started
is
called
an
unconnected
lead.
A.
Component
Installation
(Figures
3-1,
3-2,
And
3-3)
1.
Open
and
secure
right
side
door.
On
a
BIG
30A
DIESEL
model,
open
and
secure
left
side
door
also.
2.
Remove
panel
guard
(see
Figure
3-1).
3.
Remove
retaining
screw
and
open
component
box
cover
(see
Figure
3-1).
4.
Insert
supplied
6-32
x
3/8
in.
mounting
screws
through
resistor
board
R2
mounting
holes
in
com
ponent
box
wall
(see
Figure
3-3)
so
screw
heads
face
front
panel.
5.
Install
supplied
resistor
board
R2
onto
screws
in
stalled
in
Step
4
so
resistor
board
is
on
outside
rear
of
component
box
(see
Figure
3-3).
Install
supplied
lock
washers
and
6-32
nuts
onto
resistor
board
mounting
screws
and
tighten
securely.
On
a
BIG
30A
DIESEL
model,
it
is
easiestto
install
re
sistor
board
R2
from
the
left
side
of
the
unit.
a
Component
Box
Cover
Front
Panel
Retaining
Screw
Panel
Guard
Figure
3-1.
Panel
Guard
And
Component
Box
Locations
SC-134
108
OM-2801
Page
3
6.
Install
supplied
CV
board
PC2
onto
plastic
stand
offs
in
lower
left
of
component
box
so
that
recep
tacle
RC1
is
towards
the
top
of
the
welding
gener
ator.
Press
CV
board
P02
into
place
until
plastic
retainers
on
standoffs
snap
into
place
on
PC
board.
7.
Insert
plug
PLG2
(unconnected
plug
in
compo
nent
box)
into
receptacle
RC2
on
CV
board
P02.
IMPORTANT:
Mounting
holes
for
components
mounted
in
front
panel
are
prepunched
in
front
panel
but
not
in
nameplate.
8.
Locate
holes
in
front
panel
(behind
nameplate)
for
AMPERAGENOLTAGE
Control
switch,
OUT
PUT
(CONTACTOR)
switch,
CONSTANT
CUR
RENT/CONSTANT
VOLTAGE
(CC/CV)
switch,
REMOTE
14
Amphenol
receptacle,
and
circuit
breakers
CB3
and
CB4.
Using
rear
of front
panel
as
a
template,
mark
component-mounting
holes
onto
nameplate
by
applying
pressure
from
rear
with
a
sharp
tool.
a
CAUTION:
METAL
FILINGS
~
AND/OR
TOOL
CONTACT
WITH
INTERNAL
COM
PONENTS
can
damage
unit.
Cover
internal
components.
Clean
unit,
and
remove
internal
covering
material
before
resuming
operation.
9.
Punch,
cut,
or
drill
correct
diameter
holes
at
marked
locations
for
installing
components.
10.
Install
supplied
SPDT
AMPERAGENOLTAGE
Control
switch
S4
onto
front
panel
from
rear
at
lo
cation
labeled
PANEL/REMOTE
14
on
the
name
plate.
Be
sure
that
S4
terminals
are
positioned
vertically
so
switch
positions
match
nameplate
la
beling.
11.
Secure
switch
S4
using
supplied
nut
and
switch
lever
boot.
12.
Install
supplied
SPDT
OUTPUT
(CONTACTOR)
switch
S5
onto
front
panel
from
rear
at
location
la
beled
ON/REMOTE
14
on
the
nameplate.
Be
sure
that
S5
terminals
are
positioned
vertically
so
switch
positions
match
nameplate
labeling.
13.
Secure
switch
S5
using
supplied
nut
and
switch
lever
boot.
14.
Install
supplied
DPDT
CONSTANT
CURRENT!
CONSTANT
VOLTAGE
(CC/CV)
switch
S9
onto
front
panel
from
rear
at
location
labeled
CC/CV
on
the
nameplate.
Be
sure
that
S9
terminals
are
po
sitioned
vertically
so
switch
positions
match
nameplate
labeling.
15.
Secure
switch
S9
using
supplied
nut
and
switch
lever
boot.
16.
Install
supplied
circuit
breakers
CB3
and
CB4
onto
front
panel
from
rear
at
labeled
locations.
In
stall
one
supplied
nut
and
washer
onto
circuit
breaker
before
installing
onto
front
panel,
and
use
remaining
supplied
nut
to
secure
circuit
breaker
onto
front
panel
(see
Figure
3-3).
17.
Install
supplied
14-socket
REMOTE
14
Amphe
nol
receptacle
onto
front
panel
from
rear,
and
se
cure
with
supplied
6-32
x
3/8
in.
self-tapping
screws
(insert
screw
used
in
lower
left
corner
through
link
of
receptacle
cover
chain
before
se
curing
screw
into
REMOTE
14
receptacle).
18.
Check
to
see
if
terminal
strip
3T
mounting
holes
shown
in
Figure
3-2
are
present
on
lower
front
panel.
If
holes
are
present,
proceed
to
Step
20.
If
holes
are
not
present,
proceed
to
Step
19.
a
CAUTION:
METAL
FILINGS
AND/OR
TOOL
CONTACT
WITH
INTERNAL
COM
PONENTS
can
damage
unit.
Cover
internal
components.
Clean
unit,
and
remove
internal
covering
material
before
resuming
operation.
19.
Using
insert
in
Figure
3-2
as
a
guide,
drill
7/32
in.
(5.5
mm)
holes
at
indicated
locations.
20.
Install
terminal
strip
3T
onto
rear
of
lower
front
panel
using
supplied
10-32
x
1.0
screws,
lock
washers,
and
nuts
as
shown
in
Figure
3-2.
21.
Apply
supplied
label
below
3T
on
rear
of
lower
front
panel.
22.
Locate
supplied
copper
bus
bar,
and
install
supplied
1/4-20
x
.875
screws
and
nuts
onto
lower
two
holes
as
shown
in
Figure
3-2.
23.
Locate
bus
bar
mounting
hole
provided
in
lower
front
panel
(see
Figure
3-2),
and
install
supplied
1/4-20
xl
.5
screw
into
hole
from
front
of
panel.
In
stall
supplied
copper
spacer
onto
shaft
of
this
screw.
24.
Remove
nut
from
rear
of
ground
terminal
on
frame
of
unit
(see
Figure
3-2).
25.
Install
supplied
external
tooth
star
washer
onto
shaft
of
ground
terminal
extending
through
rear
of
front
panel.
26.
Position
bus
bar
vertically
as
shown
in
Figure
3-2,
and
install
onto
screw
installed
in
Step
23
and
ground
terminal.
27.
Secure
bus
bar
by
installing
supplied
1/4-20
hex
nut
onto
upper
mounting
screw
and
replacing
ground
terminal
nut
removed
in
Step
24.
Tighten
nuts
securely.
OM-2801
Page
5
B.
Circuit
Breakers
CB3
And
CB4
Wiring
Connec
tions
(Figures
3-3
And
3-4)
For
Big
40G
models
prior
to
Serial
No.
KB064495,
and
all
other
models
prior
to
Serial
No.
KB058480,
proceed
as
follows:
a.
Connect
insulated
male
friction
connector
on
loose
lead
110
to
lead
110
extending
from
back
of
duplex
receptacle
RC2
(see
Figures
3-3
and
3-4).
b.
Connect
remaining
end
of
loose
lead
110
to
male
friction
connector
on
circuit
breaker
CB3
upper
terminal.
2.
For
Big
40G
models
following
Serial
No.
KB064495,
and
all
other
models
following
Serial
No.
KB058480,
proceed
as
follows:
a.
Connect
insulated
male
friction
connector
on
loose
lead
1
to
insulated
female
friction
connec
tor
on
unconnected
lead
1
extending
from
back
of
circuit
breaker
CB2
(see
Figures
3-3
and
3-4).
b.
Connect
remaining
end
of
loose
lead
1
to
circuit
breaker
CB3
upper
terminal.
3.
Disconnect
existing
lead
130
from
terminal
strip
iT
terminal
A.
4.
Connect
female
piggyback
friction
connector
on
loose
lead
130
to
terminal
strip
iT
terminal
R.
5.
Connect
lead
removed
from
terminal
strip
iT
in
Step
3
to
piggyback
male
friction
connector
on
terminal
strip
11
terminal
R.
6.
Connect
remaining
end
of
loose
lead
130
to
male
connector
on
circuit
breaker
CB4
upper
terminal.
Circuit
Breaker
CB3
Figure
3-3.
Component
Locations
Component
Resistor
Board
Resistor
Board
R2
Terminal
Strip
iT
14
Receptacle
RC3
Front
Panel
Duplex
Receptacle
RC2
Circuit
Breaker
CB4
Ground
Terminal
SC.134
263-A
OM-2801
Page
6
C.
Terminal
Strip
3T
Wiring
Connections
(Figures
3-3
And
3-4)
IMPORTANT:
In
this
Section,
directions
such
as
left
or
right
are
with
respect
to
the
operator
facing
the
rear
of
the
front
panel.
IMPORTANT:
When
making
connections
to
terminal
strip
2Ton
a
BIG
30A
DIESEL
model,
it
is
helpful
to
use
a
needle-nose
pliers
when
installing
friction
connectors
onto
terminal
strip
connections.
Bring
needle-nose
pli
ers
near
the
terminal
strip,
route
the
desired
lead
into
po
sition
with
the
other
hand
from
the
side,
and
grasp
the
friction
connector
with
the
pliers
to
insert
the
connector
onto
the
applicable
terminal.
1.
Connect
unconnected
lead
131
from
terminal
strip
3T
terminal
A
to
the
lower
terminal
on
circuit
breaker
CB4
(see
Figures
3-3
and
3-4).
2.
Connect
unconnected
lead
56
from
terminal
strip
3T
terminal
B
to
terminal
strip
2T
terminal
F.
3.
Connect
unconnected
lead
47
from
terminal
strip
3T
terminal
C
to
terminal
strip
2T
terminal
D.
4.
Connect
unconnected
lead
18
from
terminal
strip
3T
terminal
D
to
terminal
strip
2T
terminal
A.
5.
Connect
unconnected
lead
55
from
terminal
strip
3T
terminal
E
to
terminal
strip
2T
terminal
E.
6.
Disconnect
existing
lead
from
terminal
strip
iT
terminal
N.
7.
Connect
unconnected
lead 3
from
terminal
strip
3T
terminal
G
to
terminal
strip
iT
terminal
N.
8.
Connect
lead
removed
from
terminal
strip
iT
ter
minal
N
in
Step
6
to
piggyback
connector
on
ter
minal
strip
iT
terminal
N.
9.
Connect
unconnected
lead
132
from
terminal
strip
3T
terminal
Ito
the
lower
terminal
on
circuit
breaker
CB3.
10.
Connect
unconnected
lead
42
from
terminal
strip
3T
terminal
K
to
ground
terminal
on
frame.
11.
Connect
unconnected
lead
58
from
terminal
strip
3T
terminal
J
to
terminal
strip
2T
terminal
G.
12.
Cut
adequate
length
of
supplied
plastic
slit
tubing,
install
onto
leads
from
terminal
strip
3T
right
straight
terminals,
and
secure
in
place
with
four
supplied
cable
ties.
D.
Resistor
Board
R2
Wiring
Connections
(Figures
3-3
And
3-4)
IMPORTANT:
When
making
connections
to
resistor
board
R2
on
a
BIG
30A
DIESEL
model,
it
is
helpful
to
work
from
the
left
side
of
the
unit
and
to
use
a
needle-
nosed
pliers
when
installing
friction
connectors
onto
re
sistor
board
terminals.
1.
Connect
loose
lead
56
to
resistor
board
R2
bot
tom
terminal
(either
one)
(see
Figures
3-3
and
3-4).
2.
Connect
remaining
end
of
loose
lead
56
to
piggy
back
connector
on
terminal
strip
2T
terminal
F.
3.
Connect
loose
lead
58
to
resistor
board
R2
top
terminal
(either
one).
4.
Connect
remaining
end
of
loose
lead
58
to
piggy
back
connector
on
terminal
strip
2T
terminal
G.
E.
Switches
S4,
S5,
and
S9
Wiring
Connections
(Figures
3-3
And
3.4)
IMPORTANT:
The
following
connections
are
all
made
inside
the
component
box.
Unless
otherwise
specified,
all
directions,
such
as
left
or
right,
are
with
the
operator
facing
the
rear
of
the
mounted
switch.
1.
Connect
unconnected
lead
55
to
switch
S4
top
terminal
(see
Figures
3-3
and
3-4).
2.
Locate
and
disconnect
the
friction
terminal
con
nection
between
leads
47
and
98.
3.
Connect
piggyback
friction
connector
on
loose
lead
47
to
switch
S4
bottom
terminal.
4.
Connect
remaining
end
of
loose
lead
47
to
lead
47
disconnected
in
Step
2.
5.
Connect
unconnected
lead
47
to
piggyback
fric
tion
connector
connected
in
Step
3
to
switch
S4
bottom
terminal.
6.
Connect
unconnected
lead
56
to
switch
S5
top
terminal.
7.
Locate
and
disconnect
the
friction
terminal
con
nection
between
leads
57
and
130.
8.
Connect
loose
lead
57
to
lead
57
disconnected
in
Step
7.
9.
Connect
remaining
end
of
loose
lead
57
to
switch
S5
center
terminal.
10.
Connect
lead
130,
disconnected
in
Step
7,
to
switch
S5
bottom
terminal.
11.
Connect
unconnected
lead
66
to
switch
S9
top
left
terminal.
12.
Connect
lead
98,
disconnected
in
Step
2,
to
switch
S9
center
left
terminal.
13.
Disconnect
lead
48
from
Idle
Module
terminal
B.
The
Idle
Module
is
located
in
the
upper
left
corner
of
the
component
box
when
looking
into
the
com
ponent
box.
14.
Connect
loose
lead
48
to
lead
48
disconnected
in
Step
13.
Connect
remaining
end
of
loose
lead
48
to
switch
S9
center
right
terminal.
15.
Connect
loose
lead
68
to
Idle
Module
terminal
B.
Connect
remaining
end
of
loose
lead
68
to
switch
S9
bottom
right
terminal.
16.
Connect
piggyback
friction
connector
on
loose
lead
65
to
switch
S9
bottom
left
terminal.
Connect
remaining
end
of
loose
lead
65
to
switch
S4
cen
ter
terminal.
17.
Connect
unconnected
lead
65
to
piggyback
fric
tion
connector
on
switch
S9
bottom
left
terminal.
OM-2801
Page
7
A
131
To
CB4
Lower
Terminal
B
56
To
2T
Terminal
F
C
To
21
Terminal
0
______
18
To2TTerminalA
E
To
2T
Terminal
E
G
~
To
iT
Terminal
N
I
132
To
CB3
Lower
Terminal
K
42
To
Ground
Terminal
_______
58
To
2T
Terminal
G
r
1
I
See
Section
3-1
B,
Step
2
I
I
CB3
CB2
I
I
T0RC2
I
!~.
To3T
!2L.
Terminal
I
I
I
J
Figure
3-4.
Component
Wiring
Connections
0
I)
0
-u
(a
18
To
3T
Terminal
0
47
To3TlerminalC
To
3T
Terminal
E
To
3T
Terminal
B
561
To
R2
Lower
Terminal
To
3T
Terminal
J
58
To
R2
Upper
Terminal
2T
-~J
S4
IT
A
B
C
D
E
F
G
H
J
K
L
M
N
P
0
A
S
I
U
To
2T
Terminal
G
To
2T
Terminal
F
31
To
3T
Terminal
G
130
T0CB4
130
I
Upper
Terminal
(Unconnected
Lead)
(Disconnected
From
Lead
47)
To
Disconnected
Lead
47
(Unconnected
Lead)
(Unconnected
Lead)
To
Disconnected
Lead
57
(Unconnected
Lead)
Install
Onto
Bus
Bar
(See
Section
3-iF)
CB4
To1T
130
Terminal
~~~-;~
3B,t~
-
I
L
J
S-O
34
1-0
18.
Close
component
box
cover
and
reinstall
retain
ing
screw.
19.
Reinstall
panel
guard.
20.
Close
and
secure
right
side
door.
and
left
side
door
if
applicable.
Resume
operation.
F.
Capacitor
Assembly
Wiring
Connections
(Fig
ures
3-2
And
3-4)
IMPORTANT:
In
this
Section,
directions
such
as
left
or
right
are
with
respect
to
the
operator
facing
the
rear
of
the
front
panel.
1.
Locate
eight
supplied
loose
capacitor
assemblies
having
female
friction
connectors
on
one
end and
ring
terminals
on
the
other
end.
2.
Connect
female
friction
connectors
on
capacitor
assemblies
to
the
following
90
terminals
on
left
side
of
terminal
strip
3T:
A,
B,
C,
D,
E,
G,
I,
and
J
(see
Figures
3-2
and
3-4).
There
is
no
capacitor
assembly
connected
to
terminal
K.
Note
that
ter
minals
K
and
J
are
not
in
sequence.
3.
Install
ring
terminals
on
capacitor
assemblies
connected
to
terminals
A,
B,
C,
and
0
onto
shaft
of
screw
in
upper
hole
of
lower
two
holes
in
bus
bar.
Install
supplied
1/4-20
nut
onto
screw
and
tighten
securely.
4.
Install
ring
terminals
on
capacitor
assemblies
connected
to
terminals
E,
G,
I,
and
J
onto
shaft
of
screw
in
lower
hole
of
lower
two
holes
in
bus
bar.
Install
supplied
1/4-20
nut
onto
screw
and
tighten
securely.
3-2.
CV-3
INSTALLATION
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Stop
engine,
and
disconnect
negative
()
batter,
cable
from
battery
before
inspecting
or
installing.
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.
IMPORTANT:
In
order
to
use
the
CV-3
option,
the
weld
ing
generator
must
include
the
Remote
Control
option.
This
subsection
covers
the
installation
of
the
compo
nents
for
the
CV-3
option
only.
CV-3
components
consist
of
CV
board
PC2
and
CC/CV
switch
S9.
The
necessary
Remote
Control
components
are
included/n
the
field
in
stallation
kit,
but
need
not
be
installed
if
the
welding
gen
erator
already
contains
the
Remote
Control
option.
Therefore,
the
Remote
Control
option
components
(re
sistorboardR2,
REMOTE
14
receptacle
RC3,
AMPER
AGEAOLTAGE
Control
switch
S4,
OUTPUT
(CON
TACTOR)
switch
S5,
and
circuit
breakers
CB3
and
C84)
can
be
retained
as
spare
parts
or
discarded.
IMPORTANT:
Unless
otherwise
specified,
all
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
fac
ing
the
welding
generator
front
panel.
Retain
all
hard
ware
removed
during
this
procedure
for
reinstallation
unless
specifically
told
otherwise.
IMPORTANT:
In
some
cases,
more
than
one
lead
is
identified
with
the
same
number.
A
lead
that
is
provided
as
part
of
the
field
installation
kit
and
arrives
not
connected
to
anything
is
called
a
loose
lead,
even
after
a
connection
has
been
made
at
one
end.
A
lead
that
already
has
a
connection
made
at
one
end
when
these
procedures
are
started
is
called
an
unconnected
lead.
A.
Component
Installation
(Figures
3-1
And
3.3)
1.
Remove
retaining
screw
and
open
component
box
cover
(see
Figure
3-1).
2.
Install
CV
board
P02
onto
plastic
standoffs
in
low
er
left
of
component
box
so
that
receptacle
RC
1
is
towards~the
top
of
the
welding
generator
(see
Fig
ure
3-3).
Press
CV
board
PC2
into
place
until
plastic
retainers
on
standoffs
snap
into
place.
3.
Insert
plug
PLG2
(unconnected
plug
in
compo
nent
box)
into
receptacle
RC2
on
CV
board
PC2.
IMPORTANT:
Mounting
holes
for
components
mounted
in
front
panel
are
prepunched
in
front
panel
but
not
in
nameplate.
4.
Locate
hole
in
front
panel
(behind
nameplate)
for
CC/CV
switch.
Using
rear
of
front
panel
as a
tem
plate,
mark
hole
onto
nameplate
by
applying
pressure
from
rear
with
a
sharp
tool.
5.
Punch,
cut,
or
drill
correct
diameter
hole
for
in
stalling
CC/CV
switch
into
nameplate.
6.
Install
supplied
DPDT
CV/CC
switch
S9
onto
front
panel
from
rear
in
hole
created
in
Step
5.
Position
switch
so
terminals
are
positioned
vertically.
B.
Switch
S9
Wiring
Connections
(Figures
3-3
and
3.5)
IMPORTANT:
The
following
connections
are
all
made
inside
the
component
box.
Unless
otherwise
specified,
all
directions,
such
as
left
or
right,
are
with
the
operator
facing
the
rear
of
the
mounted
switch.
1.
Connect
unconnected
lead
66
to
switch
S9
top
left
terminal
(see
Figures
3-3
and
3-5).
2.
Disconnect
lead
98
from
switch
S4
center
termi
nal.
3.
Connect
lead
98
disconnected
in
Step
2
to
switch
S9
center
left
terminal.
4.
Disconnect
lead
48
from
Idle
Module
terminal
B.
The
Idle
Module
is
located
in
the
upper
left
corner
of
the
component
box
when
looking
into
the
com
ponent
box.
a
OM-2801
Page
9
3-4.
TERMINAL
STRIP
3T
(Figures
3-2
And
3-7)
WARNING:
ELECTRICAL
SHOCK
can
kill;
UNEXPECTED
OUTPUT
can
cause
serious
injury.
Do
not
touch
live
electrical
parts.
Stop
engine,
and
disconnect
negative
()
battery
cable
from
battery
before
making
any
internal
inspection
or
connections.
Do
not
connect
to
REMOTE
14
recep
tacle
and
terminal
strip
at
the
same
time.
Since
the
OUTPUT
(CONTACTOR)
can
be
energized
from
either
the
receptacle
or
ter
minal
strip,
it
is
vital
to
use
only
one
remote
control
method.
MOVING
PARTS
can
cause
serious
injury.
Keep
away
from
moving
parts
such
as
fans,
belts,
and
rotors.
Terminal
strip
3T,
mounted
on
right
rear
side
of
the
front
panel
(see
Figure
3-2),
is
included
in
case
the
plug
supplied
on
the
remote
control
cord
is
not
suitable
for
connections
to
the
REMOTE
14
receptacle
RC3.
Terminal
strip
3T
is
used
to
connect
any
of
the
following
equipment
to
the
welding
generator
control
circuitry:
a.
Remote
Contactor
b.
Remote
Amperage
or
Voltage
control
c.
Wire
feeder
which
provides
contactor
control
to
the
welding
generator
d.
Combination
of
the
above.
To
make
connections,
proceed
as
follows:
1.
Remove
existing
plug
from
remote
control
cord.
2.
Open
and
secure
right
front
side
door.
3.
Remove
panel
guard
(see
Figure
3-2).
4.
Route
remote
control
cord
from
right
side
of
unit
to
terminal
strip
3T.
5.
Connect
leads
to
terminal
strip
3T
using
terminal
information
provided
in
Section
3-3
and
Figure
3-7.
Sockets
and
terminals
labeled
with
the
same
letter
have
identical
functions.
For
example,
the
function
of
socketAin
receptacle
RC3
is
identical
to
the
function
of
terminal
A
on
terminal
strip
3T.
6.
Reinstall
panel
guard.
7.
Make
sure
remote
control
cord
is
routed
Out
just
above
base
rail
to
allow
closure
of
right
side
door.
8.
Close
and
secure
right
side
door.
a
3T
Circuit
Common
G
<~
.~
~
22~
<~
Equipment
S.138
042
Figure
3-7.
Terminal
Strip
3T
Information
Label
OM-2801
Page
II
Work
Electrode
Holder
Optional
Remote
Contactor
And
Amperage
~
Connection
To
CV-3
14-Socket
Amphenol
Receptacle
RC3
04
4
1
Diagram
3-1.
Connection
Diagram
For
Remote
Control
Diagram
3-2.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
Spoolmatic
3
Gun/Feeder
Diagram
3-3.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
S-32P
Series
Wire
Feeders
04 42
S0443
Welding
Generator
Work
Welding
Generator
Gas
Hose
3
ft.
(914
mm)
Long
Pigtail
With
Amphenol
Gas
Hose
OM-2801
Page
12
Diagram
3-4.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
Porta-Mig
Model
Wire
Feeder
Gas
Supply
With
Flowmeter
And
0
Regulator
Diagram
3-5.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
50
Series
Wire
Feeder
SECTION
4
OPERATOR
CONTROLS
4-1.
AMPERAGENOLTAGE
SWITCH
(Figure
3-3)
A/V
AMPERAGE/VOLTAGE
If
remote
current
control
is
desired,
make
connections
to
the
REMOTE
14
receptacle
or
terminal
strip
3T
as
in
structed
in
Sections
3-3
and
3-4.
Place
the
AMPERAGE!
VOLTAGE
Control
switch
in
the
REMOTE
14
position.
When
a
remote
Current
Control
is
being
used,
the
re
mote
control
functions
as
a
fine
amperage
adjustment
for
the
AMPERAGE
&
VOLTAGE
ADJUSTMENT
con-
trol
on
the
welding
generator.
For
example,
if
the
AM
PERAGE
&
VOLTAGE
ADJUSTMENT
control
on
the
welding
generator
is
set
at
mid-range,
the
Remote
Cur
rent
Control
will
provide
(from
minimum
to
maximum
ad
justment)
fine
amperage
adjustment
of
one
half
of
the
welding
generator
output
for
the
amperage
range
se
lected
on
the
Range
switch.
If
remote
control
is
not
desired,
place
the
AMPERAGE!
VOLTAGE
Control
switch
in
the
PANEL
position.
Only
the
front
panel
control
will
then
adjust
the
output.
Gas
Hose
S-0444
Work
Wire
Drive
Assembly
/
Interconnecting
Cord
Electrode
Cable
Supplied
With
Feeder
/
Welding
Gun
50
Series
Model
Wire
Feeder
/
/
/
1
Connection
To
CV-3~
14-Socket
Amphenol
Receptacle
RC3
Welding
Generator
/
Gas
Hose
S
-04
4
5
OM-2801
Page
13
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Miller KB058480 Owner's manual

Miller
Brand
Miller
Model
KB058480
Category
Welding System
Type
Owner's manual
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