Miller CV-3 Owner's manual

Miller

r

May1996

Form:

OM-2801D

Effective

With

Serial

No.

KC289996

OWNERS

MANUAL

~

CV-3

Constant

Voltage

Module

For

GMAW

And

FCAW

Model

Rated

Weld

Output

Voltage

Range

CVIDC

Open-Circuit

Voltage

CV/DC

Big

30A

Diesel

200

A

@

28

V

CV/DC,

100%

Duty

Cycle

1035

40

Big

40G,

Big

40

Diesel,

Big

50

Diesel

300

A

At

32

V

CV/DC,

100%

Duty

Cycle

1035

40

cover_om

4/95

'

1996

MILLER

Electric

Mfg.

Co.

PRINTED

IN

liSA

UMITED

WARRANTY



Subject

to

the

terms

and

conditions

below,

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

wan-ants

to

its

original

retail

purchaser

that

new

MILLER

equipment

acId

after

the

effective

date

ot

thia

limited

warranty

ia

free

of

de

fects

in

material

and

workmanahip

at

the

time

it

is

ahipped

by

MILLER.

ThIS

WAR

RANTt

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPUED,

INCLUDING

THE

WARRAN11ES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

or

replace

any

war

ranted

parts

orcomponenta

tt-ratfeil

due

to

such

defects

in

material

orworkmanahip.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

failure,

at

which

time

MILLER

will

previde

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

auch

a

failure

within

the

warranty

time

periods.

All

warranty

time

periods

atarI

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaaer,

or

one

year

after

the

equipment

is

sent

to

a

North

American

diatributor

or

eighteen

months

after

the

equipment

is

sent

to

an

Intemational

distributor.

1.

5YearsParta3YearaLabor

*

Original

main

power

rectifiers

*

Inverters

(input

and

output

rectifiers

only)

2.

3

Years



Parts

and

Labor

*

Tranaformer/Rectifler

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feedem

Inverter

Power

Supplies

*

Intellitig

*

Robots

(1

year

tabor)

3.

2

Years



Perle

and

Labor

*

Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer.)

*

Air

Compreaaors

4.

1

Year

Parts

and

Labor

*

Motor

Driven

Guns



Process

Controllers

*

IHPS

Power

Sources

*

Water

Coolant

Syatema



HFUnita

*

Grids

-

*

Spot

Welders

*

Load

Banks

*

SDX

Transformers

*

Miller

Cyclomatic

Equipment

*

Running

Gear/Trailers

*

Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)



Tecumaeh

Engines

*

Deutz

Engines

(outside

North

America)

*

Field

Options

(NOTE:

Field

options

are

covered

under

True

Blueﬁ

for

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year

whichever

is

greater.)

5.

6

Months



Batteriea

6.

g~

Days



Parts

and

Labor

*

MIG

GunaTtlG

Torchse



APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torchea

*

Remote

Controls



Accessory

Kits



Replacement

Parts

MILLERS

True

Blueﬁ

Umited

Warranty

shall

not

apply

to:

1.

Items

fumiahed

by

MILLER,

but

manufactured

by

others,

such

as

engines

or

trade

accessories.

These

itema

are

covered

by

the

manufacturers

warranty,

if

any.

2.

Consumable

components;

auch

as

contact

tips,

cutting

nozztea,

contactors

and

relays

or

parts

that

foil

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

that

haa

been

improperty

installed,

improperly

operated

or

misused

based

upon

industry

atandarda,

or

equipment

which

has

not

had

reasonable

and

neceaaary

maintenance,

orequipment

which

has

been

used

foroperation

outaide

of

the

apecifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BYCOMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

ThE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT.

In

the

event

of

a

warranty

claim

covered

by

thia

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

reaaonable

coat

of

repair

or

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

of

orcredit

forthe

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

retum

of

the

goods

at

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factor-yet

Appleton,

Wiaconain,

or

FOB,

at

a

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

transportation

costa

of

any

kind

will

be

allowed.

TO

ThE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

ThE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENTSHALLMILLER

BE

UABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTALOR

CONSEQUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT,

TORT

OR

ANY

OTHER

LEGAL

ThEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATtON

ASTO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OThER

LEGAL

ThEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPLICA11ON,

OPERA11ON

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PAR11CULAR

PURPOSE,

WiTh

RESPECTTO

ANYAND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

ellow

limitations

of

how

long

en

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

ape

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

state

to

state.

In

Canada,

legislation

in

aome

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

stated

herein,

and

to

the

extent

that

they

may

nut

be

waived,

the

limitations

and

exclusions

set

out

above

may

not

apply.

This

Umited

Warranty

provides

specific

legal

righta,

and

other

righta

may

be

available,

but

may

vary

from

province

to

province.

WHO

DO

I

CONTACT?

For

help,

U

COntaCt

your

distributor

For

additional

information,

such

as

TeChnical

Manuals

(ServiCe

And

Parts)

Engine

Manuals

CirCujt

And

Wiring

Diagrams

To

file

a

claim

for

loss

or

damage

during

shipment,

U

contaCt

the

delivering

Carrier

For

assistance

in

filing

or

settling

claims,

U

contact

your

distributor

and/or

equipment

manufaCturers

Transportation

Department

j31!~ji~



i~E2~i

Miller

Electric

Mfg.

Co.



CALL:

414-735-4505

FAX:

800-637-2348

(jn

USA),

or

414-735-4136

(outside

USA)

Process

Handbooks

Users

Guides

Distributor

Directories

o~

e

.

WRITE:

Miller

ElectriC

Mtg.

Co,



contact

your

distributor

P,O,

BOX

1079

Appleton,

WI

54912

USA

Always

provide

Model

Name

and

Serial

or

Style

Number

MILLERS

TRUE

BLUEﬁ

LIMITED

WARRANTY

Effective

February

7,

1996

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

warranty

aupersedea

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expreased

or

implied.

.

1~

I.

miller

wan

3/~6

TABLE

OF

CONTENTS

SECTION

1



SAFETY

PRECAUTIONS

FOR

ARC

WELDING

1

1-1.

Symbol

Usage

1

1-2.

Arc

Welding

Hazards

1

1-3.

Engine

Hazards

2

1-4.

Additional

Installation,

Operation,

And

Maintenance

Hazards

3

1-5.

Principal

Safety

Standards

3

1-6.

EMF

Information

3

SECTION

2INSTALLATION

4

2-1.

Installing

CV-3

And

Remote

Control

4

2-2.

Installing

CV-3

In

Unit

Equipped

With

Remote

Control

12

SECTION

3OPERATION

14

3-1.

Front

Panel

Controls

14

3-2.

Volt-Ampere

Curves

15

3-3.

Remote

14

Receptacle

Information

And

Connections

15

3-4.

Terminal

Strip

3T

Connections

16

3-5.

Typical

Process

Connections

17

3-6.

Overload

Protection

18

3-7.

Maintenance

18

3-8.

Troubleshooting

18

SECTION

4

ELECTRICAL

DIAGRAMS

20

SECTION

5

PARTS

LIST

24

OM-2801

D

-

5196

SECTION

1

-

SAFETY

PRECAUTIONS

FOR

ARC

WELDING

1-1.

Symbol

Usage

safety_romi

4195

4A

Means

Warning!

Watch

Out!

There

are

possible

hazards

with

this

A

Marks

a

special

safety

message.

procedure!

The

possible

hazards

are

shown

in

the

adjoining

symbols.

11r

Means

NOTE;

not

safety

related.

This

group

of

symbols

means

Warning!

Watch

Out!

possible

ELECTRIC

SHOCK,

MOVING

PARTS,

and

HOT

PARTS

hazards.

Consult

symbols

and

below

for

necessary

________________________________

actions

to

avoid

the

hazards.

1-2.

ArC

Welding

Hazards

a

WARNING

The

symbols

shown

below

are

used

throughout

this

manual

to

call

attention

to

and

identify

possible

hazards.

When

you

see

the

symbol,

watch

out,

and

follow

the

to

avoid

the

hazard.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

found

in

the

Safety

Standards

listed

in

Section

1-5.

Read

and

follow

all

Safety

Standards.

Only

qualified

persons

should

install,

operate,

maintain,

and

repair

this

unit.

During

operation,

keep

everybody,

especially

children,

away.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

to

OSHA

29

CFR

191

0.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

oower

cord

around

wire

is

nronerlv

~

to

around

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

9.

Turn

off

all

equipment

when

not

in

use.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

15.

Wear

a

safety

harness

if

working

above

floor

level.

16.

Keep

all

panels

and

covers

securely

in

place.

17.

Clamp

work

cable

with

good

metal-to-metal

contact

to

or

-~~

near

the

weld

I

-

~

..

-

Y~Ifl~ICt~

-

TY~Iflt~IIC~O~

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

NOISE

can

damage

hearing;

FLYING

~

SLAG

OR

SPARKS

can

injure

eyes.

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

Arc

rays

from

the

welding

process

produce

intense

protect

yourface

and

eyes

when

welding

or

watching

(see

ANSI

Z49.1

and

Z87.1

listed

in

Safety

Standards).

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

bum

eyes

and

skin.

Noise

from

some

3.

Wear

approved

safety

glasses

with

side

shields.

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

cooling

throw

off

pieces

of

4.

Use

protective

screens

or

bamers

to

protect

others

from

flash

metal

or

slag.

and

glare;

warn

others

not

to

watch

the

arc.

NOISE

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while



to

your

health.

wearing

an

air-supplied

respirator.

Always

have

a

trained

%Q

Welding

produces

fumes

and

gases.

Breathing

watchpersonnearby.Weldingfumesandgasescandisplaceair

these

fumes

and

gases

can

be

hazardous

to

your

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

health.

breathing

air

is

safe.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

form

highly

toxic

and

irntating

gases.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

cleaners,

and

degreasers.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

OM-2801

Page

1

CYLINDERS

can

explode

if

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

2.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

support

or

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

5.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

6.

Never

weld

on

a

pressurized

cylinder



explosion

will

result.

7.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

10.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

off

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

bums.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pipes,

unless

they

are

property

prepared

according

to

AWS

F4.

1

(see

Safety

Standards).

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

1-3.

Engine

Hazards

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

Batteries

contain

acid

and

generate

explosive

gases.

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

It

is

best

to

check

coolant

level

when

engine

is

cold

to

avoid

scalding.

i.

Always

wear

a

face

shield

when

working

on

a

battery.

2.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

5.

Observe

correct

polarity

(+

and

)

on

batteries

1.

It

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

and

3.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

3.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

completely

removing

cap.

1.

2.

3.

AA

WARNING

ENGINE

EXHAUST

GASES

can

kill.

i.

Use

equipment

outside

in

open,

well-ventilated

areas.

Engines

produce

harmful

exhaust

gases.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

w

ENGINE

FUEL

can

cause

explosion,

Engine

fuel

is

highly

flammable.

fire

or

2.

3.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

4.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

1.

Sto

p

engi

ne

and

let

it

cool

off

before

checking

or

a

dding

fuel,

engine.

MOVING

PARTS

can cause

injury.

3.

Have

only

qualified

people

remove

guards

or

covers

for

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing.

4.

5.

maintenance

and

troubleshooting

as

necessary.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

parts.

securely

in

place.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

2.

Stop engine

before

installing

or

connecting

unit.

finished

and

before

starting

engine.

OM-2801

Page

2

1-4.

Additional

Installation,

Operation,

And

Maintenance

Hazards

a

WARNING

MOVING

PARTS

can

cause

injury.

1.

Before

working

of

generator,

remove

spark

plugs

or

injectors

to

keep

engine

from

kicking

back

or

starting.

2.

Block

flywheel

so

that

it

will

not

turn

while

working

on

generator

components.

FLYING

PIECES

OF

METAL

or

DIRT

can

injure

eyes.

1.

Wear

safety

glasses

with

side

shields

or

face

shield.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.

1.

Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

2.

Use

proper

static-proof

bags

and

boxes

to

store,

move,

or

ship

PC

boards.

MAGNETIC

FIELDS

FROM

HIGH

CURRENTS

can

affect

pacemaker

operation.

1.

Pacemaker

wearers

keep

away.

2.

Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

operations.

HOT

PARTS

can

cause

severe

burns.

1.

.Allow

cooling

period

before

maintaining.

2.

Wear

protective

gloves

and

clothing

when

working

on

a

hot

engine.

FALLING

EQUIPMENT

can

cause

serious

personal

injury

and

equipment

damage.

1.

Use

lifting

eye

to

lift

unit

only,

NOT

running

gear,

gas

cylinders,

or

any

other

accessories.

2.

Use

equipment

of

adequate

capacity

to

lift

unit.

.

I

READ

INSTRUCTIONS.

1.

Use

only

genuine

MILLER

replacement

parts.

2.

Reinstall

injectors

and

bleed

air

from

fuel

system

according

to

engine

manual.



1~

~

DO

NOT

LET

ENGINE

EXHAUST

SPARKS

CAUSE

FIRE.

1.

Use

approved

engine

exhaust

spark

arrestor

in

required

areas



see

applicable

codes.

,

6

~

LOW

VOLTAGE

AND

FREQUENCY

CAN

DAMAGE

electrical

equipment

such

as

MOTORS.

1.

Turn

off

or

unplug

equipment

before

starting

or

stopping

engine.

.~

~

OVERUSE

can

cause

OVERHEATED

EQUIPMENT.

1.

Allow

cooling

period.

2.

Reduce

current

or

reduce

duty

cycle

before

starting

to

weld

again.

3.

Follow

rated

duty

cycle.



I

~

TILTING

OF

TRAILER

can

cause

injury.

1.

Use

tongue

jack

or

blocks

to

support

weight.

2.

Properly

install

welding

generator

onto

trailer

according

to

instructions

supplied

with

trailer.

1-5.

Principal

Safety

Standards

BATTERY

ACID

can

BURN

SKIN

AND

EYES.

1.

Do

not

tip.

2.

Replace

damaged

battery.

3.

Flush

eyes

and

skin

immediately

with

water.

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1

,from

American

Safe

Handling

of

Compressed

Gases

in

Cyllnders,

CGA

Pamphlet

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Highway,

Suite

501,

Arlington,

VA

22202.

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Code

forSafetyin

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Washington,

D.C.

20402.

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

American

Welding

Society

Standard

AWS

F4.1,

from

American

Protection,ANSlStandardZ87.1,fromAmericanNationalStandards

Welding

Society,

550

N.W.

LeJeune

Rd, Miami,

FL

33126

Institute,

1430

Broadway,

New

York,

NY

10018.

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Cutting

And

Welding

Processes,

NFPA

Standard

51B,from

National

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

1-6.

EMF

Information

Considerations

About

Welding

And The

Effects

Of

Low

Frequency

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

Electric

And

Magnetic

Fields

procedures:

.

The

following

is

a

quotation

from

the

General

Conclusions

Section

of

1.

Keep

cables

close

together

by

twisting

or

taping

them.

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields

Background

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):.

.

there

is

now

a

very

large

volume

of

scientific

3.

Do

not

coil

or

drape

cables

around

the

body.

findings

based

on

experiments

at

the

cellular

level

and

from

studies

4.

Keep

welding

power

source

and

cables

as

far

away

as

with

animals

and

people

which

clearly

establish

that

low

frequency

practical.

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

possible.

interpret

the

evidence

in

a

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

allow

us

to

draw

definite

conclusions

about

About

Pacemakers:

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

The

above

procedures

are

also

recommended

for

pacemaker

strategies

to

minimize

or

avoid

potential

risks.

wearers.

Consult

your

doctor

for

complete

information.

OM-2801

Page

3

SECTION

2

INSTALLATION

NOTE

~

The

CV-3

control

cannot

be

installed

on

models

prior

to

Serial

No.

JK728391.

If

installing

CV-3

and

optional

Remote

Control,

go

to

Section

2-1.

If

installing

CV-3

in

a

unit

with

optional

Remote

Control,

go

to

Section

2-2.

If

CV-3

was

factory

installed,

go

to

Section

3.

A

Big

40

Diesel

model

is

shown

throughout

Section

2.

2-1.

Installing

CV-3

And

Remote

Control

A.

Installing

Circuit

Board

PC5

A

Cover

parts

before

drilling.

Clean

unit

before

using.

1

Panel

Guard

Open

doors.

Remove

panel

guard.

2

Reference

Hole

3

Circuit

Board

PC5

If

necessary,

use

reference

hole

to

mark

location

of

first

hole.

Use

PC5

as

template

to

mark

remaining

two

holes.

Drill

three

5/32

in

(4

mm)

Location

Of

PC5

holes

as

marked.

Installation

4

6-32

x

3/8

in

Screw

5

Stand-Oft

1

6

Self-Locking

Nut

7

Ground

Strap

Install

PC5

as

shown.

Secure

ground

strap

to

stand-off.

8

Ground

Lead

42

9

Ground

Stud

10

Ground

Terminal

A

Connect

lead

42

ring

terminal

to

rear

of

ground

stud.

Connect

other

end

of

lead

to

terminal

A.

Go

to

Section

B.

5/32

in

Ref.

ST-134

108

/

Ref.

ST-I

56

194-c

2-1/2

in

(62

mm)

Mark

And

Drill

Hole

3

Mark

And

Drill

Two

Holes

8

6

Tools

Needed:

1/2

in

1EII~~3===u

1/4,5/l6in

OM-2801

Page

4

B.

Installing

Circuit

Board

PC6

5-1/2

in

(140

mm)

1-1/4

in

~

I

(32

mm)

1

in

(25

mm)

A

Follow

safety

precautions

at

beginning

of

this

section.

A

Cover

parts

before

drilling.

Clean

unit

before

using.

If

necessary,

mark

holes

as

shown.

Drill

two

5/32

in

(4

mm)

holes

as

marked.

1

6-32

x

3/8

in

Screw

2

Stand-Off

3

Self-Locking

Nut

4

Circuit

Board

PC6

Install

PC6

as

shown.

Go

To

Section

C.

2

Mark

And

Drill

2

Holes

Tools

Needed:

5/32

in

c:I::I:::::z:J=::=in

1/4,5/l6in

Ref.

ST-i

57

511

OM-2801

Page

5

C.

Connecting

To

Circuit

Board

PC6

Parts

And

Location

GROUND

Terminal

GROUND

Terminal

A

Follow

safety

precautions

at

beginning

of

this

section.

1

Circuit

Breaker

CB1

2

Receptacle

RC1

3

Receptacle

RC2

4

Circuit

Breaker

CB2

5

Ground

Stud

Make

connections

as

shown

below.

Go

To

Section

D.

Connections

for

Big

40G

models

with

Serial

No.

KB064496

and

fol

lowing,

and

Big

40,

Big

50,

and

Big

30A

Diesel

Models

With

Serial

No.

KB058481

and

following.

Ref.

ST-i

56

194-A

I

S-0761

Tools

Needed:

.3

4

5

Wiring

Connections

RC2

Lead

120

RC1

Lead

110

Connections

for

Big

40G

models

prior

to

Serial

No.

KB064495,

and

Big

40,

Big

50,

and

Big

30A

Diesel

models

prior

to

Serial

No.

KB058480.

Supplied

Lead

(

1

~

15/8inH

Cut

off

piggyback

connector

and

strip

insulation

from

end

a

~

102.

0

CB2

Lead

101

Supplied

Lead

102

OM-2801

Page

6

A

Follow

safety

precautions

at

beginning

of

this

section.

For

Big

30A

Diesel

models

only:

1

Right

Front

Upright

2

Base

If

necessary,

drill

two

7/32

in

(5.6

mm)

holes

as

shown.

For

all

other

models:

3

Right

Front

Upright

4

Existing

Hole

5

Base

If

necessary,

drill

one

7/32

in

(5.6

mm)

hole

above

existing

top

hole

as

shown.

6

Mounting

Bracket

7

3TLabel

8

Terminal

Strip

31

9

No.

10

Mounting

Hardware

10

Insulation

Panel

Install

label,

strip,

and

panel

on

bracket.

11

Mounting

Bracket

Hardware

Attach

bracket

on

upright,

and

se

cure

with

1/4-20

x

1/2

in

screws.

12

Plug

PLG8

(Free-Hanging

From

3T)

Connect

PLG8

to

receptacle

RC3

on

PC5.

Go

to

Section

E.

~

1/4,

3/8

in

Ref.

ST-156

200-A

/

Ref.

ST-i

56

195

I

S-0802

OM-2801

Page

7

D.

Installing

Mounting

Bracket

And

Terminal

Strip

3T

E.

Installing

Resistor

Board

R2

And

CV

Board

PC2

F.

Component

Installation

7

1

2

A

Follow

safety

precautions

at

beginning

of

this

section.

1

Rotaining

Screw

2

Component

Box

Cover

Remove

screw

and

open

cover.

3

Resistor

Board

R2

4

Mounting

Holes

5

6-32

x

3/8

Screw

6

Lock

Washer

And

Nut

Install

R2

as

shown.

7

CV

Board

PC2

8

Stand-Off

Support

Install

PC2

with

receptacle

RC1

up.

Connect

plug

PLG2

(in

compo

nent

box)

to

RC1.

Go

to

Section

F.

Tools

Needed:

C

3/8

in

Ref.

5T-l56

866

A

Follow

safety

precautions

at

beginning

of

this

section.

Use

front

panel

as

guide

to

make

holes

in

nameplate

for

parts

shown.

1

AmperageNoltage

Control

Switch

S4

2

Output

(Contactor)

Switch

S5

3

Constant

Voltage/Constant

Current

Switch

S9

4

Remote

14

Receptacle

RC3

5

6-32

x

3/8

Self-Tapping

Screw

6

Receptacle

Cover

7

Plug

PLG7

Connect

PLG7

to

receptacle

RC2

g

on

PC5.

8

Circuit

Breaker

CB3

9

Circuit

Breaker

CB4

Go

to

Section

G.

Tools

Needed:

~

5/8,9/16

in

Ref.

ST-I

56

866-B

OM-2801

Page

8

G.

Circuit

Breakers

CB3

And

CB4

Wiring

Connections

CB3

i

~

Supplied

Lead

110

~

RC2

A

Follow

safety

precautions

at

beginning

of

this

section.

1

Terminal

Strip

iT

2

Circuit

Breaker

CB3

3

Circuit

Breaker

CB4

4

Circuit

Breaker

CB2

5

Duplex

Receptacle

RC2

Make

connections

shown

below.

Go

to

Section

H.

Tools

Needed:

Connections

for

Big

40G

models

prior

to

Serial

No.

KB064495,

and

all

other

models

prior

to

Serial

No.

KB058480.

CB3

Supplied

Lead

110

iT

00

go

00

CB2

C~4-L)=cJ

Lead

1

(Pigtail

In

Harness)

I

Connections

for

Big

40G

models

effective

with

Serial

No.

KB064495

and

following.

Connections

for

all

other

models

effective

with

Serial

No.

KB058480

and

following.

4

Parts

And

Location

Wiring

Connections

N

P

c

R

For

all

models.

Lead

130

Sunoiled

Lead

130

I

U

~156

866B

/

Ref.

S-0744-A

OM-2801

Page

9

H.

Supplied

Wiring

Harness

Connections

Lead

47

D:cj

~

-,

iT

00

oe

00

A

Follow

safety

precautions

at

beginning

of

this

section.

1

Supplied

Wiring

Harness

2

Resistor

Board

R2

3

Terminal

Strip

2T

(Located

On

Back

Of

Component

Box)

4

Terminal

Strip

iT

5

Circuit

Breaker

CB3

6

Circuit

Breaker

CB4

Connect

wiring

harness

to

leads

and

components

as

shown

below.

Go

to

Section

I.

Tools

Needed:

Parts

And

Location

Wiring

Connections

Connect

to

either

--~-~--c~-~

2T

00

B

00

C

00

D

00

E

00

F

00

G

00

-

00

Existing

Lead

Connect

to

either

bottom

terminal

CB3

CB4

Lead

131

ST-i

56

866-B

/

Ref.

SA-i

55

737-B

/

S-0745-B

OM-2801

Page

10

I.

Switches

S4,

S5,

And

S9

Wiring

Connections

A

Follow

safety

precautions

at

beginning

of

this

section.

1

Switch

S4

2

Switch

S5

3

Switch

S9

4

Component

Box

5

Idle

Module

(Not

Visible)

Make

connections

to

switches

as

shown

below.

All

loose

leads

are

located

in

component

box.

Install

panel

guard.

Close

door(s)

and

component

box

cover.

Tools

Needed:

-

~

3/8

in

Parts

And

Location

Wiring

Connections

Loose

Lead

55

Sup

lied

Lead

47

~

Lead

56

to

0

I

Loose

Lead66

S9

Idle

Module

~156

886-B

I

S-0747

OM-2801

Page

11

2-2.

Installing

CV-3

In

Unit

Equipped

With

Remote

Control

N

OTE

~

This

Field

Kit

includes

optional

Remote

Control

components

(resistor

board

R2,

Remote

14

receptacle

RC3,

AmperageNoltage

Control

switch

S4,

Output

(Contactor)

switch

S5,

and

circuit

breakers

CB3

and

CB4).

These

components

do

not

have

to

be

installed

if

welding

generator

already

contains

the

Remote

Control

option.

Retain

parts

for

use

as

spares,

or

discard.

A.

CV-3

Component

Installation

A

Follow

safety

precautions

at

beginning

of this

section.

Open

doors.

1

Panel

Guard

Remove

guard.

2

Retaining

Screw

3

Component

Box

Cover

Remove

screw

and

open

cover.

4

CV

Board

PC2

5

Stand-Off

Supports

Install

PC2

with

receptacle

RC1

up.

Insert

plug

PLG2

(in

component

box)

in

receptacle

RC1.

6

Constant

Voltage/Constant

Current

Switch

S9

Use

front

panel

as

template

to

mark

hole

for

Constant

Voltage/

Constant

Current

switch

S9

on

nameplate.

Punch

or

drill

hole

where

marked.

Install

S9

so

switch

positions

match

nameplate

labeling

Go

to

Section

B.

Tools

Needed:

~

3/8,9/16in

ST-156

455

OM-2801

Page

12

B.

Switch

S9

Wiring

Connections

A

Follow

safety

precautions

at

beginning

of

this

section.

1

AmperageNoltage

Control

Switch

S4

2

Output

(Contactor)

Switch

S5

3

Constant

Voltage/Constant

Current

Switch

S9

4

Component

Box

5

Idle

Module

(Not

Visible)

6

Label

Make

connections

to

switches

as

shown.

All

loose

leads

are

located

in

component

box.

Install

panel

guard.

Close

door(s)

and

component

box

cover.

Parts

And

Location

Wiring

Connections

ST-i

56

866-B

I

S-0748-A

1

234

5

a



Tools

Needed:

~

3/8

in

Lead

98

Supplied

Lead

65

Idle

Module

Supplied

Lead

65

OM-2801

Page

13

3-1.

Front

Panel

Controls

2

3

SECTION

3-

OPERATION

4

Ref.

ST-142

608-A

.

1

AmperageNoltage

Switch

S4

To

use

front

panel

control,

place

switch

in

Panel

position.

To

use

remote

control,

place

switch

in

Remote

14

position

and

connect

remote

control

to

Remote

14

receptacle

RC3

or

terminal

ship

3T.

2

Output

(Contactor)

Switch

S5

To

use

front

panel

control,

place

switch

in

On

position.

To

use

remote

control,

place

switch

in

Remote

14

position

and

connect

remote

control

to

Remote

14

receptacle

RC3

or

ter

minal

strip

3T.

3

Constant

Current/Constant

Voltage

Switch

S9

Place

switch

in

CC

position

for

welding

pro

cesses

requinng

constant

current

output

(SMAW

and

GTAW).

Place

switch

in

CV

po

sition

for

welding

processes

requiring

con

stant

voltage

output

(GMAW

and

FCAW).

117

When

using

CV

mode,

place

Ampere

Ranges

switch

on

welding

generator

in

the

maximum

amperage

range.

4

AmperageNoltage

Adjustment

Control

Ri

See

welding

generator

owners

manual

for

control

information.

0

OM-2801

Page

14

3-2.

Volt-Ampere

Curves

3-3.

Remote

14

Receptacle

Information

And

Connections

The

remaining

sockets

are

not

used.

OUTPUT

(cONTACTOP)

010

FEEDER

A

24

volts

ac.

Protected

by

circuit

breaker

CB4.

B

Contact

closure

to

A

completes

24

volts

ac

contactor

control

circuit.

I

115

volts

ac.

Protected

by

circuit

breaker

CB3.

J

Contact

closure

to

I

completes

115

volts

ac

contactor

control

circuit.

G

Circuit

common

for

24

and

115

volts

ac

circuits.

D

Remote

control

circuit

common.

E

0

to

+10

volts

dc

input

command

signal

from

remote

control.

A.

Big

30A

Diesel

Models

2

Volt-ampere

curves

show

mini

mum

and

maximum

voltage

and

amperage

output

capabilities

of

unit.

Curves

of

other

settings

fall

between

curves

shown.

DC

AMPERE8

B.

Big

40

Diesel

And

Big

40G

Models

60

40

~30

220

C.

Big

50

Diesel

Models

40

~2

~EOST~

ox

~sw

~30

0

220

0

~x

~s~

W

200

300

400

DC

AMPERES

U

~0

200 300

400

500

800

DC

AMPERES

700

va_curvel

4195



SB-ill

680-B

/

SB-ill

679-A

/

SB-ill

678-A

REMOTE

14

Socket*

Socket

Information

C

A

i~i

AMPER~E

FtI

V

VOLTP~E

+10

volts

dc

output

to

remote

control.

K

Chassis

common.

OM-2801

Page

15

3-4.

Terminal

Strip

3T

Connections

Tools

Needed:

A

Follow

safety

precautions

at

beginning

of this

section.

1

Terminal

Strip

3T

2

Terminal

Strip

3T

Cover

Make

connections

to

terminal

strip

3T

if

the

plug

supplied

on

the

re

mote

control

cord

does

not

connect

to

Remote

14

receptacle

RC3.

A

Do

not

connect

to

Remote

14

receptacle

RC3

and

ter

minal

strip

3T

at

the

same

time.

Terminal

strip

3T

is

used

to

connect

any

of

the

following

equipment

to

the

welding

generator

control

circuitry:

3

a

Remote

Contactor

b

c

Remote

Amperage

or

Voltage

Control

Wire

feeder

which

pro

vides

contactor

control

to

the

welding

generator

Remote

Control

Cord

To

make

connections,

remove

ex

isting

plug

from

remote

control

cord.

Connect

cord

leads

to

3T

us

ing

terminal

information

from

3T

cover

and

Section

3-3.

Sockets

and

terminals

with

the

same

letter

have

identical

functions.

Route

remote

control

cord

out

just

above

base

rail.

Close

and

secure

side

door.

ST-156865/ST-155758-A

I

LINCOLN

cONt~ECTION

N~ER

MILLER

3

T

CONNECTION

NU~ER

75-.c~-

3

OM-2801

Page

16

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