MO
0
January
1990
FORM:
OM-2801
Etfec
tive
With
Serial
No.
JK728391
MODEL:
CV-3
CONSTANT
VOLTAGE
CONTROL
OPTION
HLE
Copy
RETURN
TO
FOLDER
OWNERS
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
fuily
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Mifler
Group
Ltd.
Corri~any
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
PRINTED
IN
U.S.A
J
LIMITED
WARRANTY
EFFECTIVE:
MARCH
15,
1989
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
I
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
fur
nished
by
Miller
is
free
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
ac
cessones
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
war
ranted
by
their
manufacturer
for
one
year
from date
of
original
purchase,
except
Tecumseh
and
Onan
engines
which
have
a
two
year
warranty.
Except
as
specified
below,
Millers
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,
MILLER
MATIC
parts
that
come
in
contact
with
the
welding
wire
includ
ing
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
Miller
shall
be
required
to
honor
warranty
claims
on
warranted
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.
Loadbanks
lyear
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
daims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
Millers
breach
of
warranty
or
any
other
dutywith
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
Millers
option
(1)
repair
or(2)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
service
station
or(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
F.O.B.,
Factory
atAppleton,
Wisconsin,
or
F.O.B.
at
a
MILLER
authorized
serv
ice
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
daimant
on
the
war
ranty
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
PRO
VISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FUR
NISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTI
MATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CON
SUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
6>
I.
I
011.2801
-1)90
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
2
2-2.
Descnption
2
SECTION
3-
INSTALLATION
3-1.
CV-3
And
Remote
Control
Installation
2
3-2.
CV-3
Installation
8
3-3
Remote
14
Receptacle
Information
And
Connections
9
SECTION
4-
OPERATOR
CONTROLS
4-1.
AmperageNoltage
Switch
11
4-2.
Output
(Contactor)
Switch
11
4-3.
Constant
Voltage
(CV)/Constant
Current
(CC)
Switch
11
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
Gas
Metal
Arc
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
12
5-2.
Shielded
Metal
Arc
Welding
(SMAW)
13
5-3.
Shutting
Down
13
SECTION
6-
MAINTENANCE
AND
TROUBLESHOOTING
6-1.
Routine
Maintenance
14
6-2.
Overload
Protection
14
6-3.
Circuit
Board
Handling
Precautions
14
6-4.
Troubleshooting
14
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam
age
that
may
have
occurred
dunng
shipment.
File
any
claims
for
loss
or
damage
with
the
delIverIng
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur
ers
Transportation
Department.
Use
the
following
spaces
to
record
the
Model
Designa
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
mation
is
located
on
the
data
card
or
the
nameplate.
Model
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Number.
Serial
or
Style
No.
Date
of
Purchase
Section
No.
Page
No.
SECTION
7
ELECTRICAL
DIAGRAMS
Diagram
7-1.
Circuit
Diagram
For
BIG
30A
DIESEL
Models
With
CV-3
Option
16
Diagram
7-2.
Circuit
Diagram
For
BIG
40
DIESEL
Models
With
CV-3
Option
17
Diagram
7-3.
Circuit
Diagram
For
BIG
40G
Models
With
CV-3
Option
18
Diagram
7-4.
Circuit
Diagram
For
BIG
50
DIESEL
Models
With
CV-3
Option
19
SECTION
8
PARTS
LIST
Figure
8-1.
CV-3
Module
20
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
CV
Mode
Specifications
1
Chart
2-1.
DC
Voit-Ampere
Curves
(CV
Mode)
2
Table
6-1.
Troubleshooting
15
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
forthe
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
Owners
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
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
attention
to
the
safety
statements.
a
a
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
ir3jury
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
Max.
Open-Circuit
Volts*
BIG
30A
DIESEL
200
Amperes
At
28
Volts
10-35
40
BIG
40
DIESEL
And
BIG
40G
300
Amperes
At
32
Volts
BIG
50
DIESEL
300
Amperes
At
32
Volts
*See
Owners
Manual
for
specifications
in
CC
mode.
OM-2801
Page
1
Chart
2-1.
DC
Volt-Ampere
Curves
(CV
Mode)
50
U)
0
>
(3
0
50
40
30
20
10
0
100
200
300
400
DC
AMPERES
500 600
B-lu
679
U)
I-
-j
0
>
(2
0
The
volt-ampere
curves
show
the
output
voltage
and
amperage
of
the
welding
generator
available
at
any
point
fIx)m
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
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.
SECTION
3-
INSTALLATION
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
INSTALLATION
(FIgures
3-1,
3-2,
and
3-3)
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Stop
engine,
and
disconnect
negative
(-)
battery
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.
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:
In
order
to
use
the
CV-3
option,
the
w~
ing
generator
must
include
the
Remote
Control
c~
This
subsection
covers
the
installation
of
the
compo
nents
for
both
the
C
V-3
option
and
the
Remote
Control
option.
C
V-3
components
consist
of
CV
board
PC2
and
50
40
30
20
10
U)
I
-I
0
>
(3
0
S
40
30
20
10
0
B-Ill
680-A
2-1.
VOLT-AMPERE
CURVES
(Chart
2-1)
50 100
150
200 250
300
350 400
DC
AMPERES
100
200
300
400
500
600
DC
AMPERES
B-ill
678
BIG
40
DIESEL
And
BIG
400
Modele
100%
RH
EOSTAT
0%
RHEOSTAT
OM-2801
Page
2
CC/CV
switch
89.
Remote
Control
components
consist
of
resistor
board
R2,
REMOTE
14
receptacle
RC3,
AM
PERAGE)
VOL
TAGE
Control
switch
S4,
OUTPUT
(CON
TACTOR)
switch
85,
andcircuitbreakers
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
aftera
connection
has
been
made
at
one
end.
A
lead
that
a/ready
has
a
connection
made
at
one
end
when
these
procedures
are
started
is
called
an
unconnected
lead.
A.
Component
installation
(Figures
3-1
and
3-2)
1.
Open
and
secure
right
side
door.
On
a
BIG
30A
DIESEL
model,
open
and
secure
left
side
door
also.
Remove
panel
guard
(see
Figure
3-1).
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
corn-
ponent
box
wall
(see
Figure
3-2)
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
3-2).
Install
supplied
lock
washers
and
6-32
nuts
onto
resistor
board
mounting
screws
and
tighten
securely.
On
a
BIG
30A
DIESEL
model,
it
is
easiest
to
install
resistor
board
R2
from
the
left
side
of
the
unit.
6.
Install
supplied
CV
board
PC2
onto
plastic
stand-
oils
in
lower
left
of
component
box
so
that
recep
tacle
Rd
is
towards
the
top
of
the
welding
genera
tor.
Press
CV
board
PC2
into
place
until
plastic
re
tainers
on
standoffs
snap
into
place
on
PC
board.
7.
Insert
plug
PLG2
(unconnected
plug
in
component
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.
8.
Locate
holes
in
front
panel
(behind
nameplate)
for
AMPERAGENOLTAGE
Control
switch,
OUTPUT
(CONTACTOR)
switch,
CONSTANT
CU
RRENT/
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.
2.
3.
Component
Box
Cover
Screw
Front
Panel
Guard
Figure
3-1.
Panel
Guard
And
Component
Box
LocatIons
TC.134
108
OM-2801
Page
3
a
CAUTION:
METAL
FILINGS
AND/OR
TOOL
CONTACT
WITH
INTERNAL
COM
PONENTS
can
damage
unit.
Cover
internal
components.
Clean
unit,
and
remove
internal
cover
ing
material
before
resuming
operation.
9.
Punch,
cut,
ordnll
correct
diameter
holes
at
marked
locations
for
installing
components.
10.
Install
supplied
SPDT
AMPERAGE/VOLTAGE
Control
switch
S4
onto
front
panel
from
rear
at
loca
tion
labeled
PANEL/REMOTE
14
on
the
name
plate.
Be
sure
that
S4
terminals
are
positioned
ver
tically
so
switch
positions
match
nameplate
label
ing.
11.
Secure
switch
S4
using
supplied
nut
and
switch
le
ver
boot.
12.
Install
supplied
SPDT
OUTPUT
(CONTACTOR)
switch
S5
onto
front
panel
from
rear
at
location
la
beled
ON/REMOTE
l4on
the
nameplate.
Be
sure
that
S5
terminals
are
positioned
vertically
so
switch
positons
match
nameplate
labeling.
13.
Secure
switch
S5
using
supplied
nut
and
switch
le
ver
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
posi
tioned
vertically
so
switch
positions
match
name
plate
labeling.
15.
Secure
switch
S9
using
supplied
nut
and
switch
le
ver
boot.
16.
Install
supplied
circuit
breakers
CB3
and
CB4
onto
front
panel
from
rear
at
labeled
locations.
Install
one
supplied
nut
and
washer
onto
circuit
breaker
before
installing
onto
front
panel,
and
use
remain
ing
supplied
nut
to
secure
circuit
breaker
onto
front
panel
(see
Figure
3-2).
17.
Install
supplied
14-socket
REMOTE
14
Amphenol
receptacle
onto
front
panel
from
rear,
and
secure
with
supplied
6-32
x
3/8
in.
self-tapping
screws
(in-
sert
screw
used
in
lower
left
corner
through
link
of
receptacle
cover
chain
before
secunng
screw
into
REMOTE
14
receptacle).
B.
Circuit
Breakers
CB3
And
CB4
Wiring
Connec
tions
(FIgures
3-2
and
3-3)
1.
Locate
supplied
loose
capacitor
assemblies
(two)
having
a
female
piggyback
friction
connector
on
one
end
and
a
ring
terminal
on
the
other
end.
2.
Connect
female
piggyback
friction
connector
on
one
capacitor
assembly
to
upper
male
terminal
on
circuit
breaker
CB3.
Connect
female
piggyback
friction
connectoron
remaining
capacitor
assembly
to
upper
male
terminal
on
circuit
breaker
CB4.
3.
Connect
insulated
male
friction
connector
on
loose
lead
110
to
insulated
female
friction
connector
on
unconnected
lead
110
extending
from
back
of
du
plex
receptacle
RC2.
4.
Connect
remaining
end
of
loose
lead
110
to
piggy
back
male
friction
connector
on
circuit
breaker
CB3
upper
terminal.
5.
Disconnect
existing
lead
from
terminal
strip
1
T
ter
minal
A.
6.
Connect
female
piggyback
friction
connector
on
loose
lead
130
to
terminal
strip
iT
terminal
A.
7.
Connect
lead
removed
from
terminal
strip
iT
in
Step
5
to
piggyback
male
friction
connector
on
ter
minal
strip
iT
terminal
R.
8.
Connect
remaining
end
of
loose
lead
130
to
male
piggyback
connector
on
circuit
breaker
CB4
upper
terminal.
9.
Remove
nut
and
washer
from
ground
terminal
on
frame
of
unit
(see
Figure
3-2).
10.
Install
ring
terminals
on
capacitor
assemblies
con
nected
to
upper
terminals
of
circuit
breakers
CB3
and
CB4
onto
ground
terminal.
11.
Install
supplied
copper
bus
bar
onto
ground
termi
nal
so
bus
bar
is
vertical
with
unused
hole
at
upper
end.
.
OM-2801
Page
4
Resistor
Board
R2
Mounting
Holes
Resistor
Board
R2
JJk~
CV/CC
Switch
S9
2T
CV
Board
PC2
~IL
Remote
14
Receptacle
RC3
Circuit
-
Breaker
CB3
Capacitor
Assemblies
cult
Breaker
CB4
Strip
IT
TC.134
203
Figure
3-2.
Component
Locations
58
S4
Idle
Module
CE
D
GB
To
S9
Bottom
Right
Terminal
0
0
-o
a
a
0)
To
2T
Terminal
G
2T
I~1
iT
A
B
C
D
E
F
G
H
J
K
L
M
N
p
0
R
S
T
U
RC3
Lead
18
RC3
Lead
47
RC3
Lead
55
1.
RC3
Lead
56
561
To
R2
Lower
Terminal
RC3Lead58
~
To
R2
Upper
Terminal
To
Upper
To
2T
Terminal
F
RC2
RC3LeadlOO
~
1-
130~
ToCB4
130
b
Upper
Terminal
To
To
(Unconnected
Lead)
To
S9
Bottom
LeftTerminal
To
Disconnected
Lead
47
(Unconnected
Lead)
(Unconnected
Lead)
To
Disconnected
Lead
57
(Unconnected
Lead)
To
Disconnected
Lead
48
To
Idle
Module
Terminal
B
(Unconnected
Lead)
(Disconnected
From
Lead
47)
To
S4
Center
Terminal
(Unconnected
Lead)
To
2T
Terminal
55
131
-To
CB4
Lower
Terminal
To
CB3
Lower
Terminal
To
Ground
Terminal
.
To
2T
Terminal
F
~~To
Ground
Terminal
110
ToRC2
Lead
110
RC3
Lead
132
Figure
3-3.
Component
Wiring
Connections
.
S-0342
S
C.
REMOTE
14
Receptacle
RC3
Wiring
Connec
tions
(Figures
3-2
and
3-3)
1.
Connect
ring
terminal
on
receptacle
RC3
lead
42
to
ground
terminal
on
frame.
2.
Replace
washer
and
nut
onto
ground
terminal
and
tighten
securely.
3.
Connect
receptacle
RC3
lead
131
to
bottom
termi
nal
on
circuit
breaker
CB4.
4.
Connect
receptacle
RC3
lead
132
to
bottom
termi
nal
on
circuit
breaker
CB3.
IMPORTANT:
When
making
connections
to
terminal
strip
2Ton
a
BIG
30A
DIESEL
model,
it
is
help
fulto
use
a
needle-nosed
pliers
when
installing
friction
connectors
onto
terminal
strip
terminals.
Bring
the
needle-nosed
pli
ers
near
the
terminal
strip
from
below,
route
the
desired
lead
into
position
with
the
other
hand
from
the
side,
and
grasp
the
friction
connector
with
the
pliers
to
insert
the
connector
onto
the
applicable
terminal.
5.
Connect
receptacle
RC3
lead
18
to
terminal
strip
2T
terminal
A.
6.
Connect
receptacle
RC3
lead
47
to
terminal
strip
2T
terminal
D.
7.
Connect
receptacle
RC3
lead
56
(has
a
piggyback
friction
connector)
to
terminal
strip
2T
terminal
F.
8.
Connect
receptacle
RC3
lead
55
to
terminal
strip
2T
terminal
E.
9.
Connect
receptacle
RC3
lead
58
(has
a
piggyback
friction
connector)
to
terminal
strip
2T
terminal
G.
10.
Disconnect
existing
lead
from
terminal
strip
iTter
minal
N.
11.
Connect
receptacle
RC3
lead
100
(has
a
piggyback
friction
connector)
to
terminal
strip
iT
terminal
N.
12.
Connect
lead
removed
from
terminal
N
in
Step
9
to
piggyback
connector
on
terminal
strip
iT
terminal
N.
13.
Insert
supplied
1/4-20
x
1/2
in.
bolt
through
unused
hole
in
upper
end
of
bus
bar
installed
onto
ground
terminal
in
Step
11
of
Subsection
B.
14.
install
ring
terminals
on
ends
of
capacitor
leads
ex
tending
from
back
of
receptacle
RC3
onto
bolt
in
serted
through
hole
in
bus
bar
in
Step
13.
Install
supplied
1/4-20
nut
onto
bolt
and
tighten
securely.
D.
Resistor
Board
R2
Wiring
Connections
(Figures
3-2
and
3-3)
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
~r
board
terminals.
1.
Connect
loose
lead
56
to
resistor
board
R2
bottom
temmnal
(either
one).
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
ter
minal
(either
one).
4.
Connect
remaining
end
of
loose
lead
58
to
piggy
back
connector
on
terminal
strip
2T
terminal
G.
E.
Switches
54,
S5,
and
S9
Wiring
Connections
(FIgures
3-2
and
3-3)
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
ter
minal.
2.
Locate
and
disconnect
the
friction
terminal
connec
tion
between
leads
47
and
98.
3.
Connect
piggybackfnction
connectoron
loose
lead
47
to
switch
S4
bottom
terminal.
4.
Connect
remaining
end
of
loose
lead
4710
lead
47
disconnected
in
Step
2.
5.
Connect
unconnected
lead
47
to
piggyback
friction
connector
connected
in
Step
3
to
switch
S4
bottom
terminal.
6.
Connect
unconnected
lead
56
to
switch
S5
top
ter
minal.
7.
Locate
and
disconnect
the
friction
terminal
connec
tion
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
7,10
switch
S5
bottom
terminal.
11.
Connect
unconnected
lead
6610
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
cornerof
the
component
box
when
looking
into
the
compo
nent
box.
14.
Connect
loose
lead
48
to
lead
48
disconnected
in
Step
13.
Connect
remaining
end
of
loose
lead
48to
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
connectoron
loose
lead
65
to
switch
S9
bottom
left
terminal.
Connect
re
maining
end
of
loose
lead
65
to
switch
S4
center
terninal.
17.
Connect
unconnected
lead
65to
piggyback
friction
connector
on
switch
S9
bottom
left
terminal.
OM-280i
Page
7
18.
Close
component
box
cover
and
reinstall
retaining
screw.
19.
Reinstall
panel
guard.
20.
Close
and
secure
right
side
door,
and
left
side
door
if
applicable.
Resume
operation.
3-2.
CV-3
INSTALLATION
(Figures
3-1,3-2
and
3-3)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Stop
engine,
and
disconnect
negative
(-)
battery
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
in
the
field
in
stallation
kit,
but
need
not
be
installed
if
the
welding
gen
erator
afready
contains
the
Remote
Control
option.
Therefore,
the
Remote
Control
option
components
(re
sistorboardR2,
REMOTE
14
receptacle
RC3,
AMPER
AGE/VOLTAGE
Control
switch
S4,
OUTPUT
(CON
TACTOR)
switch
S5,
and
circuit
breakers
CB3
and
CB4)
can
be
retained
as
spare
parts
or
discarded.
IMPORTANT:
Unless
otherwise
specified,
all
dire
ctions,
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
aftera
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
3-2)
1.
Remove
retaining
screw
and
open
component
box
cover
(see
Figure
3-1).
2.
Install
CV
board
PC2
onto
plastic
standoffs
in
lower
left
of
component
box
so
that
receptacle
RC1
is
to
wards
the
top
of
the
welding
generator.
Press
CV
board
PC2
into
place
until
plastic
retainers
on
standoff
S
snap
into
place.
3.
Insert
plug
PLG2
(unconnected
plug
in
component
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
pres
sure
from
rear
with
a
sharp
tool.
5.
Punch,
cut,
or
drill
correct
diameter
hole
for
install
ing
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
3-2
and
3-3)
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.
Idle
Module
CE
0GB
~
To
S9
Bottom
Right
Terminal
Rel.
S-0342
Figure
3-4.
Component
Wiring
ConnectIons
1.
Connect
unconnected
lead
66
to
switch
S9
top
left
terminal.
2.
Disconnect
lead
98
from
switch
S4
center
terminal.
3.
Connect
lead
98
disconnected
in
Step
2
to
switch
S9
center
left
terminal.
S4
S9
To
S9
Bottom
Left
Terminal
To
Disconnected
Lead
48
To
Idle
Module
Terminal
B
(Unconnected
Lead)
jDisconnected
From
Lead
47)
To
S4
Center
Terminal
(Unconnected
Lead)
OM-2801
Page
8
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
compo
nent
box.
5.
Connect
loose
lead
48
to
lead
48
disconnected
in
Step
4.
Connect
remaining
end
of
loose
lead
48
to
switch
S9
center
right
terminal.
6.
Connect
loose
lead
68
to
Idle
Module
terminal
B.
Connect
remaining
end
of
loose
lead
68
to
switch
S9
bottom
right
terminal.
7.
Connect
piggybackf
rictionconnectoron
loose
lead
65
to
switch
S9
bottom
left
terminal.
Connect
re
maining
end
of
loose
lead
65
to
switch
54
center
terminal.
8.
Connect
unconnected
lead
65
to
piggyback
friction
connector
on
switch
S9
bottom
leftterminai.
9.
Close
component
box
cover
and
reinstall
retaining
screw.
Resume
operation.
3-3
REMOTE
14
RECEPTACLE
INFORMATION
AND
CONNECTIONS
(Figures
3-2
and
3-5)
AJV
AMPERAGE/VOLTAGE
OUTPUT
(CONTACTOR)
REMOTE
14
REMOTE
14
receptacle
RC3
is
used
to
connect
any
of
the
following
equipment
to
the
welding
generatorcircuit
ry:
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,
align.
keyway,
insert
plug,
and
ro
tate
threaded
collar
fully
clockwise.
The
following
socket
information
is
included
in
case
the
supplied
cord
is
not
suitable,
and
it
is
necessary
to
wire
a
plug
or
cord
to
interface
with
REMOTE
14
receptacle
RC3.
Socket
A:
Socket
B:
Up
to
10
amperes
0124
volts
ac,
60Hz,
with
respect
to
socket
G
(circuit
common);
pro
tected
by
circuit
breaker
CB4.
Input
control
to
energize
weld
contactor
for
24
volts
ac
wire
feeder.
A
contact
closure
from
socket
A
to
socket
B
completes
the
24
volt
circuit.
Socket
C:
+10
volts
dc
with
respect
to
socket
D.
Socket
D:
Control
circuit
common
for
remote
control
device.
Socket
E:
Input
command
signal
from
wiper
of
remote
control
potentiometer;
0
volts
equals
ma
chine
minimum;
+10
volts
equals
machine
maximum.
Socket
G:
24
and
115
volts
ac
circuit
common;
also
connected
to
welding
generator
chassis.
Socket
I:
Up
to
10
amperes
of
115
volts
ac,
60
Hz,
with
respect
to
socket
G
(circuit
common);
protected
by
circuit
breaker
CB3.
Socket
J:
Input
control
to
energize
weld
contactor
for
115
volts
ac
wire
feeder.
A
contact
closure
from
socket
Ito
socket
J
completes
the
115
volt
circuit.
Socket
K:
Machine
chassis
(circuit
common).
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
S-0004
FIgure
3-5.
Front
View
Of
14-Socket
Receptacle
WIth
Socket
LocatIons
Work
Electrode
~
Optional
Remote
Contactor
And
Amperage
~
Connection
To
CV4
S~41
Figure
3-6.
Connection
Diagram
For
Remote
Control
o~
Welding
Generator
OM-2801
Page
9
.
Welding
Generator
Gas
Hose
Figure
3-7.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
Spoolmatlc
3
Gun/Feeder
S-0442
Wire
Drive
Assembly
3
ft.
(914
mm)
Long
Pigtail
With
Amphenoi
Gas
Hose
S-0443
Figure
3-8.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
S-32P
Series
Wire
Feeders
Gas
Hose
s-ow
Figure
3-9.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
Porta-Mig
Model
Wire
Feeder
OM-2801
Page
10
interconneclln
Cord
Electrode
Cable
Supplied
With
ender
Figure
3-10.
Gas
Metal
Arc
Welding
(GMAW)
Connection
Diagram
For
50
Series
Wire
Feeder
SECTION
4-OPERATOR
CONTROLS
4-1.
AMPERAGENOLTAGE
SWITCH
(Figure
3-2)
A/V
AMPERAGE/VOLTAGE
If
remote
current
control
is
desired,
make
connections
to
the
REMOTE
l4receptacie
as
instructed
in
Section
3-3.
Place
the
AMPERAGE/VOLTAGE
Controi
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.
4-2.
OUTPUT
(CONTACTOR)
SWITCH
(Figure
3-2)
0*
4~
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Do
not
touch
weld
output
terminals
when
contactor
is
energized.
Do
not
touch
electrode
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
en
gine
is
running.
IMPORTANT:
Although
the
term
contactor
is
used
on
the
nameplate
and
throughout
this
manual,
the
output
is
not
switched
on
oroff
bya
physical
contactor;
rather,
the
output
is
controlled
by
opening
and
closing
the
windings
of
the
revolving
field,
thereby
functioning
as
a
contactor.
if
remote
contactor
control
is
desired,
make
connections
to
the
REMOTE
14
receptacle
as
instructed
in
Section
3-3.
Place
the
OUTPUT
(CONTACTOR)
switch
in
the
REMOTE
14
position.
Open-circuit
voltage
is
present
at
the
weld
output
terminals
when
the
Remote
Contactor
Control
switch
is
closed.
If
remote
contactorcontrol
is
not
desired,
place
the
OUT
PUT
(CONTACTOR)
switch
in
the
ON
position.
Open-
circuit
voltage
will
be
available
at
the
weld
output
termi
nals
whenever
the
engine
is
running.
4-3.
CONSTANT
VOLTAGE
(CV)/CONSTANT
CUR
RENT
(CC)
SWITCH
(Figure
3-2)
kCC
F-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
Am
pere
Range
switch
on
the
welding
generatorin
the
maxi
mum
amperage
range
position.
Work
Wire
Drive
Assembly
/
Welding
Gun.
/
HI
.1
50
SerIes
Model
Wire
Feeder
1
Connection
To
CV.3T22~(
14-Socket
Amphenol
Receptacle
RC3
Welding
Generator
/
Gas
Hose
Flowmeter
And
~Gas
Supply
With
Regulator
S-0445
OM-2801
Page
11
SECTION
5-
SEQUENCE
OF
OPERATION
a
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
tire
and
burns.
Watch
for
fire.
Keep
a
fire
extinguisher
nearby,
and
know
how
to
use
ft.
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
tunning.
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
neararc
welding,
gouging,
orspot
welding
operations.
See
Section
1-Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
the
welding
gener
ator
Owners
Manual
for
basic
welding
safety
in
formation.
5-1.
GAS
METAL
ARC
(GMAW)
AND
FLUX
CORED
ARC
WELDING
(FCAW)
4~
WARNING:
Read
and
follow
safety
Information
at
begInnIng
of
entIre
SectIon
5
before
proceedIng.
1.
Ensure
that
the
welding
generator
has
been
prepared
as
instructed
in
its
Owners
Manual.
2.
Install
and
connect
CV-3
according
to
Sectlon
3,
U
applicable.
3.
Install
and
connect
wire
feeder
to
the
CV-3
RE
MOTE
14
receptacle
according
to
Section
3
and
wire
feed
equipment
Owners
Manual.
4.
If
shielding
gas
is
required,
make
all
the
necessary
connections.
5.
Rotate
the
AMPERE
RANGES
switch
and
AM
PERAGE
&
VOLTAGE
ADJUSTMENT
control
to
the
desired
positions
(see
welding
generator
Own
ers
Manual).
IMPORTANT:
When
using
the
CVmode,
place
the
AM
PERE
RANGES
switch
on
the
welding
generator
in
the
maximum
position,
and
use
the
AMPERAGE
&
VOLT
AGE
ADJUSTMENT
control
to
select
the
desired
volt
age.
If
remote
voltage
control
is
used,
the
minimum
to
maximum
voltage
range
selection
at
the
remote
control
will
be
a
percentage
of
the
AMPERAGE
&
VOLTAGE
ADJUSTMENTcontr0I
setting
(see
Section
4-2).
When
using
the
CC
mode,
place
the
AMPERE
RANGES
switch
and
the
AMPERAGE
&
VOLTAGE
ADJUST
MENT
control
on
the
welding
generator
in
the
desired
positions.
If
remote
amperage
control
is
used,
the
mini
mum
to
maximum
amperage
range
selection
at
the
re
mote
control
will
be
a
percentage
of
the
AMPERAGE
&
VOLTAGE
ADJUSTMENT
control
setting
(see
Section
4-2).
GMAW
normally
uses
the
CV
mode;
FCAW
may
use
either
CVor
CC
depending
on
the
selected
welding
wire.
6.
Place
the
CV/CC
switch
in
the
proper
position
as
determined
by
the
selected
welding
process
(see
Section
4-1).
7.
If
remote
amperage
or
voltage
control
is
not
used,
place
the
CV-3
AMPERAGENOLTAGE
Control
switch
in
the
PANEL
position.
If
remote
amperage
orvoitage
control
isto
be
used,
place
the
AMPERA
GENOLTAGE
Control
switch
in
the
REMOTE
14
position.
If
remote
contactor
control
is
not
used,
place
the
CV-3
OUTPUT
(CONTACTOR)
switch
in
the
ON
position.
If
remote
contactor
control
is
to
be
used,
place
the
OUTPUT
(CONTACTOR)
switch
in
the
REMOTE
14
position.
4
8.
OM-2&Oi
Page12
4.
Place
the
CV/CC
switch
in
the
CC
position.
9.
If
the
welding
generator
contains
the
optional
ACt
DC
Selector
switch,
place
the
AC/DC
Selector
switch
in
the
proper
position
as
determined
by
the
selected
welding
process.
a
WARNING:
ELECTRIC
SHOCK
Can
kill.
Do
not
use
AC
output
in
damp
areas,
if
move
mentis
confined,
on!
there
isa
dangerof
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
Rules
at
beginning
of
this
manual.
10.
Wear
dry
insulating
gloves
and
clothing,
and
wear
welding
helmet
with
proper
filter
lens
according
to
ANSI
Z49.1.
11.
Prepare
for
welding
as
follows:
a.
Connect
work
clamp
to
clean,
bare
metal
at
workpiece.
b.
Select
and
obtain
proper
welding
wire,
and
thread
as
instructed
in
wire
feeder
Owners
Manual.
12.
Turn
on
shielding
gas
supply
at
the
source,
if
applicable.
13.
Start
the
engine
as
instructed
in
the
welding
generator
Owners
Manual.
14.
Place
the
Engine
Control
switch
in
the
RUN
posi
tion
(see
welding
generator
Owners
Manual).
IMPORTANT:
Power
requirements
by
CV-3
compo
nents
will
cause
the
welding
generator
engine
to
operate
at
weld
rpm
continuously
in
the
CV
mode
if
the
Engine
Control
switch
is
placed
in
the
AUTO
IDLE
position.
Placing
the
Engine
Control
switch
in
the
RUN
position
will
pre
vent
mistaking
unit
operation
as
a
malfunction
in
the
Auto
Idle
circuitry.
15.
Begin
welding.
5-2.
SHIELDED
METAL
ARC
WELDING
(SMAW)
a
WARNING:
Read
and
follow
safety
information
at
beginning
of
entIre
SectIon
5
before
proceeding.
1.
Ensure
that
the
welding
generator
has
been
prepared
as
instructed
in
its
Owners
Manual.
2.
Install
and
connect
CV-3
according
to
Section
3,
if
applicable.
3.
Rotate
the
AMPERE
RANGES
switch
and
AM
PERAGE
&
VOLTAGE
ADJUSTMENT
control
to
the
desired
positions
(see
welding
generator
Own
ers
Manual).
5.
It
remote
amperage
or
voltage
control
is
not
used,
place
the
CV-3
AMPERAGENOLTAGE
Control
switch
in
the
PANEL
position.
If
remote
amperage
orvoltage
control
is
to
be
used,
place
the
AM
PERA
GENOLTAGE
Control
switch
in
the
REMOTE
14
position.
6.
If
remote
contactor
control
is
not
used,
place
the
CV-3
OUTPUT
(CONTACTOR)
switch
in
tbe
ON
position.
If
remote
contactor
control
is
to
be
used,
place
the
OUTPUT
(CONTACTOR)
switch
in
the
REMOTE
14
position.
7.
If
the
welding
generator
contains
the
optional
AOl
DC
Selector
switch,
place
the
AC/DC
Selector
switch
in
the
proper
position
as
determined
by
the
selected
welding
process.
a
WARNING:
ELECTRIC
SHOCK
can
kill.
In
wet
or
confined
areas,
use
only
DC
output
or
remote
output
controL
ReadSafety
Rules
atbeginningof
the
welding
generator
ManuaL
8.
Wear
dry
insulating
gloves
and
clothing,
and
wear
welding
helmet
with
proper
filter
lens
according
to
ANSI
Z49.1.
9.
Prepare
for
welding
as
follows:
a.
Connect
work
clamp
to
clean,
bare
metal
at
workpiece.
-
b.
Select
and
obtain
proper
electrode,
and
insert
in
electrode
holder.
10.
Start
the
engine
as
instructed
in
the
welding
generator
Owners
Manual.
11.
Place
the
Engine
Control
switch
in
the
desired
posi
tion
(see
welding
generator
Owners
Manual).
12.
Begin
welding.
5-3.
SHUTrING
DOWN
1.
Stop
welding.
2.
Turn
oft
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.
a
WARNING:
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kIll.
Shut
off
gas
supply
when
not
in
use.
OM-2801
Page
13
SECTION
6-
MAINTENANCE
AND
TROUBLESHOOTING
6-1.
ROUTINE
MAINTENANCE
IMPORTANT:
Follow
the
procedures
for
routine
mainte
nance
found
in
the
Owner~s
Manualforthe
welding
gen
erator.
6-2.
OVERLOAD
PROTECTION
A.
Circuit
Breaker
CB3
Circuit
breaker
CB3
protects
the
unit
wiring
from
over
load
and
damage.
If
CB3
opens,
the
115
votts
ac
output
to
pin
I
of
REMOTE
14
receptacle
RC3
is
stopped.
If
CB3
opens,
locate
and
correct
the
problem,
and
manually
re
set
the
circuit
breaker.
B.
CIrcuit
Breaker
CB4
Circuit
breaker
CB4
protects
the
unit
wiring
from
over
load
and
damage.
If
CB4
opens,
the
24
volts
ac
output
to
pin
A
of
REMOTE
14
receptacle
RC3
is
stopped.
If
CB3
opens,
locate
and
correct
the
problem,
and
manually
re
set
the
circuit
breaker.
6-3.
CIRCUIT
BOARD
HANDLING
PRECAUTIONS
4~
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.
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
wosk
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.
6-4.
TROUBLESHOOTING
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.
Troubleshooting
to
be
performed
oniy
by
qualified
persons.
IMPORTANT:
Before
beginning
any
troubleshooting
procedures,
check
and
be
sure
that
all
connections
are
corre
ctand
secure
and
that
al/switches
are
in
the
proper
position.
a
OM-2801
Page
14
Table
6-1.
TroubleshootIng
TROUBLE
PROBABLE
CAUSE
REMEDY
Wire
feeder
inoperative
Circuit
breaker
CB3
or
CB4
open.
Reset
CB3
or
CB4
according
to
Section
6-2.
No
remote
control
of
contactor;
open-circuit
voltage
present
all
the
time
when
engine
is
run-
fling.
OUTPUT/CONTACTOR
switch
S5
in
the
ON
position.
Place
S5
in
the
REMOTE
14
position
(see
Sec
tion
4-2).
No
contactor
control;
no
weld
output;
no
open-circuit
voltage,
.
CV-3
not
correctly
installed
if
done
as
a
field
kit.
Review
Section
3
and
check
all
connections.
.
Incorrect
orpoorconnectionsto
REMOTE
14
receptacle
RC3.
Check
and
secure
connections
(see
Section
3-3).
Remote
Contactor
Control
de-
vice,
Check
and
repair
or
replace
remote
device
as
necessary.
Nocontrolofvoltage;maximum
or
very
low
or
no
open-circuit
voltage
present.
AMPERAGE
&
VOLTAGE
AD-
JUSTMENT
control
not
set
at
100%
position.
Rotate
AMPERAGE
&
VOLTAGE
ADJUST
MENT
control
to
100%
position.
~
AMPERAGE/VOLTAGE
Con-
trol
switch
not
in
correct
posi-
tion.
Be
sure
AMPERAGENOLTAGE
Control
switch
isincorrectposition:
REMOTE
l4ifremotecon-
trol
is
used,
PANEL
if
remote
control
not
used.
Incorrectorpoorconnectionsto
REMOTE
14
receptacle
RC3.
Check
and
secure
connections
(see
Section
3-3).
RemoteVoltageControldevice.
Check
and
repair
or
replace
remote
device
as
necessary.
CV
Regulator
Board
PC2.
Replace
PC2
according
to
Section
6-3.
I
OM-2801
Page
15
0
0
-p
Co
CD
0)
ABC
0
OF
0
NJ
0
L
N
N
FOR
IT
0
0
0
0
0
0
0
0
0
0
0 0
0
0 0 0
0
6
8
/04245495078788/
2/50/03/56/50
ABC
D
E
F
0
ST
0
0
0
0
0
0
0
/8
/9
50
17
50
56
58
Circuit
Diagram
No.
SC-i
30
397-A
Cl)
m
C)
-f
0
z
ii
I
m
C,
-l
I
C)
1~
C)
I
U)
WITH
IRE
Pa.ARITY
SWITOI
~II(1~.
LEADS
I9~.3O
50
TO
1)8
P(LAPITY
SWITOl RATIER
THAN
nE
WTP(JT
STI.X3S.
n.E
~.JTPCJT
STWS
ARE
LABELED
D..ECTR~
NC
W500.
Diagram
7-1.
Circuit
Diagram
For
BIG
30A
DIESEL
Models
With
CV-3
Option
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