Miller JK728391 Owner's manual

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

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

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

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,

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,

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

Millers

breach

of

warranty

or

any

other

dutywith

respect

to

the

quality

of

any

goods,

the

exclusive

remedies

therefore

shall

be,

at

Millers

option

(1)

repair

or(2)

replacement

or,

where

authorized

in

writing

by

Miller

in

appropriate

cases,

(3)

the

reasonable

cost

of

repair

or

replacement

at

an

authorized

Miller

service

station

or(4)

payment

of

or

credit

for

the

purchase

price

(less

reasonable

depreciation

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

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.

MILLERS

WARRANTIES

DO

NOT

EXTEND

TO,

AND

NO

RESELLER

IS

AUTHORIZED

TO

EXTEND

MILLERS

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

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

This

safety

alert

symbol

is

used

with

the

signal

words

WARNING

and

CAUTION

to

call

attention

to

the

safety

statements.

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

Owners

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

-o

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

(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

Owners

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

Owners

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

Owners

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

ers

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

Owners

Manual.

12.

Turn

on

shielding

gas

supply

at

the

source,

if

applicable.

13.

Start

the

engine

as

instructed

in

the

welding

generator

Owners

Manual.

14.

Place

the

Engine

Control

switch

in

the

RUN

posi

tion

(see

welding

generator

Owners

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

Owners

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

ers

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

Owners

Manual.

11.

Place

the

Engine

Control

switch

in

the

desired

posi

tion

(see

welding

generator

Owners

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

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

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

-p

Co

CD

0)

ABC

0

OF

0

NJ

0

L

N

FOR

IT

0

0 0

0

0 0 0

0

6

8

/04245495078788/

2/50/03/56/50

ABC

D

E

F

0

ST

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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