Miller KC286939 Owner's manual

Miller

December

1994

Form:

OM-2801C

Effective

With

Serial

No.

KC289996

OWNERS

MANUAL

CV-3

Control



Read

and

follow

these

instructions

and

all

safety

blocks

carefully.



Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.



Call

your

distributor

if

you

do

not

understand

the

directions.



Constant

Voltage

Control



For

Big

30A,

40,

And

50

Diesels,

And

Big

4oG

Models

With

Serial

No.

JK728391

And

Following



For

GMAW

And

FCAW

Welding



100%

Duty

Cycle

At

Welding

Generator

Rated

Load



Give

this

manual

to

the

operator.



For

help,

call

your

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

cover

5194

'

1994

MILLER

Electflc

MIg.

Co.

PRINTED

IN

USA

u-f

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1995

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

warranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

1~I

LIMITED

WARRANTY



Subject

to

the

terms

and

conditions

below,

MILLER

Electric

Mt

g.

Co.,

Appleton,

Wisconsin,

warrants

to

its

original

retail

purchaser

that

new

MILLER

equipment

sold

alter

the

effective

date

ot

this

limited

warranty

is

tree

ot

de

fects

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

or

replace

any

war

ranted

parts

or

components

that

tail

due

to

such

detects

in

material

or

workmanship.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

failure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

such

a

failure

within

the

warranty

time

periods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

onginal

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

a

North

American

distributor

or

eighteen

months

after

the

equipment

is

sent

to

an

tntemational

distributor.

1,

5YearsParts3YearsLabor

Original

main

power

rectifiers

2.

3

Years



Parts

and

Labor

Transformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources



SemI-Automatic

and

Automatic

Wire

Feeders

Robots

3.

2

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer

for

a

period

of

Iwo

years.)



Air

Compressors

4.

1

Year



Parts

and

Labor



Motor

Driven

Guns



Process

Controlters



Water

Coolant

Systems

HF

Units



Grids



Spot

Welders



Load

Banks

SDX

Translormers



Running

Gear/Trailers



Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)



Field

Options

(NOTE:

Field

options

are

covered

under

True

BIueTM

for

the

remaining

warranty

period

of

the

product

they

are

installed

in.

or

for

a

minimum

of

one

year



whichever

is

greater.)

6

Months



Batteries

90

Days



Parts

and

Labor

MIG

Guns/TIG

Torches



APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches

u-I



Remote

Controls



Accessory

Kits

Replacement

Parts

MILLERS

True

BlueTM

Umited

Warranty

shall

not

apply

to:

1.

Items

furnished

by

MILLER,

but

manufactured

by

others.

such

as

engines

or

trade

accessories.

These

it

ems

are

covered

by

the

manufacturers

warranty,

if

any.

2.

Consumable

components;

such

as

contact

lips,

cutting

nozzles.

contactors

and

relays

or

parts

that

fatl

due

10

normat

wear.

3.

Equipmenl

that

has

been

modified

by

any

party

other

than

MILLER.

or

equip

ment

Ihat

has

been

improperly

installed,

improperly

operaled

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonabte

and

necessary

maintenance,

or

equipment

which

has

been

used

for

operation

outside

01

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT.

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be,

at

MILLERS

option:

(1)

repair:

or

(2)

replacement:

or,

where

authorized

in

writing

by

MILLER

in

appropriate

cases,

(3)

the

reasonable

cost

of

repair

or

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

of

or

credit

br

the

pur

chase

price

(less

reasonable

deprecialion

based

upon

actual

use)

upon

return

ol

the

goods

at

customers

risk

and

expense.

MILLERS

option

01

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

FOB.

at

a

MILLER

authorized

ser

vice

lacility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

br

transportation

costs

of

any

kind

wilt

be

allowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

OR

CONSEQUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT.

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

spe

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

state

10

state.

In

Canada,

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

stated

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

exclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

~

vary

from

province

to

province.

5.

6.

Ii

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier,

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

miller

11/94

ERRATA

SHEET

March

21,

1995

FORM:

OM-2801C

Use

above

FORM

number

when

ordering

extra

manuals.

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manuaL

CHANGES

TO

SECTION

3INSTALLATION

Replace

Figure

3-1.

Installing

Circuit

Board

PC5

Open

and

secure

right

side

door.

On

a

Big

30A

Diesel

model,

open

and

secure

left

side

door

also.

1

Panel

Guard

Remove

panel

guard.

2

Reference

Hole

Mark

hole

location

shown.

(Holes

are

pre-drilled

on

models

with

Seri

al

No.

KC289996

and

following.)

3

Circuit

Board

PC5

Use

PC5

as

template

to

locate

and

mark

remaining

two

holes.

Drill

three

5/32

in

(4

mm)

holes

at

marked

locations.

1

4

6-32

x

3/8

in

Screw

5

Stand-Off

Insert

supplied

screws

through

holes

in

front

panel,

and

secure

stand-offs

to

screws.

2-1/2

in

6

Self-Locking

Nut

(62

mm)

Install

PC5

as

shown.

7

Ground

Terminal

Stud

8

Male

Friction

Ground

Termi

nalA

9

Ground

Lead

42

Connect

female

friction

end

of

supplied

ground

lead

to

male

fric

tion

terminal

A.

Connect

ring

termi

nal

end

of

lead

to

rear

of

ground

ter

minal

stud.

10

Ground

Strap

M~rl~A~i09~rill

Secure

ground

strap

to

stand-off

when

installing

circuit

board.

Go

to

Section

B.

9

E~ZJ~fl

1/4,5/16

in

Ref.

ST-134

108/Ref.

ST-156

194-C

Tools

Needed:

5/32

in

Install

PC5

~iiiii~~

1/2

in

Figure

3-1.

Installing

Circuit

Board

PC5

Replace

Figure

3-7.

Circuit

Breaker

CB3

And

CB4

Wiring

Connections

E~J~j

E~Jp

E~Jc

E~J~

E~JT

E~Ju

CHANGES

TO

SECTION

7-

PARTS

LIST

Connections

for

all

other

models

effective

with

Serial

No.

KB058480

and

following.

Change

Parts

Lists

as

follows:

Description

Quantity

25-8

....

039

885

....

170

391

..

CONNECTOR,

circ

protective

cap

1

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

1

Terminal

Strip

iT

2

Circuit

Breaker

CB3

3

Circuit

Breaker

CB4

4

Circuit

Breaker

CB2

5

Duplex

Receptacle

RC2

Make

connections

shown

below.

Go

to

Section

H.

Tools

Needed:

Parts

And

Location

Wiring

Connections

CB3

DTh

CB3

CB2

____

Supplied

Lead

lD~~

~

Lead

IC

(

Harness

11

Lead

130

Suoolied

Lead

130

RC2

Connections

for

Big

40G

models

prior

to

Serial

No.

KB064495,

and

all

other

models

prior

to

Serial

No.

KB058480.

Connections

for

Big

40G

models

effective

with

Serial

No.

KB064495

and

following.

For

all

models.

CB4

Figure

3-7.

Circuit

Breaker

CB3

and

CB4

Wiring

connections

ST-156

866-B

/

Ref.

S-0744-A

**

Part

No.

Replaced

With

OM-2801C

Page

2

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

livewhen

powerison.

In

semlautomaticorautomatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touchin9

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockoutitagout

input

power

according

to

OSHA

29

CFR

1910.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

cower

cord

around

wire

is

orołerlv

connected

to

around

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing;

FLYING

SLAG

OR

SPARKS

can

injure

eyes.

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high

FUMES

AND

GASES

can

be

hazardous

to

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

3.

If

ventilation

is

poor,

use an

approved

air-supplied

respirator.

4.

Read

the

Material

Safety

Data

Sheets

(MSDSS)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

and

degreasers.

CYLINDERS

can

explode

if

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

1.

Protect

compressed

gas

cylinders

from

excessive

heat.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

2. Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

support

or

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

ARC

RAYS

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

protect

your

face

and

eyes

when

welding

or

watching

(see

ANSI

Z49.1

and

Z87.1

listed

in

Safety

Standards).

3.

Wear

approved

safety

glasses

with side

shields.

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Always

have

a

trained

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

if

welded.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

5.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

6.

Never

weld

on

a

pressurized

cylinder



explosion

will

result.

7.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses.

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

10.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

_________________________

4A

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

Inwelding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

9.

Turn

off

all

equipment

when

not

in

use.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

15.

Wear

a

safety

harness

if

working

above

floor

level.

16.

Keep

all

panels

and

covers

securely

in

place.

17.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workoiece

or

worktable

as

near

the

weld

as

cractical.

NOISE

511.1.1

2/94

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

off

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pip~s,

unless

they

are

properly

prepared

according

t0AWS

F4.1

(see

Safety

Standards).

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wearoil-freeprotectivegarmentssuchasleathergloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

ENGINE

EXHAUST

GASES

can

kill.

Engines

produce

harmful

exhaust

gases.

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

1.

Stop

engine

and

let

it

cool

off

before

checking

or

adding

fuel.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and hands and

catch

loose

clothing.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

Stop

eng

ne

before

installing

or

connecting

unit

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

Batteries

contain

acid

and

generate

explosive

~ases.

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

It

is

best

to

check

coolant

level

when

engine

is

cold

to

avoid

scalding.

ENGINES

can

be

hazardous.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

Always

wear

a

face

shield

when

working

on

a

battery.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

Observe

correct

polarity

(

and

)

on

batteries.

1.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

and

3.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

3.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.

1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Haza

rdous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.

1,

from

American

Welding

So

ciety,

550

N.W.

LeJeune

Rd. Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park.

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders.

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

516,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

AA

WARNING

3.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

4.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

1.

2.

4.

5.

srl.l.1

2/94

EMF

INFORMATION

NOTE

~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

___________________

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

procedures:

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



1.

Keep

cables

close

together

by

twisting

or

taping

them.

Background

Papel

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):.

.

there

is

now

a

very

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

large

volume

of

scientific

findings

based

on

experiments

at

the

3.

Do

not

coil

or

drape

cables

around

the

body.

cellular

level

and

from

studies

with

animals

and

people

which

clearly

4.

Keep

welding

power

source

and

cables

as

far

away

as

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

nractjcal

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

possible.

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

About

Pacemakers:

allow

us

to

draw

definite

conclusions

about

questions

of

possible

The

above

procedures

are

among

those

also

normally

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

or

avoid

potential

risks.

complete

information.

modlO.1

4~93

TABLE

OF

CONTENTS

SECTION

1

-

SAFETY

INFORMATION

1

SECTION

2

SPECIFICATIONS

1

2-1.

Volt-Ampere

Curves

2

SECTION

3

INSTALLATION

2

3-1.

Installing

CV-3

And

Remote

Control

3

3-2.

Installing

CV-3

In

Unit

Equipped

With

Remote

Control

11

3-3.

Remote

14

Receptacle

Information

And

Connections

13

3-4.

Terminal

Strip

3T

Wiring

Connections

14

3-5.

Typical

Process

Connections

15

SECTION

4-OPERATION

16

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

18

5-1.

Routine

Maintenance

18

5-2.

Overload

Protection

18

5-3.

Troubleshooting

19

SECTION

6

ELECTRICAL

DIAGRAMS

20

SECTION

7

PARTS

LIST

24

Figure

7-1.

CV-3

Module

24

oM-28o1c

-

12194

SECTION

1

-

SAFETY

INFORMATION

modl.1

2/93

_______

:1~lI~eU

3

ELECTRIC

SHOCK

can

kiII.d~



Do

not

toucl~

five

electrical

parts.



Disconnect

input

power

before

4

installing

or

servicing.

1

Safety

Alert

Symbol

2

Signal

Word

WARNING

means

possible

death

or

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

or

equipment

damage

can

happen.

3

Statement

Of

Hazard

And

Result

4

Safety

Instructions

To

Avoid

Hazard

5

Hazard

Symbol

(It

Available)

6

Safety

Banner

Read

safety

blocks

for

each

sym.

bol

shown.

7

NOTE

Special

instructions

for

best

oper

ation



not

safety.

Figure

1-1.

Safety

Information

SECTION

2-

SPECIFICATIONS

Table

2-1.

For

Welding

Generators

In

CV

Mode*

Specification

Description

Big

30A

Diesel

Big

40

Diesel

&

Big

40G

Big

50

DIesel

Rated

Weld

Output

At

100%

Duty

Cycle

Load

Voltage

Range

Max.

Open-Circuit

Voltage*

200A

At

28V

10.35

40

Volts

DC

300A

At

32V

10-35

40

Volts

DC

300A

At

32V

1

0~35

40

Volts

DC

See

Owners

Manual

for

specifications

in

CC

mode.



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

1

2

\.

A~

CAUTION

/

5



MOVING

PARTS

can

Injure.

~



l(eep

away

from

moving

pans.

S

Keep

all

panels

and

covers

closed

when

operating.

6

a

WARNING

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

7~~j

NOTE

Ei

Turn

Off

switch

when

using

high

frequency.

OM-2801

Page

1

2-1.

Volt-Ampere

Curves

Figure

2-1.

Volt-Ampere

Curves

SECTION

3-INSTALLATION

a

WARNING

ELECTRIC

SHOCK

can

kill



Do

not

touch

live

electncal

parts.



Stop

engine

and

disconnect

negative

()

battery

cable

from

battery

before

beginning

this

nstallation.

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts

such

as

fans,

belts,

and

rotors.

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.



Always

wear

a

face

shield

and

proper

protective

clothing

when

working

on

a

battery.



Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

HOT

PARTS

can

cause

severe

burns.



Allow

cooling

period

before

touching.



Wear

protective

gloves

and

clothing

when

working

on

a

hot

engine.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.



Use

proper

static-proof

bags

and

boxes.

FILINGS

AND

TOOLS

HITTING

INSIDE

PARTS

can

damage

unit.



Cover

parts.

1%

I



Clean

unit

and

remove

covers

before

operating.

Have

only

qualified

persons

familiar

with

and

following

standard

safety

practices

install

this

kit.

~

A.

Big

30A

Diesel

Models

Volt-ampere

curves

show

minimum

and

maximum

voltage

and

amper

age

output

capabilities

of

the

weld

ing

generator.

Curves

of

other

set

tings

fall

between

the

curves

shown.

C.

Big

50

Diesel

Models

50

40

30

0

>

g2o

10

0

B.

Big

40

Diesel

And

Big

40G

Models

50

40

30

~20

10

0

DC

AMPERES

50

40

30

X20

10

0

~OX

~EO8ThT

0

100

200

300

400

500

DC

AMPERES

600

100

200

300

400

500

600

700

DC

AMPERES

Ssbl.l

10/91

SB-ill

680-B/SB-ill

679-A(SB~111

678-A

OM-2801

Page

2

NOTE

The

CV-3

control

cannot

be

installed

on

models

prior

to

Serial

No.

JK728391.

If

installing

CV-3

and

optional

Remote

Control,

go

to

Section

3-1.

If

installing

CV-3

in

a

unit

with

optional

Remote

Control,

go

to

Section

3-2.

If

CV-3

was

factory

installed,

go

to

Section

3-3.

A

Big

40

Diesel

model

is

shown

throughout

Section

3.

3-1.

Installing

CV-3

And

Remote

Control

READ

SAFETY

BLOCKS

at

start

of

Section

3

before

proceeding.

Figure

3-1.

Installing

Circuit

Board

PC5

Open

and

secure

right

side

door.

On

a

Big

30A

Diesel

model,

open

and

secure

left

side

door

also.

1

Panel

Guard

Remove

panel

guard.

2

Reference

Hole

Mark

hole

location

shown.

(Holes

are

pre-drilled

on

models

with

Seri

al

No.

KC289996

and

following.)

3

Circuit

Board

PC5

Use

PC5

as

template

to

locate

and

mark

remaining

two

holes.

Drill

three

5/32

in

(4

mm)

holes

at

marked

locations.

4

6-32

x

3/8

in

Screw

5

Stand-Off

Insert

supplied

screws

through

holes

in

front

panel,

and

secure

stand-offs

to

screws.

6

Self-Locking

Nut

Install

P05

as

shown.

7

Ground

Terminal

Stud

8

Male

Friction

Ground

Termi

nal

A

9

Ground

Lead

42

Connect

female

friction

end

of

supplied

ground

lead

to

male

fric

tion

terminal

A.

Connect

ring

termi

nal

end

of

lead

to

rear

of

ground

ter

minal

stud.

10

Ground

Lead

Secure

ground

lead

to

stand-off

when

installing

circuit

board.

Go

to

Section

B.

A.

Installing

Circuit

Board

PC5

2-1/2

in

(62

mm)

Mark

And

Drill

Hole

7

Mark

And

Drill

Two

Holes

9

Tools

Needed:

5/32

in

Install

PC5

c:::::=J=:cI

1/4,5/l6in

1/2in

Ret.

ST-134

108/

Ret.

ST-156

194-8

OM-2801

Page

3

Mark

And

Drill

2

Holes

Mark

location

of

holes

as

shown.

(Holes

are

pre-drilled

on

models

with

Serial

No.

KC289996

and

following.)

Drill

two

5/32

in

(4

mm)

holes

at

marked

locations.

1

6-32

x

3/8

in

Screw

2

Stand-Off

Insert

supplied

screws

through

holes

in

front

panel,

and

secure

stand-offs

to

screws.

3

Self-Locking

Nut

Install

PC6

as

shown.

Go

To

Section

C.

Tools

Needed:

5/32

in

CT~z]==~u

1/4,5/16

in

Figure

3-2.

Installing

Circuit

Board

PC6

ST-157

511

B.

Installing

Circuit

Board

PC6

5-1/2

in

(140

mm)

1-1/4

in

~

(32

mm)

1

in

(25

m)

2

Install

PC6

OM-2801

Page

4

C.

Connecting

To

Circuit

Board

PC6

Connections

for

Big

40G

models

prior

to

Serial

No.

KB064495,

and

Big

40,

Big

50,

and

Big

30A

Diesel

models

prior

to

Serial

No.

KB058480.

Rear

Of

RC1

Connections

for

Big

40G

models

with

Serial

No.

KB064496

and

fol

lowing,

and

Big

40,

Big

50,

and

Big

30A

Diesel

Models

With

Serial

No.

KB058481

and

following.

Figure

3-3.

Connecting

To

Circuit

Board

PC6

Tools

Needed:

1

Circuit

Breaker

CB1

2

Receptacle

RC1

3

Receptacle

RC2

4

Circuit

Breaker

CB2

5

Ground

Terminal

Stud

Make

connections

as

shown

below.

Go

To

Section

0.

2

3

4

5

Parts

And

Location

Wiring

Connections

Rear

Of

RC2

Lead

120C

I

It,

r

  

-l

OPTIONAL

CBI

~-cc-~-

~-

<

>

<

12

>

,

<

r)7

PCI

120V.

>

<

r)~

PC2

240V.

-,'

GROUND

Terminal

r

I

20V/240V1

1E409

C~)

A

OPTI~1

c526

I

Cr

RC

I

II~.)

~

I

(240V.)

L

CB2

Lead

101

Supplied

Lead

101

O

0 0

PC6

Lead

102

~

CB1

Supplied

Lead

102

Supplied

Lead

42

GROUND

Terminal

Ref.

ST-iSO

194-Al

S-0761

/

Ref.

50-136

915/

Ref.

SD-155

077

OM-2801

Page

5

D.

Installing

Mounting

Bracket

And

Terminal

Strip

3T

Hole

layout

for

Big

30A

Diesel

models

only.

(Holes

are

pre

drilled

on

models

with

Serial

No.

KC289996

and

following.)

1

Right

Front

Upright

2

Base

Drill

two

7/32

in

(5.6

mm)

bracket

mounting

holes

at

locations

shown.

Hole

layout

for

all

other

applica

ble

models.

(Holes

are

pre

drilled

on

models

with

Serial

No.

KC289996

and

following.)

3

Right

Front

Upright

4

Existing

Hole

5

Base

Use

top

existing

hole

for

lower

mounting

bracket

hole.

Drill

one

7/32

in

(5.6

mm)

bracket

mounting

hole

above

top

existing

hole

at

location

shown.

6

Mounting

Bracket

7

3T

Label

Install

supplied

label

to

bracket.

8

Terminal

Strip

31

9

Terminal

Strip

Mounting

Hardware

10

Insulation

Panel

Install

terminal

strip

and

panel

to

bracket

as

shown,

and

secure

with

no.

10

hardware.

11

Mounting

Bracket

Hardware

Install

bracket

to

upright,

and

se

cure

with

1/4-20

x

1/2

in

screws

as

shown.

12

Plug

PLG8

(Free-Hanging

From

31)

Connect

PLG8

into

receptacle

RC3

located

on

PC5.

Go

to

Section

E.

Tools

Needed:

7/32

in

Ref.

ST-156

200-A

I

Ref.

ST-156

i951

S-0802

Figure

3-4.

InstallIng

Mounting

Bracket

And

Terminal

Strip

3T

1/4,3/8in

OM-2801

Page

6

E.

Installing

Resistor

Board

R2

And

CV

Board

PC2

Figure

3-5.

Installing

Resistor

Board

R2

And

CV

Board

PC2

F.

Component

Installation

Tools

Needed:

_______~

5/8,9/161n

Locate

holes

in

front

panel

(behind

name-

Install

switches

onto

front

panel

with

termi-

7

Plug

PLG7

plate)

for

components

numbered

1

through

nals

positioned

vertically,

so

switch

posi

4,

and

8

and

9

below.

Use

rear

of

front

panel

tions

match

nameplate

labeling

(see

Section

Connect

PLG7

into

receptacle

RC2

located

as a

template,

and

mark

component

mount-

4).

Secure

switches

with

supplied

nut,

wash-

on

PC5.

ing

holes

onto

nameplate

by

applying

pres-

er,

and

switch

lever

boot.

sure

from

rear

with

a

sharp

tool.

8

Circuit

Breaker

CB3

4

Remote

14

Receptacle

RC3

Punch,

cut,

or

drill

correct

diameter

holes

at

9

Circuit

Breaker

CB4

marked

locations.

5

Screw

1

AmperageNoltage

Control

Switch

S4

6

Receptacle

Cover

Install

supplied

circuit

breakers

onto

front

panel

at

labeled

locations,

and

secure

with

2

Output

(Contactor)

Switch

S5

Install

RC3

and

receptacle

cover

onto

front

supplied

nuts

and

washers

as

shown.

3

Constant

Voltage/Constant

Current

panel,

and

secure

with

6-32

x

3/8

in

self

.tap.

Switch

S9

ping

screws

as

shown.

Go

to

SectIon

G.

3

2

1

Front

Panel

2

Component

Box

Cover

3

Retaining

Screw

Remove

retaining

screw,

and

open

component

box

cover.

4

Resistor

Board

R2

5

Resistor

Board

R2

Mounting

Holes

6

Hardware

For

Installing

Re

sistor

Board

R2

Insert

6-32

x

3/Bin

screws

through

mounting

holes

from

inside

com

ponent

box.

Install

R2

onto

screws

outside

component

box,

and

secure

with

supplied

lock

washers

and

6-32

nuts.

On

Big

30A

Diesel

models,

it

is

easiest

to

install

R2

from

left

side

of

unit.

7

CV

Board

PC2

8

Stand-Off

Support

Install

PC2

onto

stand-offs

inside

component

box

with

receptacle

Tools

Needed:

RC1

up.

Insert

plug

PLG2

(unconnected

plug

in

component

box)

into

recep

_______

tacle

RCI

on

PC2.

~3/8in

Go

to

Section

F.

Ref.

ST-156

868

9

Ref.

ST-156 866~B

Figure

3-6.

Component

Installation

OM-2801

Page

7

CB3

~

Supplied

Lead

110

1

Terminal

Strip

iT

2

Circuit

Breaker

CB3

3

Circuit

Breaker

CB4

4

Circuit

Breaker

CB2

5

Duplex

Receptacle

RC2

Make

connections

shown

below.

Go

to

Section

H.

Connections

for

Big

40G

models

prior

to

Serial

No.

KB064495,

and

all

other

models

prior

to

Serial

No.

KB058480.

CB3

CB2

Lead

1

Connections

for

Big

40G

models

effective

with

Serial

No.

KB064495

and

following.

Connections

for

all

other

models

effective

with

Serial

No.

KB058480

and

following.

For

all

models.

5T-158

868-B

I

Ref.

S-0744-A

G.

Circuit

Breakers

CB3

And

CB4

Wiring

Connections

Parts

And

Location

Wiring

Connections

Tools

Needed:

RC2

Figure

3-7.

Circuit

Breaker

CB3

And

CB4

Wiring

Connections

OM-2801

Page

8

H.

Supplied

Wiring

Harness

Connections

6

1

Supplied

Wiring

Harness

Wiring

harness

consists

of

the

fol

lowing:

plug

PLG6,

and

leads

3,

18,

47, 55, 56,

58,

130,

131,

and

132.

2

Resistor

Board

R2

3

Terminal

Strip

2T

(Located

On

Back

Of

Component

Box)

4

Terminal

Strip

iT

5

Circuit

Breaker

CB3

6

Circuit

Breaker

CB4

Connect

wiring

harness

to

leads

and

components

as

shown

below.

Go

to

Section

I.

Tools

Needed:

Wiring

Connections

iT

00

r

C

R

S

1

U

Figure

3-8.

Supplied

Wiring

Harness

Connections

Parts

And

Location

B

Lead

47

~

Lead 55

~

~

2T

00

Existing

Lead

&J~3

C

0

E

F

G

Connect

to

either

bottom

terminal

CB3

Lead

132

CB4

Lead

131

ST-i

56

866-B

I

Ref.

SAl

55

737-B!

S-0745-B

OM.2801

Page

9

I.

Switches

S4, S5,

And

S9

Wiring

Connections

1

Switch

S4

2

Switch

S5

3

Switch

S9

4

Component

Box

5

Idle

Module

(Not

Visible)

Idle

module

is

located

in

upper

left

corner

of

component

box.

Make

connections

to

switches

as

shown

below.

All

loose

leads

are

located

in

component

box.

Install

panel

guard,

close

and

se

cure

door(s)

and

component

box

cover.

Tools

Needed:

-

~

3/8

in

Parts

And

Location

Wiring

Connections

ST-I

56

866-8

/

S-0747

FIgure

3-9.

Switches

S4,

S5,

And

S9

Wiring

Connections

OM-2801

Page

10

3-2.

Installing

CV-3

In

Unit

Equipped

With

Remote

Control

~

_

7~

READ

SAFETY

BLOCKS

at

start

4

1

~

~Z

~

~-~VJ

of

Section

3

before

proceeding

N

OTE

~

This

Field

Kit

includes

optional

Remote

Control

components

(resistor

board

R2,

_____________________

Remote

14

receptacle

RC3,

Amperage/Voltage

Control

switch

S4,

Output

(Contactor)

switch

S5,

and

circuit

breakers

CB3

and

CB4).

These

components

do

not

have

to

be

installed

if

welding

generator

already

contains

the

Remote

Control

option.

Retain

parts

for

use

as

spares,

or

discard.

A.

CV-3

Component

Installation

Open

and

secure

right

side

door.

On

a

Big

30A

Diesel

model,

open

and

secure

left

side

door

also.

1

Panel

Guard

Remove

guard.

2

Front

Panel

3

Component

Box

Cover

4

Retaining

Screw

Hole

Remove

retaining

screw,

and

open

component

box

cover.

5

CV

Board

PC2

6

Stand-Off

Supports

Install

PC2

onto

stand-offs

inside

component

box

with

receptacle

RC1

towards

top

of

welding

generator.

Insert

plug

PLG2

(unconnected

plug

in

component

box)

into

receptacle

RC2

on

CV

board

PC2.

7

Constant

Voltage/Constant

Current

Switch

S9

Locate

hole

in

front

panel

(behind

nameplate)

for

Constant

Voltage/

Constant

Current

switch

59.

Use

rear

of front

panel

as

a

template,

and

mark

hole

onto

nameplate

by

apply

ing

pressure

from

rear

with

a

sharp

tool.

Punch,

cut,

or

drill

correct

diameter

hole.

Install

S9

onto

front

panel

with

switch

terminals

positioned

vertically

so

switch

positions

match

nameplate

labeling

(see

Figure

4-4).

Go

to

Section

8.

Tools

Needed:

ST-158

455

FIgure

3-10.

CV-3

Component

Installation

3/8,

9/16

in

OM-2801

Page

11

B.

Switch

S9

Wiring

Connections

Wiring

Connections

1

AmperageNoltage

Control

Switch

S4

2

Output

(Contactor)

Switch

S5

3

Constant

Voltage/Constant

Current

Switch

S9

4

Component

Box

5

Idle

Module

(Not

Visible)

Idle

module

is

located

in

upper

left

corner

of

component

box.

Make

connections

to

switches

as

shown

below.

All

loose

leads

are

located

in

component

box.

Install

panel

guard,

close

and

se

cure

door(s),

and

component

box

cover.

Tools

Needed:

~

3/8

in

J

Figure

3-11.

Switch

S9

Wiring

Connections

ST-I

56

866-B

I

S.0748-A

Parts

And

Location

Lead

98

S9

Loose

Lead

65

Supplied

Lead45...~,~

idle

Module

Suooli&d

Lead

65

OM-2801

Page

12

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