Miller CV-3 Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

CV-3 Constant Voltage
Module
Processes
Description
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
For Engine Driven Welding Generators
OM-2801 131 759J
July 2000
Visit our website at
www.MillerWelds.com
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Installing CV-3 And Remote Control 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installing CV-3 In Unit Equipped With Remote Control 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATION 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Front Panel Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Remote 14 Receptacle Information And Connections 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Terminal Strip 3T Connections 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Volt-Ampere Curves 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Typical Process Connections 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Overload Protection 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Troubleshooting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – ELECTRICAL DIAGRAMS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – PARTS LIST 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
CALIFORNIA
Proposition 65
Warning
Diesel engine exhaust and
some of its constituents
are known to the State of
California to cause
cancer, birth defects, and
other reproductive harm.
WARNING
Battery posts, terminals
and related accessories
contain lead and lead
compounds, chemicals
known to the State of
California to cause
cancer and birth defects
or other reproductive
harm. Wash hands after
handling.
OM-2801 Page 1
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING
rom _nd_11/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owners Manual and national, state, and local codes.
D Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conduc-
tor first double-check connections.
D Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after stopping
engine on inverters.
D Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
ARC RAYS can burn eyes and skin.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes from arc rays and sparks when welding or
watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant mate-
rial (wool and leather) and foot protection.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D 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.
OM-2801 Page 2
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.
WELDING can cause fire or explosion.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D 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.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use ap-
proved air-supplied respirator.
HOT PARTS can cause severe burns.
D Allow cooling period before maintaining.
D Wear protective gloves and clothing when
working on a hot engine.
D Do not touch hot engine parts or just-welded
parts bare-handed.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
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.
CYLINDERS can explode if damaged.
D Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Engine Hazards
FUEL can cause fire or explosion.
D Stop engine and let it cool off before checking or
adding fuel.
D Do not add fuel while smoking or if unit is near
any sparks or open flames.
D Do not overfill tank allow room for fuel to expand.
D Do not spill fuel. If fuel is spilled, clean up before starting engine.
D Dispose of rags in a fireproof container.
STEAM AND HOT COOLANT can burn.
D If possible, check coolant level when engine is
cold to avoid scalding.
D Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
D If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before completely
removing cap.
OM-2801 Page 3
MOVING PARTS can cause injury.
D Keep away from fans, belts, and rotors.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Stop engine before installing or connecting unit.
D Have only qualified people remove guards or covers for maint-
enance and troubleshooting as necessary.
D To prevent accidental starting during servicing, disconnect
negative () battery cable from battery.
D Keep hands, hair, loose clothing, and tools away from moving
parts.
D Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
D Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
D Block flywheel so that it will not turn while working on generator
components.
BATTERY EXPLOSION can BLIND.
D Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
D Stop engine before disconnecting or connect-
ing battery cables or servicing battery.
D Do not allow tools to cause sparks when working on a battery.
D Do not use welder to charge batteries or jump start vehicles.
D Observe correct polarity (+ and ) on batteries.
D Disconnect negative () cable first and connect it last.
BATTERY ACID can BURN SKIN and EYES.
D Do not tip battery.
D Replace damaged battery.
D Flush eyes and skin immediately with water.
ENGINE EXHAUST GASES can kill.
D Use equipment outside in open, well-ventilated
areas.
D If used in a closed area, vent engine exhaust
outside and away from any building air intakes.
ENGINE HEAT can cause fire.
D Do not locate unit on, over, or near combustible
surfaces or flammables.
D Keep exhaust and exhaust pipes way from
flammables.
EXHAUST SPARKS can cause fire.
D Do not let engine exhaust sparks cause fire.
D Use approved engine exhaust spark arrestor in
required areas see applicable codes.
1-4. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other
accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
FLYING SPARKS can cause injury.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires keep flammables away.
OVERHEATING can damage motors.
D Turn off or unplug equipment before starting or
stopping engine.
D Do not let low voltage and frequency caused by
low engine speed damage electric motors.
D Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
TILTING OF TRAILER can cause injury.
D Use tongue jack or blocks to support weight.
D Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
D Use only genuine MILLER replacement parts.
D Perform engine maintenance and service
according to this manual and the engine
manual.
OM-2801 Page 4
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Be sure this welding machine is installed and grounded
according to this manual.
D If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-5. 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 Cut-
ting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 SPECIFICATIONS
Model Rated Weld Output Voltage Range CV/DC Open-Circuit Voltage CV/DC
Big 30A Diesel
200 A @ 28 V CV/DC, 100%
Duty Cycle
14 40 40
Big 40G, Big 40 Diesel
300 A At 32 V CV/DC, 100%
Duty Cycle
14 38 40
Big 50 Diesel
350 A At 34 V CV/DC, 100%
Duty Cycle
14 38 40
OM-2801 Page 5
SECTION 3 INSTALLATION
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 4.
A Big 40 Diesel model is shown throughout Section 3.
NOTE
3-1. Installing CV-3 And Remote Control
A. Installing Circuit Board PC5
Ref. ST-157 511-A / Ref. ST-156 194-C
Y Cover parts before drilling.
Clean unit before using.
1 Panel Guard
Open doors. Remove panel guard.
2 Reference Hole
3 Circuit Board PC5
If necessary, use reference hole to
mark location of first hole. Use PC5
as template to mark remaining two
holes. Drill three 5/32 in (4 mm)
holes as marked.
4 6-32 x 3/8 in Screw
5 Stand-Off
6 Self-Locking Nut
7 Ground Strap
Install PC5 as shown. Secure
ground strap to stand-off.
8 Ground Lead 42
9 Ground Stud
10 Ground Terminal A
Connect lead 42 ring terminal to
rear of ground stud. Connect other
end of lead to terminal A.
Go to Section B.
Tools Needed:
2
3
1
5/32 in
1/4, 5/16 in
1/2 in
Mark And Drill
Two Holes
Mark And Drill Hole
2-1/2 in
(62 mm)
Location Of PC5
Installation
4
5
10
9
3
8
7
6
Remove Paint around stand-off
mounting hole to ensure good
ground connection.
OM-2801 Page 6
B. Installing Circuit Board PC6
Ref. ST-157 511-A
Y Follow safety precautions at
beginning of this section.
Y Cover parts before drilling.
Clean unit before using.
If necessary, mark holes as shown.
Drill two 5/32 in (4 mm) holes as
marked.
1 6-32 x 3/8 in Screw
2 Stand-Off
3 Circuit Board PC6
4 Self-Locking Nut
Install PC6 as shown.
Go To Section C.
Tools Needed:
1
2
4
1-1/4 in
(32 mm)
5-1/2 in
(140 mm)
1 in
(25 mm)
Mark And Drill 2 Holes
1/4, 5/16 in
5/32 in
3
OM-2801 Page 7
C. Connecting To Circuit Board PC6
Ref. ST-156 194-C / S-0761
Y Follow safety precautions at
beginning of this section.
1 Circuit Breaker CB1
2 Receptacle RC1
3 Receptacle RC2
4 Ground Stud
5 Circuit Breaker CB2
Make connections as shown below.
Go To Section D.
Tools Needed:
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.
1
2
1
2
COM
Supplied Lead 42
PC6
Cut off piggyback connector
and strip insulation from end of
supplied leads 101 and 102.
1 23
5
4
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.
Parts And Location
Wiring Connections
5/8 in
Lead 120
Lead 110
Supplied Lead 101
Supplied Lead 102
Supplied Lead 42
GROUND
Terminal
com
PC6
CB2
Lead 101
Supplied Lead 101
Lead 102
Supplied Lead 102
CB1
GROUND
Terminal
RC1RC2
OM-2801 Page 8
D. Installing Mounting Bracket And Terminal Strip 3T
Ref. ST-156 200-A / Ref. ST-156 195-A / S-0802
Y Follow safety precautions at
beginning of this section.
For Big 30A Diesel models only:
1 Right Front Upright
2 Base
If necessary, drill two 7/32 in (5.6
mm) holes as shown.
For all other models:
3 Right Front Upright
4 Existing Hole
5 Base
If necessary, drill one 7/32 in (5.6
mm) hole above existing top hole as
shown.
6 Mounting Bracket
7 3T Label
8 Terminal Strip 3T
9 No. 10 Mounting Hardware
10 Insulation Panel
Install label, strip, and panel on
bracket.
11 Mounting Bracket Hardware
Attach bracket on upright, and se-
cure with 1/4-20 x 1/2 in screws.
12 Plug PLG8 (Free-Hanging
From 3T)
Connect PLG8 to receptacle RC3
on PC5.
Go to Section E.
Tools Needed:
7/32 in
1/4, 3/8 in
11
6
10
8
12
9
1
2
3
5
4
3T
131
56
47
18
55
3
132
42
58
7
1/2 in (12 mm)
1/2 in (12 mm)
5-5/8 in
(143 mm)
5-5/8 in
(143 mm)
1-1/8 in (29 mm)
Big 30A Model
All Other Models
8
OM-2801 Page 9
E. Installing Resistor Board R2 And CV Board PC2
Ref. ST-156 866-B
Y Follow safety precautions at
beginning of this section.
1 Retaining Screw
2 Component Box Cover
Remove screw and open cover.
3 Resistor Board R2
4 Mounting Holes
5 6-32 x 3/8 Screw
6 Lock Washer And Nut
Install R2 as shown.
7 CV Board PC2
8 Stand-Off Support
Install PC2 with receptacle RC1 up.
Connect plug PLG2 (in component
box) to RC1.
Go to Section F.
Tools Needed:
3/8 in
2
1
5
6
34
7
8
F. Component Installation
Ref. ST-156 866-C
Y Follow safety precautions at
beginning of this section.
Use front panel as guide to make
holes in nameplate for parts shown.
1 Amperage/Voltage Adjust
Switch S4
2 Output (Electrode) Switch S5
3 Process Switch S9
4 Remote 14 Receptacle RC3
5 6-32 x 3/8 Self-Tapping Screw
6 Receptacle Cover
7 Plug PLG7
Connect PLG7 to receptacle RC2
on PC5.
8 Circuit Breaker CB3
9 Circuit Breaker CB4
Go to Section G.
Tools Needed:
5/8, 9/16 in
2
3
1
4
7
8
9
6
5
OM-2801 Page 10
G. Circuit Breakers CB3 And CB4 Wiring Connections
ST-156 866-C / Ref. S-0744-A
Y Follow safety precautions at
beginning of this section.
1 Terminal Strip 1T
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:
2
3
1
5
4
Connections for Big 40G models
prior to Serial No. KB064495, and
all other models prior to Serial No.
KB058480.
Connections for Big 40G models ef-
fective with Serial No. KB064495
and following.
Connections for all other models ef-
fective with Serial No. KB058480
and following.
Parts And Location
Wiring Connections
CB3
Supplied Lead 110 Lead 110
RC2
CB3
Supplied Lead 110
Lead 1 (Pigtail In Harness)
CB2
OM-2801 Page 11
H. Supplied Wiring Harness Connections
Y Follow safety precautions at
beginning of this section.
1 Supplied Wiring Harness
2 Resistor Board R2
3 Terminal Strip 2T (Located On
Back Of Component Box)
4 Terminal Strip 1T
5 Circuit Breaker CB3
6 Circuit Breaker CB4
Connect wiring harness to leads
and components as shown below.
Go to Section I or J.
5
6
4
3
N
P
Q
R
S
T
U
A
B
C
D
E
F
G
Connect to either
bottom terminal
1
2
Tools Needed:
Parts And Location
Wiring Connections
Connect to either
top terminal
Lead 18
Lead 47
Lead 55
Lead 56
Lead 58
2T
R2
1T
Existing Lead
Lead 3
Lead 132
Lead 131
CB3
CB4
ST-156 866-C / Ref. SA-155 737-B / S-0745-B
Existing Lead
Lead 130
OM-2801 Page 12
I. Switches S4, S5, And S9 Wiring Connections Prior to Serial No. KH360783
ST-156 866-C / S-0747
Y Follow safety precautions at
beginning of this section.
1 Switch S4
2 Switch S5
3 Switch S9
4 Component Box
5 Idle Module (Not Visible)
Make connections to switches as
shown below. All loose leads are lo-
cated in component box.
Install panel guard. Close door(s)
and component box cover.
Tools Needed:
3/8 in
Lead 98 Lead 47
Lead 130 Lead 57
CE
DGB
Lead 48
1 234 5
Parts And Location
Wiring Connections
Loose Lead 55
Loose Lead 47
Supplied Lead 47
Loose Lead 56
Loose Lead 66
Lead 98
Loose Lead 65
Supplied Lead 65
Supplied Lead 68
Supplied Lead 48
Lead 130
Supplied Lead 57
Supplied Lead 65
S4
S5
S9
Supplied Lead 68
Idle Module
Supplied Lead 65
OM-2801 Page 13
J. Switches S4, S5, And S9 Wiring Connections Effective With Serial No. KH360783
ST-156 866-C / Ref. S-0747
Y Follow safety precautions at
beginning of this section.
1 Switch S4
2 Switch S5
3 Switch S9
4 Component Box
5 Idle Module (Not Visible)
Make connections to switches as
shown below. All loose leads are lo-
cated in component box.
Install panel guard. Close door(s)
and component box cover.
Tools Needed:
3/8 in
1 234 5
Parts And Location
Wiring Connections
Lead 59
Lead 47
Lead 130 Lead 57
CE
DGB
Lead 48
Loose Lead 55
Loose Lead 47
Supplied Lead 47
Loose Lead 56
Loose Lead 66
Lead 98
Supplied Lead 68
Supplied Lead 48
Lead 130
Supplied Lead 57
Existing Lead 59
S4
S5
S9
Supplied Lead 68
Idle Module
Existing Lead 59 (From PLG9-2)
Lead 60 (From PLG9-1)
Lead 59 (From PLG2)
Lead 98 (from PC1)Lead 98 (from PLG9)
Insulate and tie off.
Insulate
and
tie off.
OM-2801 Page 14
3-2. Installing CV-3 In Unit Equipped With Remote Control
This Field Kit includes optional Remote Control components (resistor board R2,
Remote 14 receptacle RC3, Amperage/Voltage Adjust switch S4, Output
(Electrode) 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.
NOTE
A. CV-3 Component Installation
ST-156 455-C
Y Follow safety precautions at
beginning of this section.
Open doors.
1 Retaining Screw
2 Component Box Cover
Remove screw and open cover.
3 CV Board PC2
4 Stand-Off Supports
Install PC2 with receptacle RC1 up.
Insert plug PLG2 (in component
box) in receptacle RC1.
5 Constant Voltage/Constant
Current Switch S9
Use front panel as template to mark
hole for Process switch S9 on
nameplate. Punch or drill hole
where marked.
Install S9 so switch positions match
nameplate labeling
Go to Section B or C.
Tools Needed:
3/8, 9/16 in
2
1
3 4
5
OM-2801 Page 15
B. Switch S9 Wiring Connections Prior to Serial No. KH360783
ST-156 866-C / S-0748-A
Y Follow safety precautions at
beginning of this section.
1 Amperage/Voltage Adjust
Switch S4
2 Output (Electrode) Switch S5
3 Process Switch S9
4 Component Box
5 Idle Module (Not Visible)
6 Label
Make connections to switches as
shown. All loose leads are located
in component box.
Install panel guard. Close door(s)
and component box cover.
Tools Needed:
3/8 in
12345
CE
DGB
Lead 48
Parts And Location
Wiring Connections
Supplied Lead 65
Lead 98
S4
S5
S9
Loose Lead 66
Lead 98
Loose Lead 65
Supplied Lead 65
Supplied Lead 48
Supplied Lead 68
Supplied Lead 68
Idle Module
Supplied Lead 65
6
OM-2801 Page 16
C. Switch S9 Wiring Connections Effective With Serial No. KH360783
ST-156 866-B / Ref. S-0748-A
Y Follow safety precautions at
beginning of this section.
1 Amperage/Voltage Adjust
Switch S4
2 Output (Electrode) Switch S5
3 Process Switch S9
4 Component Box
5 Idle Module (Not Visible)
6 Label
Make connections to switches as
shown. All loose leads are located
in component box.
Install panel guard. Close door(s)
and component box cover.
Tools Needed:
3/8 in
12345
CE
DGB
Lead 48
Parts And Location
Wiring Connections
Existing Lead 59
S4
S5
S9
Loose Lead 66
Lead 98
Supplied Lead 48
Supplied Lead 68
Supplied Lead 68
Idle Module
Existing Lead 59 (From PLG9-2)
6
Lead 60
From PLG 9-1
Lead 59 (From PLG2)
Lead 98 (from PC1)Lead 98 (from PLG9)
Insulate and
tie off.
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Miller CV-3 Owner's manual

Category
Welding System
Type
Owner's manual
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