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Miller Electric CV-2 manual

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Table of contents for the manual

  • Page 1

    cover 6/93 – ST-1 1 1 216-A PRINTED IN USA 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. Give this manual to the operator . For help, call your distributor or: MILLER Electric Mfg. C[...]

  • Page 2

    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. T o locate your near est distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW el[...]

  • Page 3

    OM-880B – 7/93 T ABLE 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 – SPECIFICA TIONS 2-1. V olt-Ampere C[...]

  • Page 4

    [...]

  • Page 5

    OM-880 Page 1 SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMA TION AND SAFETY A. General Information presented in this manual and on various la- bels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe[...]

  • Page 6

    OM-880 Page 2 Chart 2-1. DC V olt-Ampere Curves (CV Mode) A. BIG 30 DIESEL And BIG 30A DIESEL Models B. BIG 40 DIESEL And BIG 40G Models C. BIG 50 DIESEL Models SB-1 1 1 680-B SB-1 1 1 679-A SB-1 1 1 678-A Chart 2-2. AC V olt-Ampere Curves (Single-Phase, CC Mode) A. BIG 30 DIESEL And BIG 30A DIESEL Models B. BIG 40 DIESEL And BIG 40G Models C. BIG [...]

  • Page 7

    OM-880 Page 3 2-1. VOL T -AMPERE CUR VES (Charts 2-1 And 2-2) The volt-ampere curves show the output voltage and amperage of the welding generator available at any point from the minimum to maximum of each coarse am- perage range. With the use of the volt-ampere curves it is possible to determine what the weld amperage will be at a particular arc v[...]

  • Page 8

    OM-880 Page 4 ST-145 421 T ransformer T2 Installed Onto Base Mounting Strip Right Front Cover Of Unit BIG 30 DIESEL And BIG 30A DIESEL T ransformer T2 Installation Figure 3-1. Location For T ransformer T2 Installation B. T ransformer And Lower Panel Installation 1. Locate and install supplied transformer T2 onto the welding generator as follows: a.[...]

  • Page 9

    OM-880 Page 5 SB-1 12 688-A Left Front Upright When Viewed From Front Of Control Panel Electrode (Negative) W eld Out p u t T erminal W eld Output T erminal Assembly W ork (Positive) W eld Output T erminal Bimetal Jumper Bar-Copper Side Of Bar Against T erminal Surface Cable 19 Selector Switch S1 Cable Lug Connection With T ubing And T ies Rear Vie[...]

  • Page 10

    OM-880 Page 6 Rectifier SR3: Connect CV -2 Leads 17 And 27 With Existing Leads On SR3 FRONT BIG 30 DIESEL And BIG 30A DIESEL Rectifier SR3 Range Switch S3: Connect CV -2 Leads 17 And 27 With Existing Leads On SR3 FRONT BIG 40 DIESEL, BIG 40G, And BIG 50 DIESEL Rear View Of Range Switch ST-145 422 / ST -145 423 Figure 3-3. Selector Switch S1 AC Conn[...]

  • Page 11

    OM-880 Page 7 18. Disconnect leads 623 and 625 at insulated fric- tion terminals, and connect these leads to the matching leads from the CV -2 panel (see Figure 3-4). 19. Connect lead 632 from Current Regulator box to lead 632 from CV -2 panel (see Figure 3-4). 20. Connect lead 49 from CV -2 panel to terminal at AUTO IDLE switch S4 on BIG 30 DIESEL[...]

  • Page 12

    OM-880 Page 8 SB-1 12 332-A LEFT FRONT W elding Generator Frame Big 40 Diesel, Big 40G, And Big 50 Diesel T ransformer Mounting Bracket T ransformer T2 RIGHT Use Switch Guard As T emplate T o Mark Hole Locations Switch Guard (Angle Bracket) Install Switch Guard Onto Lower Front Portion Of Base Just Below New Lower Front Panel Figure 3-5. Location F[...]

  • Page 13

    OM-880 Page 9 th e welding power source. T o connect the Remote Con- tactor and/or Amperage or V oltage Control to the RE- MOTE-5 receptacle, align keyway , insert plug from the Remote Control, and rotate threaded collar fully clock- wise. E AD BC S-0005 Figure 3-6. Front View Of 5-Socket Amphenol Re- ceptacle With Socket Designations Receptacle RC[...]

  • Page 14

    OM-880 Page 10 SA-1 12 730 W elding Generator Connection T o CV -2 5-Socket Amphenol Receptacle RC3 W ork Electrode Holder Optional Remote Contactor And Amperage Control Figure 3-8. Connection Diagram For Remote Control Using 5-Socket Amphenol Receptacle RC3 SA-1 12 732 W elding Generator Gas Supply With Flowmeter And Regulator Gas Hose Electrode C[...]

  • Page 15

    OM-880 Page 1 1 SA-1 12 734 W elding Generator Gas Supply With Flowmeter And Regulator Gas Hose Electrode Cable Connection T o CV -2 14-Socket Amphenol Receptacle RC4 - Use W ork 14-Pin T o 14-Pin Interconnecting Cord Wire Drive Assembly W elding Gun Porta-Mig Model Wire Feeder Figure 3-1 1. Connection Diagram For Porta-Mig T ype Wire Feeders Using[...]

  • Page 16

    OM-880 Page 12 SA-1 12 734 W elding Generator Gas Supply With Flowmeter And Regulator Gas Hose Electrode Cable Connection T o CV -2 14-Socket Amphenol Receptacle RC4 - Use W ork 14-Pin T o 14-Pin Interconnecting Cord Wire Drive Assembly W elding Gun 50 Series Wire Feeder Figure 3-14. Connection Diagram For 50 Series Wire Feeder Using 14-Socket Amph[...]

  • Page 17

    OM-880 Page 13 SECTION 4 – OPERA TOR CONTROLS SC-1 1 1 216-A Circuit Breaker CB5 Remote-14 Receptacle RC4 Circuit Breaker CB6 Output/Contactor Switch S10 Current Control Switch S1 1 Constant V oltage (CV)/ Constant Current(CC) Switch S12 Prepunched Hole For Securing Key Chain Remote-5 Receptacle RC3 Receptacle Dust Cups AC/DC Selector Switch S1 C[...]

  • Page 18

    OM-880 Page 14 When a Remote Current or V oltage Control is being used, the remote control functions as a fine amperage or voltage adjustment for the AMPERAGE & VOL T AGE adjustment control setting of the welding generator . For example: If the AMPERAGE & VOL T AGE adjustment control on the welding generator is set at midrange, the Remote C[...]

  • Page 19

    OM-880 Page 15 SECTION 5 – SEQUENCE OF OPERA TION W ARNING: ELECTRIC SHOCK can kill; MOVING P ARTS 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. •[...]

  • Page 20

    OM-880 Page 16 10. If remote contactor control is not used, place the CV -2 OUTPUT/CONT ACTOR switch in the ON position. If remote contactor control is to be used, place the OUTPUT/CONT ACTOR switch in the REMOTE position (see Section 4-3). 1 1. If remote amperage or voltage control is not used, place the CV -2 CURRENT CONTROL switch in the P ANEL [...]

  • Page 21

    OM-880 Page 17 5. If high frequency is desired, install and connect the high frequency unit according the the equip- ment Owner ’ s Manual. 6. Select and obtain proper tungsten electrode (see T able 6-2). 7. Prepare tungsten electrode according to Section 6-4, and insert into torch. 8. Wear dry insulating gloves and clothing. 9. Connect work clam[...]

  • Page 22

    OM-880 Page 18 SECTION 6 – MAINTENANCE & TROUBLESHOOTING 6-1. ROUTINE MAINTENANCE IMPORTANT : Every six months inspect the labels on this unit for legibility . All precautionary labels must be maintained in a clearly readable state and replaced when necessary . See the Parts List for part numbers o f precautionary labels. W ARNING: ELECTRIC S[...]

  • Page 23

    OM-880 Page 19 SC-1 12 013-A V oltage Control Board PC4 Wiring Harness Plug Standoff Support (4) Contactor Control Board PC3 Wiring Harness Plug Standoff Support (3) Figure 6-1. Circuit Board Locations And Components CAUTION: ELECTROST A TIC DISCHARGE (ESD) can damage circuit boards. • Put on properly grounded wrist strap BEFORE handling circuit [...]

  • Page 24

    OM-880 Page 20 T able 6-2. T ungsten Electrode Size Electrode Diameter Pure T ungsten .010 ” .020 ” .040 ” 1/16 ” 3/32 ” 1/8 ” 5/32 ” 3/16 ” 1/4 ” 2% Thorium Alloyed T ungsten .010 ” .020 ” .040 ” 1/16 ” 3/32 ” 1/8 ” 5/32 ” 3/16 ” 1/4 ” Zirconium Alloyed T ungsten .010 ” .020 ” .040 ” 1/16 ” 3/32 ” 1/8 [...]

  • Page 25

    OM-880 Page 21 Stable Arc Straight Ground Flat (The Dia. Of This Flat Governs Amperage Capacity) Arc W ander Point Radial Ground TUNGSTEN PREP ARA TION: IDEAL TUNGSTEN PREP ARA TION: WRONG S-0162 Figure 6-3. T ungsten Preparation Shape tungsten electrodes on a fine grit, hard abrasive wheel used only for tungsten shaping. Grind tungsten electrodes [...]

  • Page 26

    OM-880 Page 22 T able 6-3. T roubleshooting TROUBLE PROBABLE REMEDY Wire feeder inoperative. Circuit breaker CB5 or CB6 open. Reset CB5 or CB6 according to Section 6-2. No remote control of con- OUTPUT/CONTACTOR switch S10 Place S10 in the REMOTE position tactor; open-circuit voltage in the ON position. (see Section 4-3). present all the time when [...]

  • Page 27

    OM-880 Page 23 SECTION 7 – ELECTRICAL DIAGRAM Circuit Diagram No. SB-1 10 336-B Diagram 7-1. Circuit Diagram For CV -2 Ref. D-1 1 1 326-N Diagram 7-2. Wiring Diagram For CV -2[...]

  • Page 28

    OM-880 Page 24 SECTION 8 – P ARTS LIST[...]

  • Page 29

    OM-880 Page 25 SD-1 1 1 208-B 1 2 34 5 6 7 8 7 9 10 11 12 13 14 15 16 17 18 19 Figure 8-1. Main Assembly[...]

  • Page 30

    OM-880 Page 26 Description Quantity Part No. Dia. Mkgs. Figure 8-1. Main Assembly Item No. 1 S1 1 12 003 SWITCH, polarity 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +1 10 641 P ANEL, front - lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 31

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

  • Page 32

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 West Spenc er St reet Applet on, W I 54914 US A International He adquarters – USA USA Phone: 920-735-4505 Aut o-A t t ended USA & C anada F A X : 9 20-735-4134 Int ernati onal F A X: 920-735-4125 European Headquarters – U[...]