Miller Electric CV-2 Owner's Manual
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Miller Electric CV-2 Owner's Manual

Miller Electric CV-2 Owner's Manual

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cover 6/93 – ST-111 216-A
OWNER'S
MANUAL
CV-2 Control Option
Constant Voltage Control
For Big 30, 30A, 40, And 50 Diesels, And Big 40G Models
For SMAW, GMAW, FCAW, And GTAW Welding
100% Duty Cycle At Welding Generator Rated Load
Adapter And Extension Cords May Be Needed
July 1993
Form: OM-880B
Effective With Serial No. JJ490601
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
PRINTED IN USA

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  • Page 1 6/93 – ST-111 216-A July 1993 Effective With Serial No. JJ490601 CV-2 Control Option Form: OM-880B 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 PRINTED IN USA...
  • Page 2 ISO 9001 Quality System Standard. service information for your particular model are also provided. 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.

  • Page 3: Table Of Contents

    ..........SECTION 7 – ELECTRICAL DIAGRAM Diagram 7-1. Circuit Diagram For CV-2 Diagram 7-2. Wiring Diagram SECTION 8 –...

  • Page 5: Section 1 - Safety Precautions And Signal Words

    SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMATION 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 and effective use of this equipment.
  • Page 6 Chart 2-1. DC Volt-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 OM-880 Page 2 Chart 2-2. AC Volt-Ampere Curves (Single-Phase, CC Mode) A.

  • Page 7: Volt-Ampere Curves

    Drill out the pop rivet securing the key chain to the lower front panel. b. Install and secure key with key chain onto CV-2 panel at the prepunched hole location (see Fig- ure 4-1: hardware not supplied). Remove and discard lower front panel from unit;...
  • Page 8 1/2 in. self-tapping screws. IMPORTANT: To ease CV-2 electrical connections, re- move weld output terminal mounting bracket from left front upright Also, before securing CV-2 panel after in- stallation, check for clearance between lugs of preinstalled cables on the AC/DC Selector switch termi- nals and any welding generator components.
  • Page 9 27 at appropriate terminals on S3 (see Figure 3-3). Connect lead 100 from installed transformer T2 to terminal D on CV-2 terminal strip 3T (see Parts List view for CV-2 component locations). Connect lead 205 from T2 to piggyback connec-...
  • Page 10 Lead 628 Current Regulator Lead 634 Lead 632 Lead 623 Leads From CV-2 Control Lead 625 Nameplate Lead 623 Lead 632 Lead 634 Lead 628 SC-111 077-A Figure 3-4. Lead Connections From CV-2 To Current Regulator Circuitry OM-880 Page 6...
  • Page 11 110 was disconnect in Step a. Connect the two leads 100 from terminal strip 3T on CV-2 panel to lead 100 at the 120V duplex re- ceptacle as follows: a. Locate and disconnect the friction terminal con- nection on lead 100 near the rear of the 120V duplex receptacle.

  • Page 12: Remote-5 Receptacle Information And Connections

    LEFT Install Switch Guard Onto Lower Front Portion Of Base Just Below New Lower Front Panel Switch Guard (Angle Bracket) FRONT Figure 3-5. Location For Switch Guard Installation D. Switch Guard Installation (Figure 3-5) IMPORTANT: Switch guard installation is only neces- sary on welding generators without this bracket installed from the factory.

  • Page 13: Remote-14 Receptacle Information And Connections

    Socket D: Amperage or voltage control connection (minimum side). Socket E: Amperage or voltage control connection (wiper contact). IMPORTANT: Use only one CV-2 receptacle at a time for remote current and/or voltage control or welding gen- erator may not work properly. 3-3. REMOTE-14 RECEPTACLE INFORMATION...
  • Page 14 CV-2 5-Socket Amphenol Receptacle RC3 SA-112 730 Figure 3-8. Connection Diagram For Remote Control Using 5-Socket Amphenol Receptacle RC3 Electrode Cable Work Welding Connection To CV-2 Generator 14-Socket Amphenol Receptacle RC4 Spoolmatic 3 Gun/Feeder Gas Supply With Flowmeter And Regulator...
  • Page 15 14-Socket Amphenol Receptacle RC4 - Use 14-Pin To 14-Pin Interconnecting Cord Gas Hose 14-Socket Amphenol Receptacle RC4 Electrode Cable Connection To CV-2 5-Socket Amphenol Receptacle RC3 – Use 5-Pin To 5-Pin Interconnecting Cord Gas Hose 5-Socket Amphenol Receptacle RC3 Interconnecting Cord...
  • Page 16 Wire Drive Work Assembly Electrode Cable Welding Welding Generator 50 Series Wire Feeder Connection To CV-2 14-Socket Amphenol Receptacle RC4 - Use 14-Pin To 14-Pin Interconnecting Cord Gas Supply With Flowmeter And Regulator Gas Hose SA-112 734 Figure 3-14. Connection Diagram For 50 Series Wire Feeder Using 14-Socket Amphenol Receptacle RC4...

  • Page 17: Constant Voltage (Cv)/Constant Current (Cc) Switch

    Circuit Breaker CB5 Remote-14 Receptacle RC4 Circuit Breaker CB6 Figure 4-1. CV-2 Panel Components (CV)/CONSTANT 4-2. CURRENT CONTROL SWITCH (Figure 4-1) WARNING: ELECTRIC SHOCK can kill. Do not touch live electrical parts. Do not touch weld output terminals when contactor is energized.

  • Page 18: Output/Contactor Switch

    BREAKER Two circuit breakers, CB5 and CB6, are provided on the CV-2 panel. Circuit breaker CB5 protects the primary of transformer T2 and the unit wiring from overload and damage. If CB5 opens, there would be no 115 volts ac or 24 volts ac output and the wire feeder would stop.

  • Page 19: Section 5 - Sequence Of Operation

    (see Section 4-2). GMAW normally uses the CV mode; FCAW may use either CV or CC depending on the se- lected welding wire. Place the CV-2 CV/CC switch in the proper posi- tion as determined by the selected welding proc- ess (see Section 4-1).

  • Page 20: Shielded Metal Arc Welding (Smaw)

    PERAGE AND VOLTAGE ADJUSTMENT con- trol to the desired position (see welding generator Owner’s Manual). Place the CV-2 CV/CC switch in the CC position (see Section 4-1). If remote amperage control is not used, place the CV-2 CURRENT CONTROL switch in the PANEL position.

  • Page 21: Shutting Down

    PERAGE AND VOLTAGE ADJUSTMENT con- trol to the desired position (see welding generator Owner’s Manual). Place the CV-2 CV/CC switch in the CC mode (see Section 4-1). Connect a Remote Contactor Control to the ap- propriate CV-2 REMOTE-5 or REMOTE-14 re-...

  • Page 22: Section 6 - Maintenance & Troubleshooting

    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 of precautionary labels.

  • Page 23: Tungsten Electrode

    Standoff Support (3) Figure 6-1. Circuit Board Locations And Components 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.
  • Page 24 Electrode Diameter Pure Tungsten DC-Argon Electrode (Green Band) Negative/Straight Polarity .010” Up to 15 .020” 5-20 .040” 15-80 1/16” 70-150 3/32” 125-225 1/8” 225-360 5/32” 360-450 3/16” 450-720 1/4” 720-950 2% Thorium Alloyed Tungsten (Red Band) .010” Up to 25 .020”...

  • Page 25: Troubleshooting

    TUNGSTEN PREPARATION: IDEAL Stable Arc Straight Ground Flat (The Dia. Of This Flat Governs Amperage Capacity) TUNGSTEN PREPARATION: WRONG Arc Wander Point Radial Ground Figure 6-3. Tungsten Preparation Shape tungsten electrodes on a fine grit, hard abrasive wheel used only for tungsten shaping. Grind tungsten electrodes so that grinding marks run lengthwise with the electrode.

  • Page 26: Table 6-3. Troubleshooting

    No control of voltage; CV-2 not correctly installed if done as a maximum or very low or field kit (cables 19 and 30 from rectifier no open-circuit voltage SR3 reversed to Selector Switch cables).

  • Page 27: Diagram 7-1. Circuit Diagram For Cv-2

    SECTION 7 – ELECTRICAL DIAGRAM Circuit Diagram No. SB-110 336-B Diagram 7-1. Circuit Diagram For CV-2 Ref. D-111 326-N Diagram 7-2. Wiring Diagram For CV-2 OM-880 Page 23...

  • Page 28: Section 8 - Parts List

    SECTION 8 – PARTS LIST OM-880 Page 24...

  • Page 29: Figure 8-1. Main Assembly

    SD-111 208-B Figure 8-1. Main Assembly OM-880 Page 25...
  • Page 30 Item Dia. Part Mkgs... . 112 003 ... . . +110 641 ....110 375 .
  • Page 31 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 32: Owner's Record

    Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

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