Miller Electric owner manual Installation or Relocation, Description, CV-2 Installation

2-1. VOLT-AMPERE CURVES (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 voltage. The volt-ampere curves show the minimum and maximum curves of each coarse am- perage range.

2-2. DESCRIPTION

This Constant Voltage control panel is designed for use with the BIG 30 DIESEL, BIG 30A DIESEL, BIG 40 DIE- SEL, BIG 40G, and BIG 50 DIESEL welding generator models.

The CV-2 expands capabilities of the welding generator to include constant voltage dc and single–phase ac weld output selections. A switch is provided for making the ac selection or for changing the dc polarity. In addition, the 5-socket and 14-socket Amphenol receptacles on this panel provide a junction point with the unit internal cir- cuitry for connecting equipment used in Shielded Metal Arc (SMAW), Gas Metal Arc (GMAW), Flux Cored Arc (FCAW), and Gas Tungsten Arc (GTAW) Welding proc- esses.

A 1 ft. (254 mm) adapter cord with 2-prong and 3-socket plugs to a 14-pin Amphenol plug is required to provide CV-2 connection capability to wire feed equipment using an interconnecting cord with 2-socket and 3-prong twistlock plugs. Other adapter cords and extension cords with different plug combinations can be obtained for connecting various welding system devices and con- trols to the CV-2 receptacles.

SECTION 3 – INSTALLATION OR RELOCATION

IMPORTANT: If CV-2 was factory installed, proceed di- rectly to Section 3-2.

3-1. CV-2 INSTALLATION

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

•Stop engine, and disconnect negative (–) battery cable from battery before inspecting, maintaining, or servicing.

MOVING PARTS can cause serious injury.

•Keep away from moving parts such as fans, belts, and rotors.

HOT ENGINE PARTS can cause severe burns.

•Wear protective gloves and clothing when working on a hot engine.

•Allow unit to cool down, if applicable, before beginning installation.

Installation to be performed only by qualified persons.

A. Preparing Unit For Installation

IMPORTANT: On all welding generator models except BIG 30A DIESEL, it is necessary to move the top cover back approximately 1 ft. (0.3 m) away from the front panel to gain access to components.

1.Remove all necessary top cover securing hard- ware and components.

2.Raise both side doors and tie together across the cover.

3.Loosen the clamp securing the air cleaner hose to the engine intake manifold and remove the hose from the manifold.

4.For BIG 40 DIESEL, BIG 40G, and BIG 50 DIE- SEL models: Loosen the clamp securing the muffler to the exhaust pipe, and remove the muf- fler from the unit.

5.Raise and slide cover with side doors approxi- mately 1 ft. (0.3 m) back over radiator.

CAUTION: METAL FILINGS AND/OR TOOL CONTACT WITH INTERNAL COM- PONENTS can damage unit.

•Cover internal components.

•Clean unit, and remove internal covering material before resuming operation.

6.On all welding generator models except BIG 30A DIESEL install key chain onto CV-2 panel as fol- lows:

a.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).

7.Remove and discard lower front panel from unit; retain securing hardware.

8.If applicable, disconnect electrode holder and work clamp cables from weld output terminals.

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