Miller.
February
1991
FORM:
OM-881
I
Effective
With Style
No.
JG-63
MODEL:
DVC
DM-1
DVC
DM-2
OWNER’S
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents of
both
this
manual
and
the
power
source
manual
used
with this unit,with
special
emphasis
on
the safety
material
throughout
both manuals,
before
installing,
operating,
or
maintaining
this
equipment.
Thisunit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
-
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this unit.
Contact
your
distributor
if
you
do
not fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
M,Iier
Group
Lid.
Com~a~y
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
TB-Ill
793
PRINTED
IN
USA
—I
I—
I—
LIMITED
WARRANTY
EFFECTIVE:
AIJGusT6,
1990
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied
LiMITED
WARRANTY—
Sublect
to
the
terms
and
Conditions
hereof
MILLER
Electric
Mfg
Co..
Appleton.
Wisconsn
war-
rants
to ts
Distrbutor
Dealer
that
all
new
and
unused
Equipment furnished
by
MILLER
5
tree
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
Cy
MILLER.
No
warranty
s
made
by
MILLER
with
respect
to
engines
trade
accessor
es
or
other
items
manufactured
by
others
Such
engines.
!‘ade
accessor
es
and
other
Items
are
sold
s...btect
to
the
warrantiesoftheir
respective
manufacturers.
if
any.
All
engines
are
warranted
by
their
manufacturer
for
two
years
from
date
of or ginal
purcnase.
except
Deutz
engines
whch
nave
a
one
year
2000
noLr
warranty.
Except
as
specif
ed
below.
MILLER
s
warranty
does
not
apply
to
components
having normal
usefu
life
of
ess
than
one
ii
year. sucn
as
spot
welder
tips,
relay
and
contactor
points.
ML~..ERMATlC
parts
tnat
come
,n
contact
with
the
welding
wire
including
nozzies
and
nozzle
insuators
where
fa
lure
does
not
resut
from
defect
in
workmanship
or
material.
MILLER
shal
be
requred
to
honor
warranty
claims on
war
-
ranted
Equipment
in
the
event
offailure
resulting
from
a
defect
within
the
following
periods
from
the
date of
delivery
of
Equipment
to
the
original
user’
1.
Arc
welders,
power
sources,
robots. ano
.
.
1
year
compcnents
2.
Loadbanks
tyear
3.
Orignai
main
power
rectifiers
.
3
years
labor —
1
year
onlyl
4.
All
welding
guns.
feeder
guns
and
torches
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts.
exclusive of labor 60
days
7
Batteries
.
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty
1301
days
of
the
date
of
such
failure.
As
a
matterof
general
policy
only.
MILuER
may
honor
claims
s~bm~itdO
by
the
original userwithin
the
foregoing
periods
In
the
case of
MILLERs
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods.
tne
exclusive remedies
therefore
shall
be.
at
MILLERs
option
it.
repair
or
‘2l
replace.
ment
or
where
authorized
n
wrting
by
MILLER
n
approprate
cases.
l3i
the
reasonabie
cost of
repa
r
or
‘eplacement
at
an
authorized
MILLER service station
or
i4
payment
of
or
credii
for
the
purchase
price
less
reasonaole
depreciaton
basec
upon
actual
usei
upon
return
of
the
goods
at
Customer
5
risk
and
expense
MILLER
s
option
of
repair
or
replacement
wi
I
be
F.O.B
Factory
at
Appleton. Wisconsin.
or
FO
B
at
a
MiL.ER
authorizec
service
facilty
therefore,
no
compensation
for
transportation
costsof
any
k
nd
wIl
be
ailowed.
Upon
‘ece
0’ of
notice
of
apparent
defect
or
failure
MILLER
shail
nstruct
:~.e
claimant
on
the
warranty
claim
procedures
to
be
foilowed
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY IMPLIED
WARRANTY GUARANTY
OR
REORE.
SENTATiON
AS
TO
PERFORMANCE
AND ANY REMEDY
FOR
BREACH
OF
CONTRACT
WHICH.
BUT
FOR THIS
PROVISION.
MIGHT
ARISE
BY
IMPLICAT:ON. OPERA
ON
OF
LAW.
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING.
INCLUDING
ANY
IMPIED
WARRANTY
CF
MERCHAN
-
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE
WITH
RESPECT
TO
ANY AND
ALL
EOUIPMENT
FURNISHED
BY
MILLER
S
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MIuLER
iN
WRITING.
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
PURCHASE
BY
COMMERCIAu
INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE USE AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE
MILLER
S
WARRANTIES
DO
NOT
EXTEND
TO.
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLER
S
WARRANTIES
TO.
ANY
CONSUMER
—i
I-
I.
—i
QM•~8
—2.91
RECEIVING-HANDLING
Before unpacking
equipment, check
carton
for
any
dam
-
age that
may
have
occurred
during
shipment.
Pile
any
claims
for
loss
or
damage
with
the delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or the
equipment
manufactur
-
er’s
Transportation
Department.
When
requesting
information about
this
equipment,
al
-
ways
provide
the
Model
Description
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record the
Model
Designa
-
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor-
mation
is
located
on
the
data card
or
the
nameplate.
Model
Serial
or
Style
No.
Date
of
Purchase
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL WORDS
1-1.
General Information
And
Safety
1-2.
Safety
Alert
Symbol
And
Signal Words
SECTION
2
-
SPECIFICATIONS
2-1.
Description
SECTION
3-
INSTALLATION
3-1.
Installation
3-2.
voltage
Control Connections
. .
.
. . . -
Diagram
3-1.
DVC
DM-1
Connection
Diagram
(Electrode
Positive/Reverse
Polarity
CV
Connections
Shown)
. -
Diagram
3-2.
DVC
DM-2
Connection
Diagram (Electrode
Positive/Reverse
Polarity
CV
Connections
Shown)
3-3.
Voltage
Sensing
Connections
3-4.
115
Volts
AC/Contactor Control Connection
To
DVC
Unit
3-5.
115
Volts
AC/Contactor Control Connection
To
Wire
Feeder
3-6.
DVC
Switching
Relay
Connection(DVC
DM-2
Models
Only)
. . -
3-7.
Optional
Control Connection
SECTION
4-OPERATOR
CONTROLS
4-1.
4-2.
4-3.
4-4.
Voltage
Control(s)
Remote
Control
Switch(es)
Error
Reset
Push
Button
Digital
Volts
Meter
SECTION
5—
SEQUENCE
OF
OPERATION
5-1.
Gas
Metal Arc
(GMAW)
And
Flux
Cored
Arc
Welding
(FOAW)
5-2.
Shutting
Down
SECTION
6-
MAINTENANCE
AND
TROUBLESHOOTING
6-1.
Routine
Maintenance
6-2.
Circuit
Board
PCi
Replacement
Procedure
6-3.
Troubleshooting
1
1
2
2
2
3
3
4
4
4
4
4
5
5
5
5
6
6
6
7
9
Section
No.
Page
No
SECTION
7
-
ELECTRICAL DIAGRAMS
Diagram
7-1.
Circuit
Diagram For
DVC
DM-1
Models
10
Diagram
7-2.
Circuit
Diagram For
DVC
DM-2
Models
11
Diagram
7-3.
Wiring
Diagram For
DVC
DM-1
Models
12
Diagram
7-4
Wiring
Diagram For
DVC
DM-2
Models
13
Diagram
7-S
Circuit
Diagram For
Voltage
Control
Board
PCI
.
14
SECTION
8—
PARTS
LIST
Figure
8-1.
Main
Assembly
(Model DM-2
Illustrated)
16
Figure
8-2.
Circuit
Card,
Voltage
Control
PCi
18
LIST OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1
Table
6-1.
Troubleshooting
9
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.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble-
shooting
of
arc welding
equipment
requires
practices
and
procedures
which
ensure personal
safety
and
the
safety
of
others. Therefore, this
equipment
is
to
be
in
-
stalled,
operated, and maintained
only
by
qualified
per
-
sons
in
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those listed
at
the
end
of
Section
1
—
Safety
Rules
For Operation
Of
Arc
Weld-
ing
Power
Source
in
the
welding
power
source
Owner’s
Manual.
1-2.
SAFETY
ALERT SYMBOL
AND
SIGNAL
WORDS
The
following
safety alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call attention
to
and
iden-
tify
different
levels
of
hazard
and
special
instructions,
A
This
safety alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten-
tion
to
the
safety
statements.
A
WARNING statements
identify
procedures
or
practices which
must
be
followed
to
avoid
seri
-
ous personal
injury
or
loss
of
life.
A
CAUTION
statements
identify
procedures
or
practices which
must
be
followed
to
avoid minor
personal injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient operation of
this
equip-
ment.
SECTION
2—
SPECIFICATIONS
Table
2-1. SpecificatIons
Model
Input Power
Wei
ht
Net
Ship
DVC
DVC
DM-1
DM-2
115
Volts
AC
50/60
Hz
0.5
Amperes
9.7
lbs.
(4.4
kg)
10.7
lbs.
(4.9
kg)
11.4
lbs.
(5.2
kg)
12.4
lbs.
(5.6
kg)
10-1/4
in.
1260.4
mini
4-5/8
in.
1117.5
minI
Figure
2-1. Dimensions
TB-Ill
793
OM-881
Page
1
2-1.
DESCRIPTION
to
be
used
with
a
dual
digital
wire
feeder
to
control load
voltage
alternately between
two
welding
guns.
This
unit
is
a
Digital
Voltage Control that
is
designed to
be
used
with
the
DIMENSION’
400 welding
power
source
and
a
digital
wire
feeder
for
Gas
Metal Arc
(GMAW)
and
Flux Cored
Arc
(FDAW)
processes.
The
DVC
DM-1
model
is
designed to
be
used
with
a
single
digital
wire
feeder,
and
The
DVC
DM-2
model
is
designed
The
DVC
unit provides
the
capability
of
presetting
the
welding
power
source
output
voltage to
the
nearest
tenth
of
a
volt
before
an
arc
is
struck.
This
preset
voltage
is
maintained
while
welding
regardless
of
line
and
load
variations
within
the
capability
of
the
welding
power
source.
SECTION
3-
INSTALLATION
115
Volts
AC!
Contactor
Control
Receptacle
TA.II~
792
A
WARNING:
ELECTRIC
SHOCK
can kill.
•
Do
not
touch live
electrical
parts.
•
Shut
down
welding
power
source
and
wire
feeder,
and
disconnect
input
power
employ-
ing
lockout/tagging
procedures
before
in
-
specting
or installing.
Lockout/tagging
procedures
consist
of
pad-
locking
line
disconnect switch
in open position,
removing
fuses
from
fuse
box,
or shutting
off
and red-tagging circuit breaker or
other
discon-
necting
device.
IMPORTANT:
If
the
supplied
plug(s)
or
receptacle(s)
do
not
match
the
welding
power
source
or
wire
feeder,
ob
-
tain
the
necessary
adapter
from
your
welding
power
source
equipment
distributer.
3-1.
INSTALLATION
The
DVC
unit
is
designed
to
mount
on
top
of
the
digital
wire feeder.
To
install
the DVC
unit,
proceed
as
follows:
1.
Place
DVC
unit
on
top
of
wire
feeder
with
front
panels
facing
same
direction.
2.
Loosen
four
wire feeder
wrapper
screws
that
match
the DVC
unit
wrapper
screw
slots.
3.
Slide
DVC
unit
down
onto screws.
4.
Tighten
the
wire
feeder
wrapper
screws.
3-2.
VOLTAGE
CONTROL CONNECTIONS
(Fig-
ure
3-1
And
Diagrams
3-1
And
3-2)
1.
Locate
supplied
10ff.
(3.lm)
long
interconnection
cord
with
4-socket
Amphenol
plug
on
one
end and
5-pin
Amphenol plug
on
other
end.
2.
Connect
4-socket
Amphenol
plug
to
Remote
Control
Receptacle
on
rear
of
DVC
unit
(see
Fig-
ure
3-1)
as
follows:
align
keyway,
insert
plug,
and
rotate
threaded collar
fully
clockwise.
3.
Route
and
connect
remaining
end
of
cord
with
5-pin
Amphenol
plug
attached
to
REMOTE
CON-
TROL receptacle
on
front
of welding
power
source
as
follows:
align
keyway,
insert
plug,
and
rotate
threaded collar
fully
clockwise.
4.
Place welding
power
source
REMOTE
CON-
TROL
switch
in
the
ON
position.
Voltage
Sense
Receptacle
115
Volts
AC/Contactor
~DVC
DM-2
Model Shown
Control
Plug
Figure
3-1.
Rear
Panel
View
OM-881
Page
2
115
Volts
AC/Contactor
controi
cord
To
DVC
unit
IContact
Distributor!
Dealer
For
Proper
Interconnecting Cordl
Digital
Dual
Schedule
control
Rear
View
Digital
Voltage
control
Digital
Wire
Feeder
115
Volta
AC/Contactor
Control
Cord
To
Wire
Feeder
Front
View
Woitage
control
cord
To
Rear
Of
DDSC
TA.~’’
848
Diagram
3-1.
DVC
DM-1
Connection
Diagram
(Electrode
Shown)
wire
Drive-
Motor
Positive/Reverse
Polarity
CV
Connections
‘A.
847
Diagram
3-2.
DVC
DM-2 Connection
Diagram
(Electrode Positive/Reverse
Polarity
CV
Connections
Shown)
Connection to
base
mounted
wire
feeder
iliustrated.
Au
cabie
carrying
weid
output
must
be
of
adequate
capacity
for
the anticipated
maximum
load
—Indicates
Weld
Current
Path
-
-
Trigger connections
When
DDSC
Is Not
Used
Trigger Control
Cord
Without
DDSC
Front
View DIMENSION
400
Power
Source
115
Volta
AC/Contactor
Control
Cord
To
DVC
Unit
IContact
Distributor/Dealer
For
Proper
Interconnecting
Cordl
Motor
Drive
Assembli
OM-881
Page
3
3-3.
VOLTAGE
SENSING
CONNECTIONS
(Fig-
ures
3-1
And
3-2
And
Diagrams
3-1
And
3-2)
A
WARNING:
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch live
electrical
parts.
•
Shut
down
welding
power
source
and
wire
feeder,
and
disconnect
input
power
employ-
ing
lockout/tegging
procedures
before
mak
-
ing
voltage
sensing
connections.
Lockout/tagging
procedures
consist
of
pad
-
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or shutting
off
and
red-tagging circuit breaker or
other
discon-
necting
device.
A
CAUTION:
EXCESSIVELY
HIGH
WELDING
AMPERAGE can
cause
the
electrode
wire
to
vaporize.
•
Be
sure
the
voltage
sensing
leads
are
con
-
nected as
instructed.
If
the
voltage sensing
leads
are
not
connected
correctly
or
left
unconnected,
the
power
source
output
goes
to
maximum
with
no
control.
1.Locate
supplied
voltage sensing
cord,
and
con
-
nect 4-socket Amphenol
plug
to
the
Voltage
Sense
receptacle
on
rear of
DVC
unit
(see
Figure
3-i)
as
follows:
align keyway,
insert
plug,
and
ro
-
tate
threaded collar
fully
clockwise.
2.
Connect
the
voltage
sensing
lead
with
the
ring
terminal
attached
to
weld
cable
terminal
on
wire
drive
housing
as
shown
on
Figure
3-2.
3.
Connect
voltage sensing
lead
with
clamp
at
-
tached
to
the work
clamp
or
workpiece.
Figure
3-2.
Voltage
Sensing Lead
And
Weld
Cable
Locations
3-4.
115
VOLTS
AC/CONTACTOR
CONTROL
CONNECTION
TO
DVC
UNIT
(Figure
3-1
And
Diagrams
3-1
And
3-2)
A
WARMNG:
ELECTRIC
SHOCK
can
kill.
touch live
electrical
parts.
The
DVC
unit
will
be
electrically
hot
internally
and
ready to operate
as
soon
as
the
115
volts
ac
power
plug
is
connected
to
the
115
volts
ac
source
and
the
welding
power
source
is
ener-
gized.
1.
Locate
the
115
Volts
AC/Contactor
Control
inter-
connecting
cord
supplied
with
DIMENSION
400.
2.
Connect
14-pin
Amphenol
plug
on
interconnect
-
ing cord
to
WIRE
FEED
receptacle
on
front
of
welding
power
source
as
follows:
align
keyway,
insert
plug,
and
rotate
threaded collar
fully
clock
-
wise.
3.
Route
and connect
remaining
end
of
intercon
-
necting
cord
to
the
115
Volts
AC/Contactor
Con-
trol
receptacle
on
rear of
DVC
unit
as
foilows:
align keyways,
insert
plug,
and
rotate threaded
collar
fully
clockwise.
3-5.
115
VOLTS
AC/CONTACTOR
CONTROL
CONNECTION
TO
WIRE
FEEDER (Figure
3-1
And
Diagrams
3-1
And
3-2)
A
WARNING:
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch live
electrical
parts.
The
wire
feeder
will
be
electrically
hot
internally
and ready
to
operate
as
soon
as
the
ii
5
volts
ac
power plug
is
connected
to
the
115
volts
ac
source
and
the
welding
power
source
is
ener-
gized.
Route
and
connect 4-socket,
115
Volts AC/Contactor
Control
plug
from
rear
of
DVC
unit
(see
Figure
3-1)
to
115
Volts
AC/Contactor Control
receptacle
on
rear
of
wire
feeder
as
follows:
align keyways,
insert
plug,
and
rotate
threaded collar
fully
clockwise.
3-6.
DVC
SWITCHING
RELAY
CONNECTION
(Fig-
ure
3-1)(DVC
DM-2
Models
Only)
Route
and
connect
Switching
Relay
plug
from
rear
of
unit
(see
Figure
3-1)
to
DVC Switching
Relay
receptacle
on
rear of
wire feeder.
3-7. OPTIONAL CONTROL CONNECTION
(Figure
4-1
And
Diagrams
3-1
And
3-2)
A
receptacle(s)
is
provided
on
each
side
of
the
front
pan-
el
for
connecting
an
optional Digital
Dual
Schedule
Con-
S.0401
trol(s)(DDSC).
Route
and
connect
plug(s)
from
the
op
-
tional
control(s)
to
the
appropriate
receptacle
as
follows:
align
keyway,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
Nut
Flat
Washer
OM-881
Page
4
SECTION
4-
OPERATOR
CONTROLS
Left
Remote
Control
Switch
Left
Control
Receptacie
For
Optional
Dual
Schedule
Control
‘7
Left
Voltage
Control
*DVC DM-2
Modei
Shown
Digital
Volta
Meter
Error
Reset
Push
Button
Right
Voltage
Control
Right
Remote
Control
Switch
Control
Receptacle
For
Optional
Dual
Schedule
Controi
TA.1I¶
791
Figure
4.1.
Front Panel
VIew*
4-1.
VOLTAGE
CONTROL(s)
(Figure
4-1)
The
VOLTAGE
control(s)
is
a
ten-turn
potentiometer
which
provides
a
means
of
presetting
the
arc
voltage
from
the
DVC
unit when
the Remote
Control
switch(es)
on
the
DVC
unit
is
in
the STANDARD
position. Rotating
the
control(s)
clockwise increases the arc voltage.
Ro-
tating
the
control(s)
counterclockwise decreases
the arc
voltage.
4-2.
REMOTE
CONTROL SWITCH(es)
(Figure
4-1)
The
Remote
Control
switch
(es)
is
provided
for
selecting
single
scheduling
by
means
of
the DVC
unit
or
dual
scheduling
by
means
of
an
optional Digital
Dual
Sched
-
ule
Control
(DOSO)
and
dual
scheduling switch.
The
Re-
mote
Control
switch must
be
in
the STANDARD
position
to
preset the
welding voltage
parameter
at
the
DVC
unit.
The
Remote
Control
switch
must
be
in
the REMOTE
po
-
sition
to
preset
the
welding voltage
parameter
from
the
DDSC
and
to
dual
schedule
the
welding
voltage
param
-
eter.
4-3.
ERROR
RESET
PUSH BUTTON
(Figure
4-1)
The
ERROR
RESET
push
button
is
provided
to
reset
the
VOLTS
meter
if
the preset
voltage
is
beyond
the
range
of
the
welding
power
source.
If
the arc
voltage
remains
lower
or
higher
than
the preset
voltage
for
more
than
2
seconds,
the
VOLTS meter
display begins
to
flash. Once
the
display begins
to
flash,
it
will
continue
to
do
so
even
if
the preset
voltage
can
be
obtained
by
the
welding power
source
or
until
welding
operations
stop.
Depress
the
ER-
ROR
RESET
push button
to
stop
the
VOLTS meter
dis-
play
from
flashing.
4-4.
DIGITAL
VOLTS
METER
(Figure
4-1)
The
volts meter
displays
the output
voltage
to
the
near
-
est
tenth
of
a
volt.
Before
the
gun
trigger
is
depressed,
the
meter
displays
the
preset
voltage
as
set
by
the
VOLTAGE control.
When
the
gun
trigger
is
depressed
before
an
arc
is
struck,
the
meter
displays
the
welding
power
source
open-circuit
voltage.
After
an
arc
is struck
the
meter
displays
an
actual
voltage
as
set
by
the
VOLT
-
AGE
control.
SECTION
5-
SEQUENCE
OF
OPERATION
WARNING:
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause serious
injury;
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT can
damage
internal
parts.
e
Do
not
touch live electrical
parts.
e
Keep
all covers
and
panels
in place
while
operating.
Warranty
is
void
if
the welding
power
source
is
operated
with
any portion
of
the
outer
enclosure
removed.
ARC
RAYS,
SPARKS,
AND HOT
SURFACES
can
burn eyes
and
skin; NOISE
can
damage
hearing.
•
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
a
Keep
your
head
out
of
the
fumes.
a
Ventilate
to
keep
from
breathing
fumes
and
gases.
e
If
ventilation
is
inadequate, use
approved
breathing
device.
WELDING
WIRE can
cause puncture
wounds.
Do
not
point
gun
toward
any part
of
the
body,
any
conductive
surface,
or
other
personnel.
9
A
OM-881
Page
5
HOT
METAL,
SPATTER,
AND SLAG
can
cause
fire
and
burns.
•
Watch
for
fire.
•
Keep
a
fire
extinguisher
nearby,
and
know
how
to
use
it.
•
Do
not
use
near
flammable
material.
•
Allow
work
and
equipment
to
cool before
handling.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker operation.
•
Wearers
should consult
their doctor
before
going
near
arc
welding, gouging,
or
spot
weld-
ing
operations.
See
Section
1
-
Safety
Rules
For Operation
Of
Arc
Welding
Power
Source
in
the
welding
power
source
Owner’s
Manual
for
basic
welding
safety
information.
5-1.
GAS
METAL
ARC
(GMAW)
AND
FLUX
CORED
ARC
WELDING
(FCAW)
WARNING:
Read
and
follow safety
informa
-
tion
at
beginning
of entire
Section
5
before
proceeding.
1.
Install
and
prepare welding
power
source,
wire
feeder,
and
guns
as
instructed
in
their
respective
Owner’s
Manuals.
2.
Install
and
connect
DVC
unit
according
to
Section
3.
3.
Place
the
welding
power
source CV-CC
switch
in
the CV
position.
4.
Wear
dry
insulating
gloves
and
clothing.
S.
Place
the
welding
power
source
REMOTE
CON-
TACTOR switch
in
the
ON
position.
6.
Place
the
welding
power
source
REMOTE
CON-
TROL
switch
in
the
ON position.
WARNING:
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch live
electrical
parts.
•
Disconnect
welding
cables
for
unused
pro
-
cess,
if
applicable.
Both
positive
power
source
weld
output
termi-
nals
are
energized while welding.
7.
Energize
the
welding
power
source.
8.
Place
the
DVC Remote
Control
switch(es)
in
the
STANDARD
position
(see
Section
4-2).
9.
Rotate
the
DVC
(Right)
VOLTAGE
control
until
the
desired
arc
voltage
is
displayed
on
the
VOLTS
meter (see
Section
4-1).
10.
For
DVC
DM-2
models
only,
momentarily
de-
press
the
Leff
JOG
switch
on
the
dual
digital
wire
feeder,
and
rotate
the DVC
Leff
VOLTAGE
control
until
the
desired
arc
voltage
is
displayed
on
the
VOLTS
meter.
11
-
Turn
on
shielding gas
supply.
12.
Wear
welding
helmet
with
proper filter
lens
ac
-
cording
to
ANSI
Z49.i.
13.
Depress
the PURGE push button
to
purge
the
gas
line, if
required.
14.
Hold
tip
of
(desired)
gun
approximately
1/2
in.
(13mm) from
workpiece.
A
WARNING:
ELECTRIC SHOCK
can
kill.
•
Do
not
touch live
electrical
parts.
•
Do
not
touch
either
electrode
wire when
either
gun
switch
is
closed,
if
applicable.
•
Isolate
unused gun
from
workpiece,
fapplica-
ble.
Both
electrode
wires
are
electrically
energized
when
either gun
trigger
is
depressed
when
using
one
welding
power
source
unless
an
optional
Polarity
Reversing/Isolation Control
is installed.
Welding
wire
and
all
metal parts
in
contact
with
it
carry
weld
output
when
the
welding power
source
contactor
is
energized.
iS.
Begin
welding.
5-2.
SHUTTING DOWN
1.
Stop
welding.
2.
Shut down
welding
power
source.
3.
Shut
down wire feeder.
4.
Turn
off
shielding
gas
supply
at
the
source
A
WARNING:
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kill.
•
Shut
off
gas supply
when
not
in use
SECTION
6—
MAINTENANCE
AND
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
Parts
List
for
part
number
of
precautionary
labels.
A
WARNING:
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch
live
electrical
parts
a
Shut
down
welding
power
source
and
wire
feeder,
and
disconnect
input
power
employ
-
ing
lockout/tagging
procedures
before
in
-
specting,
maintaining,
or
servicing.
A
A
OM-881
Page
6
Lockout/tagging
procedures
consist
of
pad
-
locking
line
disconnect
switch
in open position,
removing
fuses
from
fuse
box,
or shutting
off and
red-tagging circuit breaker or
other
disconnect
-
ing
device.
MOVING
PARTS
can
cause serious
injury.
•
Keep
away
from
moving parts.
HOT SURFACES
can
cause
severe burns.
•
Allow
cooling
period
before
sen~icing.
Maintenance
to
be
performed
only
by
qualified
persons.
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
At
minimum,
inspect
equip-
ment every three
months
as
follows:
1.Inspect
all
interconnecting
cords
for
damage
to
or
breaks
in
the insulation jacket,
particularly
at
the
plugs.
Repair
or
replace
the
cord(s)
as
necessary.
2.
Remove grease
and grime
from
components;
moisture
from
electrical parts
and
cable.
6-2.
CIRCUIT
BOARD
PCi
REPLACEMENT
PRO.
CEDURE
(Figure
6.1)
WARNING:
ELECTRIC
SHOCK
can kill.
a
Do
not
touch live
electrical
parts.
a
Shut
down
welding
power
source
and
wire
feeder,
and
disconnect
input
power
employ
-
ing
lockout/tagging
procedures
before
in
-
specting
or
installing.
Lockout/tagging
procedures
consist
of
pad
-
locking
line
disconnect
switch
in
open position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging circuit breaker or
other
discon-
necting
device.
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
A
A
IMPORTANT:
All
directions such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
unit
front panel.
Retain
all
hardware
removed during
this
procedure for
reins
tal.
lation
unless
specifically
told
otherwise.
1.
Remove
wrapper.
2.
For
DVC
DM-2
models
only:
a.
Disconnect
plug
PLG7
on
rear
of
VOLTS
meter.
b.
Remove
meter
bezel
on
front
of
VOLTS
meter.
c.
Remove
two
screws securing
VOLTS meter
to
front panel, slide meter
Out
from front
of
unit
and
set meter aside.
3.
Disconnect
plug
PLG6,
leads
38
with
piggyback
friction
connector
and
lead
4
with
female
friction
connector
from
circuit
board.
4.
Remove
four
screws securing
the
circuit
board
to
unit,
and
set
circuit
board aside.
5.
Using
four
screws removed
in
Step
4,
install
and
secure new
circuit
board
with
receptacle
RC6
po
-
sitioned
toward
left
side
of
unit
for
DVC
DM-1
models or with
receptacle
RC6
positioned
toward
rear
of
unit
for
DVC
DM-2
models.
A
CAUTION; INCORRECT
INSTALLATION
or
misaligned
plugs
can
damage
circuit board.
•
Be
sure
that
plugs
are
properly
installed
and
aligned
before
reinstalling
wrapper.
a
Put
on
properly
grounded wrist
strap
BE
-
FORE 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.
•
Be
sure
that
plugs
are
properly
installed
and
aligned.
EXCESSIVE
PRESSURE
can
break
circuit
board.
•
Use
only
minimal
pressure
and
gentle
move-
ment
when
disconnecting
or
connecting
board
plugs
and removing or
installing
board.
6.
Reconnect
plug
PLG6
to
receptacle
RC6,
leads
38
with
piggyback friction
connector
onto
terminal
T,
and
lead
4
with
female
friction
connector
onto
terminal
U.
7.
For
DVC
DM
2
models
only,
reverse
the
proce
-
dure
in
Step
2
and
reinstall
the
VOLTS
meter.
8.
Reinstall wrapper.
9.
Energize
wire
feeder
and
welding
power
source,
and
resume
operation.
OM-881
Page
7
Control
Relay
CR50
Board
PCI
Modei
ovc
DM-2 Shown
Rel
SC-,,1 ~94
Figure
6-1. Component Locations*
.Receptacle
RC6
<C
—
—
(
N
N
<N
Piug
PLG7
Volts
Meter
N
‘3
Meter Benzei
Switching
Relay CR2
OM-881
Page
8
6-3.
TROUBLESHOOTING
(Table 6-1)
WARNING:
ELECTRIC
SHOCK
can kill.
•
Do
not
touch live
electrical
parts.
•
Shut
down
welding
power
source
and
wire
feeder,
and
disconnect
input
power
em
ploy
-
ing
lockout/tagging
procedures
before
in
-
specting,
maintaining,
or servicing.
Lockout/tagging
procedures
consist
of
pad
-
locking
line
disconnect
switch
in open position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging circuit
breaker
or
other
disconnect
-
ing
device.
MOVING
PARTS
can
cause serious
injury.
•
Keep
away
from
moving parts.
HOT
SURFACES
can
cause
severe
burns.
•
Allow
cooling
period
before servicing.
Troubleshooting
to
be
performed
only
by
qualified
persons.
It
is
assumed that
the
unit
was
properly
installed
accord
-
ing
to Section
3
of
this
manual, the
operator
is
familiar
with
the function
of
controls,
the
welding
power
source
was
working
properly,
and
that
the
trouble
is
not
related
to
the
welding
process.
The
following
table
is
designed
to
diagnose
and
provide
remedies
for
some
of
the troubles
that
may
develop
in
this
unit.
Use
this
table
in
conjunction with
the
circuit
dia
-
gram
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing these
proce
-
dures,
contact
the
nearest Factory
Authorized
Service
Station.
In
all
cases of
equipment malfunction,
strictly
follow
the
manufacturer’s
procedures
and
instructions.
IMPORTANT:
Be
sure
that
all
connections
at
the DVC
unit,
welding
power
source,
and
wire
feeder
are
secure
and
that
all
switches
are
in
the
proper
position for
the
welding
application
before
proceeding
with
trouble
-
shooting.
Table
6-1.
Troubleshooting
TROUBLE CAUSE REMEDY
No
control
of
arc voltage;
me-
ter
display
flashes.
Voltage
control
connections.
Be
sure
that voltage
control
connections
on
the
welding
power
source
and
DVC
unit
are
secure
(see
Section
3-2).
Welding
power
source
RE-
MOTE
CONTROL
switch
in
the
OFF
position.
Place
REMOTE
CONTROL
switch
in
the
ON
position.
Improper or
loose
voltage
sensing connections.
Check
voltage sensing
connections
(see
Sec-
tion
3-3).
Circuit
Board
PCi.
Replace
PCi
(see
Section
6-2).
Control
relay
CR50
(DVC
DM-2
models
only).
Check
and
replace CR50
if
necessary.
No
control
of
arc
voltage
on
1(either)
gun; meter
display
normal.
Circuit
Board
PCi.
Replace
PCi
(see
Section
6-2).
DVC
DM-2
models
only: no
control
of
arc
voltage
on
one
gun;
meter
display
normal.
Switching relay
CR2.
Check
and
replace
CR2
if
necessary.
Meter
display
flashes
during
welding.
Voltage set
on DVC
unit
is
above
or below
range
of
weld-
ing
power
source.
Be
sure
that voltage
set
on
DVC
unit
is within
the
range
of
the
welding
power
source
(see
Section 4-1).
Weld
cable connected
to
wrong output
terminal
on
welding
power
source.
Connect
weld
cable
to
CV
POSITIVE
(+)
out-
put terminal
(see welding
power
source Own-
er’s Manual).
I
Meter
display
flashes
even
af-
ter
ERROR
RESET
push
but
ton
is
depressed.
Circuit
Board
PCI.
Replace
PCi
(see
Section
6-2).
No
meter
display.
No
115
volts
ac
at
WIRE
FEED
receptacle
on
welding
power
source.
Reset circuit breaker
CB1
on
welding
powerI
source
(see
welding
power
source
Owners
Manual).
Meter.
Replace
meter (see Section 6-2).
Circuit
Board
PCI.
Replace
PCi
(see Section 6-2).
A
OM-881
Page
9
SECTION
7—
ELECTRICAL
DIAGRAMS
AC
N
A B C 0
pcs
Diagram 7-1.
Circuit
Diagram
For
DVC
DM-1
Models
D
P E~
SC
PCE
;NLP~C
‘lB
~ N
1~
-
A
C
2
>
PC
BCAPC
D
PC.
5<
PC3
Circuit
Diagram
No.
A-hO
401
OM-881
Page
10
AC
N
~STD CR
2 CR2
45
45
I
23
42
C
9
A
A B C
LEF’
REMOTE
R~C,T
/
RC
5
0
Circuit
Diagram
No.
A-lb
574
Diagram
7-2.
Circuit
Diagram
For
DVC
DM-2
Models
46
~
CF~1~
42
~r7
CR
2
7
8
~LG2
OM-881
Page
11
n
C-)
a
C.)
a
U,
V
0
0
C)
C
0
U
-
S
C’
08
C’
C
08
C
d
N
S
Cu
08
C’
5
N
U,
6
z
S
a
C’
1~
08
C’
C
-08
U)
C
OM-881
Page
12
U,
6
z
E
C’
08
Cu
0
08
(J) C
Cl,
0
0
C-)
0
0
U
-
E
Cu
08
Cu
S
08
C
S
Cu
08
Cu
5
Cu
CC
0~
CC
-J
OM-881
Page
13
8
0
N
M
P
0
Y
G
F
Circuit
Diagram
No.
B-hO
402
Diagram 7-5.
Circuit
Diagram
For
Voltage Control Board
PCi
OM-881
Page
14
SECTION
8—
PARTS
LIST
OM-881
Page
15
C
A
S
C.,’
U,
N
C
0
E
U,
Cl,
4
Cu
5)
08
0
N
I
-
1~
a’
ID
0
1
N?
OM-881
Page
16
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