Miller DVC DW-1 Owner's manual

Miller
Brand
Miller
Model
DVC DW-1
Category
Welding System
Type
Owner's manual

This manual is also suitable for

April
1980
FORM:
OM-857A
Effective
With
Style
No.
HK-26
MODEL
DVC
MP-1
DVC
DW-1
OWN
ERS
MANUAL
hullER
MILLER
ELECTRIC
MFG.
CO~
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,WI
54912
USA
NWSA
CODE
NO.
4579
PAINTED
IN
U.S.A.
~~P
t~~
~..
l~~p
L~P
~
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY~Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
(
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(
1)
repair
or
(2)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
(
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase.
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
~
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
Ill
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
.
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
onlyl
.
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
,~,
~
t,
J!~
~,
~
~,
j~
~%
.~
~
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
N
3
AMENDMENT
TO
SECTiON
5
-
TROUBL.ESHOOTING
Amend
F~gue
5-4.
Circtht
Dia9ram
For
DVC
OW-i
Printed
Circuit
Board
x
Q
C2rcuit
Diagram
No.
3-044
035
F~gure
5-4.
Circuit
Diagram
F~r
DVC
OW-i
Pnntad
Circuit
Board
Effective
With
Style
No.
JA-25
OM-857A
Page
A
SECTION
1
-
INTRODUCTION
Model
Input
Power
Overall
Dimensions
Weight
Net
jShP
1-1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiar.
izing
personnel
with
the
design,
installation,
operation,
main
tenance.
and
troubleshooting
of
this
equipment.
All
informa
tion
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
1-2.
RECEIVING-HANDLING
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
f
or
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equipment,
it
is
essential
that
Model
Description
and
Serial
(or
Scyle4
Number
of
the
equipment
besupOlied.
Figure
2-1.
Rear
Panel
View
2.1
VOLTAGE
CONTROL
CONNECTiON
(Figures
2-1
&
2-2)
A
receptacle
on
the
control
and
interconnecting
cable
are
provided
for
making
connections
between
the
welding
power
source
voltage
control
circuitry
and
the
control.
Align
plug
keyways
and
insert
the
plug
into
the
receptacle
on
tht
control
and
rotate
the
plug
threaded
collar
clockwise
as
far
as
possible.
Por
OVC
MP
models:
insert
the
three-ode
twistlock
plug
into
the
voltage
control
receptacle
on
the
welding
power
source
and
rotate
clockwise
to
lock
in
place.
Fcr
OVC
OW
models:
Insert
five
pin
amphenol
plug
into
the
voltage
con
trol
receptacle
on
the
welding
power
tource
and
rotate
threaded
collar
clockwise
as
far
as
possible.
1-3.
DESCRIPTION
This
unit
is
a
Digital
Voltage
Control
that
is
designed
to
be
used
with
a
constant
potential
welding
power
source
and
digital
control/feeder
for
Gas
Metal-Arc
Welding
(GMAWI.
With
this
control,
the
welding
power
source
output
voltage
may
be
preset
before
the
arc
is
struck.
This
preset
voltage
will
be
maintained
during
welding
even
in
the
presence
of
line
arid
load
variations
within
the
capability
of
the
welding
power
source.
1-4.
SAFETY
Before
the
equipment
is
put
into
operation,
the
safety
sec
tion
at
the
front
of
the
weldiog
power
source
or
welding
generator
manual
should
be
read
completely.
This
will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughous
this
manual:
Under
this
heading,
installation,
operating,
and
main
tenance
proceduresor
practices
will
be
found
that
if
riot
carefully
followed
may
create
a
hazard
to
per-
sonnel.
I
IMPORTANT
I
-
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip
merit.
NOTE
Under
this
heading,
explanatory
statements
will
be
l
found
that
need
special
emphasis
to
obtain
the
most
f~ent
operation
of
the
equipment.
2-1
&
2.2)
A
receptacle
on
the
control
and
interconnecting
cables
are
provided
for
making
voltage
sensing
connections.
Align
plug
keyways
and
insert
the
plug
into
the
receptacle
on
the
control
and
rotate
the
plug
threaded
collar
clockwise
as
far
as
possible.
Attach
the
supplied
lead
with
clamp
onto
the
woricqiece.
Attach
the
supplied
lead
with
ring
terminal
to
the
weld
cable
terminal
where
the
weld
cables
from
the
welding
power
source
and
gun
are
connected.
If
the
unit
is
mounted
on
a
boom,
route
the
lead
with
ring
terminal
through
the
boom
to
the
weld
cable
terminal.
2-3.
VOLTS/CONTACTOR
CONNECTiON
(Figures
2-1
&
2-2)
A
receptacle
on
the
control
is
provided
for
making
connec
tions
between
the
welding
power
source
1
15
,olts
ac
re
ceptacle
and
contactor
control
circuitry
and
the
control.
The
interconnecting
cable
is
supplied
with
the
control/
feeder.
Insert
the
plug
into
the
receptacle
on
the
control
and
rotate
the
threaded
collar
clockwise
as
far
as
possi
ble.
Insert
the
115
vOlts
ac
three-qole
twistlock
plug
into
the
115
vOlts
ac
receptacle
on
the
welding
power
source
and
rotate
clockwise
to
lock
irs
place.
Insert
the
two-pole
twistloclc
contactor
control
plug
into
the
contactor
control
receptacle
on
the
welding
power
source
and
rotate
clockwise
to
lock
in
place.
Height
DVC-MP
Width
_______
115
Volts
Length
@
.5
Amps
Height
OVC-OW
Width
Length
-4..
-11-1/2
9
I
10
-
11-1/2
-4
-
11-1/2
-
10-1/4
8
9
Fiqure
1-1.
Specifications
Voltage
Receptacle
Current
Relay
R.ceptaclS
OVC
MP
Models
Only
SECTION
2
-
INSTALLATION
2-2..
VOLTAGE
SENSING
CONNECTiONS
(Figures
115
VOltS
Contactor
Receptacle
WIre
Feed
Control
Pug
TA-047
217
OM-857
Page
1
the
meter
displays
the
desired
load
voltage
as
set
by
the
VOLTAGE
control.
When
the
gun
trigger
is
depressed
and
before
an
arc
is
struck,
the
meter
displays
the
welding
power
source
open-circuit
voltage,
which
on
MP
&
FC
type
power
sources
is
considerably
higher
than
the
weld
volts.
After
an
arc
is
struck
the
meter
displays
actual
load
voltage
as
set
by
the
VOLTAGE
control.
The
Voltage
Reset
button,
labeled
ERROR
RESET,
is
provided
to
reset
the
VOLTS
meter
if
the
present
voltage
is
beyond
the
limitations
of
the
welding
power
source.
If
the
load
voltage
remains
lower
or
higher
than
the
preset
voltage
for
more
than
0.6
seconds
on
MP
unitS
or
1.5
seconds
on
OW
unitS,
the
VOLTS
meter
display
will
begin
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
welding
operations
cease.
Depress
the
Voltage
Reset
button
to
stop
the
VOLTS
meter
displayfrom
f
lash
ing.
1.
Make
necessary
electrical
and
mechanical
Connections
to
the
welding
power
source,
control/feeder,
and
gun
as
outlined
-in
their
respective
Owners
Manual.
2.
Make
all
necessary
connections
as
instructed
in
Section-
2.
3.
Place
the
welding
power
source
Contactor
Control
and
Voltage
Control
switches
in
the
Remote
position.
4.
Energize
the
welding
power
source.
5.
Place
the
welding
power
source
Load
Voltage
Range
switch
in
the
Single
Wide
position
(MP
&
PC
welding
power
sources
only
I.
6.
Rotate
the
OVC
VOLTAGE
control
until
the
desired
load
voltage
is
displayed
on
the
VOLTS
meter.
7.
Turn
on
shielding
gas
at
source.
During
normal
equipment
operation
the
condition
which
would
cause
the
display
to
flash
would
be
a
preset
voltage
which
is
Out
of
the
range-of
the
welding
power
source
(at
a
particular
line
voltage
and
load
current)
or
improper
con
nection
of
voltage
sensing
leads.
Ensure
leads
are
properly
connected
(see
Section
2.2)
and
that
connections
are
clean
and
tight.
Readjust
the
preset
voltage
before
resuming
operation.
-
3-4.
REMOTE
CONTROL
RECEPTACLE
AND
SWITCH
(Figure
3-1~
4-2.
The
remote
control
receptacle
and
switch
are
provided
for
use
in
conjunction
with
certain
optional
controls,
It
a
remote
control
is
to
be
used,
make
connections
as
instructed
in
Section
2.6
and
place
the
Remote
Control
switch
in
the
REMOTE
position.
Pull
out
on
the
toggle
before
changing
the
position
of
the
switch,
If
a
remote
control
is
not
to
be
used,
place
the
Remote
Control
switch
in
the
STANDARD
position.
8.
Hold
the
tip
of
the
gun
approximately
1/2
inch
from
the
workpiece.
9.
Depress
the
gun
trigger.
Gas
will
start
to
flow
and
wire
will
start
to
feed.
-
The
welding
wire
and
all
metal
parts
in
contact
with
it
are
energized
while
welding.
Do
not
touch
the
welding
wire
or
any
metal
part
making
contact
with
it.
SH
UTTING
DOWN
1.
Turn
off
shielding
gas
at
source.
2.
Turn
off
all
equipment.
If
welding
is
performed
in
a
confined
area,
failure
to
turn
off
the-
shielding
gas
supply
could
result
in
a
build.up
of
gas
fumes,
thereby
endangering
personnel
reentering
the
welding
area.
3-3.
VOLTAGE
RESET
BUTTON
(Figure
3-1)
SECTION
4~
-
SEQUENCE
OF
OPERATION
4-1.
GAS
METAL.ARC
WELDING
(GMAW)
a
I
Prior
to
welding,
it
is
imperative
that
proper
protective
clothing
(welding
coat
and
gloves)
and
eye
protection
(glasses
and
welding
helmet)
be
put
on.
Failure
to
comply
may
result
in
serious
or
permanent
bodily
~
damage.
OM.857
Page
3
SECTION
5
-
TROUBLESHOOTING
llazardous
voltages
are
present
on
the
internal
cir~
cuitry
of
this
unit
as
long
as
power
is
connected.
Disconnect
power
before
attempting
any
inspection
or
work
on
the
inside
of
the
unit.
Troubleshooting
of
internal
circuitry
should
be
performed
by
qualified
personnel
only.
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
It
is
assumed
that
proper
installation
has
been
made,
according
to
Section
2
of
this
manual,
and
that
the
unit
rias
been
functioning
properly
until
this
trouble
developed.
Use
this
chart
ri
cori~urtction
with
the
circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble
is
riot
remedied
after
performing
these
procedures,
the
nearest
Factory
Authorized
Service
Station
should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
TROUBLE
PROBABLE
CAUSE
REMEDY
No
control
of
arc
voltage;
meter
display
flashes,
.
Voltage
control
connections.
Ensure
mat
voltage
control
connections
on
the
welding
power
source
and
control
are
secure.
Welding
power
source
remote
voltage
control
switch
in
Standard
position.
Place
switch
in
Remote
position.
Fuse
in
welding
power
source
open.
Check
welding
power
source
internal
fuses.
Voltage
sensing
connections.
Check
connections.
See
Section
2-2.
Defective
printed
circuit
board,
Replace
printed
circuit
board.
No
control
of
arc
voltage;
meter
display
normal,
Weld
cable
not
routed
through
current
relay.
Ensure
that
weld
cable
is
reuted
through
current
relay.
See
Section
2-5.
Defective
current
relay.
Replace
current
relay.
Defective
printed
circuit
board.
Replace
printed
circuit
board.
Meter
display
flashes
during
welding,
~
~
Range
switch
on
welding
power
source
in
wrong
position.
Ensure
that
Range
switch
is
in
Single
Wide
position,
IMP
&
FC
welding
power
sources
only
I.
Voltage
set
on
control
is
above
or
below
range
of
welding
power
source.
Ensure
that
voltage
set
on
control
is
within
the
range
of
the
welding
power
source.
Weld
cable
connected
to
wrong
output
terminal
on
welding
dower
source.
The
weld
cable
should
be
connected
to
the
proper
output
terminal
for
the
weld
output
desired.
Meter
display
flashes
even
after
ERROR
RESET
button
is
depressed.
Defective
current
relay.
Replace
current
relay.
Defective
printed
circuit
board.
Replace
printed
circuit
board.
No
meter
display.
Defective
meter.
Replace
meter.
Defective
printed
circuit
boards
Replace
printed
circuit
board.
Fuses
ir~
welding
power
source
keep
opening.
Defective
printed
circuit
board
in
control
(DVC
MP
models
only).
Replace
control
,.jrinted
circuit
board~
Defect
in
welding
power
source.
Refer
to
welding
power
source
Owners
Manual.
I
I
L~E
1
Ensure
that
all
connections
to
the
control
and
welding
I
power
source
are
secure
and
that
all
switches
are
in
the
proper
position
for
the
welding
application
before
beginning
troubleshooting
procedures.
/
Page
4
ACM
Figure
5-1.
Circuit
Diagram
For
DVC
MP-1
Contro
Circuit
Diagram
No.
046
740
Figure
5-2.
Circuit
Diagram
For
DVC
MP.1
Printed
Circuit
Board
AC
Our
>
CURRENT
>
L
o
REL.AY
~
>
~
J
>
RC3
REMOTE-
Circuit
Diagram
No.
A-047
839
OM-857
Page
5
April
1980
FORM:
OM-85Th
PARTS
LIST
Effective
With
Style
No.
HK26
MODEL
DVC
MP-1
DVC
DW-1
Figure
A
Main
Assembly
-S
31
TD041
2198
I.
Quantity
Model
MR-i
)
DW-1
Figure
A
Main
Assembly
1
CR2
027810
1
2
CR1
048028
1
079
844
2
3
027811
2
4
048588
1
5
048029
2
6
010926
1
7
Cl
048504
1
8
049173
1
+045
506
9
R3
047825
1
10
RC6
079748
1
048
027
1
ii
PCi
048032
1
ii
PCi
047007
12
073
756
4
13
049
172
1
14
R2
000012
1
15
049
171
1
16
010476
1.
17
604
571
3
ft.
18
048284
1
19
079 534
4
20
079
531
1
21
057087
1
22
010487
1
23
047
365
1
24
079
531
1
25
079
878
1
26
079
535
4
27
073
507
1
27
047
544
28
073
331
1
28
039 828
29
600
341
30
605
797
30
039
273
039
685
31
601228
1
32
601
226
1
33
600
848
35
ft.
34
604109
19ft.
35
039 828
1
36
073 686
1
37
RC2
073
505
1
37
RC3
047
543
38
RC4
076
624
1
39
Ri
603
856
1
40
Si
079722
1
41
02,3
028
291
2
42
RC5
073
687
1
43
RC3
048
282
1
079
534
4
44
RC1
048
283
1
079
535
4
45
049
174
1
45
047
005
46
Item
Dia.
No.M~
Factory
Part
No.
Description
1
1
1
4
1
3
ft.
1
4
RELAY,
enclosed
24
volts
dc
4PDT
RELAY,
enclosed
120
voltsac4PDT
SPRING,
hoiddown
-
relay
CONNECTOR,
14
pin
BRACKET,
mounting
-
relay
CUP,
retaining
-
socket
relay
HANGER,
minerallic
No.
2
CAPACITOR,
electrolytic
5000
uf
50
volts
.
WRAPPER
COVER,
locking
RESISTOR,
/.1W
fixed
12
watt
180
ohm
HOUSING,
terminal
18
position
PLUG,
connector
-
keying.(located
in
housing).
CIRCUIT
CARD
ASSEMBLY,
voltage
control
(see
Fig.
B
Page
4)
CIRCUIT
CARD
ASSEMBLY,
voltage
control
(See
Fig.
C
Page
6)
STAND-OFF,
No.
6-32
x
5/8
long
1/4
hex
BRACKET,
mounting
-
wrapper
resistor
RESISTOR,
WW
fixed
50
watt
0.5
ohm
WRAPPER,
resistor
BUSHING,
strain
relief
CORD,
portable
No.
18
4/c
(order
by
ft.)
HOtJS1NG
PLUG
&
SOCKET
(consisting
of)
TERMINAL,
female
CLAMP,
cable
CORE,
relay
-
current
FITTING,
brass
-
compression
union
1
/4TBG
SWITCH,
reed
(consisting
of)
CLAMP,
cable
HOUSING
PLUG
&
PINS
(consisting
of)
TERMINAL,
male
1
pin
PLUG,
6
socket
MS-3106A-18-12S
PLUG,
4
socket
MS-3106A-14S-2SX
CLAMP,
cable
STRAIN
RELIEF,
receptacle/plug
CORD,
portable
No.16
3/c(orderbyft.)
CAP,
twistlock
3P3W
PLUG,
5
pin
MS
3106A-16S-8P
CLAMP,
cable
CLAMP,
universal
INSULATOR,
vinyl
-
clamp
universal
WIRE,
motor-lead
stranded
12
ga
(order
byft)
WIRE,
stranded
16
ga
(order
by
ft)
STRAIN
RELIEF,
receptacle/plug
PLUG,
4
socket
MS-3106A-14S-2S
RECEPTACLE,
6
pin
MS-3102A-18-12P
RECEPTACLE.
4
pin
MS-3102A-14S-2PX
RECEPTACLE.
4
pin
MS-3102A-14S-2P
POTENTIOMETER,
WW
10
turn
2
watt
10K
ohm
SWITCH,
toggle
SPOT
0.4
amp
2-4
volts
dc
CAPACITOR,
ceramic
1
uf
400
volts
dc
RECEPTACLE,
4
socket
MS-3102A-14S-2S
RECEPTACLE,
w/socket
(consisting
of)
TERMINAL,
female
1
socket
RECEPTACLE,
w/pins
(consisting
of)
TERMINAL,
male
1
pin
size
16
18-14
wire
CASE
SECTiON,
front/bottom/rear
CASE
SECTION,
front/bottom/rear
NAMEPLATE
(order
by
model
and
style
no.)
10
1
1
ft.
lOft.
1
1
1
1
35
ft.
19
ft.
1
2
4
1
OM.857
Page
2
Item
Dia.
Factory
No.
Mkgs.
Part
No.
Description
Quantity
Model
MP-1
I
DW~1
F~qure
A
47
48
49-
50
51
52
53
54
Main
Assembly
(Contd.)
COMPONENTS
TO
BE
REPLACED
BY
QUALIFIED
PERSONNEL
ONLY
Figure
B
Circuit
Card
Assembly,
Voltage
Control
1
1
1
1
1
1
1
1
1
1
TS.047
220
024
366
RC7
028
598
081
798
P81
079
723
079 725
Ti
035 759
iT
038839
Dl
028293
-s-
Optional
Equipment.
BE
SURE
TO
PROVIDE
KNOB,
pointer
CONNECTOR,
edge
PC
card
15
socket
METER,
digital
SWITCH,
push
button
SPDT
6
amp
125
volts
ac
GUARD,
switch
TRANSFORMER,
control
115/36
volts
BLOCK,
terminal
20
amp
5
pole
DIODE,
zener
6.2
volts
1
watt
MODEL
AND
STYLE
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
I
F
100
0000000
0000
000001
0
I~I
LJ
FD6~j
0067
Q54
0680
0069
R108
0700
____
=~E~EII~~
C68
1074
Q~5__
Q56~
C
~i
Q57
_J
0
i~1
!
____
~
RhO
L~j
0
P~qe
3
Dia.
Mkc~s.
Factory
Part
No.
Description
Quantity
Figure
B
048 032
Circuit
Card
Assembly,
Voltage
Control
(See
Fig.
A
Page
2
Item
10)
A50
51
052
133
AMPLIFiER
operational
quad
741
2
A52,53
009
159
AMPLIFIER,
operational
32
volts
dc
..
2
C50,53,54
000
340
CAPACITOR,
ceramic
0.01
uf
50
volts
3
C51,62
028 294
CAPACITOR,
mylar
1
uf200voitsdc
2
C52,56
031
677
CAPACITOR,
tantalum
5.6
uf
35
volts
dc
2
C55,57,59-
61,63,64
073
738
CAPACITOR,
ceramic
0.1
uf
50
volts
7
C58,66,67
053
992
CAPACITOR,
ceramic
0.001
uf
1000
volts
3
C65
028
292-
CAPACITOR,
ceramic
0.005
uf
1000
volts
dc
1
C68
035 833
CAPACITOR,
mylar
0~033
uf
1.00
volts
dc
1
C69,70
039
482
CAPACITOR,
electrolytic
100
uf
35
volts
dc
2.
C71
000
348
CAPACITOR~
tantalum
0.47
uf
35
volts
1
C72
005
023
CAPACITOR,
tantalum
2.2
uf
20
volts
1
050-66
028
351
DIODE,
signal
0.02
amp
75
volts
straight
polarity
17
067-70
026
202
DIODE,
rectifier
1
amp
400
volts
straight
polarity
4
D71,72
081
831
DIODE,
fastrecovery3amp
lOOvolts
2.
073,74
037
250
DIODE,
zener
24
volts
1
watt
straight
polarity
2
075
037
449
DIODE,
zener
15
volts
1
wart
straight
polarity
1
050
035842.
TRANS1STOR,6amp4OvoltsPNP
1
Q51,52,
.
54,56
037200
TRANSISTOR,200MA4OvoltsNPN
4
053,55
037
201
TRANSISTOR,
200
MA
40
volts
PNP
2
057
039
355
TRANSISTOR,
urlijunction
15
MA
40
volts
1
0.58
005
274
TRANSISTOR,
10
amp
80
volts
NPN
1
0.59
081
829
TRANSISTOR,
10
amp
80
volts
PNP
1
R50,62,68,
96,98,102
035
825
RESISTOR,
carbon
film
0.25
watt
1K
ohm
6
R51
,55-57,59,64
67,76,77,82,
84,85,95
035
827
RESISTOR,
carbon
film
0.25
watt
10K
ohm
13
R52,63,78,
89,90
035
888
RES1STOR,
carbon
film
0.25watt2200
ohm
5
R53
078
431
RESISTOR,
carbon
0.25
watt
330
ohm
1
R54,60,
69,107
039332
RESISTOR,
carbon
film0.25watt
15K
ohm
4
R58
039
336
RESISTOR,
carbon
film
0.25watt22OK
ohm
1
R61
035
885
RESISTOR,
carbon
film
0.25
watt
68K
ohm
1
R65,
73,80,
86,100,101
039
331
RES1STOR,
carbon
film
0.25
watt
4700
ohm
6
R66
000
342
POTENTIOMETER,
cermet
trimmer
1
turn
0.5
watt
5K
ohm
I
R70,74
035
896
RESISTOR,
carbon
film
0.25
watt
33K
ohm
1
R71
052
138
RESISTOR,
carbonfilm
0.25
watt
20K
ohm
1
R72,110
006424
POTENTiOMETER,
cermet
trimmer
1
turn
0.5
watt
2K
ohm
2
R75,93,94.
052
137
RESISTOR,
carbon
film
0.25
watt
5.1K
ohm
3
R79,87
039
330
RESISTOR,
carbon
film
0.25
watt
3900
ohm
2
R81 039
333
RESISTOR,
carbon
film
0.25
watt
18K
ohm
1
R83
035
887
RESISTOR,
carbon
film
0.25
watt
3300
ohm
1
R88
081
833
RESiSTOR,
carbon
film
0.25
watt2.7
meg
ohm
1
R91
039
337
RESiSTOR,
carbon
film
0.25
watt
330K
ohm
1
R92
035
886
RESISTOR,
carbon
film
0.25
watt
22K
ohm
1
R97,99,104
035
826
RESiSTOR,
carbon
film
0.25
watt
6800
ohm
3
R103
053
572
RESISTOR,
carbon
film
0.25
watt
12K
ohm
1.
R105
035
884
RESiSTOR,
carbon
film
0.25
watt
lOOK
ohm
1
R106
605919
RES1STOR,carbon0.25watt47ohm
1
R108
030127
RESISTOR,
carbon2watt220
ohm
1
R109
049
400
RESiSTOR,
wire
-
nichrorne
1
VR5O
081
832
080506
079
749
REGULATOR,
voltage3terminal0.5amp
15
volts
HEATS1NK,dual
TERMINAL,
header
18
position
1
1
1
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBER
W}-iEN
ORDERING
REPLACEMENT
PARTS.
OM-857
Page
4
COMPONENTS~TO
BE
REPLACED
BY
QUALIFiED
PERSONNEL
ONLY
S
C67
LR84
1
LR861~
-,
S
CS
1
0
ABCDEFGHJKLMNOPQRS
0
IIT
____________
CR50
_____________________
o
0
D54
0
E~1
0
D52
LC~56
I
Q51~
(
JR731
__3Q52~
EI~I581
1R911
~
____
~IA74I
LE~7
I
Figure
C
Circuit
Card.
Voltage
Control
TA-O~7
4~.A
Paqe
S
Dia.
Factory
Mkgs.
Part
No.
Description
Quantity
A50
1
A51-53
3
C50,60,69,
70,71
5
C51
1
C52
1
C53,55-
59,68
7
C54
1
C61
1
C62
1
C63
1
C64,65
2
C66,67
2
CR50
1
050
1
D51-54
4
D55-64
10
0c50
1
0.50
1
0.51,52
2
R50
1
R51
,65,69
80,86,87
039
331
6
R52,78,
91,93
4
R53,73
2
R54
1
R55-57
.64,
67;76,84,85035
827
8
R58,61
039336
2
R59,60,63
035
826
3
R62,68,82
035
825
3
R66,74
000
342
2
R71,72
006424
2
R75,89
052
137
2
R77
039333
1
R79
039
330
1
R81 035 886
1
R83
035887
1
R88,92
081
~
2
R90
035~5
1
R94
035823
1
VR5O
081
832
1
079749
1
8E
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Figure
C
047
007
Circuit
Card,
Voltage
Control
(See
Fig.
A
Page
2
Item
10)
052
133
AMPLIFIER,
operational
009
159
AMPLIFIER,
operational32voltsdc
000
340
CAPACITOR,
ceramic
0.01
uf
50
volts
028
294
CAPACITOR,
mylar
1
uf
200
volts
dc
031
677
CAPACITOR,
tantalum.5.6uf35voltsdc
073
739
CAPACITOR,
ceramic
0.1
uf
50
volts
000
861
CAPACITOR,
electrolytic
33
uf
35
volts
005
023
CAPACITOR,
tantalum
2.2
uf
20
volts
009
577
CAPACITOR,
tantalum
15
uf
35
volts
dc
053
992
CAPACITOR,
ceramic
0.001
uf
1000
volts
039
482
CAPACITOR,
electrolytic
100
uf
35
volts
dc
000
348
CAPACITOR,
tantalum
0.47
uf
35
volts
048028
RELAY,
l2Ovoltsac4PDT
037
449
DIODE,
zener
15
volts
1
watt
straight
polarity
026
202
DIODE,
rectifier
1
amp
400
volts
straight
polarity
028
351
DIODE,
signal
0.02
amp
75
volts
straight
polarity
047
034
OPTO
COUPLER,
transistor
-
isolator
035
842
TRANSISTOR,
6
amp
40
volts
PNP
037
200
TRANSiSTOR,
200
MA
40
volts
NPN
030
127
RESISTOR,
carbon2watt220
ohm
035
888
078
431
039
332
RESISTOR,
carbon
film
0.25
watt
4700
ohm
RESISTOR,
carbon
film
0.25
wart
2200
ohm
RESiSTOR,
carbon
0.25
watt
330
ohm
RESISTOR,
carbon
film
0.25
watt15K
ohm
RESISTOR,
carbon
film
0.25
watt
10K
ohm
RESISTOR,
carbon
film
0.25
watt
220K
ohm
RESISTOR,
carbon
film
0.25
watt
6800
ohm
RESISTOR,
carbon
film
0.25
watt
1K
ohm
POTENTiOMETER,
cermet
trimmer
1
turn
0.5
watt
5K
ohm
POTENTIOMETER,
cermet
trimmer
1
turn
0.5
watt
2K
ohm
RESISTOR,
carbon
film
0.25
watt
150K
ohm
RESISTOR,
carbon
film
0.25
watt
18K
ohm
RESISTOR,
carbon
film
0.25
watt
3900
ohm
RESiSTOR,
carbon
film
0.25
watt
22K
ohm
RESISTOR,
carbon
film
0.25
wart
3300
ohm
RESiSTOR,
carbon
film
0.25
watt
2.7
meg
ohm
RESiSTOR,
carbon
film
0.25
watt
68K
ohm
RESISTOR,
carbon
film
0.25
watt
100
ohm
REGULATOR,
voltage
3
terminal
0.5
amp
15
volts
TERMINAL,
header
18
position
OM-857
Page
6
-a
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Miller DVC DW-1 Owner's manual

Miller
Brand
Miller
Model
DVC DW-1
Category
Welding System
Type
Owner's manual
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