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Miller DVC-2, DVC-1, KC332313 Owner's manual

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Miller.
OWNERS
MAN
UAL
DVC-1
And
DVC-2
S
Read
and
follow
these
instructions
and
all
S
Give
this
manual
to
the
operator.
safety
blocks
carefully.
S
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
.
U
S
For
help,
call
your
distributor
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
July
1993
Effective
With
Form:
Serial
No.
OM-896C
KC33231
3
cover
7/93
ST-i
28
781
'
1993
MILLER
ElectrIc
Mtg.
Co.
PRINTED
IN
USA
WIthin
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
pane
or
components
that
fail
due
to
such
defects
in
material
or
workmanshla
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
or
fallurt
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
2.
Consumable
components:
such
as
confect
tips,
cutting
nozzles,
contactors
and
relays
or
parts
that
tall
due
to
normal
wear.
3.
Equipment
that
has
been
modIfied
by
any
party
other
than
MILLER.
or
equip
ment
that
has
been
Improperly
installed.
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenence.
or
eqtilpment
which
has
been
used
for
operation
outside
of
the
speciflcstione
for
the
equipment
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIALI1NDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENt
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedIes
shall
be,
at
MILLERS
option:
(t)
repair
or
(2)
replacement:
or,
where
authorized
in
writing
by
MILLER
In
appropriate
cases.
(3)
the
reaaoneble
cost
of
repair
or
replace
ment
stan
authorized
MILLER
service
station:
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
flex
end
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB..
Factory
stAppleton.
WIsconsin.
orF.O.B.
ate
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
trsnsportatlon
costs
of
any
kind
wtil
be
allowed.
TO
THE
EXTENT
PERMITtED
BY
LAW,
THE
REMEDIES PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEOIES.
IN
NO
EVENT
SHALL
MILLER
BE
LIASLE
FOR
DIRECt
INDIRECT.
SPECIAL.
INCIDENTAL
OR
CONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT).
WHETHER
BASED
ON
CON
TRACT.
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH.
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW.
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
C~L1DING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EOUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indIrect,
special
or
consequentIal
damages,
so
the
above
lImitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
other
fights
may
be
available,
but
may
vary
from
state
to
state.
In
Canada.
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedIes
other
than
as
stated
herein.
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available.
but
may
very
from
province
to
province.
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
EffectIve
January
1,1992
(Equipment
With
a
serial
number
preface
of
ICC
or
newer)
This
lImited
warranty
supersedes
all
previous
MILLER
warranties
and
Ia
exclusive
with
no
other
guarantees
or
wsrrenties
expressed
or
implIed.
UMITED
WARRANTY
-
Sub)ect
to
the
tsrms
and
condition
below.
MILLER
ElesIc
Remote
Controis
Mfg.
Co..
Appleton.
Wisconsin.
warrants
to
Its
original
retail
purchaser
that
new
Accessory
Kits
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warranty
is
free
of
do-
R
.,.
facts
in
material
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS
OR
re
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILiTY
AND
niP-
MILLERS
True
Blue
Umited
Wsrrst~y
shall
not
apply
to:
NESS.
t.
Items
furnished
by
MILLER.
but
manufactured
by
others,
such
as
engines
or
bade
acceasofles.
These
itsms
are
covered
by
the
manufacturers
warranty,
if
any
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
elter
the
equipment
is
sent
to
the
distributor.
t.
SYeareParts3YearsLabor
*
Original
main
power
rectifiers
2.
3YearsPartsandLebor
*
Transfonner/Rectifles
Power
Sources
Plasma
Arc
Cutting
Power
Sources
Semi-Automatic
and
Automatic
Wire
Feeders
Robots
3.
2
Years
Parts
end
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
&
tYear.PnandLabor
-
Motor
Driven
Guns
Proceas
Controters
Water
Coolant
Systems
HFt,Inits
Grids
Spot
Welders
Load
Banks
SDX
Transformers
Running
Gear/Trailers
Field
Options
(NOTE:
FIeld
options
are
covered
under
True
BlueTe
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year
whIchever
is
greater.)
5.
S
Months
Batteries
6
BODaysParteandLabor
MIG
Guns/TIG
Torches
Ptasms
Cutting
Torches
~~1
I
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
Occurred
during
shipment.
File
any
claims
for
loss
or
damage
with the
delIvering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No,
Date
of
Purchase
miller
5193a
OM.898C
-
7(93
TABLE
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SPECIFICATIONS
2-1.
Description
2
SECTION
3
INSTALLATION
OR
RELOCATION
3-1.
Installation
2
3-2.
Voltage
Sensing
Connections
2
3-3.
DVC
Switching
Relay
Connection
4
3-4.
115
Volts
AC/Contactor
Control
Connection
To Wire
Feeder
4
3-5.
115
Volts
AC/Contactor
Control/Remote
Voltage
Control
Connection
4
3-6.
Optional
CQntrol
Connection
4
3-7.
Reed
Relay
Connection
4
3-8.
Setting
Dip
Switches
On
Voltage
Control
Board
PCI
4
3-9.
Voltage
Control
Board
Modification
For
Early
Model
Welding
Power
Source
4
SECTION
4
OPERATOR
CONTROLS
4-1.
Voltage
Control(s)
7
4-2.
Remote
Control
Switch(es)
7
4-3.
Digital
Volts
Meter
7
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
Gas
Metal
Arc
And
Flux
Cored
Arc
Welding
(GMAW
And
FCAW)
8
5-2.
Shutting
Down
9
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
9
6-2.
Circuit
Board
Replacement
Procedure
9
6-3.
Troubleshooting
11
SECTION
7
ELECTRICAL
DIAGRAMS
Diagram
7-1.
Circuit
Diagram
For
DVC-1
Models
12
Diagram
7-2.
Circuit
Diagram
For
DVC-2
Models
12
Diagram
7-3.
Wiring
Diagram
For
DVC-1
Models
13
Diagram
7-4.
Wiring
Diagram
For
DVC-2
Models
14
Diagram
7-5.
Circuit
Diagram
For
Voltage
Control
Board
PCI
15
SECTION
8PARTS
LIST
16
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1
Table
6-1.
Maintenance
Schedule
9
Table
6-2.
Troubleshooting
11
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.
The
nameplate
of
this
unit
uses
international
symbols
for
labeling
the
front
panel
controls.
The
symbols
also
ap
pear
at
the
appropriate
section
in
the
text.
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
safety
pre
cautions
listed
in
the
Arc
Welding
Safety
Precautions
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
a
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
personal
injury
or
loss
of
life.
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identifr~
special
instructfons
necessary
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2
SPECIFICATIONS
Table
2-1.
SpecIfications
Model
Input
Power
Weight
Net
Ship
DVC-1
DVC-2
115
Volts
AC
50/60
HZ
.5
Amperes
11
lbs.
(5
kg)
l2lbs,
(5
kg)
12
lbs.
(5
kg)
13
lbs.
(6
kg)
*2.7/8
in.
(98.4
mm)
for
DVC.1
models
Model
OVC-2
Shown
Figure
2-1.
Dimensions
SA.128
181
0
11-5/8
in.
(295.3
mm)
-
10-1/4
in.
(260.4
mm)
OM-896
Page
1
2-1.
DESCRIPTION
control
load
voltage
alternately
between
two
welding
This
unit
is
a
Digital
Voltage
Control
that
is
designed
to
be
used
with
a
welding
power
source
having
the
proper
interconnecting
circuitry
and
a
digital
wire
feeder
for
Gas
Metal
Arc
(GMAW)
and
Flux
Cored
Arc
Welding
(FCAW)
processes.
The
DVC-1
model
is
designed
to
be
used
with
a
single
digital
wire
feeder,
and
the
DVC-2
model
is
designed
to
be
used
with
a
dual
digital
wire
feeder
to
guns.
The
DVC
unit
provides
the
capability
of
presetting
the
welding
power
source
Qutput
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.
115
OCV-2
Model
Only
SECTION
3
INSTALLATION
OR
RELOCATION
ST.128
733
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
disconnect
ing
device.
3-1.
INSTALLATION
The
OVC
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
pan
els
facing
same
direction.
2.
Loosen
wire
feeder
wrapper
screws
(4)
that
match
DVC
unit
wrapper
screw
slots.
3.
Slide
DVC
unit
down
onto
screws.
4.
Tighten
wire
feeder
wrapper
screws.
3-2.
VOLTAGE
SENSING
CONNECTIONS
(Figures
3-1
And
3-2,
And
Diagrams
3-1
And
3-2)
a
CAUTION:
EXCESSIVELY
HIGH
WELDING
AMPERAGE
can
cause
the
electrode
wire
to
vaporize.
Be
sure
the
voltage
sensing
leads
are
con
nected
as
instructed.
lf~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
connect
4-socket
Amphenol
plug
to
the
Voltage
Sense
re
ceptacle
on
rear
of
DVC
unit
(see
Figure
3-1)
as
fol
lows:
align
keyway,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
2.
Connectthe
voltage
sensing
lead
with
the
ring
termi
nal
attached
to
weld
cable
terminal
on
wire
feeder
as
shown
on
Figure
3-2.
3.
Connect
voltage
sensing
lead
with
clamp
attached
to
the
work
clamp
or
workpiece.
Lug
$.0401
FIgure
3-2.
Voltage
Sensing
Lead
And
Weld
Cable
Locations
(Single
Wire
Feeder)
Figure
3-1.
Rear
Panel
VIewS
Nut
Lock
Washer
Voltage
Sensing
Lead
Ring
Terminal
Location
Flat
Washer
OM-896
Page
2
115
Volts
AC/Contactor
Control!
Remote
Voltage
Control
Digital
Dual
Schedule
Control
Digital
Voltage
Control
Digital
Wire
Feeder
115
Volts
AC/Contactor
Control
Cord To
Wire
Feeder
Gas
input
Fitting
Welding
Power
Source
Motor
Control
Cord
Wire
Drive
Motor
Drive
Assembly
Trigger
Control
And
Dual
Schedule
Cord
Voltage
Control
Cord
To
Rear
Of
DDSC
Gas
Valve
Trigger
Control
Cord
Without
DDSC
S-0838
Diagram
3-1.
DVC-1
Connection
Diagram
(Electrode
Positive/Reverse
Polarity
Coni
ections
Shown)
Welding
Power
Source
Motor
Control
Cord
Wire
Drive
Motor
Drive
Assemblles*
Trigger
Control
And
Dual
Schedule
Cords
115
Volts
AC/Contactor
Control/
Remote
Voltage
Control
Digital
Dual
Schedule
Controls
Dual
Digital
Voltage
Control
Dual
Digital
Wire
Feeder
115
Volts
AC/Contactor
Control
Cord
To
Wire
Feeder
Switching
Relay
Connection
Gas
Input
Fittings
Voltage
Control
Cord
To
Rear
Of
DDSC
Gas
Valves
S0839
Diagram
3-2.
DVC-2
Connection
Diagram
(Electrode
Positive/Reverse
Polarity
Connections
Shown)
*
Connection
to
base
mounted
wire
feeder
illustrated.
All
cable
carrying
weld
output
must
be
of
adequate
capacity
for
the
anticipated
maximum
load.
indicates
Weld
Current Path
Trigger
Connections
When
OOSC
Is
Not
Used
OM-896
Page
3
a
CAUTION:
INCORRECT
DVC
BOARD
DIP
SWITCH
POSITION
can
cause
equipment
malfunction.
.
DVC
DiP
switch
is
factory
set
for
operation
with
Delta
weld
450
or
451
welding
power
source.
See
Figure
3-3
for
DVC
DIP
switch
setting
when
using
another
welding
power
source.
DVC
SWITCH
SETr!NGS
..
S2-
-
Si
1
2
1
2
3
4
5
DELTAWELD
300
ON
ON
ON
DELTAWELD
451,450
0
ON ON
DELTAWELD
651,650
0
ON ON
MAXTRON
300,
400
ON ON
MAXTRON
450
ON
ON
ON
XMT
200/300
ON ON
ON
ARC
PAK
350
ON ON ON
SHOPMASTER
300
ON
ON
ON
DIMENSION
400
ON
ON
PULSTAR
450
ON
O
On
For
Optional
Soft
Start.
Turn
Off
Si
-3.
i~
On
For
Optional
Hot
Start.
S.150884.C
Figure
3-3.
Voltage
Control
Board
DIP
Switch
Setting
Label
IMPORTANT:
A
customer-supplied
cord
(Miller
#042
562)
is
required
to
connect
the
welding
power
source
to
the
DVC
unit.
-
1.
Remove
wrapper.
2.
Mark
and
disconnect
leads
from
voltage
control
board
PCi.
3.
Mark
and
disconnect
plugs
from
PCi.
4.
Note
position
of
Circuit
board
and
remove
from
unit.
5.
Place
circuit
board
on
a
stationary
work
surface
so
that
component
side
is
facing
up.
6.
Locate
jumpers
Ji
thru
J8
on
surface
of
board
(see
Figure
3-4).
7.
Use
a
sharp
tool
to
remove
sealant
coating
from
all
jumper
locations,
and
remove
foil
jumper
be
tween
pads
at
J2,
J4, J6,
and
J8.
8.
Apply
a
small
amount
of
solder
to
bridge
the
foil
pads
at
jumper
Ji,
J3, J5,
and
J7.
9.
Apply
a
sealant
coating
over
all
jumper
locations.
10.
Reinstall
circuit
board
into
unit
in
its
original
posi
tion.
11.
Reconnect
marked
leads
and
plugs
to
appropri
ate
locations.
Plug
PLG2
leads
48,49,
and
51
must
be
changed
at
plug
PLG6
connected
to
receptacle
RC1
on
voltage
control
board
PCi
as
follows:
IMPORTANT:
See
receptacle
RC1
pin
designations
etched
on
circuit
board
to
identify
plug
openings.
1.
Locate
and
disconnect
plug
PLG6
from
recep
tacle
RC1
on
voltage
control
board
PCi.
2.
Mark
and
remove
leads
48, 49,
and
51
from
plug
PLG6
by
inserting
end
of
a
small,
flat-tip
screw
driver
into
window
on
side
of
plug
to
bend
down
locking
tab,
and
pull
contact
attached
to
lead
from
plug.
3.
Bend
locking
tabs
on
lead
contacts
out
so
that
they
secure
contacts
when
inserted
into
plug.
4.
Insert
lead
contacts
into
plug
as
follows:
a.
Lead
48
to
plug
opening
9.
b.
Lead
49to
plug
opening
10.
c.
Lead
51
to
plug
opening
8.
5.
Reconnect
plug
PLG6
to
receptacle
RCI
on
volt
age
control
board
PCi.
6.
Reinstall
wrapper.
OM-896Page5
*
Ref.
50-148
322
Jumper
Jumper
Jumper
Jumper
J8
J7
J6
J5
Figure
3-4.
Jumper
Locations
On
Voltage
Control
Board
PCi
OM-896
Page
6
SECTION
5
SEQUENCE
OF
OPERATION
a
WARNING:
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury;
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT
c~n
damage
internal
parts.
Do
not
touch
live
electrical
parts.
Keep
all
covers
and
panels
in
place
while
operating.
Warranty
is
void
if
the
unit
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.
Keep
your
head
Out
of
the
fumes.
Ventilate
to
keep
from
breathing
fumes
and
gases.
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.
HOT
METAL
SPATrER,
AND
SLAG
can
cause
fire
and
burns.
Watch
for
fire.
Keep
a
fire
extioguisher
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,
orspot
weld
ing
operations.
See
safety
precautions
listed
in
the
Arc
Welding
Safety
Precautions
in
the
welding
power
source
Owners
Manual.
5-1.
GAS
METAL
ARC
AND
FLUX
CORED
ARC
WELDING
(GMAW
AND
FCAW)
a
WARNING:
Read
and
follow
safety
informa
tion
at
beginning
of
entire
Section
5
before
proceeding.
1.
Install
and
prepare
welding
power
source
according
to
its
Owners
Manual.
2.
Install
and
prepare
wire
feeder
according
to
its
Own
ers
Manual.
3.
Install
Remote
Control
as
instructed
in
Section
3.
4.
Wear
dry
insulating
gloves
and
clothing.
5.
Connect
work
clamp
to
clean,
bare
metal
at
workpiece.
6.
Select
and
obtain
proper
welding
wire,
and
thread
as
instructed
in
wire
feeder
Owners
Manual.
-7~
Place
the
welding
power
source
CV-CC
switch
in
the
CV
position,
if
applicable.
8.
Place
the
welding
power
source
OUTPUT
(CON
TACTOR)
switch
in
the
REMOTE
position.
9.
Place
the
welding
power
source
VOLTAGE
CON
TROL
switch
in
the
REMOTE
position.
10.
Place
the
welding
power
source
voltage
adjustment
control
in
its
maximum
position.
a
WARNING:
USING
BOTH
WELDING
POWER
SOURCE
POSITIVE
(+)
WELD
OUTPUT
TER
MINALS
at
same
time
can
cause
serious
electric
shock
and
arcing
hazards.
Do
not
use
both
positive
(+,)
weld
output
termi
nals
at
the
same
time.
Read
welding
power
source
Owners
Manual
for
additional
information.
11.
Wear
welding
helmet
with
proper
filter
lens
accord
ing
to
ANSI
Z49.1.
12.
Energize
the
welding
power
source.
13.
Place
the
DVC
Remote
Control
switch(es)
in
the
PANEL
position
(see
Section
4-2).
14.
Rotate
the
OVC
(Right)
VOLTAGE
control
until
the
desired
arc
voltage
is
displayed
on
the
VOLTS
me
ter
(see
Section
4-1).
15.
For
DVC-2
models
only,
momentarily
depress
the
Left
JOG
switch
on
the
dual
digital
wire
feeder,
and
rotate
the
DVC
Left
VOLTAGE
control
until
the
de
sired
arc
voltage
is
displayed
on
the
VOLTS
meter.
16.
Turn
on
shielding
gas
supply.
17.
Depress
the
PURGE
push
button
to
purge
the
gas
line,
if
required.
18.
Hold
tip
of
(desired)
gun
approximately
1/2
inch
(13
mm)
from
workpiece.
J~
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,
ifapplica
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.
19.
Begin
welding.
OM-896
Page
8
5-2.
SHUTTING
DOWN
4.
Turn
off
shielding
gas
supply
at
the
source.
1.
Stop
welding.
2.
Shut
down
welding
power
source.
3.
Shut
down
wire
feeder.
a
WARNING:
HIGH
CONCENTRATION
OF
SHIELDING
GA~
can
harm
health
or
kill.
Shut
off
gas
supply
when
not
in
use.
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
6-1.
ROUTINE
MAINTENANCE
(Table
6-1)
IMPORTANT:
Every
six
months
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
rep/aced
when
necessary.
See
Parts
List for
part
number
of
precautionary
labels.
J~
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,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
~removing
fuses
from
fuse
box,
or
shqtting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
M~VING
PARTS
can
cause
serious
injury.
Keep
away
from
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
Maintenance
to
be
performed
only
by
qualified
persons.
Table
6-1.
Maintenance
Schedule
FREOUENCY*
MAINTENANCE
Every
month.
Units
in
heavy
service
environ
ments:
Check
labels,
weld
cables,
clean
internal
parts.
Every
6
months.
Check
all
labels
(see
IMPORT
ANT
block,
Section
6-1)
and
interconnecting
cords.
*Frequency
of
service
is
based
on
units
operated
40
hours
per
week.
Increase
frequency
of
maint
enance
if
usage
exceeds
40
hours
per
week.
Every
six
months,
inspect
all
interconnecting
cords
and
plugs
for
damage
to
the
insulation
jacket.
Repair
or
re
place
the
cord(s)
as
necessary.
6-2.
CIRCUIT
BOARD
REPLACEMENT
PROCE
DURE
(Figure
6-1)
f~
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,
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.
a
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.
Be
sure
that
plugs
are
properly
installed
and
aligned.
EXCESSIVE
PRESSURE
can
break
circuIt
board.
Use
oniy
minimal
pressure
and
gentle
move
ment
when
disconnecting
or
connecting
board
plugs
and
removing
or
installing
board.
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
reinstallation
unless
specifically
told
otherwise.
OM-896Page9
Plug
PLG6
Ret
ST.tiI
794.A
1.
Remove
wrapper.
2.
For
DVC-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
fric
tion
connector;
and
lead
4
with
female
friction
con
nector
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
se
cure
new
circuit
board
with
receptacle
RC6
posi
tioned
toward
left
side
of
unit
for
DVC-1
models
or
with
receptacle
RC6
positioned
toward
rear
of
unit
for
DVC-2
models.
6.
Reconnect
plug
PLG6
to
receptacle
RC6
leads
38
with
piggyback
friction
connector
onto
terminal
T,
and
lead
4
with
female
friction
connector
onto
termi
nal
U.
7.
For
DVC-2
models
only,
reverse
the
procedure
in
Step
2,
and
reinstall
the
VOLTS
meter.
8.
Reinstall
wrapper.
9.
Energize
wire
feeder
and
welding
power
source,
and
resume
operation.
Circuit
Board
PCi
Plug
PLG7
Meter
Bezel
Volts
Meter
Switch
ma
*Model
DVC-2
Shown
Relay
CR~
Figure
6-1.
Component
Locations*
OM-896
Page
10
6-3.
TROUBLESHOOTiNG
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
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,
maintaining,
or
sefvicing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position.
removing
fuses
from
fuse
box,
or
shutting
oft
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
MOVING
PARTS
can
cause
serious
injury.
Keep
away
from
moving
parts.
Troubleshooting
to
be
performed
only
by
qualified
persona.
It
is
assumed
that
the
uni~was
properly
installed
accord
ing
to
Section
3
of
this
manual,
the
operator
is
familiar
With
the
function
of
controls,
the
welding
power
source
and
wire
feeder
were
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/Service
Distributor.
In
all
cases
of
equipment
malfunction,
strictly
follow
the
manufacturers
proce
dures
and
instructions.
TROUBLE
PROBABLE
CAUSE
REMEDY
No
control
of
arc
voltage.
.
.
.
Voltage
control
connection.
.
-
Be
sure
that
voltage
control
connections
to
welding
power
source
are
secure
(see
Section
3-5).
Welding
power
source
VOLTAGE
CONTROL
switch
in
the
OFF
position.
Place
VOLTAGE
CONTROL
switch
in~
the
REMOTE
position.
Improper
or
loose
voltage
sensing
connections.
Check
voltage
sensing
connections
(see
Section
3-2).
Control
relay
CR50
(DVC-2
models
only).
Check
and
replace
CR50
if
necessary.
~
Circuit
board
PCi.
See
Section
6-2,
and
contact
nearest
Factory
Authorized
Service
Station/Service
Distributor.
No
control
of
arc
voltage
on
(either)
gun;
meter
display
normal.
Circuit
board
PCi.
.
See
Section
6-2,
and
contact
nearest
Factory
Authorized
Service
Station/Service
Distributor.
DVC-2
models
only;
no
con-
trol
of
arc
voltage
on
one
gun;
meter
display
normal.
Switching
relay
CR2.
Check
and
replace
CR2
if
necessary.
No
meter
display.
No
115
volts
ac
at
REMOTE
receptacle
on
welding
power
source.
Reset
applicable
circuit
breaker
on
welding
power
source
(see
welding
power
source
Owners
Manual).
Meter.
Replace
meter
(see
Section
6-2).
Circuit
board
PCi.
See
Section
6-2,
and
contact
nearest
Factory~
Authorized
Service
Station/Service
Distributor.
Table
6-2.
Troubleshooting
OM-896
Page
11
SECTION
7
ELECTRICAL
DIAGRAMS
AC
OUT
AC
IN
I
IC
0
POWER
SOURCE
CONTROL
DC
2
.1
v_v
_______
V
I
T421,7
C2r2f
f_ac
i
I~4
WCP
if
!RC4
C
0
ARC
SENSE
4
5
5/
42
52
ITO
0 0
0 0
CIrcuit
Diagram
No.
SB-152
174
2
>
~
TI
Diagram
7-1.
Circuit
Diagram
For
DVC-1
Models
Diagram
7-2.
Circuit
Diagram
For
DVC-2
Models
PLG2
-
PLOI
TI
RC7
756
lB
13
12
II
4
PC
I
VOLTAGE
CONTROL
BOARD
I-IS
ON
RCI/PLG6
RC6/PI~IO
IA
IA
A
6 C 0
RE~TE
(P10141)
AC
IN
POWER
SOLPCE
CONTROL
DC
E
PLG2
I
q
5C7
I
2
-<<
4
-<<
0
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L
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H
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7
VOLT
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wJ1
5/
49 48
i
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2
V
A~
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42
52
T
756
960
U
16131211
4
PC
I
V0t.TAGE
CONTROL
60*60
I-15
ON
RCI/PLG6
5C6/PLG
0
o o
-
2
I
_____
V
V
_____
V
I
F)~
C2~Jf1C3
6C9
I
4
!6C4
C
B
ARC
SENSE
IA
IA
CR
2
7
8
PLG3
SIDE
SELECT
4
5
5/
42
52
ITO
0 0 0
0
605
O
C
BA
AS
C
0
RE)CTE(LEP~TI
REP~TE(PtGHTJ
Circuit
Diagram
No.
SB-152
166
OM-896
Page
12
PLGI
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STUD
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RC4
RC5
SI
Wiring
Diagram
No.
SC-i
52
173-A
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Diagram
7-3.
Wiring
Diagram
For
DVC-i
Models
PLGI
PLG3
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C,
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C
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STUD
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I
35
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11216110
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459(611
Diagram
7-4.
Wiring
Diagram
For
DVC-2
Models
~?~(Rc~A(
J
Wiring
Diagram
No.
SC-152
165
9
0
do
(0
a
Circuit
Diagram
No.
SC-i
33
836
S
Diagram
7-5.
Circuit
Diagram
For
Voltage
Control
Board
PCi
SECTION
8PARTS
LIST
Dia.
Part
Mkgs.
No.
Description
Quantity
.
Complete
Assembly
DVC-1
DVC-2
.
C2,3
028291
CR2
093558
027811
049 970
079844
048 029
152371
073 756
048
284
079 534
079531
604571
141
162
134731
079 739
110015
PLG3
056264
PLG1O
131
054
113746
Al
603856
...
R1,4
603856
097 922
RC4
076624
RC5
073
687
RC5,8
073687
053075
039
828
RC6
079748
079
747
RC7
028598
RC8
048282
RC9
048282
079
534
Reed
140789
079
878
079
535
079531
Si
011770
011770
TI
108025
iT
038839
081
798
049 989
073
686
039 828
600
848
604109
601
226
601228
600
750
115104
....PC1
..PLG1
PLG2
CAPACITOR,
cer
disc
.luf
500VDC
2
..
..
2
RELAY,
end
1
2OVAC
4PDT
3N1
2OVAC
1
SOCKET
relay
14
pin
1
BRACKE1~
mtg
relay
1
SPRING,
hold
down
relay
1
CLIP,
retaining
socket
1
CIRCUIT
CARD,
voltage
control
1
....
1
STAND-OFF,
No.
6-32
x
.625
4
.
..
4
CONNECTOR
&
SOCKETS,
(consisting
of)
1
....
1
CONNECTOR,
circ
skt
push-in
14-l8ga
Amp
66358-6
4
.
.
.
4
CONNECTOR,
circ
clamp
str
rh
sz
11
Amp
206358-2
1
....
1
CABLE,
port
No.
18
4/c
(order
by
if)
3ft
...
3ft
CONNECTOR
&
PINS,
(consisting
of)
1
....
1
CONNECTOR,
circ
pin
push-in
14-l8ga
Amp
213603-1
.
14
...
14
CONNECTOR,
circ
clamp
str
rlf
sz
17-20
Amp
206322-2
-
1
...
1
CABLE,
port
No.
18
7/c
(order
by
if)
lift
..
lift
CONNECTOR,
male
4cont
1OA
1
.:
CONNECTOR
&
SOCKETS,
(consisting
of)
1
....
1
CONNECTOR,
rect
skt
24-lBga
Molex
39-00-0038
2
...
2
POTENTIOMETER,
WW
sltd
sft
10/T
2W
10K
ohm
1
POTENTIOMETER,
WW
sltd
sit
iO/T
2W
10K
ohm
2
KNOB,
pointer
I
...
2
CONNECTOR,
circ
4
pin
rcpt
MS-3i02A-14S-2P
I
...
1
CONNECTOR,
circ
4skt
rcpt
MS-3102A-14S-2S
1
CONNECTOR.
circ
4skt
rcpt
MS-3102A-14S-2S
2
CONNECTOR,
circ
4
pin
plug
MS-3106A-14S-2P
CONNECTOR,
circ
clamp
str
rif
sz
14-14S
AN-3057-6
CONNECTOR,
rect
l8skt
plug
Amp
1-640250-8
1
....
1
CONNECTOR,
rect
skt
14-1
8ga
Amp
350980-i
18
...
18
CONNECTOR,
edge
I
Sskt
plug
Amp
582772-3
1
...
1
CONNECTOR
w/SOCKETS,
(consisting
of)
1
CONNECTOR
w/SOCKETS,
(consisting
of)
1
CONNECTOR,
circ
skt
push-in
14-i
8ga
Amp
66358-6
4
.
.
.
4
SWITCH,
reed
(consisting
of)
1
...
1
CONNECTOR
&
PINS,
(consisting
of)
1
....
1
CONNECTOR,
circ
pin
push-in
14-l8ga
Amp
66359-6
4
...
.
4
CONNECTOR,
circ
clamp
str
rlf
sz
11
Amp
206358-2
1
...
1
SWITCH,
tgl
SPOT
5A
1
25V
I
SWITCH,
tgl
SPOT
5A
125V
2
TRANSFORMER,
control
1
.....
1
BLOCK,
term
20A
5P
1
....
1
METER,
digital
0
to
19.99V
1
....
1
CABLE,
volt
sensing
(consisting
of)
1
...
1
CONNECTOR,
circ
4skt
plug
MS-3l06A-14S-2S
1
....
1
CONNECTOR,
circ
clamp
str
rtf
sz
14-14S
AN-3057-6
1
....
1
WIRE,
lead
mot
1
2ga
strd
(order
by
it)
35ft
..
35ft
WIRE,
lead
l6ga
strd
(order
by
it)
19ft
.
19ft
INSULATOR,
vinyl
clamp
univ
25A
1
....
1
CLAMP,
univ
25A
1
....
1
TERMINAL,
ring
tng
.500
stud
16-14
wire
1
....
1
CONNECTOR,
clamp
cable
.500
1
...
1
0
OM-896
Page
16
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