MM DVI Problem

[Trooper]

I recently purchased the MM DVI and have run into a problem… I plug the NEMA 5-15 (household current plug) into a dedicated 20 amp outlet and she “pops” the circuit breaker every time I turn her on. When I run her at 230 with a “rigged” dryer outlet, I have no problems. I was under the assumption that I can run the machine with either voltage. I always start the DVI at minimum volts and wire speed and “crank ‘er up” from there. Am I forgetting to do something or am I supposed to fire up the DVI at the circuit breaker (the DVI is switched on and I flip the breaker)? Any ideas would be of great help!

[DevEmp]

You may want to check the breaker, especially if it's old or has ever gotten wet. Also check to make sure that the neutral and ground is tight at the recep and panel. If it's a GFI or an Arc Fault breaker, you might want to consider changing it to a normal breaker - the sensitive and cheaply made electronics in those breakers may not like what the welder is doing to the neutral. If you replace the existing breaker and the new breaker still pops, you might want to get a hold of an amp probe and see what the welder is actually pulling at start up or when it pops the breaker. If it's less than what breaker is rated for, my guess would be that it has something to do with the wire - too long, wrong size, etc.

Obvious warnings about getting into a hot electrical box and panel apply. I'm an electrician, not sure about you.

[MAC702]

Does the DVI have a switch for which voltage you are feeding it?

So you are saying that after it immediately pops the breaker, that you can then reset that breaker and use the machine normally? I like the theor about it possibly being an overly sensitive GFCI or AFCI breaker. Is that it?

Try the machine in another 120V receptacle on another circuit.

[harcosparky]

I plug the NEMA 5-15 (household current plug) into a dedicated 20 amp outlet and she “pops” the circuit breaker every time I turn her on.

I think you problem may be the breaker rated at 20 Amps.

The DVI Manual says at 120V the unit will pull 24.5 Amps at " rated output "

According to the web site " rated power " at 120V = 90 Amps

Rated Output

* 230 V operation: 150A at 23 VDC, 40% Duty Cycle
* 115 V operation: 90A at 18 VDC,
20% Duty Cycle

My guess is since it works on 230V fine, if you had a 30 AMp breaker it would work on 120V


Look in the manual SECTION 4 - Installation

The chart will show you the required amps.

[MAC702]

I was under the impression the breaker was popping as soon as he turned the machine on, not while he was welding with it.

[harcosparky]

Well I wasn't so sure, however I read the manual for his welder and found this interesting tidbit.

It says, you will need a .........

15 Amp -OR- 20 Amp TIME DELAYED fuse or circuit breaker.

My understand is where a TIME DELAYED breaker is not used, a 30 Amp can be used.

I guess the use of a Time Delayed device allows for any inrush current.

Also after reading the manual there is no mention of a Voltage Selector switch. It seems, as I believed the voltage selection was sort of automatic and dependent on the connector you installed on the power cord.


The DVI comes with, according to the manual 3 input power connectors.

[Trooper]

I had to verify what I was doing. After I plug it in, I turn on the welder, breaker pops. Leave the welder on, go to the panel reset the breaker, pops again. Without fail, reset breaker on everything goes well. It is a 20 amp breaker that was created for a 120 fryer

[Trooper]

Well I wasn't so sure, however I read the manual for his welder and found this interesting tidbit.

It says, you will need a .........

15 Amp -OR- 20 Amp TIME DELAYED fuse or circuit breaker.

My understand is where a TIME DELAYED breaker is not used, a 30 Amp can be used.

I guess the use of a Time Delayed device allows for any inrush current.

Also after reading the manual there is no mention of a Voltage Selector switch. It seems, as I believed the voltage selection was sort of automatic and dependent on the connector you installed on the power cord.


The DVI comes with, according to the manual 3 input power connectors.

The DVI has a voltage lever and a wire speed knob. I probably used the wrong words when describing my problem. But in a rookie maneuver, I turn everything down just in case. Add more confusion, I plugged it in the outlet that powers the rest of the garage outlets (protected by a 15 amp breaker) and she turned on the first go round but, I am not going to try to weld with that breaker.

Called the neighbor (a "handyman") over for a beer and manual reading. He said the breaker is the time delay. Since I don't have fuses in the house he told me to go get a Bobcat (not skid-steer) and forget the house power.

[harcosparky]

Add more confusion, I plugged it in the outlet that powers the rest of the garage outlets (protected by a 15 amp breaker) and she turned on the first go round but, I am not going to try to weld with that breaker.

What? You did this on a 15 Amp and it turned on OK. You did the same thing on the 20 Amp and it POPPED the 20 Amp.????

What else is on that 20 Amp circuit? Were there other things running off of it?

Washer? Lights? Fans?

If it turned on, on the 15, and popped the 20, there is a problem on the 20 circuit. Unless something else is being missed.

Let me delete my last reply!

[MAC702]

Swap out that breaker and let us know what happens. Breakers just sometimes do that with certain machines, and its usually just some idiosynchrocy that can't be explained. Are we now assuming this is not an AFCI or GFCI breaker?

So your handyman's official advice is to use a $3500 generator instead?

[harcosparky]

So your handyman's official advice is to use a $3500 generator instead?

Just a guess, but I bet that advice was given AFTER the beer was consumed.

[Trooper]

Swap out that breaker and let us know what happens. Breakers just sometimes do that with certain machines, and its usually just some idiosynchrocy that can't be explained.

Oh how true...

We replaced the breaker with the washer breaker, and it worked. I know that the electric bill will go through the roof now from flipping it on and off as much as we did. It did pop twice, but from what it was doing I will take it, and that is par with what the 15 amp outlet was providing. This also is odd, because when I used the washer outlet it popped every time.

I really appreciate all the help that everyone gave me.

The neighbor has the Bobcat, and I know that he was trying to make me "take it off his hands".