OCV, open circuit voltage, has more to do with initiating the arc than anything else. I was under the impression that the maximum OCV was between 80 and 84 volts to ensure the welder does not get a shock every time a new electrode is placed in the electrode holder.

The arc voltage is the voltage drop across the arc while the welder is welding. The longer the arc, the higher the arc voltage. The bigger the arc length, the more voltage is required for the arc to "jump" the gap.

The relationship between the arc voltage and the welding current is described by the slope of the volt/ampere curve when the relationship is plotted on a graph. In this case, using a constant current power supply, the longer the arc length, the higher the arc voltage, the lower the welding current. The shorter the arc length, the lower the arc voltage, the higher the welding current.

Depending on the electrode classification and the diameter, there is a "sweet spot" for both arc voltage and welding current. The fluidity of the weld pool and flux is a function of the composition of the electrode covering. Changes in composition can affect the penetration, fluidity, and temperature at which the flux solidifies.

Electrodes that employ a cellulous based flux typically have higher arc voltages than do those with limestone based flux coverings.

Without seeing exactly what you are up against, it tough to actually say what your problem is.

Best regards - Al