Saf-Fro DIGIWAVE III Series, Instruction For Operation And Maintenance

Page 1: ...DIGIWAVE III EN INSTRUCTIONS FOR OPERATION AND MAINTENANCE Cat n 8695 1263 Rev Date 06 2016 Contact www saf fro com...

Page 2: ...EN Arc welding and plasma cutting may be dangerous for the operator and persons close to the work area Read the operating manual...

Page 3: ...OL PROCESS 29 5 TIG MMA WELDING 31 6 DETAILED INSTALLATION 32 6 1 GONFIGURATION OF COOLING UNIT 32 6 2 AUTOMATION INTERFACE DECRIPTION 33 6 3 EXTERNAL COMMUNICATIONS 35 7 MAINTENANCE OF INSTALLATION 3...

Page 4: ...livered as ready for use package associated with the DVU W500 wire feeder The power source of this set may also be used for simple automatic applications 1 2 WELDING SET COMPONENTS The welding set con...

Page 5: ...EN DIGIWAVE III 5 WARNING The plastic handles are not intended for slinging the set Stability of the equipment is guaranteed only for an incline of maximum 10 1 2 3 4 5 7 6...

Page 6: ...420A 15A 500A Duty cycle at 100 en MIG 10 min cycle at 40 C 350A 450A Duty cycle at 60 en MIG 6 min cycle at 40 C 420A 500A Duty cycle at maximum current at 40 C en MIG 60 60 Miscelleanous Dimensions...

Page 7: ...erly outfitted with the wear parts corresponding to the wire used for welding If you use a WATER COOLED torch make sure to connect your cooling unit to the rear of the power source as well as to the w...

Page 8: ...s switch to turn the machine on This switch must never be flipped during welding At each start up the generator displays the software version the power and the connected optional device as relevant of...

Page 9: ...INTERFACE HMI The human machine interface HMI is located on the front panel of the power source 1 Validation 2 Escape button to cancel the operations in progress or go back to the previous menu or pag...

Page 10: ...I CONFIGURATION STEPS For the first use of the power source you must do the 4 following steps STEP 1 Choice of the interface language Language selection Validation of the selection 1 Position 2 Select...

Page 11: ...ation is to be re done in case of polarity change or change of one of these following components torch harness ground cable position of the clip of the ground cable Access in the menu MIG SETUP Harnes...

Page 12: ...rgies Some synergies require reversing the polarity of the power source inversion of the 2 power cables Follow the on screen instructions Choice of the consumables metal diameter gas MIG MAG Welding r...

Page 13: ...control Program call by trigger out of welding The Spot Mode is a special mode and you can define the time of the welding step 3 in the cycle welding paremeters Description The 4T mode implies that t...

Page 14: ...50 0 2 FINE TUNING The fine tuning is defined according to the regime of arc Flat Arc dynamism Pulsed Current impulsion energy setting Mode Unit Interval Step SYN MAN Relative fine tuning by 10 increm...

Page 15: ...ing time includes all the steps of the welding cycle The motor current of the wire feeder is proportional to the motor torque Beyond 1 3A at constant regime check that the wire feeder liner is not clo...

Page 16: ...f the phases of the cycle 2 Selected cycle phase 3 Parameters table of the selected cycle phase Use the left encoder to scroll the settings Use the right encoder to adjust the selected parameter 4 Swi...

Page 17: ...gimes 1 and 2 which can have different arc transfers Flat or Pulsed The arc transfer of the regime 1 is the one selected on the synergy bar of the main welding tuning page Variables Arc transfer regim...

Page 18: ...wire speed m min 1 0 25 0 You can activate the option Shorten down slope control in the menu Configuration Installation Cycle 5 Burn back Evite le collage du fil dans le bain en d calant l arr t du fi...

Page 19: ...in few very specific application cases the user may want to modify the striking characteristics Tuning parameters of striking K Variable coefficient de 10 0 10 Name of the parameter Description Striki...

Page 20: ...oints that will serve as support for the new synergic curves Select at least 2 points then validate 2 The second step is the modification of the selected points the addition of new points or the suppr...

Page 21: ...ergy suppression 4 2 MIG WELDING CYCLE ADVANCED SETTING PRESENTATION OF PROGRAMS The program management is the same for the 3 welding processes MIG MMA and TIG Working programs MIG MMA TIG By default...

Page 22: ...appears meaning that the modification can be saved To save the modifications press on select Save program then press on OK and the symbol will disappear To cancel the modifications done since the las...

Page 23: ...rogram Suppress the program the associated number becomes vacant Mask a program Mask the program from the program selection page the program is only accessible to users who have the right access to th...

Page 24: ...al 4T mode The transitory steps hot start craterfiller are managed as in a normal 4T mode Cycle 4T with fainting mode with trigger calling of the program during welding and downslope phase The first p...

Page 25: ...in the top left corner of this page The programs are chained in the same order as they were added into the list It is not possible to create a program while a list is activated If one of the programs...

Page 26: ...tain identical programs between A and B suppress all the programs of the power source B before making the import FREE mode The DIGIWAVE III has a free mode in which the operator can access additional...

Page 27: ...to the maintenance menu Administrator Setup Access to the MIG SETUP menu Welder Calibration Harness calibration Welder User management Access to the users management page Administrator User management...

Page 28: ...to the pages Welding tuning Cycle tuning Display of the former welding parameters Homepage User identification The user can save the modifications rename the current program but he cannot create nor l...

Page 29: ...e previous weld Those values are accessible in the menu Tuning Help The control process parameters are associated to one welding program Those parameters can be different from one program to another T...

Page 30: ...lay after welding T s 1 100 Selecting the Welding trace adds extra parameters to the report Two export choices are possible USB needs a tunable delay before export to avoid electromagnetic perturbatio...

Page 31: ...torch to the wire feeder positive polarity or on the power source positive and negative polarity The functioning of the page MMA is similar with the MIG page The working program is the MMA program Th...

Page 32: ...rface Language Time and date Name Page 10 Post display welding Setting of the post display timing of the welding parameters Backlight Setting of the Backlight of the power source screen Administrator...

Page 33: ...signals SIGNAL SENS TYPE REMARKS 1 DCY CLOSE TO START WELDING INPUT TOR OPTO COUPLER 5 V 5 MA 2 RI CLOSE WHEN CURRENT IS DETECTED OUTPUT TOR RELAY CONTACT 2 A 48 V 3 DEFAUT CLOSE WHEN THERE IS NO DETE...

Page 34: ...current level goes under the RI threshold Parameter Detection level of the RI threshold RI ARC Fast RI The relay RI closes 20 ms as soon as the current goes over 15 A The relay RI opens at the end of...

Page 35: ...ams Power source configuration see below Installation Backup User Synergies Import Export of welding programs and power source configuration is available in the menu Configuration Import Export This p...

Page 36: ...ait until the end of the import Welding programs import is detailed in the IMPORT EXPORT page 26 The import of the power source configuration restores the previous configuration The import of the Inst...

Page 37: ...sociated to a threshold tunable or not if the associated counter goes over the threshold value a warning is reported to the user requiring acknowledgment Item Associated counter Maintenance action to...

Page 38: ...f welding Calling a welding job and running it Chaining several jobs in the same process Modifying and saving a welding job Displaying adjustable welding parameters during and out of welding as well a...

Page 39: ...0373703 8 7 RC JOB II PLUG ON THE GENERATOR REF W000374008 8 8 TUBE HANDLE REF W000279930 8 9 PUSH PULL CARD OPTION REF W000275907 8 10 OPTION POWERBOX REF W000305106 The POWERBOX unit can supply powe...

Page 40: ...rness 5 M 95 MM2 ref W000275899 WATER harness 10 M 95 MM2 ref W000275900 WATER harness 15 M 95 MM2 ref W000275901 WATER harness 25 M 95 MM2 in order ref W000276902 WATER harness 50 M 95 MM2 Consult us...

Page 41: ...The motor reduction unit requires no maintenance 9 3 TORCH Regularly check the proper tightness of the connections of the welding current supply Mechanical stresses related to thermal shocks tend to...

Page 42: ...EN DIGIWAVE III 42 9 4 SPARE PARTS Capots...

Page 43: ...EN DIGIWAVE III 43 Composants internes et onduleur...

Page 44: ...EN DIGIWAVE III 44...

Page 45: ...d the characteristics of the current source mode including free DISPLAY OF THE MESSAGE E07 Power supply over voltage or Power supply under voltage Overvoltage or undervoltage phase supply network of t...

Page 46: ...iate stop welding Demand immediate cessation of welding user DISPLAY OF THE MESSAGE E49 Check Device Connection More communication with a device Check the device connection displayed It is imperative...

Page 47: ...eling user defined DISPLAY OF THE MESSAGE E85 Detection Process Control Reel Imax Exceeded high threshold monitoring motor current reeling user defined DISPLAY OF THE MESSAGE E86 absent Software Missi...

Page 48: ...1 ATAL 5 ARCAL Force X X X X Ar 92 CO2 8 M20 ARCAL 21 ARCAL Speed X X X X Ar 96 CO2 3 O2 1 M14 ARCAL 14 X X X X Fil Massif Inox 308L 316L Ar CO2 H2 M11 NOXALIC 12 X X X X Ar 98 CO2 2 M12 ARCAL 12 ARCA...

Page 49: ...CAL Prime X X X He 70 Ar 30 I3 ARCAL 37 X X X Aluminium Magn sium 4 5 Ar I1 ARCAL 1 ARCAL Prime X X X He 70 Ar 30 I3 ARCAL 37 X X X Aluminium Silicium Ar I1 ARCAL 1 ARCAL Prime X X X He 70 Ar 30 I3 AR...

Page 50: ...O2 H2 M11 NOXALIC 12 X X X X Ar 98 CO2 2 M12 ARCAL 12 ARCAL Chrome X X X X Ar 81 He 18 CO2 1 M12 ARCAL 121 X X X X Fil Fourr Poudre M talique Acier Ar 82 CO2 18 M21 ATAL 5 ARCAL Force X Galvanis Ar 82...

Page 51: ...First pass Extends the area of behavior Short Arc Fast forward speed small deformations High P n tration Speed Acier Packing Penetration Large free wire Puls All materials thin layers Universal for al...

Page 52: ...ontrol connection Ethernet Connection Minus output power connection plus output power connection Power source connexion if automation level 1 is activated RI Cooler unit W000275516 Connection Warning...

Page 53: ...DIGIWAVE III 53 ELECTRICAL SCHEMES DIGIWAVE III 420...

Page 54: ...DIGIWAVE III 520...