Saf-Fro DIGIWAVE III 420 Instruction For Operation And Maintenance Download

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

Summary of Contents for DIGIWAVE III 420

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: ...ROL 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 37 8 OPTIONS 38 8 1 UNIT COOLER REF W000273516 38 8 2 WIRE FEEDER DVU W500 REF W000372327 38 8 3 REMOTE CONTROL RC JOB II REF W000371925 38 8 4 REMOTE CONTROL RC SIMPLE REF W000275904 38 8 5 WORKSHOP ...

Page 4: ...elivered 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 consists of 7 main components 1 420A or 500A power source including its power supply cable 5m and its ground cable 5m 2 Cooling unit 3 Wire feeder 4 Double disconnectable harness between the wire feeder...

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 Lxwxh 720x295x525 720x295x525 Weight 36 kg 40 kg Operating temperature 10 C 40 C 10 C 40 C Storage temperature 20 C 55 C 20 C 55 C Torch connection Européen Européen Protection index IP 23 IP 23 Insu...

Page 7: ...perly 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 water harness WARNING Use exclusively the liquid provided by Air Liquide Welding to fill up the cooling unit Configuration on the interface is needed to ensure a good working of the cooling unit cf 6 ...

Page 8: ...is 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 the power source WARNING When starting up for the first time the configuration is required cf 6 1 ...

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 page 3 Tuning encoder 4 Selection and navigation encoder 5 Button corresponding to the current icons on the screen 6 Colour Screen HUMAN MACHINE INTERFACE HMI SCREEN Main menu selection Validation of th...

Page 10: ...MI 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 Selected language STEP 2 Time date settings The clock is used for the functions of traceability and export Change of the value Change of the column Save ...

Page 11: ...bration 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 Harness calibration Automatic Calibration Only available in MIG Follow the instructions on the screen WARNING During this operation a current of 400A for 1 second is generated It is imperative then to wea...

Page 12: ...ergies 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 require the use of adapted wire for type and diameter as well as the use of the appropriate gas See synergies table in the annex 1 Choice of the arc transfer annex 2 Choice of the working mode SYN mod...

Page 13: ...e 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 the welder can weld without keeping the trigger pressed He presses and releases the trigger a first time to launch the welding then he presses and releases a second time to end the welding Option Conf...

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 increments around the programmed synergic value Increments 10 10 1 Tuning advice In flat regime a low value of the fine tuning enables a quick rise of the short cut current Thus the regime is dynamic and h...

Page 15: ...ding 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 clogged with dirt The previous welding parameters are accessible on the SETUP page from the MIG MAG menu If call off the trigger program welding is not active Short press the trigger vacuum if program c...

Page 16: ...of 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 Switch the cursor between cycle phase selection and parameter table Also possible with the OK and ESC buttons 1 Pregas Gas timing before the welding cycle starts Variables T s 0 0 10 0 2 Hotstart Softst...

Page 17: ...egimes 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 regime 2 Transfer2 Main welding parameters of the regimes 1 and 2 The timing of regimes 1 and 2 are independent and allow tuning of a dissymmetrical cycle T s 0 1 5 0 Transit time T s 0 00 1 00 Intermitte...

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 décalant l arrêt du fil et l arrêt de la puissance Variables Manual Burn back time ms 0 500 Automatic Burn back fine tuning ms 100 200 6 Sharpening thread You can set 3 parameters Sharpening thread The Post Retract Spray ...

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 Striking low wire advance K Allows modifying the low wire advance before striking Striking current K Allows tuning the striking current energy Striking transition energy K Allows tuning the arc energy duri...

Page 20: ...points 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 suppression of existing points Select a point among the list press on edit See below the settable parameters Wire speed m min to create a new point change this value and press the add point button Arc len...

Page 21: ...nergy 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 the welding tuning pages of the processes MIG MMA TIG use the working programs MIG MMA TIG This program provides a working base allowing immediate welding once the quick settings are done This progra...

Page 22: ...l 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 last save select Restore and press on OK Rename a program To rename a program press on select rename a program then press OK Note This function will not backup any changes Load a program To load a progr...

Page 23: ... program 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 the program management Lock a program Lock the synergic parameters of a program The only settings you can modify from the welding tuning page are the main welding parameters Action on all the programs...

Page 24: ...mal 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 program of the list can be freely chosen among the existing programs The adding of a program into the list is limited to the existing and compatible programs those which can be enchained with the firs...

Page 25: ...s 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 of a list is masked or supressed the list cannot be activated anymore The program lists are made for out of welding chaining You can activate the program call out of welding in the menu Configuratio...

Page 26: ...obtain 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 welding parameter settings This allows you to adjust the generator for particular applications Additional settings smooth running Arc Voltage Tension crête Dynamism Additional settings pulsed curren...

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 The first user profile must be a profile Administrator with a password The profiles Technician and Welder are unaccessible when the first profile has not been created A welder profile can be created...

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 load a program To remove or modify the limitation go back to the Limitations page If the user management is implemented on the power source the access to the Limitations page can be denied to certain ...

Page 29: ...he 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 There are three types of fault detection defined in the menu Configuration Installation Fault Type Effect Content of the displayed window Blocking Immediate blocking as soon as a fault is detected Ext...

Page 30: ...elay 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 perturbations FTP server connected to the power source Traceability report Display the traceability report of the last weld To export a traceability report connect an external storage medium and press export bu...

Page 31: ...e 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 The user has to create a numbered program to save program s data When the user selects a MMA program the power is activated only after a time of 10 seconds to avoid the inconvenient starts during the p...

Page 32: ...erface 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 session time Setting of the timing before user log out Screensaver Setting of the timing before screensaver activation Installation General Inverter Power of the power source inverter Wire feeder mod...

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 DETECTED DEFAULT ON THE POWER SOURCE OUTPUT TOR RELAY CONTACT 2 A 48 V Cycle Departure Welding current detection Figure Wiring for N1 interface on connector J2 Installation configuration in automation le...

Page 34: ...e 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 the welding as soon as the current level goes under 15 A MOUVEMENT COMMAND The relay RI closes as soon as the striking and the timing defined in the SETUP are over The relay RI opens as soon as the ...

Page 35: ...rams 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 page allows managing the input output to Ethernet and USB of the following data Welding programs All the existing welding programs and lists on the power source Program lists MIG 4T Program Lists Powe...

Page 36: ...wait 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 Installation Backup restores the previous Installation Backup except Software versions of power source Power source identifier to do manually The welding programs won t be erased if their number is not a...

Page 37: ...ssociated 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 do Contact tube Striking number Replacement Nozzle Time of welding Cleaning Cooling liquid Time of activation of the cooling unit Draining Spool useful when only one wire type is used Length of unwou...

Page 38: ...of 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 as the number and the name of the job The information and the ergonomics of the RC Job II are the same as on the central screen of the wire feeder 8 4 REMOTE CONTROL RC SIMPLE REF W000275904 Remote co...

Page 39: ...00373703 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 power to the DIGIWAVE III from mains electrical three phase 230V 8 11 ADAPTATOR TIG REF W000379466 8 12 OPTION SECURITE DE DEBIT REF W000376539 ...

Page 40: ...arness 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 WATER ALU harness 2 M 95 MM2 ref W000371044 WATER ALU harness 5 M 95 MM2 ref W000371045 WATER ALU harness 10 M 95 MM2 ref W000371175 WATER ALU harness 15 M 95 MM2 ref W000371174 WATER ALU harness 25...

Page 41: ...n 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 loosen some parts of the torch particularly The contact tube The coaxial cable The welding nozzle The quick connector Check that the gasket of the gas inlet spigot is in good condition Remove the spa...

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: ...ed 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 the power source 400V Tolerance 3 15 20 Check network characteristics DISPLAY OF THE MESSAGE E15 Maximum current average Overflow Exceeding the authorized power source Check the program settings weldi...

Page 46: ...diate 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 to connect and disconnect the device when the system is off DISPLAY OF THE MESSAGE E50 Cooling problem Problem of pressure or flow of cooling unit DISPLAY OF THE MESSAGE E52 Stuck electrode MMA only ...

Page 47: ...eeling 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 Missing for a given device please make an update generator software DISPLAY OF THE MESSAGE Error bus CAN Communication with a device is very disturbed Check the connection of the device It is imperative t...

Page 48: ...8 M21 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 ARCAL Chrome X X X X Ar 81 He 18 CO2 1 M12 ARCAL 121 X X X X Aluminium Magnésium 5 Ar I1 ARCAL 1 ARCAL Prime X X X He 70 Ar 30 I3 ARCAL 37 X X X Aluminium Magnésium 3 5 Ar I1 ARCAL 1 ARCAL Prime X X X...

Page 49: ...RCAL Prime X X X He 70 Ar 30 I3 ARCAL 37 X X X Aluminium Magnésium 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 ARCAL 37 X X X Aluminium Ar I1 ARCAL 1 ARCAL Prime X X He 70 Ar 30 I3 ARCAL 37 X X Cuivre Aluminium Ar I1 ARCAL 1 ARCAL Prime X X Cuivre Nickel Ar I1 ARCAL 1 ARCAL Prime X Cuivre Silicium Ar I1 ARCAL 1...

Page 50: ...2 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 Fourré à Poudre Métalique Acier Ar 82 CO2 18 M21 ATAL 5 ARCAL Force X Galvanisé Ar 82 CO2 18 M21 ATAL 5 ARCAL Force X X X Fil Massif Acier Inoxidable à 17 Cr Ar 92 CO2 8 M20 ARCAL 21 ARCAL Speed X Ar 98 O2 2 M13 CARGAL 22 X SPRAY MODAL SM Métal Gaz 0 6 0 8 0 9 1 0 1 2 1 4 1 6 Alumi...

Page 51: ...First pass Extends the area of behavior Short Arc Fast forward speed small deformations High Pénétration Speed Acier Packing Penetration Large free wire Pulsé All materials thin layers Universal for all positions No projection Soft Silence Pulsé Acier Inox Inox Best Location in Pulsed 50 reduction in the noise of the arc Spray Modal Alu Alu unprepared Reduction of porosity Increased penetration Ad...

Page 52: ...control 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 possible presence of hazardous voltage do not touch Earth connection ...

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

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

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