Air Liquide SAF-FRO DVU W500 Installation instructions

DVU W500
EN
INSTRUCTIONS FOR OPE
RATION AND MAINTENAN
CE
Cat n°: 8695-1215
Rev :
Date : 11/201
Contact :
www.SAF-FRO.com

2
EN
Arc welding and plasma cutting may be dangerous for the operator and persons
close to the work area. Please ensure you read the operating manual carefully
before use.

EN
CONTENTS
1 - GENERAL INFORMATION ......................................................................................................................................................................................................................... 4
1.1. PRESENTAT ON OF NSTALLAT ON ............................................................................................................................................................................................... 4
1.2. WELD NG SET CONST TUENT ........................................................................................................................................................................................................ 4
1.3. TECHN CAL SPEC F CAT ONS ........................................................................................................................................................................................................ 4
1.4. D MENS ONS AND WE GHT............................................................................................................................................................................................................. 4
2 - SETTING UP ................................................................................................................................................................................................................................................ 5
2.1. PRECAUT ONS .................................................................................................................................................................................................................................. 5
2.2. ASSEMBLY OF OPT ONS ................................................................................................................................................................................................................. 5
2.3. W RE FEED UN T CONNECT ON ..................................................................................................................................................................................................... 5
2.4. POS T ONN NG THE W RE............................................................................................................................................................................................................... 6
- INSTRUCTIONS FOR USE ......................................................................................................................................................................................................................... 7
3.1. PRESENTAT ON AND SETT NG UP ................................................................................................................................................................................................ 7
3.2. WELD NG PARAMETERS SETT NG ................................................................................................................................................................................................ 8
3.3. PREV EW ANS WELD NG MEASUREMENT ................................................................................................................................................................................. 12
3.4. PROGRAMS MANAGEMENT.......................................................................................................................................................................................................... 13
3.5. W RE FEEDER CONF GURAT ON ................................................................................................................................................................................................. 14
4 - OPTIONS ................................................................................................................................................................................................................................................... 16
5 - MAINTENANCE ......................................................................................................................................................................................................................................... 17
5.1. W RE ROLLERS AND GU DES ....................................................................................................................................................................................................... 17
5.2. W RE-FEED PLATE WEAR PART ................................................................................................................................................................................................. 17
5.3. RECYCL NG ..................................................................................................................................................................................................................................... 18
5.4. SPARE PARTS ................................................................................................................................................................................................................................ 18

EN
4
1 - GENERAL INFORMATION
1
.1. PRESENTATION OF
INSTALLATION
The Wirefeeder
DVU W500
has been specially developed for high standard applications that have particular requirements for the power source range of
DIGIWAVE II, an expert range for manual applications
ts optimized design
makes it easy to use in a harsh environment whether for rolling (workshop trolley in option) or against exterior aggressive c
onditions
(wet, dust, projections, etc…)
The
DVU W500
will allow you to achieve high quality welds with a nice appearance
.
The w
ire feeder can only be used in the
DIGIWAVE
II
range.
Optimum use of the system requires full knowledge of this manual; it is important to follow all the instructions described in this document.
1.2. WELDING SET CON
STITUENT
The welding-set is comprise of :
☞
a wire feeder,
☞
An adapter for ecological spool
,
☞
User instruction
☞
Safety instruction
1. .
TECHNICAL SPECIFICAT
IONS
DVU W500 - REF. W000 72 27
Roller plate
4 galets
/ 4 rollers
Wire feed speed
1
to
25 m / mn
Wire speed regulation
Numerical
W
ire dia. usable
0.6 to 1,6 mm
Designed to fit through a manhole
yes
Protection index
P 23 S
nsulation
class
H
Standard
EN 60974
-
5 / EN 60974
-
10
Torch
connection
European
type
Duty cycle 60% at t=40°C
500 A
NOTE
: This wirefeeder cannot be used
in falling rain or snow. t may be stored outside, but it is not designed for use without protection during raining.
Degrees of protection provided by the covering
Code letter P Equipment protection
First number 2 Against the penetration of solid foreign bodies with Ø ≥12,5 mm
Second number 1 Against the penetration of vertical drops of water with harmful effects
3 Against the penetration of rain (inclined up to 60° in relation to the vertical) with harmful effects
S
ndicates that the protection test against de
trimental effects due to water penetration has been done
with all parts of the equipment at rest.
1.4.
DIMENSIONS AND WEIGH
T
Dimensions
(L×W×h)
Net
weight
Packed
weight
Wire feeder DVU W500 603 X 262 X 446 17.5 kgs
(without trolley option)
20 kgs
This wire feeder isn’t designed for automatic applications, and is only applicable for manual installations.
While welding in M G, the tension is present on the MMA connection. n the same way, while welding in MMA, the tension is
present on the M G torch connection and on the wire and the contact tube of the M G torch if this one is still connected.
Avoid any contact of these connections with you or any other element: risk of electric arc (burning, dazzling, deterioration of
material)

EN
5
2 - SETTING UP
2.1. PRECAUTIONS

To protect the front projections, hold closed the transparent cover.

Ensure not to pinch the cables and gas pipes and water

Ensure correct installation of power connections.
The quarter turn connection must be well tightened

Do not leave, liquid, hot material in contact with the cables.

The stability of the system is supported up to angles of 10 °.

When slinging wire feeder, do not use ecological spool.

The connection of the wire feeder unit is to made while the generator i
s off.
2.2. ASSEMBLY OF OPT
IONS
Before connecting the wire feeder, the following options have to be assembled :
Trolley option
Liter flow option
Pivot support option
Push pull option
2. .
WIRE FEED
UNIT
CONNECTION
For the wire feeder and conn
ection options, follow the instructions of the
quick start
.
P1 Euro-connection M G & T G -
P2 Connection MMA
P3 Remote plug
P4 Push Pull plug option
P5 Torch water connections
Any connection or disconnection of the wire feeder on the installation has to be done when the installation is switched off.
For slinging the wire feeder, you must use the metal hook at the base of the handle.

EN
6
2.4. POSITIONNING TH
E WIRE
1 Wire Feed unit
2 Pin of the shaft of the reel locator
3 Spool axle nut
4 Flow meter option
5 Wire speed setting
6 Gas purge button
7 Lever locker of the idlers
8 dlers
Open the door of the wire-feed unit ( 1) and ensure that it cannot fall.
Unscrew the spool axle nut. ( 3).
nsert the spool of wire on the axis. Make sure that the locating pin of the shaft ( 2) is properly located into the reel locator
Screw the spool nut ( 3) back on to the shaft, turning it clockwise.
Lower the lever ( 7) in order to free the idler rollers ( 8):
Take the end of the wire of the spool and cut the distorted end piece.
Straighten the first 15 centimetres of wire.
nsert the wire via the inlet wire-guide of the plate.
Lower the idlers ( 8) and raise the lever ( 7) in order to immobilise the idlers.
Adjust the pressure of the idlers ( 8) on the wire to the correct tension.

EN
7
- INSTRUCTIONS FOR USE
.1. PRESENTATION AN
D SETTING UP
Wire feed interface :
Zone A Welding parameter setting (§ 3.2 )
Zone B Preview and welding measurement (§ 3.3)
Zone C Program management (§3.4)
Zone D Wire feeder configuration (§3.5)
Starting up of the installation :
At the start-up, the LCD display shows these following steps:
Displays the software version and the number of the wire feeder if several wire feeders are
used
Transit display « Air Liquide Welding »
Work display depending on the state in which the installation was stopped.
Adjustment in progress
:
When the power source is in a configuration where the setting is not allowed, the wire
feeder’s interface is inactive and shows this message.
Contrast and backlight intensity setting :
The contrast and the backlight intensity are pre
-
set at the factory. However, it is possible to change them from the wire feeder when it is in adjustment.
To change the contrast, press and hold the OK button and turn the left encoder.
To change the backlight intensity, press and hold the button OK and turn the right encoder.

E
N
8
Manual wire speed advance
:
To activate the wire speed advance, press and hol
d the button of manual wire speed advance. (
5
).
The wire speed is displayed and can be set with the left encoder (2) up to the limit of 12.5
m/min.
The wire is fed with the lowest speed for 1s and then increases progressively up to the reference s
peed value.
Purge gas
:
To activate the gas purge, press the button gas purge ( 6). The gas flows during the defined
timing. The timer is displayed:
Are
-
press on the button ( 7) stops the gas flow
The purge gas timing can be modified with the ri
ght encoder (4), the modification is taken into account during the next purge.
.2. WELDING PARAMETERS SETTING
Setting interface presentation :
1
Line 2 of the LCD screen that displays the parameters being adjusted
2
Left encoder for sett
ing the parameter displayed on the left
3
Scroll button
±
of displayed parameters
4
Right encoder for setting the parameter displayed on the right
The wire feeder enables you to set the main welding parameters (wire speed, arc voltage, dynamism…
) and the trigger mode. The other settings are
configured on the power source. See the User instructions of the power source.
Modifications made on the wire feeder (or the power source) are updated at the same time on the power source (or the wire fee
der
).

EN
9
Out of welding MIG program setting
The scroll button
±
(3) enables you to show the following lines in order to get access to the setting of the main welding parameters:
line 1
Working mode (SYN, MAN FREE)
Arc transfer
not settable, for information
Trigger mode
line 2
Last welding current measure
Post
welding
Last welding voltage measure
line
Thickness setting
Welding current
L
ine
4
Wire speed
Arc length
line 5
Dynamism correction
For the working mode
s FREE or MAN, the lines 3 and 4 are replaced with these following lines:
Wire speed
Arc voltage
The presentation of the main welding parameters may vary according to the phases of the welding cycle you have selected on th
e power source and to th
e arc
transfer you use.
The welding cycle setting is detailed in the instruction manual of the power source. n the following, the specific cases of
the steps mode and the
Advanced Sequencer mode are presented as examples.

E
N
10
Specific case of the step mo
de
:
Go to the appropriate line for access to the parameters you want to set, and turn the right encoder to select the step you wa
nt to set:
line 1
Working mode (
SYN
,
MAN
FREE
)
Arc transfer and step mode activated
Trigger mode
line 2
Last wel
ding current measure
Post
welding
Last welding voltage measure
line
Wire speed
Select the step to be set with the right
encoder
line 4
Hauteur d’arc
/ Arc length
Sélection du palier à régler par le
codeur droit
Select the step to be set with the right
encoder
line 5
Dynamism
Select the step to be set with the right
encoder
line 6
Number of activated steps
Specific case of the «
ADVANCED SEQUENCER
»
The mode Advanced Sequencer enables the operator to sequence the welding in
to two distinct regimes. The display is then adapted to allow setting the
same parameter for the regime 1 at the left and the regime 2 at the right.
line 1
Working mode
(SYN, MAN FREE)
Arc transfer of the regime
1 and 2
Trigger mode
line 2
L
ast welding current measure
Post soudage
Last welding voltage measure
line
On regime 1
Wire speed
On regime 2
line 4
On regime 1
Arc length
On regime 2
line 5
On regime 1
Regime time
On regime 2
line 6
On regime 1
Dynamism
On regi
me 2

EN
11
line 7
Transit time
Potentiometer settings
The wire feeder may be connected to:
•The potentiometer remote command
•The potentiometer torch
•The compatible push pull torch with potentiometers
To be considered, the potentiometers must be co
nfigured into the power source (for more details see the power source instruction manual ). You have to
specify the number of used potentiometers.
The potentiometers tune:
Potentiometer 1
Wire speed
Potentiometer
2
A
rc Voltage
The setting range of the potentiometers depends on the working mode or on the program limitations.
Only one peripheral with a potentiometer can be connected to the installation.
When the potentiometers are connected and activated, the corresponding parameters are not adjustable by digital interfaces
(wire feeder, generator and RC job)
MIG welding
n welding, the interface is automatically adapted and only the main welding parameters can be changed:
Wire speed, Arc length, Dynamism, Current, Voltage.
MMA welding
For more information about the setting of the MMA process, see the power source instruction manual.
line 1
Welding current
MMA
Process
Dynamism setting
line 2
Setting of the arc striking dynamism
line
Last welding current measure
Post soudage
Last welding voltage measure
During welding, the interface is similar to the M G process.

E
N
12
TIG welding
For more information about the setting of the T G process, see the power source instruction manual § 3.4.
1.
line 1
T G
Process
Trigger mode
line 2
Last welding current measure
Post soudage
Last welding voltage measure
line
welding current
line 4
End of welding current
Downslope timing
.
. PREVIEW ANS WELDIN
G MEASUREMENT
Pr
esentation ot the interface pf measurement display
:
5 Left measurement display
6 ndicator light of the left parameter displayed
7 Selection button of the left parameter
8 ndicator light of the installation status
9 Right measurement display
10 ndicator light of the right parameter displayed
11 Selection button of the right parameter

EN
1
The displayed values depend on the installation status:
State Displayed values on (5) and (9) Indicator (8)
Ajustement in Progress No values, these are replaced by dashes Off
Out of welding nstructions or theoretical values Off
In welding Direct measurements Blinks
Post welding Last welding measures Fixed
Notes
:
The post
welding
time
is
configurable on the power source.
The last measures are sti
ll available on the power source (see the power source
instruction manual).
Definition of serigraphy symbols:
Symbol unction Unit Symbol unction Unit
Amperage A Voltage V
Wire speed m/min Arc length
Thickness mm Fine tuning/dynamism
.4
. PROGRAMS MANAGEMEN
T
Presentation
12
The
number, the name and the status of the current program
are displayed on line 1 of the LCD.
1
Button (
-
) to select the previous program
14 Button (+) to select the next program
15 Button (OK) to access to the program management

E
N
14
The line 1 contains, in this order, the following information
•Program status (optional)
•Program number
•Program name
The status information are:
Floppy = The program has been modified since the last save.
Verrou = Le programme est verrouillé.
f the name of the program exceeds the capacity of the display, the name characters are continually shifted to allow a comple
te reading.
Program selections :
Select a program by pressing the button + (14) to move to the next program, or the button - (13) to return to the previous program.
f a program list is active, the selection is limited to the programs of the list.
Restore and save the current program
Navigate to the function « restore » by pressing the button OK (15).
Turn the encoder (2) or (4) to point the arrow at the desired operation.
Confirm the selection by pressing to the button OK (15).
f you want to leave program, press any button other than OK (15) or the trigger button.
.5
. WI
RE FEEDER CONFIGURAT
ION
Warning messages
:
When a fault occurs, the number and the text box information associated the fault are displayed.
When the fault disappears, associated message flashes. Then it can be acknowledged by pressing the button OK o
n the wire feeder or the power
source.
Once the fault is acknowledged, the message disappears.
For more information, see the power source instruction manual.

EN
15
Fault list description :
Code
Message LCD
Signification
E03
Over max pw
Exceeding the m
aximum allowed power from the current source
–
check that the welding program
parameters do not exceed the characteristics of the current source (including Free mode)
E07
Overvoltage pw
Over voltage of the 3 phase power supply of the power source of (tole
rance 400V
-
3 ~ 15 %/
-
20 %)
-
Verify the characteristics of the power supply
E07
Undervoltage pw
Under voltage of the 3 phase power supply of the power source of (tolerance 400V
-
3 ~ 15 %/
-
20 %)
-
Verify the characteristics of the power supply
E15
Max
aver current
Overtaking of the maximum average current authorized by the power source
-
verify that the parameters of
the program of welding do not exceed the characteristics of the power source (Free mode in particular)
E16
Max strikcurrent
Overtaking of
the maximum instant current authorized by the power source
-
verify that the parameters of
the program of welding do not exceed the characteristics of the power source (Free mode in particular)
E25
Over dut c cle
Overtaking of the duty cycle of the powe
r source
–
wait for the cooling of the power source
E30
Missed striking
Automatic mode only
Time out of 3 seconds after the welding launch without detecting striking
E32
Broken arc
Automatic mode only
Detection of arc break
E33
Program problem
Call of
a non authorised or non existing program
E33
Incompat. prog.
The program is not compatible with this software version. Please upgrade the software version of the
power source.
E33
Incompat. conf.
The configuration is not compatible with this software ve
rsion. Please upgrade the software version of the
power source.
E33
Corrupted prog.
A program is corrupted. This program is visible in the programs management page of the power source. A
removal of the program is required.
E33
Corrupted conf.
The install
ation configuration is corrupted. Please configure again the installation.
E33
Corrupted list
A program list is corrupted. Please configure again the program lists.
E42
Device reset
A peripheral has been reset. Please restart the power source.
E42
Unsta
ble pow sup
The power supply is unstable. Please check the electrical wiring.
E44
Calibration
mpossible to achieve the automatic calibration
Check that the procedure of calibration displayed on the screen is well respected
E45
Instant stop
mmediate req
uest from user to stop the welding
E49
Check device cnt
No communication with a peripheral.
Check the peripheral connection.
t is imperative to connect and disconnect the wire feeder when the installation is out of power.
E50
Cooling problem
Flow probl
em of the cooling
unit
E52
Stuck electrod
MMA only
Detection of the sticking of the electrode with the workpiece. Unstick the electrode
E53
Stuck wire
M G only
Detection of the sticking of the wire with the workpiece. Cut the wire
E63
Motor torque
Exces
sive torque of the wire feeder motor.
Check that the wire sheathing is clean and that nothing is blocking the motor advance or the wire feeding
movement
Check that the tightness of the rollers is not too important
E72
Not
present
S n
Launching of a weldin
g program where user synergy is not present in the generator
–
import or define the
user synergy corresponding to the current program
E80
I min control
Overtaking of the low threshold of welding current monitoring defined by the user
E81
I max control
Ov
ertaking of the high threshold of welding current monitoring defined by the user
E82
U min control
Overtaking of the low threshold of welding voltage monitoring defined by the user
E83
U max control
Overtaking of the high threshold of welding voltage mon
itoring defined by the user
E84
Wf I
motor
max
Overtaking of the low threshold of wire feeder motor current monitoring defined by the user
E85
Wf I
motor
min
Overtaking of the high threshold of wire feeder motor current monitoring defined by the user
E8
6
Missing software
Software is missing for a dedicated peripheral. Please perform again a software upgrade.
E90
Error CAN bus
The communication with a peripheral is highly disturbed. Please check the peripheral connection.
t is imperative to connect and disconnect the wire feeder when the installation is out of power

EN
16
4 - OPTIONS
Pivot support, ref. W0002799 2
Gas flow controller, ref. W000275905
Wire feeder trolley, ref. W000275908
Simple remote control, ref. W000275904
RC-job II remote control ref. W000 71925
Potentiometers torchs
D G TORCH 2 E 341 – 4m, ref. W000373831
D G TORCH 2 E 341W – 4m, ref. W000373832
D G TORCH 2 E 441W – 4m, ref. W000373833
PUSH
-
PULL Card, ref. W000257907
ADAPTATOR TIG,
ref. W000 79466

EN
17
5 - MAINTENANCE
Twice a year, according to how often the set is used, inspect :
The cleanliness of the wire feeder.
The electrical and gas connections.
Never clean or make repairs on the inside without first making sure that the set has been disconnected from the mains. Remove
the wire
feeder panels and vacuum up any dust and particles presente.
Always use a plastic nozzle when cleaning these parts to avoid any damage.
Carefully vacuum the electronic circuits, taking care to ensure that the nozzle does not damage the components.
f the wire feeder develops a malfunction, before trying to diagnose the problem, perform the following steps, check :
the electrical connections on the power, control and supply circuits.
the condition of the insulation, cables and lines.
At each startup of the welding set and before any operations, check technical sale service:
that power terminals are not poorly tightened
that the connections are correct
the gas flow
the condition of the torch
the kind and diameter of the wire
5.1. WIRE ROLLERS AN
D GUIDES
Under normal working conditions, these accessories will give you long service life before requiring replacement.
However, early wear or clogging can be caused by sticky deposits.
To reduce the risk of t
his happening, check the cleanliness of the plate at regular intervals.
The motor reducing gear set is maintenance
-
free.
The mounting of the rollers on the deck requires an adapter ref.
W000277338.
5.2. WIRE
-
FEED PLATE WEAR PAR
T
The wearing parts o
f the wire feeder, whose role is to guide and advance the welding wire, must be adapted to the type and diameter of the weldi
ng wire
used.
Their wear may affect the welding results. Replace them if needed.
wire guide input roller wire guide
intermediate wire guide output
steel
0,6 / 0,8
0,8 / 1,0
W000277333
W000305125
W000267598 W000279645 W000277335 W000277335
0,9 / 1,2
1,0 / 1,2
W000277008
W000267599 W000277335 W000277335
1,2 / 1,6
1,4 / 1,6
W000305126
W000277009 W000277336 W000277336
Flux Cored
Wire
0,9 / 1,2
W000277333
W000277335
1,2 / 1,6 W000277335
1,4 / 1,6 W000277336
ALU 1,0 / 1,2 ALUK T W000277622
1,2 / 1,6 ALUK T W000277623
Possible use of steel rollers ALU with steel wire and coated wire.

EN
18
5. . RECYCLING
The presence of the following components requires a specific end of life management (recycling):
Electronic board of the front panel
LCD screen on the electronic board of the front panel
5.4. SPARE PARTS
(



see fold
-
out FIGURE 1 a
t the end of the manual
)
Rep
REF. SAF Designation
W000 72 27
DVU W500
Front panel
1
W000374095
Front panel W500
2
W000265988
Blu buttons kit
W000373633
Plastic hood
Internal parts
W000278017
Valve
W000277985
Harness wiring
+ socket
W000277986
RC wiring
10
W000241668
Male plug 500 A ¼T
11
W000148911
Female plug
500 A ¼T
W000277987
European Connection
Chassis
W000278019
Harness fixing plate
21
W000277976
Handle
22
W000277977
Plastic parts
23
W000278020
Equipp
ed door
24
W000277978
Right panel with screws
25
W000278021
Hinges with screws
a
W000278730
Swivel front
wheel
b
W000277990
Fixed rear
wheel
Base plate
30
W000277988
Complete motor and encoder
31
W000277989
Roler’s cover
32
W000278018
Setscrew
W000277338
Wheel adapter
Harness
W000278022
Couplers for harness
Trolley option
W000147072
Front wheel
W000147075
Rear Wheel
Push pull option
W000277991
Push
-
pull wiring