Lincoln Electric SAF-FRO DIGISTEEL III 320C Operation and maintenance manual

DIGISTEEL III 320C
DIGIPULS III 320C
EN SAFETYINSTRUCTIONSFOR OPERATION AND MAINTENANCE
Catn :8695-1259
Rev:A
Date:03/2016
Contact :
http://www.lincolnelectric.com.cn/

EN Arc welding and plasmacutting maybe dangerousforthe operator and personsclosetothework area. Read the operating manual.

DIGISTEELIII/DIGIPULSIII 320C 3/28
EN CONTENTS
1-GENERALINFORMATION...............................................................................................................................................................................................4
1.1. PRESENTATIONOFINSTALLATION.....................................................................................................................................................................4
1.2. WELDING SETCOMPONENTS..............................................................................................................................................................................4
1.3. POWERSOURCES TECHNICALSPECIFICATIONS.............................................................................................................................................5
2-STARTINGUP..................................................................................................................................................................................................................6
2.1. POWERSOURCE GENERALDESCRIPTION........................................................................................................................................................6
2.2. ELECTRICALCONNECTIONSTO THE MAINS.....................................................................................................................................................6
2.3. CHOICE OFCONSUMABLES.................................................................................................................................................................................6
2.4. POSITIONING THE WIRE........................................................................................................................................................................................7
2.5. WIREDRIVERWEARPART...................................................................................................................................................................................7
2.6. CONNECTIONOFTHE TORCH..............................................................................................................................................................................7
2.7. GAS INLETCONNECTION......................................................................................................................................................................................7
2.8. SWITCH ON.............................................................................................................................................................................................................7
3-INSTRUCTIONS FORUSE...............................................................................................................................................................................................8
3.1. FRONTPANELFUNCTIONS...................................................................................................................................................................................8
3.2. CALIBRATE THE POWERSOURCE.......................................................................................................................................................................9
3.3. DYSPLAYAND USE................................................................................................................................................................................................9
4-OPTIONS, ACCESSORIES..............................................................................................................................................................................................12
5-MAINTENANCE................................................................................................................................................................................................................14
5.1. GENERAL.................................................................................................................................................................................................................14
5.2. ROLLERS ANDWIRE GUIDE..................................................................................................................................................................................14
5.3. TORCH.....................................................................................................................................................................................................................14
5.4. SPARE PARTS, COMPONENTS.............................................................................................................................................................................15
5.5. WEARPARTS..........................................................................................................................................................................................................19
5.6. TROUBLESHOOTING PROCEDURE......................................................................................................................................................................20
5.7. ELECTRICALDIAGRAM..........................................................................................................................................................................................22
6-ANNEXES.........................................................................................................................................................................................................................23
6.1. PRESENTATIONOFWELDINGPROCESSES......................................................................................................................................................23
6.2. ADVANCEDWELDING CYCLE...............................................................................................................................................................................25
6.3. LISTOFSYNERGIES..............................................................................................................................................................................................27

EN
4/28 DIGISTEELIII320C/DIGIPULSIII320C
1-GENERALINFORMATION
1.1.
PRESENTATIONOFINST
ALLATION
DIGISTEELIII 320C/ DIGIPULSIII 320Cis amanualwelding set that enablesthe following:
+MIG-MAG welding withshort arc, speed shortarc, spray-arc, normalpulsedmode (only on DIGIPULS), using currentsfrom15A
to320A.
+Feeding different typesofwire
ðSteel, stainless steel, aluminum and specialwires
ðsolidand cored wires
ðdiametersfrom 0.6-0.8-1.0-1.2mm
+Coated electrodewelding
1.2. WELDINGSETCOM
PONENTS
The welding set consistsof 4maincomponents:
1-Powersourceincluding itsprimarycable(5m)and itsground strip(5m)
2-Workshop trolley(optional),
3-Universaltrolley(optional),
4-Coolerunit (optional)
Eachitem is ordered and supplied separately.
Optionsordered withthe welding setaredeliveredseparately. Toinstall theseoptions, refertothe instructionssupplied withthe
option.
WARNING :
The plastic handlesarenot intended forslinging the set. Stabilityof the equipment is guaranteedonly foran incline of maximum 10 .
1
2
3
4
1

EN
DIGISTEELIII320C/DIGIPULS III 320C 5/28
1.3.POWERSOURCEST
ECHNICALSPECIFICATI
ONS
DIGISTEELIII 320C-W000385049 DIGIPULS III 320C-W000402089
Primaryside
Primarypowersupply 400V +/-20% 400V +/-20%
Primarypowersupply frequency 50/60Hz 50/60Hz
Effectiveprimaryconsumption 12 A 12 A
Maximum primaryconsumption 18,7A 18,7A
Fuseprimary20 A Gg 20 A Gg
Maximum apparentpower 13,1KVA 13,1KVA
Maximum activepower 12,1KW 12,1KW
Recommended powergenerator 20 KVA 20 KVA
Activepowerinstandby(IDLE) 50 W 50 W
Efficiency at maximum current 0,87 0,87
Powerfactorat maximum current 0,92 0,92
CosPhi 0,99 0,99
Secondaryside
Noload voltage(according standard) 74 V 74 V
Welding rangeMaxMIG 10V / 50V 10V / 50V
Welding rangeMaxMMA 15A / 320A 15A / 320A
Dutycycleat 100%(10mincycleat40 C) 220A220A
Dutycycleat 60%(6mincycleat 40 C) 280A280A
Dutycycleat maximum currentat 40 C 320A320A
Wirefeeder
Rollersplate 4rollers
Wirefeeding speed 0,5 –25,0m/ mn
Wirediameterusable 0.6to1,2mm
Weight, type, sizeof wirespool 300 mm
Maximum pressureofgas 6bar
Miscelleanous
Dimensions(Lxwxh) 755 x300 x523 mm
Weight 28 Kg
Operating temperature -10 C/+40 C
Storagetemperature -20 C/+55 C
Torchconnection “European type”
Protection index IP 23
Insulation class H
Standard 60974-1& 60974-5& 60974-10
WARNING: This powersourcecannot be used infalling rainorsnow. Itmaybe stored outside, but it is not designed foruse
without protection during raining.

EN
6/28 DIGISTEELIII320C/DIGIPULS III 320C
2-STARTING UP
2.1
.
POWERSOURCE GENERAL
DESCRIPTION
The powersourceis composed with:
1- Front paneldisplay
2- European plug fortorch
3- Additionalplug for2potentiometerstorch
4- Plug forgroundcableandpolarityinversion
5- Protection doorforwirefeedersection
6- Spoolaxle, shaft, axlenut
7- Gaspurge button
8- Wirefeeding button
9- Wiredriver
2.2.ELECTRICALCONNECTIONS TO THE MAINS
DIGISTEELIII 320C/DIGIPULSIII 320C is a400 V3-phasewelding set.If yourmainssupply correspondstorequirements,connectthe "three-phase+
ground"plug tothe endof thepowercable.
WARNING: Sousréserveque l'impédancede réseau public d’alimentationbassetension aupoint decouplagecommun soit inférieure
à33 m , cematérielest conforme àlaCEI 61000-3-11 et àlaCEI 61000-3-12, et peut êtreconnectéauxréseauxpublics
d’alimentation bassetension.Ilest delaresponsabilitéde l’installateuroude l’utilisateurdu matérielde s’assurer, en consultant
l’opérateurdu réseau de distribution si nécessaire, que l'impédancede réseau est conforme auxrestrictionsd'impédance.
WARNING: This Class A equipment is not intendedforuseinresidentiallocationswherethe electricalpoweris provided bythepublic
low-voltage supply system. Theremaybe potentialdifficultiesinensuring electromagnetic compatibilityinthoselocations, due to
conducted aswell asradiateddisturbances.
2.3. CHOICEOFCONSUMABLES
Arcwelding requiresthe useof wireof asuitabletype and diameteraswell asuseof appropriategas. Refertothe tableofgasesand synergiesin
Paraf 6.3.
1
2
3
4
5
6
7
8
9

EN
DIGISTEELIII320C/DIGIPULS III 320C 7/28
WARNING :
The following wiresareusedinreversepolarity: SDZN= SAFDUALZN.
2.4.POSITIONING THE WIRE
To setup thewire:
Turnthe powersourceoff.
Open the doorof the wire-feederunit [5] and ensurethat it can not fall.
Unscrewthe spoolaxlenut. [6].
Insert thespoolofwireon the axis. Makesurethat the locating pinof theshaft [6] is properly located intothe reellocator.
Screwthespoolnut [6] back on the shaft, turning it inthe direction shownbythe arrow.
Lowerthe leverof wiredriver[9] inordertoreleasethe rollers.
Takethe end of the wireofthe spooland cut thedistortedend piece.
Straighten the first15 centimetersofwire.
Insert thewireviatheinlet wire-guideof the plate.
Lowerthe rollers[9] and raisethe leverinordertoimmobiliseit.
Adjust the pressureofthe rollerson the wiretothe correct tension.
Wirefeed
The wirefeeding button (8)feedsthe wireintothetorch. The wirefeedsover1satminimum speedand the speed increasesgradually until the set
wirespeedis reached,but is limited to12 m/ min. The settingsmaybechange atanytime; thepowersourcedisplays the speed.
To feedthewirethrough thetorch
Maintainthe wirefeeding button (8).
Wirespeed can be adjustedwiththebutton onfront panel.
To full thegas lineor adjustthegas flow
Pushthe gasbleedbutton (9).
2.5. WIRE DRIVERWEAR PART
The wearingpartsof the wiredriver,whoseroleis toguide andadvancethe welding wire, must be adapted tothe type anddiameterofthe welding
wireused. Onthe otherhand,theirwearmayaffect thewelding results. Isnecessarytoreplacethem.
Pleaserefertoparagraph5.5tochoosewearingpartsforwiredriver.
2.6. CONNECTIONOFTHE TORCH
The MIG welding torchis connected tothe front ofthe wirefeeder,afterensuring it hasbeenproperly outfitted withthe wearpartscorresponding to
the wireused forwelding.
Forthis purpose, pleaserefertothetorchinstructions.
2.7.GAS INLETCONNECTION
The gasoutlet is positioned atthe rearof the powersource. Simply connect it tothe pressure-regulatoroutlet ofthe gascylinder.
+Placethe gascylinderon the trolleyat the rearof the powersourceand fasten the bottleusing thestrap.
+Open the cylindervalveslightly toallowexisting impuritiestoescapeand then recloseit.
+Mount thepressureregulator/flowmeter.
+Open the gascylinder.
During welding, thegasflowrateshouldbe between 10 and20l/min.
WARNING:
Besurethat the gascylinderis properly secured on the trolleybyattachingthe safetystrap.
2.8.SWITCH ON
The mainswitchis located at therearof the powersource.
Flipthis switchtoturnthe machine on.
Note:Thisswitchmustnever beflippedduringwelding.
At eachstart-up,the powersourcedisplays the softwareversion andrecognized power.

EN
8/28 DIGISTEELIII320C/DIGIPULS III 320C
3-INSTRUCTIONSFORUSE
3.1. FRONTPANELFUNCTIONS
Left display: Voltage,Right display: Current/ wirespeed /wirethickness 1
Displayforselection of welding mode 2
Selectorbutton forwelding mode /Button cancelinprogram mode 3
Selectorswitchesforwelding process 4
Measurement indicatorof displayed values(pre-welding, welding and 5
post-welding data)
Led indicatorforprogram mode 6
Encodervoltagesetup and navigation 7
Encoderforcurrent, wirespeed, metalsheet thickness setup and 8
navigation
Displaymode indicatorcurrent, wirespeed, metalsheet thickness 9
Selectorbutton forpre-displayand program management 10
Selectorswitchfortype ofgas, wirediameterand type of welding wire11
2
3
4
5
6
7
8
9
10
11
1

EN
DIGISTEELIII320C/DIGIPULS III 320C 9/28
3.2. CALIBRATE THE POWERSOURCE
WARNING:
When startingup forthefirst time, thecalibration is an unavoidablestep toachievequalitywelding. If polarityis reversed, this
step must be repeated.
Step1: Turnthe wirediameterswitchtoSETUP position and press theOKbutton toaccess theCOnFIG Setup screen.
Step2: Select the CaL parameterwiththe left-hand encoderand select On withthe right-hand encoder.
Step3: Press theOK button on the front panel. The displayunit indicatestriGEr.
Step4: Removethetorchnozzle.
Step5: Cutthe wire.
Step6: Placethe pieceincontact withthe contact tube.
Step7: Press thetrigger.
Step8: The displaywill indicatethe value of L(cableinductance).
Step9: Displaythe value of Rusing the right-handencoder(cableresistance).
Step10: Exit Setup.
3.3
.
DYSPLAY AND USE
3.3.1
.
Synergic mode
The Current, Voltage andThickness valueslisted foreachwirefeedspeedsetting areprovided forinformation purposesonly. Theycorrespond to
measurementsundergiven operatingconditions, suchasposition, lengthof the endsection (flat position welding, butt welding).
The unitscurrent/voltage displayed correspond tothe average measured values, and theymaydifferfrom the theoreticalvalues.
Ledindicator for programmode:
ðOFF: pre-welding displayof instructions.
ðON: Displayof measurements(average values).
ðFlashing: Measurementsduring welding.
Selection ofwire, diameter,gas, welding process
Select the type ofwire,the wirediameter, the used welding gasand welding process byturning the appropriateswitch.
Selection of the materialwill determinethe availablevaluesfordiameter, gasand processes.
If synergydoes’nt exist, powersour
cedisplays
nOt SYn
,
GAS SYn
,
DIA SYn Or PrO SYn
.
Selection ofwelding mode, arclengthand pre-weldingdisplay
Select welding mode2T, 4T, spot, synergic and manualbyusing press button return(3). Arclengthcan beadjusted withleft encoder(7)and pre-
welding displayadjustement is performed withright encoder(8). The selection of pre-welding preset is performedwithpress button OK.(10)
3.3.2
.
Manual mode
This is the disengaged modeof thewelding machine. Adjustableparametersforit arewirespeed, arcvoltageand fine setting.
Inthis mode,only the wirespeed value is displayed.
3.3.
3
.
SETUPmode
Accessing theSETUP:
The SETUP screen can only be accessed when nowelding is inprogress, bysetting the WireDiameterselectoron the frontpaneltoposition 1.
It consist intwopull-downmenu :
'CYCLE
’
à
Setting forthe cyclephases
. Refertoparagraph6.2fordetails
‘
COnFIG
’
à
P
owersourceconfiguration
ConfiguringtheSETUP:
InSETUP position, select
CYCLE
or
COnFIG by
pressing the
OK button.
Turnthe left-hand encodertoscroll throughthe availableparameters.
Turnthe right-hand encodertoset theirvalue.
Nowelding start. All the changesaresaved on exiting the SETUPmenu.
Listofaccessibleparametersin COnFIG menu

EN
10/28 DIGISTEELIII320C/DIGIPULS III 320C
Left
display Rightdisplay Step Default Description
GrE On -;OFF –Aut Aut
Configuration of the WaterCooling Unit. 3possiblesstates:
-On : Forced on,watercooleris alwaysactivated
-OFF : Forced off, watercooleris always desactivated
-Aut : Automatic mode,Watercoolerworks when accordingneed
ScU Nnc –no - OFF OFF
Securityof watercooling.3possiblestates:
-nc : Normally closed,
-no : Normally open,
-OFF : Desactivate
CPt OFF–0,01 –1,00 0,01 s 0,30 Triggerholding timeinordertocall program (Only in4Twelding mode).
Can be useonly forwelding program from 50to99.
PGM Nno
–
yES no Activate/ desactivateprogrammanagementmode
PGA OFF –;000 –020 %1 % OFF Usetosetup availableadjustementrange of the following parameters: wirespeed, arc
voltage, arcdynamics, pulsefine-setting. Useonly whenprogram management is
activated and programsarelocked.
rC Nno –yES no This parameteractivates/ desactivatesremotecontrolorpotentiometertorchwhenplug
on powersource.
CALOFF
–
on
OFF Calibration oftorch& ground harness
L 0
–
50 1
uH
14 Cablechokesetting /display
r 0–50 1
Ω
8 Cableresistorsetting / display
SoFNno
–
yES no Softwareupdatemode.
FACNno –yES no
Factorysettingsreset. Pressing
YeS
will causeareset ofthe parameterstofactory
defaultswhenexit SETUP menu.
Listofaccessibleparametersin CYCLE menu
Left
display Rightdisplay Step Default Description
tPt 00.5 –10.0 0,1s 0,5Spottime.InSpotmodeand inManualmode,the HotStart, Downslopeand sequencer
settingscannot be changed
PrG 00.0
–
10.0 0
,
1
s
0
,
5
Pre-gastime
tHS OFF
–
00.1
–
10.0 0
,
1
s
0
,
1
Hot starttime
IHS -- 70 –70 1 % 30 Hot startcurrent(wirespeed). X% ±the welding current
UHS -- 70 –70 1 % 0 Hot startvoltage X% ±thearcvoltage
dSt OFF
–
00.1
–
05.0 0
,
1
s
OFF Down-slope time
DdSI -- 70 –00.0 1% -- 30 Down-slope current(wirespeed). X% ±the welding current
dSU -- 70 –70 1 % 0 Down-slope voltage. X% ±the arcvoltage
Pr_ 0.00
–
0.20 0
,
01
s
0
,
05
Anti-stick time
PrS Nno
–
yES no Pr-Sprayactivation
PoG 00.0
–
10.0 0
,
05
s
0
,
05
Post-gastime
dYn
--
10
–
10
--20 –20 1% 0 Fine setting inshort arc
rFP
--
10
–
10
--20 –20 1% 0 Fine setting inpulse
dyA 00
–
100 1 50 Arcstriking dynamics at electrode
tSE OFF
–
0.01
–
2.50 0
,
01
s
OFF Sequencertime (Sequencer, only insynergic mode)
ISE ---50 –50 1 % 30 Sequencercurrent level. X% ±thewelding current
3.3.
4
. Program
management
DIGISTEELIII 320C/DIGIPULS III 320C allowscreating, storeandmodifying up to99 welding programsdirectly on front panelfrom
program 00 toprogram 99. This function is activated bymoving parameterPGM from no to YES in COnFIG menu.
P00 is the working program inanystate. (Program management mode activated ordesactivated). When powersourceis working on
this program, theLed indicator “JOB”is switched off. All commutatorsareaccessibleinthis mode, soit will be used toset programs.
P01 toP99 areprogram saved,only if program management mode is activated. When powersourceis workingon theseprograms,
the led indicator “JOB”is switched on. Inthis mode,commutatorswelding process, wirediameter, gasand metalarenotavailable.
When aprogram selected hasbeenmodified, the indicator “JOB”blinks.
Createand save aprogram: