Saf-Fro DIGISTEEL III 320C Operation and maintenance manual

DIGISTEEL III 320C
DIGIPULS III 320C
EN SAFETY INSTRUCTIONS FOR OPERATION AND MAINTENANCE
Cat n° : 8695-1259
Rev : C
Date : 02/2018
Contact : www.saf-fro.com

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

DIGISTEEL III /DIGIPULS III 320C 3
EN CONTENTS
1 - GENERAL INFORMATION.............................................................................................................................................................................................. 4
1.1. PRESENTATION OF INSTALLATION .................................................................................................................................................................... 4
1.2. WELDING SET COMPONENTS ............................................................................................................................................................................. 4
1.3. POWER SOURCES TECHNICAL SPECIFICATIONS............................................................................................................................................ 5
2 - STARTING UP ................................................................................................................................................................................................................. 7
2.1. POWER SOURCE GENERAL DESCRIPTION....................................................................................................................................................... 7
2.2. ELECTRICAL CONNECTIONS TO THE MAINS .................................................................................................................................................... 7
2.3. CHOICE OF CONSUMABLES ................................................................................................................................................................................ 7
2.4. POSITIONING THE WIRE....................................................................................................................................................................................... 8
2.5. WIRE DRIVER WEAR PART................................................................................................................................................................................... 8
2.6. CONNECTION OF THE TORCH............................................................................................................................................................................. 8
2.7. GAS INLET CONNECTION..................................................................................................................................................................................... 8
2.8. SWITCH ON ............................................................................................................................................................................................................ 8
3 - INSTRUCTIONS FOR USE.............................................................................................................................................................................................. 9
3.1. FRONT PANEL FUNCTIONS.................................................................................................................................................................................. 9
3.2. CALIBRATE THE POWER SOURCE...................................................................................................................................................................... 10
3.3. DYSPLAY AND USE ............................................................................................................................................................................................... 10
4 - OPTIONS, ACCESSORIES ............................................................................................................................................................................................. 13
5 - MAINTENANCE ............................................................................................................................................................................................................... 15
5.1. GENERAL................................................................................................................................................................................................................ 15
5.2. ROLLERS AND WIRE GUIDE................................................................................................................................................................................. 15
5.3. TORCH .................................................................................................................................................................................................................... 15
5.4. SPARE PARTS, COMPONENTS............................................................................................................................................................................ 16
5.5. WEAR PARTS ......................................................................................................................................................................................................... 20
5.6. TROUBLESHOOTING PROCEDURE..................................................................................................................................................................... 21
5.7. ELECTRICAL DIAGRAM......................................................................................................................................................................................... 23
6 - ANNEXES ........................................................................................................................................................................................................................ 24
6.1. PRESENTATION OF WELDING PROCESSES...................................................................................................................................................... 24
6.2. ADVANCED WELDING CYCLE .............................................................................................................................................................................. 26
6.3. LIST OF SYNERGIES ............................................................................................................................................................................................. 28

EN
4 DIGISTEEL III 320C /DIGIPULS III 320C
1 - GENERAL INFORMATION
1.1. PRESENTATION OF INSTALLATION
DIGISTEEL III 320C / DIGIPULS III 320C is a manual welding set that enables the following:
MIG-MAG welding with short arc, speed short arc, spray-arc, normal pulsed mode (only on DIGIPULS), using currents from 15A
to 320A.
Feeding different types of wire
Steel, stainless steel, aluminum and special wires
solid and cored wires
diameters from 0.6-0.8-1.0-1.2 mm
Coated electrode welding
1.2. WELDING SET COMPONENTS
The welding set consists of 4 main components :
1 - Power source including its primary cable (5m) and its ground strip (5m)
2 - Workshop trolley (optional),
3 - Universal trolley (optional),
4 - Cooler unit (optional)
Each item is ordered and supplied separately.
Options ordered with the welding set are delivered separately. To install these options, refer to the instructions supplied with the
option.
WARNING :
The plastic handles are not intended for slinging the set. Stability of the equipment is guaranteed only for an incline of maximum 10°.
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DIGISTEEL III 320C /DIGIPULS III 320C 5
1.3. POWER SOURCES TECHNICAL SPECIFICATIONS
DIGISTEEL III 320C - W000385049 DIGIPULS III 320C - W000385050
Primary side
Primary power supply 400V +/- 20% 400V +/- 20%
Primary power supply frequency 50/60Hz 50/60Hz
Effective primary consumption 12 A 12 A
Maximum primary consumption 18,7 A 18,7 A
Fuse primary 20 A Gg 20 A Gg
Maximum apparent power 13,1 KVA 13,1 KVA
Maximum active power 12,1 KW 12,1 KW
Active power in standby (IDLE) 50 W 50 W
Efficiency at maximum current 0,87 0,87
Power factor at maximum current 0,92 0,92
Cos Phi 0,99 0,99
Secondary side
No load voltage (according standard) 74 V 74 V
Welding range Max MIG 10V / 50V 10V / 50V
Welding range Max MMA 15A / 320A 15A / 320A
Duty cycle at 100% (10 min cycle at 40°C) 220A 220A
Duty cycle at 60% (6 min cycle at 40°C) 280A 280A
Duty cycle at maximum current at 40°C 320A 320A
Wire feeder
Rollers plate 4 rollers
Wire feeding speed 0,5 – 25,0 m / mn
Wire diameter usable 0.6 to 1,2 mm
Weight, type, size of wire spool 300 mm
Maximum pressure of gas 6 bar
Miscelleanous
Dimensions (Lxwxh) 755 x 300 x 523 mm
Weight 28 Kg
Operating temperature - 10°C/+40°C
Storage temperature - 20°C/+55°C
Torch connection “European type”
Protection index IP 23
Insulation class H
Standard 60974-1 & 60974-5 & 60974-10

EN
6 DIGISTEEL III 320C / DIGIPULS III 320C
WARNING: This power source cannot be used in falling rain or snow. It may be stored outside, but it is not designed for use
without protection during raining.

EN
DIGISTEEL III 320C /DIGIPULS III 320C 7
2 - STARTING UP
2.1. POWER SOURCE GENERAL DESCRIPTION
The power source is composed with :
1- Front panel display
2- European plug for torch
3- Additional plug for 2 potentiometers torch
4- Plug for ground cable and polarity inversion
5- Protection door for wire feeder section
6- Spool axle, shaft, axle nut
7- Gas purge button
8- Wire feeding button
9- Wire driver
2.2. ELECTRICAL CONNECTIONS TO THE MAINS
DIGISTEEL III 320C / DIGIPULS III 320C is a 400 V 3-phase welding set. If your mains supply corresponds to requirements, connect the "three-phase +
ground" plug to the end of the power cable.
WARNING: Sous réserve que l'impédance de réseau public d’alimentation basse tension au point de couplage commun soit inférieure
à 33 mΩ, ce matériel est conforme à la CEI 61000-3-11 et à la CEI 61000-3-12, et peut être connecté aux réseaux publics
d’alimentation basse tension. Il est de la responsabilité de l’installateur ou de l’utilisateur du matériel de s’assurer, en consultant
l’opérateur du réseau de distribution si nécessaire, que l'impédance de réseau est conforme aux restrictions d'impédance.
WARNING: This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
2.3. CHOICE OF CONSUMABLES
Arc welding requires the use of wire of a suitable type and diameter as well as use of appropriate gas. Refer to the table of gases and synergies in
Paraf 6.3.
WARNING :
The following wires are used in reverse polarity: SD ZN = SAFDUAL ZN.
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EN
8 DIGISTEEL III 320C / DIGIPULS III 320C
2.4. POSITIONING THE WIRE
To set up the wire :
Turn the power source off.
Open the door of the wire-feeder unit [5] and ensure that it can not fall.
Unscrew the spool axle nut. [6].
Insert the spool of wire on the axis. Make sure that the locating pin of the shaft [6] is properly located into the reel locator.
Screw the spool nut [6] back on the shaft, turning it in the direction shown by the arrow.
Lower the lever of wire driver [9] in order to release the rollers.
Take the end of the wire of the spool and cut the distorted end piece.
Straighten the first 15 centimeters of wire.
Insert the wire via the inlet wire-guide of the plate.
Lower the rollers [9] and raise the lever in order to immobilise it.
A
djust the pressure of the rollers on the wire to the correct tension.
Wire feed
The wire feeding button (8) feeds the wire into the torch. The wire feeds over 1s at minimum speed and the speed increases gradually until the set
wire speed is reached, but is limited to 12 m / min. The settings may be change at any time; the power source displays the speed.
To feed the wire through the torch
Maintain the wire feeding button (8).
Wire speed can be adjusted with the button on front panel.
To full the gas line or adjust the gas flow
Push the gas bleed button (9).
2.5. WIRE DRIVER WEAR PART
The wearing parts of the wire driver, whose role is to guide and advance the welding wire, must be adapted to the type and diameter of the welding
wire used. On the other hand, their wear may affect the welding results. Is necessary to replace them.
Please refer to paragraph 5.5 to choose wearing parts for wire driver.
2.6. CONNECTION OF THE TORCH
The MIG welding torch is connected to the front of the wire feeder, after ensuring it has been properly outfitted with the wear parts corresponding to
the wire used for welding.
For this purpose, please refer to the torch instructions.
2.7. GAS INLET CONNECTION
The gas outlet is positioned at the rear of the power source. Simply connect it to the pressure-regulator outlet of the gas cylinder.
Place the gas cylinder on the trolley at the rear of the power source and fasten the bottle using the strap.
Open the cylinder valve slightly to allow existing impurities to escape and then reclose it.
Mount the pressure regulator/flowmeter.
Open the gas cylinder.
During welding, the gas flow rate should be between 10 and 20l/min.
WARNING :
Be sure that the gas cylinder is properly secured on the trolley by attaching the safety strap.
2.8. SWITCH ON
The main switch is located at the rear of the power source.
Flip this switch to turn the machine on.
Note: This switch must never be flipped during welding.
At each start-up, the power source displays the software version and recognized power.

EN
DIGISTEEL III 320C /DIGIPULS III 320C 9
3 - INSTRUCTIONS FOR USE
3.1. FRONT PANEL FUNCTIONS
Left display: Voltage, Right display: Current/ wire speed /wire thickness
1
Display for selection of welding mode 2
Selector button for welding mode / Button cancel in program mode 3
Selector switches for welding process 4
Measurement indicator of displayed values (pre-welding, welding and 5
post-welding data)
Led indicator for program mode
6
Encoder voltage setup and navigation 7
Encoder for current, wirespeed, metal sheet thickness setup and 8
navigation
Display mode indicator current, wirespeed, metal sheet thickness
9
Selector button for pre-display and program management 10
Selector switch for type of gas, wire diameter and type of welding wire 11
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10 DIGISTEEL III 320C /DIGIPULS III 320C
3.2. CALIBRATE THE POWER SOURCE
WARNING :
When starting up for the first time, the calibration is an unavoidable step to achieve quality welding. If polarity is reversed, this
step must be repeated.
Step 1: Turn the wire diameter switch to SETUP position and press the OK button to access the COnFIG Setup screen.
Step 2: Select the CaL parameter with the left-hand encoder and select On with the right-hand encoder.
Step 3: Press the OK button on the front panel. The display unit indicates triGEr.
Step 4: Remove the torch nozzle.
Step 5: Cut the wire.
Step 6: Place the piece in contact with the contact tube.
Step 7: Press the trigger.
Step 8: The display will indicate the value of L (cable inductance).
Step 9: Display the value of R using the right-hand encoder (cable resistance).
Step 10: Exit Setup.
3.3. DISPLAY AND USE
3.3.1. Synergic mode
The Current, Voltage and Thickness values listed for each wire feed speed setting are provided for information purposes only. They correspond to
measurements under given operating conditions, such as position, length of the end section (flat position welding, butt welding).
The units current/voltage displayed correspond to the average measured values, and they may differ from the theoretical values.
Led indicator for program mode:
OFF: pre-welding display of instructions.
ON: Display of measurements (average values).
Flashing: Measurements during welding.
Selection of wire, diameter, gas, welding process
Select the type of wire, the wire diameter, the used welding gas and welding process by turning the appropriate switch.
Selection of the material will determine the available values for diameter, gas and processes.
If synergy does’nt exist, power source displays nOt SYn,GAS
SYn,DIA SYn Or PrO SYn.
Selection of welding mode, arc length and pre-welding display
Select welding mode 2T, 4T, spot, synergic and manual by using press button return (3). Arc length can be adjusted with left encoder (7) and pre-
welding display adjustement is performed with right encoder (8). The selection of pre-welding preset is performed with press button OK. (10)
3.3.2. Manual mode
This is the disengaged mode of the welding machine. Adjustable parameters for it are wire speed, arc voltage and fine setting.
In this mode, only the wire speed value is displayed.
3.3.3. SETUP mode
Accessing the SETUP:
The SETUP screen can only be accessed when no welding is in progress, by setting the Wire Diameter selector on the front panel to position 1.
It consist in two pull-down menu :
'CYCLE’ Setting for the cycle phases. Refer to paragraph 6.2 for details
‘COnFIG’ Power source configuration
Configuring the SETUP:
In SETUP position, select CYCLE or COnFIG by pressing the
OK button.
Turn the left-hand encoder to scroll through the available parameters.
Turn the right-hand encoder to set their value.
No welding start. All the changes are saved on exiting the SETUP menu.