Saf-Fro DIGISTEEL III 420 Installation instructions

DIGISTEEL III 420/520
DIGIPULS III 420/520
EN INSTRUCTIONS FOR OPERATION AND MAINTENANCE
Cat n° : 8695-1251
Rev : D
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.

EN CONTENTS
1 - GENERAL INFORMATION .................................................................................................................................................................................................................................4
1.1. PRESENTATION OF INSTALLATION.......................................................................................................................................................................................................4
1.2. WELDING SET COMPONENTS................................................................................................................................................................................................................4
1.3. TECHNICAL SPECIFICATIONS................................................................................................................................................................................................................5
2 - START UP ...........................................................................................................................................................................................................................................................6
2.1. ELECTRICAL CONNECTION TO THE MAINS.........................................................................................................................................................................................6
2.2. CONNECTION OF THE COOLING UNIT..................................................................................................................................................................................................6
2.3. WIRE FEEDER SPARE PARTS................................................................................................................................................................................................................6
2.4. CONNECTION OF TORCH AND COOLING UNIT ...................................................................................................................................................................................6
2.5. GAS INLET CONNECTION .......................................................................................................................................................................................................................7
2.6. STARTING UP ...........................................................................................................................................................................................................................................7
3 - INSTRUCTIONS FOR USE .................................................................................................................................................................................................................................8
3.1. FRONT PANEL FUNCTIONS....................................................................................................................................................................................................................8
3.2. CALIBRATE THE POWER SOURCE........................................................................................................................................................................................................9
3.3. DISPLAY AND USE ...................................................................................................................................................................................................................................9
4 - OPTIONS, ACCESSORIES...............................................................................................................................................................................................................................12
5 - HARNESSES AND TORCHS............................................................................................................................................................................................................................14
5.1. HARNESSES ...........................................................................................................................................................................................................................................14
5.2. TORCHES................................................................................................................................................................................................................................................14
5.3. PUSH PULL TORCHES...........................................................................................................................................................................................................................14
5.4. POTENTIOMETER TORCHES................................................................................................................................................................................................................14
6 - MAINTENANCE.................................................................................................................................................................................................................................................15
6.1. GENERAL ................................................................................................................................................................................................................................................15
6.2. ROLLERS AND WIRE GUIDE .................................................................................................................................................................................................................15
6.3. TORCH.....................................................................................................................................................................................................................................................15
6.4. SPARE PARTS ........................................................................................................................................................................................................................................16
6.5. TROUBLESHOOTING PROCEDURE.....................................................................................................................................................................................................20
6.6. SCHEMA ELECTRIQUE..........................................................................................................................................................................................................................22
7 - ANNEXES..........................................................................................................................................................................................................................................................25
7.1. PRESENTATION OF WELDING PROCESSES......................................................................................................................................................................................25
7.2. ADVANCED WELDING CYCLE ..............................................................................................................................................................................................................27
7.3. SYNERGIES LIST....................................................................................................................................................................................................................................30

EN
4DIGISTEEL III /DIGIPULS III 420-520
1 - GENERAL INFORMATION
1.1. PRESENTATION OF INSTALLATION
DIGISTEEL III 420-520 / DIGIPULS III 420-520 is a manual welding set that enables the following:
MIG-MAG welding with short arc, speed short arc and HPS, and pulse normal et pulsé bas bruit using currents from 15A to 420A
or from 15A to 520A (only on the DIGIPULS),
Feeding different types of wire
Steel, stainless steel, aluminum and special wires
Solid and cored wires
Diamèters de 0.6-0.8-1.0-1.2-1.4-1.6mm
Coated electrode welding
Gouging process (requires KIT W000010999)
Braze welding MIG wire with CUPRO Alu or CUPRO silicium
The welding set is delivered as ready-for-use package in conjunction with the DVU P400 or DVU P500 wire feeders.
1.2. WELDING SET COMPONENTS
The welding set consists of 5 main components :
1. Power source including its primary cable (5m) and its ground strip (5m)
2. Cooling unit (optional),
3. Wire feeder,
4. Double-disconnectable harness between the wire feeder and the power source,
5. Workshop trolley (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°.
3
1
5
2
4

EN
DIGISTEEL III /DIGIPULS III 420-520 5
1.3. TECHNICAL SPECIFICATIONS
DIGISTEEL III 420
W000383615
DIGISTEEL III 520
W000383617
DIGIPULS III 420
W000383661
DIGIPULS III 520
W000383662
Primary side
Primary power supply 400 V 400 V 400 V 400 V
Primary power supply frequency 50/60Hz 50/60Hz 50/60Hz 50/60Hz
Effective primary consumption 18,5 A 28,5 A 21,1 A 28,5 A
Maximum primary consumption 26 A 33,9 A 27,1 A 33,9 A
Fuse primary 25 A Gg 32 A Gg 25 A Gg 32 A Gg
Maximum apparent power 18 KVA 23,8 KVA 18,9 KVA 23,8 KVA
Maximum active power 17,2 KW 22,4 KW 17,7 KW 22,4 KW
Active power in standby (IDLE) 28 W 29 W 29 W 29 W
Efficiency at maximum current (MIG) 87 89 87 89
Power factor at maximum current (MIG) 0,96 0,94 0,93 0,94
Cos Phi 0,99 0,99 0,99 0,99
Secondary side
No load voltage (according standard) en MIG 57 V 73 V 73 V 73 V
Welding range Max MIG 14,8V / 35 V
15A / 420A
14,8V / 39 V
15A / 500A
14,8V / 35 V
15A / 420A
14,8V / 39 V
15A / 500A
Welding range Max MMA 15A / 420A 15A / 500A 15A / 420A 15A / 500A
Duty cycle at 100% en MIG (10 min cycle at 40°C) 350A 450A 350A 450A
Duty cycle at 60% en MIG (6 min cycle at 40°C) 380A 500A 420A 500A
Duty cycle at maximum current at 40°C en MIG 40% 60%
60% 60%
Miscelleanous
Dimensions (Lxwxh) 720 x 295 x
525
720 x 295 x
525
720 x 295
x 525
720 x 295 x
525
Weight 34 kg 40 kg 36 kg 40 kg
Operating temperature -10° C / +40° C -10° C / +40° C -10° C / +40° C -10° C / +40° C
Storage temperature -20° C / +55° C -20° C / +55° C -20° C / +55° C -20° C / +55° C
Torch connection “Européen” “Européen” “Européen” “Européen”
Protection index IP 23 IP 23 IP 23 IP 23
Insulation class H H H H
Standard 60974-1 &
60974-10
60974-1 &
60974-10
60974-1 &
60974-10
60974-1 &
60974-10
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
6DIGISTEEL III /DIGIPULS III 420-520
2 - START UP
2.1. ELECTRICAL CONNECTION TO THE MAINS
Le DIGISTEEL III 420-520 / DIGIPULS III 420-520 are a 400V 3-phases welding-set.
If your mains supply corresponds to requirements, connect the 3-phases + ground plug to the end oh the power cable.
WARNING : Provided that the public low voltage system impedance at the point of common coupling is
lower than :
98,2 mΩfor the DIGISTEEL III 420
28 mΩor the DIGIPULS III 420
20.6 mΩor the DIGISTEEL III 520 and DIGIPULS III 520.
This equipment is compliant with IEC 61000-3-11 and IEC 61000-3-12 and can be connected to public lowvoltage systems. It is
the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if
necessary, that the system impedance complies with the impedance restrictions.
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.
2.2. CONNECTION OF THE COOLING UNIT
WARNING: This must be carried out with the power source OFF.
Connect the harness to the wire feeder while using the appropriate connector locations.
Connect the other end of the harness to the power source.
Connect the MIG welding torch to the wire feeder.
2.3. WIRE FEEDER SPARE PARTS
INPUT
WIRE GUIDE ADAPTATOR ROLLER INTERMEDIATE WIRE GUIDE
OUTPUT
WIRE GUIDE
STEEL
Stainless
STEEL
0,6 / 0,8
Plastic
W000277333 W000277338
W000305125
W000277334
W000277335
0,9 / 1,2 W000277008
1,0 / 1,2 W000267599 W000277335 W000277336
1,2 / 1,6 W000305126 W000277336
1,4 / 1,6 W000277009
FLUX-
CORED WIRE
0,9 / 1,2
W000277333 W000277338
W000277010
W000277334
W000277335
1,2 / 1,6 W000266330 W000277335 W000277336
1,4 / 1,6 W000277011 W000277336
LIGHT ALLOYS 1,0 / 1,2 ALUKIT W000277622
1,2 / 1,6 ALUKIT W000277623
Possible use of steel rollers ALU with steel wire and coated wire.
Mounting roller
The mounting of the rollers on the deck requires an adapter réf. W000277338.
2.4. CONNECTION OF TORCH AND COOLING UNIT
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.
If you use a WATER torch, connect your cooling unit to the rear of the generator, as well as to the "water" harness.
WARNING:
No-load operation of the Cooling Unit while unconnected to a torch may cause its destruction.

EN
DIGISTEEL III /DIGIPULS III 420-520 7
2.5. GAS INLET CONNECTION
The gas hose is linked to the harness connecting the power source to the wire feeder. 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/flow meter
Connect the gas hose supplied with the wire feeder harness to the regulator's outlet
During welding, the gas flow rate should be between 10 and 20l/min.
WARNING: Make sure the gas cylinder is properly secured on the trolley by attaching the safety strap.
2.6. STARTING UP
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, the power and the connected optional device, as relevant
of the power source.

EN
8DIGISTEEL III /DIGIPULS III 420-520
3 - INSTRUCTIONS FOR USE
3.1. FRONT PANEL FUNCTIONS
1 Left display: Voltage Right display: Current/ wire speed /wire thickness
2 Display for selection of welding mode
3 Selector button for welding mode
4 Selector switches for welding process
5 Measurement indicator of displayed values (pre-welding,
welding and post-welding data)
6 Led indicator for program mode
7 Encoder navigation
8 Encoder for current, wirespeed, metal sheet thickness setup
9 Selector button for pre-display
10 Selector switch for type of gas, wire diameter and type of welding wire
8
6
5
7
3
4
1
2
7
9
10

EN
DIGISTEEL III /DIGIPULS III 420-520 9
3.2. CALIBRATE THE POWER SOURCE
WARNING:
Calibration is unavailable step to achieve quality welding. If polarity is reversed, this step must be repeated.
Step 1: Turn the selector 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 (harness inductance).
Step 9:Display the value of R using the right-hand encoder (harness 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 unit's current/voltage display corresponds 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 ou 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.
‘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.

EN
10 DIGISTEEL III /DIGIPULS III 420-520
List of accessible parameters in COnFIG menu
Left display Left display Left
display
Left
display Left display
GrE On -;OFF – Aut Aut
Configuration of the Water Cooling Unit. 3 possibles states :
-On : Forced on, watercooler is always activated
-OFF : Forced off, watercooler is always desactivated
-Aut : Automatic mode, Watercooler works when according need
ScU nc – no - OFF OFF
Security of water cooling. 3 possible states :
-nc : Normally closed,
-no : Normally open,
-OFF : Desactivate
Unit US – CE CE Unit displayed for wire speed and thickness:
- US : inch unit
- CE : meter unit
CPt OFF– 0,01 – 1,00 0,01 s 0,30 Trigger holding time in order to call program (Only in 4T welding mode).
Can be use only for welding program from 50 to 99.
LAn Fr,dE,En,It,ES,PO, ,nL,SU,Pt,rO,dA,
nO,Fi,Sh,CS,Hu En
Choose language displayed only if RC-JOB or P500 wire feeder are connected
French(Fr)-German(DE)- English(En)-Italian(It)- Spanish(ES)-Polish(PO)- Dutch(nL)-
Swedish(SU)-Portuguese(Pt)- Romanian(RO)- Danish(DA)- Norwegian(NO)- Finnish(Fi)-
Slovak(Sk)- Czech(CS)- Hungarian(Hu)
PGM no – yES no
A
ctivate / desactivate program management mode
PGA OFF – ;000 – 020 %1% OFF Use to setup available adjustement range of the following parameters: wire speed, arc
voltage, arc dynamics, pulse fine-setting. Use only when program management is
activated and programs are locked.
CAL OFF – on OFF Calibration of torch & ground harness
AdJ Loc –- rC Loc Select adjustement Wire speed and arc voltage :
- Loc : Local on the power source
- rC : remote Control or torch potentiometer
L 0 – 50 1 uH 14 Cable choke setting / display
r 0– 50 18 Cable resistor setting / display
SoF no – yES no Software update mode.
FAC no – yES no Factory settings reset. Pressing YeS
will cause a reset of the parameters to factory
defaults when exit SETUP menu.
List of accessible parameters in CYCLE menu
Left display Left display Left
display
Left
display Left display
tPt 00.5 – 10.0 0,1s 0,5Spot time.
In Spot mode and in Manual mode, the Hot Start, Downslope and sequencer
settings cannot be changed
PrG 00.0 – 10.0 0,1s 0,5Pre-gas time
tHS OFF – 00.1 – 10.0 0,1s 0,1Hot start time
IHS -- 70 – 70 1 % 30 Hot start current (wire speed). X%

the welding current
UHS -- 70 – 70 1 % 0 Hot start voltage X%

the arc voltage
dYn --10 + 10
--20 – 20 1% 0 Fine setting in short arc
rFP --10 + 10
--20 + 20 1% 0 Fine setting in pulse
dyA 00 – 100 1 50
A
rc striking dynamics at electrode
tSE OFF – 0.01 – 2.50 0,01 s OFF Sequencer time (Sequencer, only in synergic mode)
ISE ---90 + 90 1 % 30 Sequencer current level. X%

the welding current
dSt OFF – 00.1 – 05.0 0,1s OFF Down-slope time
DdSI -- 70 – 00.0 1% -- 30 Down-slope current (wire speed). X%

the welding current
dSU -- 70 – 70 1 % 0 Down-slope voltage. X%

the arc voltage
Pr_ 0.00 – 0.20 0,01 s 0,05
A
nti-stick time
PrS Nno – yES no Pr-Spray activation
PoG 00.0 – 10.0 0,05 s 0,05 Post-gas time
NOTE : The DIGISTEEL III 420-520 / DIGIPULS III 420-520 allows to lock program menu. This function is available on program screen with the parameter
cod. The locking key entered has to be written in order to desactivate the function lock.
3.3.4. Program call with trigger
This function allows to chain from 2 to 10 programs. This function is available in 4T welding mode only and
program management mode has to be activated
Program chaining :
The function program call works with programs from P50 to P99 by ten.
P50P59 ; P60P69 ; P70P79 ; P80P89 ; P90P99
Selec first program with which you want to begin your chain. Then during welding, each time you will push trigger, program will change.
To chain less than ten programs, in the program following end of loop desired put a different parameter (As synergy or welding cycle).

EN
DIGISTEEL III /DIGIPULS III 420-520 11
It is possible to setup time of trigger push to detect change of program chain : SETUP  CPT  put value from 1 to 100 exit SETUP
Example: Create a program list from P50 to P55 (6 programs).
1) In program P56, put different welding cycle or synergy than P55 in order to finish chain
2) Select program P50 (First program for start of welding
3) Start welding
4) Each time trigger will be pushed, power source will change program until P55. When chain is finished, power source will restart to P50.
3.3.5. Automatisation
a) DIGIPULS III welding sets is very easily automated. Simply connect the J2 socket provided at the back of the set.
The wire markings are : LEVEL N1
RI current contact output: dry contact
K de J2
RI shared current contact output: dry contact L de J2
Fault T de J2
Shared fault L de J2
Trigger input (+): to be placed on a dry contact U de J2
Trigger input (-): to be placed on a dry contact M de J2
To confirm the closing of contact ri, it is essential to position “aut

off ”. The delay in the closing of the contact is adjusted by the value “dep”
in the “step” sub menu of setup.
Note : By default, the mode selected is the manual mode.
The type of operation selected is shown on the RH display.
SELECTION OF THE REMOTE CONTROL AUTOMATIC MODE WITH AN ANALOGUE SIGNAL
1. Position the switch on the power source front panel on « SEt -UP ».
2. Press the « OK » key to select « Con FIG » on the display.
3. Position the LH selector to obtain « Aut » on the LH display.
4. Position the RH selector to obtain « n1 » on the RH display

EN
12 DIGISTEEL III /DIGIPULS III 420-520
4 - OPTIONS, ACCESSORIES
4.1 - WIRE FEED DVU P400, REF. W000275266
4.2 - WIRE FEED DVU P500, REF. W000275267
4-3 - COOLER UNIT, REF. W000273516

EN
DIGISTEEL III /DIGIPULS III 420-520 13
4.4 - REMOTE CONTROL RC JOB, Réf. W000273134
4.5 - REMOTE CONTROL 2 POTENTIOMETERS, Réf. W000275904
Fonctionnalities:
Adjust Wire speed during welding and out off welding
Adjust Arc voltage during welding and out off welding
4.6 - DUST FILTER, Réf. W000373703
4.7 - WORKSHOP TROLLEY, Réf. W000383000
Il permet de déplacer facilement la source de puissance dans un environnement d'atelier.
4.8 - SHIPYARD TROLLEY OPTION, Réf. W000372274
4.9 - SECURITE DE DEBIT OPTION, Réf. W000376539
4.10 - PUSH PULL OPTION, Réf. W000275907
4.11 - OPTION DEBITLITRE, Réf. W000376539

EN
14 DIGISTEEL III /DIGIPULS III 420-520
5 - HARNESSES AND TORCHS
5.1. HARNESSES
AIR harness 2 M – 70 MM2réf. W000275894
A
IR harness 5 M
–
70 MM2réf. W000275895
A
IR harness 10 M
–
70 MM2réf. W000275896
A
IR harness 15 M
–
70 MM2réf. W000275897
A
IR harness 25 M
–
70 MM2 (sur cde) réf. W000276901
A
IR harness 30 M
–
70 MM2 (sur cde) réf. W000371246
A
IR harness 40 M
–
70 MM2 (sur cde) réf. W000371245
A
IR harness 50 M
–
70 MM2 (sur cde) réf. W000371244
WATER harness 2 M
–
95 MM2réf. W000275898
WATER harness 5 M
–
95 MM2réf. W000275899
WATER harness 10 M
–
95 MM2 réf. W000275900
WATER harness 15 M
–
95 MM2 réf. W000275901
WATER harness 25 M
–
95 MM2 (sur cde) réf. W000276902
WATER harness 50 M
–
95 MM2 Nous consulter
A
LUMINIUM WATER harness 2 M
–
95 MM2réf. W000371044
A
LUMINIUM WATER harness 5 M
–
95 MM2réf. W000371045
A
LUMINIUM WATER harness 10 M
–
95 MM2réf. W000371175
A
LUMINIUM WATER harness 15 M
–
95 MM2réf. W000371174
A
LUMINIUM WATER harness 25 M
–
95 MM2réf. W000371239
5.2. TORCHES
PROMIG NG 341 - 3 M réf. W000345066
PROMIG NG 341 - 4 M réf. W000345067
PROMIG NG 341 - 5 M réf. W000345068
PROMIG NG 341 W - 3 M réf. W000345069
PROMIG NG 341 W - 4 M réf. W000345070
PROMIG NG 341 W - 5 M réf. W000345071
PROMIG NG 441 - 3 M réf. W000345072
PROMIG NG 441 - 4 M réf. W000345073
PROMIG NG 441 - 5 M réf. W000345074
PROMIG NG 441W - 3 M réf. W000345075
PROMIG NG 441W - 4 M réf. W000345076
PROMIG NG 441W - 5 M réf. W000345077
PROMIG NG 450W - 3 M réf. W000274865
PROMIG NG 450W - 4 M réf. W000274866
PROMIG NG 450W - 5 M réf. W000274867
5.3. PUSH PULL TORCHES
PROMIG PP 341 8M réf. W000385860
PROMIG PP 441W 8M réf. W000385862
PROMIG PP 341 8M WITH POTENTIOMETER réf. W000385861
PROMIG PP 441W 8M WITH POTENTIOMETER réf. W000385863
5.4. POTENTIOMETER TORCHES
DIGITORCH P 341 - 4M réf. W000345014
DIGITORCH P 341W - 4M réf. W000345016
DIGITORCH P 441W - 4M réf. W000345018
A
part from the standrd torch functions : it also enables adjusting the wire speed and arc length both during welding
and when not welding.

EN
DIGISTEEL III /DIGIPULS III 420-520 15
6 - MAINTENANCE
6.1. GENERAL
Twice a year, depending on the use of the device, inspect the following:
cleanliness of the pwer source
electrical and gas connections
WARNING :
Never carry out cleaning or repair work inside the device before making sure that the unit has been completely disconnected from
the mains.
Dismantle the generator panels and use suction to remove dust and metal particles accumulated between the magnetic circuits
and the windings of the transformer.
Work must be performed using a plastic tip to avoid damage to the insultation of the windings.
At each start-up of the welding unit and prior to calling customer cupport for technical servicing, please check that:
Power terminals are not improperly tightened.
The selected mains voltage is correct.
There is proper gas flow.
Type and diameter of the wire.Torch condition.
TWICE PER YEAR
Perform calibration of the current and voltage settings.
Check electrical connections of the power, control and power supply circuits.
Check the condition of insulation, cables, connections and pipes.
6.2. ROLLERS AND WIRE GUIDE
Under normal conditions of use, these accessories have a long serviceable life before their replacement becomes necessary. Sometimes, however,
after being used over a period of time, excessive wear or clogging due to adhering deposits may be noted.
To minimise such harmful effects, make sure the wire feeder plate remains clean.
The motor reduction unit requires no maintenance
6.3. 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 spatter between the contact tube and the nozzle and between the nozzle
and the skirt. Spatter is easier to remove if the procedure is repeated at short intervals.
Do not use hard tools that may scratch the surface of these parts and cause spatter to become attached to it..
SPRAYMIG SIB, W000011093
SPRAYMIG H20, W000010001
Blow out the liner after each change of a spool of wire. Carry out this procedure from the side of the quick fitting connector plug of the torch.
If necessary, replace the wire inlet guide of the torch.
Severe wear of the wire guide may cause gas leaks towards the rear of the torch.
The contact tubes are designed for long use. Nevertheless, the passage of wire causes them to wear off, widening the bore more than the permissible
tolerances for good contact between the tube and the wire.

EN
16 DIGISTEEL III /DIGIPULS III 420-520
6.4. SPARE PARTS
Front panel :
Composants interne et onduleur :
W000373702

EN
DIGISTEEL III /DIGIPULS III 420-520 17
91633320P

EN
18 DIGISTEEL III /DIGIPULS III 420-520

EN
DIGISTEEL III /DIGIPULS III 420-520 19

EN
20 DIGISTEEL III /DIGIPULS III 420-520
6.5. TROUBLESHOOTING PROCEDURE
Servicing of electrical equipment must be performed by qualified personnel only
CAUSES SOLUTIONS
GENERATOR IS ON WHILE THE FRONT PANEL IS OFF
Power source alimentation Check the mains supply (to each phase)
DISPLAY OF THE MESSAGE E01 ond
The maximum strking current of the power source was exceeded Press the OK button to clear the fault. If the problem persists, call Customer
Support
DISPLAY OF THE MESSAGE E02 inu
Poor recognition of the source of power
–
only at start-up. Call Customer Support
Connectors Make sure that the ribbon cable
between the inverter's main card and the cycle card is properly connected.
DISPLAY OF THE MESSAGE E07 400
Inappropriate mains voltage
Make sure that the mains voltage is between 360V and 480V.
If not, have your electrical system checked
DISPLAY OF THE MESSAGE E24 SEn
Connectors
Make sure that connector B9 is
properly connected to the cycle card (if not, temperature measurement is not
performed)
The temperature sensor is out of order. Call Customer Support
DISPLAY OF THE MESSAGE E25°C
Power source overheating Let the generator cool off
The fault disappears by itself after several minutes
Default ventilation Make sure that the inverter fan works.
DISPLAY OF THE MESSAGE E33 MEM-LIM
This message indicates that the memory is no longer operational
Malfunctioning saving memor
y
Call Customer Service.
Default component
DISPLAY OF THE MESSAGE E34 CFG
Incoherent parameter selection.
A
pply coherent selection
Ex : mode 4T en auto N1
DISPLAY OF THE MESSAGE E43 brd
Electronic card in default Call Customer Service.
DISPLAY OF THE MESSAGE E50 H2o
Cooler unit in default
Make sure that cooler unit is well plugged.
Check cooler unit (Transformer, waterpump,...)
If no cooler unit is used, desactivate parameter in SETUP menu.
DISPLAY OF THE MESSAGE E63 IMO
Mechanical problem
Pressure roller is too tight.
Wire feed hose is clogged with dirt.
The lock of the wire feed spool axle is too tight.
DISPLAY OF THE MESSAGE E65-Mot
Defective connectors
Mechanical problem
Power supply
Check the connection of the encoder ribbon cable to the wire feeder's motor.
Make sure that the wire feeder assembly is not blocked.
Check the connection of the motor's power supply.
Check F2 (6A) on the auxiliary power card.
DISPLAY OF THE MESSAGE E71 –DIA-MET-GAS
HMI selector PROCESS-DIAMETER-METAL-GAS in default Turn selector to unlock, after call customer service if always in
default
DISPLAY OF THE MESSAGE StE PUL
Inverter not well recognized Call customer service
DISPLAY OF THE MESSAGE I-A-MAX