Saf-Fro DIGIWAVE III Series Installation instructions

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DIGIWAVE III
 
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Cat n° : 8695-1263
Rev :
Date : 06/2016
Contact : www.saf-fro.com

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

CONTENTS

1.1. PRESENTAT ON OF NSTALLAT ON ................................................................................................................................................................................................. 4
1.2. WELD NG SET COMPONENTS .......................................................................................................................................................................................................... 4
1.3.POWER SOURCES TECHN CAL SPEC F CAT ONS ......................................................................................................................................................................... 6
1.4. COOL NG UN T TECHN CAL SPEC F CAT ONS............................................................................................................................................................................... 6

2.1. ELECTR CAL CONNECT ONS TO THE MA NS ................................................................................................................................................................................. 7
2.2. CONNECT ON OF THE W RE FEEDER UN T ................................................................................................................................................................................... 7
2.3. CONNECT ON OF THE TORCH AND COOL NG UN T ..................................................................................................................................................................... 7
2.4. GAS NLET CONNECT ON ................................................................................................................................................................................................................. 7
2.5. START NG UP ..................................................................................................................................................................................................................................... 8

3.1. FRONT PANEL FUNCT ONS .............................................................................................................................................................................................................. 9
3.2. F RST SETT NG FOR EASY ACCESS TO WELD............................................................................................................................................................................ 11

4.1. M G-MAG WELD NG CYCLE ADVANCED SETT NG ...................................................................................................................................................................... 16
4.2. M G WELD NG CYCLE ADVANCED SETT NG ................................................................................................................................................................................ 21
4.3. SELECT ON AND GEST ON DES PROGRAMMES DE SOUDAGE ................................................................................................................................................ 23
4.4. MPORT / EXPORT OF WELD NG PROGRAMS ............................................................................................................................................................................. 26
4.5. USERS MANAGEMENT & TRACEAB LY ......................................................................................................................................................................................... 26
4.6. PROGRAM L M TAT ONS ................................................................................................................................................................................................................. 28
4.7. CONTROL PROCESS ....................................................................................................................................................................................................................... 29


6.1. GONF GURAT ON OF COOL NG UN T ............................................................................................................................................................................................ 32
6.2. AUTOMAT ON NTERFACE DECR PT ON ...................................................................................................................................................................................... 33
6.3. EXTERNAL COMMUN CAT ONS ...................................................................................................................................................................................................... 35


8.1. UN T COOLER, REF. W000273516 .................................................................................................................................................................................................. 38
8.2. W RE FEEDER DVU W500, REF. W000372327 .............................................................................................................................................................................. 38
8.3. REMOTE CONTROL RC JOB , REF. W000371925 ....................................................................................................................................................................... 38
8.4. REMOTE CONTROL RC S MPLE, REF. W000275904 .................................................................................................................................................................... 38
8.5. WORKSHOP TROLLEY , REF. W000279927 ................................................................................................................................................................................. 39
8.6. DUST F LTER, REF. W000373703 ................................................................................................................................................................................................... 39
8.7. RC JOB PLUG ON THE GENERATOR, REF. W000374008 ......................................................................................................................................................... 39
8.8. TUBE HANDLE, REF. W000279930 ................................................................................................................................................................................................. 39
8.9. PUSH PULL CARD OPT ON, REF. W000275907 ............................................................................................................................................................................ 39
8.10. OPT ON POWERBOX, REF. W000305106 .................................................................................................................................................................................... 39
8.11. ADAPTATOR T G, REF. W000379466............................................................................................................................................................................................ 39
8.12. OPT ON SECUR TE DE DEB T, REF. W000376539 ...................................................................................................................................................................... 39
8.15. HARNESSES ................................................................................................................................................................................................................................... 40

9.1. ENTRET EN ....................................................................................................................................................................................................................................... 41
9.2. ROLLERS AND W RE GU DE ........................................................................................................................................................................................................... 41
9.3. TORCH ............................................................................................................................................................................................................................................... 41
9.4. SPARE PARTS .................................................................................................................................................................................................................................. 42
9.5. FAULT L ST DESCR PT ON .............................................................................................................................................................................................................. 45
!"
!#
!"
$



        






 is a manual welding set that enables :
☞M G-MAG welding
☞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
-
1.4
-
1.6mm
☞coated electrode welding
☞
T G
welding
☞
ARC
-
A R Gouging process, using the torch for gouging: ARC A R. (maximum electrode diameter 6.3 mm)
☞
to communicate the welding data from and to the external peripherals.
Delivered as ready-for-use package associated with the %% wire feeder. The power source of this set may also be used for simple automatic
applications.



The welding set consists of
7
main components :
1. 420A or 500A power source including its power supply cable (5m) and its ground cable (5m)
2. Cooling unit,
3. Wire feeder,
4. Double
-
disconnectable harness between the wire feeder and
the power source,
5.
Workshop trolley (optional),
6.
Wire feeder trolley (optional)
7.
Pivot stand (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.


     



:
The plastic handles are not intended for slinging the set.
Stability of the equipment is guaranteed only for an incline of maximum 10°.
















        

$


%
%%%  
%
%%% %
&'()&*+',-
Primary power supply 400 V 400 V
Primary power supply frequency 50/60Hz 50/60Hz
Effective primary consumption 21.1 A 28,5 A
Maximum primary consumption 27,1 A 33,9 A
Fuse primary 25 A Gg 32 A Gg
Maximum apparent power 18,9 KVA 23,8 KVA
Maximum active power 17,7 KW 22,4 KW
Recommended power generator 30 KVA 40 KVA
Active power in standby ( DLE) 29 W 29 W
Efficiency at maximum current (M G) 87 89
Power factor at maximum current (M G) 0,93 0,94
Cos Phi 0,99 0,99
-./0,)&*+',- 
No load voltage (according standard) en M G 73 V 73 V
Welding range Max M G
14,8V / 35 V
15A / 420A
14,8V / 39 V
15A / 500A
Welding range Max MMA 15A / 420A 15A / 500A
Duty cycle at 100% en M G (10 min cycle at 40°C) 350A 450A
Duty cycle at 60% en M G (6 min cycle at 40°C) 420A 500A
Duty cycle at maximum current at 40°C en M G 60% 60%
'+.-11-)0/2+
Dimensions (Lxwxh) 720x295x525 720x295x525
Weight 36 kg 40 kg
Operating temperature -10° C / +40° C -10° C / +40° C
Storage temperature -20° C / +55° C -20° C / +55° C
Torch connection “Européen” “Européen”
Protection index P 23 P 23
nsulation class H H
Standard
60974
-
1 &
60974-10
60974
-
1 & 60974
-
10

$



%%%
/3-&+2441*
Single
-
phase supply voltage
230 V ±15 % – 50/60 Hz
Frequency
50/60
Hz
Current consumption
1,
4
A
//1'05.'&.2'6
Maximum flow rate
3,6
l/min
Maximum pressure at
zero flow rate
4,5
bar
Tank capacity
5
l
Thermal dissipation
1,3 KW à 20°C 1l/mn
-.7)0'.)1.7)&).6-&'+6'.+

Empty weight
16
kg
Weight in operating condition
21
kg
Dimensions
700
x 279 x 268
mm
Protection class
P 23 S
Standard
CE 60974
–
2, CE 60974
-
10


     
 

$



is a 400 V 3
-
phase welding set.
f your mains supply corresponds to requirements, connect the "thre
e
-
phase + ground" plug to the end of the power cable.



:
Provided that the public low voltage system impedance at the point of common coupling is
lower than :
 8(9:/&67-%
%8(9/&67-%
This equipment is compliant with EC 61000-3-11 and EC 61000-3-12 and can be connected to public lowvoltage systems. t 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.

$


;
This must be carried out with the power source power off. The power plugs must be well tied up their tightening must be regularly
controlled, in particular after the moving of an installation.

$$



The M G welding torch is connected
to
the front of the wire feeder, a
fter ensuring it has been properly outfitted with the wear parts corresponding to the
wire used for welding.
f you use a
WATER
-
COOLED
torch, make sure to connect your cooling unit to the rear of the
power source
, as well as to the "water" harness.



:
Use exclusively the liquid provided by Air Liquide Welding to fill up the cooling unit.
Configuration on the interface is needed to ensure a good working of the cooling unit, cf § 6.1.
No-load operation of the cooling unit while unconnected to a torch may damage it.



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
cylinder
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
☞
Open the gas cylinder.
During welding, the gas flow rate (l/min) should correspond to the diameter of the nozzle (mm).


Make sure the gas cylinder is properly secured on the trolley by attaching the safety strap.
For optimal use, the welding installation must respect the following positioning constraints for correct cooling.


       


The main switch is located at the rear of the generator. Flip this switch to turn the machine on. 7'++3'6.7(2+60-<-&=-
:1'44-,,2&'053-1,'05. At each start-up, the generator displays the software version, the power and the connected optional
device, as relevant of the power source.


:
When starting up for the first time, the configuration is required cf § 6.1.


     

To ensure an optimal use of the installation and a good understanding of the following nstructions for use, we recommend you
read the Wire Feeder
operating manual first.



$$

$

>$

?

The
72()0

().7'0-

'06-&:).-
(H
M
) is located on the front panel of the power source:
1
Validation
2
Escape button to cancel the operations in progres
s or go back to the previous menu or page
3
Tuning
encoder
4
Selection
and navigation encoder
5
Button corresponding to the current icons on the screen
6
Colour
Screen
$

$

>$

?

Main menu selection
Validation of the current selection
Back
User login page
Access to the information window


%        
The homepage contains 8 Main Menus :
T G L FT Traceability
MMA Configuration
M G/MAG Maintenance
Welding Programs User Synergy
$




For the first use of the power source, you must do the 4 following steps. 


Choice of the interface language
Language selection
Validation of the selection 


Position


Sel
ected language


;

Time & date settings
The clock is used for the functions of traceability and export.

Change of the value
Change of the column
Save


     


;

Name of the power source.
This is the name used for identifyi
ng the machine when installations communicate.
Please check that different installation have different names. During an export to an external storage device, the name of the directory created is
composed of the power source name and the date.
Change in the characters column
Add or suppression of a character
Save 


;

Configuration du groupe de refroidissement s’il est utilisé. (paragraphe 6.1)
$
"

Harnesses calibration is imperative to weld with a good quality.
The calibration is to be re
-
done, in case of polarity change, or change of one of these following components:

•torch
•harness
•ground cable
•position of the clip of the ground cable
Access in the menu: M G > SETUP > Harness calibration
•Automatic Calibration: (Only available in M G). Follow the instructions on the screen.



During this operation, a current of 400A for 1 second is generated. t is imperative then to wear the correct protection equipment required for
welding during this operation, in particular, protection glasses.






$


Parameters selection
Parameters value selection
Validation
/
Welding
Programs
Management
Access Zone 1 or Zone 11
Welding Cycle Management Setup Access to the information window


        

Synergy bar + Trigger Mode 

ALW Data base Synergies / User Synergies


Choice of metal

Choice of wire diameter

Welding cycle representation

Choice of gas
%
ndicative welding values

Choice of the arc transfer

Main welding parameters

Choice of the working mode

Choice of the trigger mode

"
*0-&5'-+
Standards synergies provided by Air Liquide Welding. These synergies are specially well suited to most applications. Standard
synergies are optimized for flat fillet.
User synergies previously created or loaded by the user. The  can store up to 50 user synergies.
Some synergies require reversing the polarity of the power source (inversion of the 2 power cables). Follow the on
-
screen instructions.

7/'.-/:67-./0+2()=1-+>(-6)18,')(-6-&85)+?
M G
-
MAG
Welding require the use of adapted wire for type
and diameter, as well as the use of the appropriate gas. See synergies table in the annex 1.
7/'.-/:67-)&.6&)0+:-&>)00-@?
7/'.-/:67-3/&A'05(/,-
 mode allows to work on a predetermined operating point by adjusting only the wire speed on suitable interval
 mode allows you to adjust the voltage and wire speed over the entire range separately.
 mode is dedicated to high skilled welders, see devoted annex.Page 26
7/'.-/:67-6&'55-&(/,-
This mode defines the way the welder use his torch trigger.
The cycles below describe the mode 2T and 4T during a simple welding cycle of 5 steps:


     


Pre
-
gas




Slows
wire
forwarding




Welding
step




Crater
fill




Post
-
gas

-+.&'46'/0
The welder holds the trigger during the whole welding. Pressing the trigger will launch the welding (the beginning of the pre
gas), and releasing the
trigger will stop the welding (beginning of crater filling).
The welder can however shorten the crater filling by a short press on the trigger during this phase (if the corresponding option of configuration is
activated).

46'/0
Configuration > Installation > Cycle
:

-
Shorten
down slope
control
-
Program call by trigger out of welding
The 4/6/,- is a special mode and you can define the time of the welding step >? in the cycle welding paremeters.
-+.&'46'/0


The 4T mode implies that the welder can weld without keeping the trig
ger pressed. He presses and releases the trigger a first time to launch the
welding, then he presses and releases a second time to end the welding.

46'/0
Configuration > nstallation > Cycle
:

-
Call
the
trigger
program
out
welding
-
Call
the
trigg
er
program
in welding
.

The welding cycle is actualized with the setting of the main welding parameters.
n the paragraph below, we detail the setting of the main welding parameters
:




: Wire speed
/
: Trigger pressed/ released


        

(/,-;
By pl
acing
the cursor on
SPEED
W RELESS
, pressing
OK
shows the
parameters
together to
facilitate the adjustment of
parameters
.



Setting
/,-

Unit nterval step
 The wire speed varies in a range settled by the synergy. (#(0 -4-0,'05/:
+*0-&5* %
 The wire speed is not limited by the synergy table. (#(0 BCD %


The arc tension is defined according to the regime of arc
:
•flat: average voltage
•pulsed: choose voltage


Setting
/,-

Unit nterval Step

Arc length:
Relative tuning of the arc voltage by ±50 increments around the
programmed synergic value.
0.&-(-06+ -%EE+%


Volts -10 || +10 0.2
 Arc voltage:
Absolute tuning of the arc voltage during the welding phase. /16+ B%C%D %

The
fine tuning is defined according to the regime of arc
:
•Flat: Arc dynamism
•Pulsed: Current impulsion energy


setting
/,-

Unit nterval Step


&

Relative fine tuning by ±10 increments around the programmed
synergic value. 0.&-(-06+ %EEF% 
20'05

),<'.-
;

n flat regime, a low value of the fine tuning enables a quick rise of the short cut current. Thus, the regime is dynamic and hot which allows welding in
position but has the drawback of generating more spatter. On the contrary, a high value of the fine tuning reduces the dynamism and cools the weld pool.
/6- : The welding position is further facilitated by "speed short arc" arc transfer than"smooth" arc transfer.
n Pulsed mode , fine tuning adjusts the energy of the current pulse and optimize the drop detachment.
Specifically, if fine projections detach from the wire, reduce the fine tuning, if rather large drops off, increase the fine tuning.









Volts
equivalent


     


you are allowed to weld only if the color of the top left icon is green . 


Arc
current
measure


Arc
voltage
measure


Wirespeed


Motor current of the wire feeder


Welding time (includes all the steps of the welding cycle)

The motor current of the wire feeder is proportional to the motor torque. Beyond 1.3A at constant regime, check that the wire feeder liner is not
clogged with dirt.
The previous welding parameters are accessible on the SETUP page from the M G-MAG menu.
f "call off the trigger program welding" is not active: Short press the trigger vacuum (if program change).


        

















The M G welding cycle setting menu distinguishes 7 phases on the welding cycle:
1.
Pregas
2.
Hotstart
3.
Welding
step
4.
Crater
filler
5.
Burn
back
6.
Affûtage fil
7.
Post
gas


the voltage is present at the end of the wire from the slow wire forwarding phase to the post retract spray phase.


List of the phases
of the cycle


Selected
cycle phase


Parameters table of the selected cycle phase.
Use the left encoder to scroll the settings
.
Use the right encoder to adjust the selected parameter


Switch the cursor between cycle phase selection and parameter table.

Also possible with the OK and ESC buttons
&-5)+
Gas timing before the welding cycle starts
Variables : T(s) B%%C%%D
$
/6+6)&6#/:6+6)&6

n the hotstart phase, a wire speed greater than the welding phase wire speed allows
quicker penetration on start-up. Otherwise, the hotstart phase allows a low start-up with
a progressive ramp up of wire speed.
Variables : T
(s)

B%%

C%%D


     
/:6+6)&6

The softstart phase can be pre-set for the start of the weld, allowing a limited wire speed with
low energy.

Variables
:
Temps de palier : T(s) B%%%C%%%D
Temps de transitions : T(s) B%%%C%%%D
Paramètres principaux de soudage du palier de Hostart/Softstart.

/6-: f the setting exceeds the capacity of the source, the curve appears red
-()&A:
With the  mode, the wire speed of the Hotstart / Softstart step is tuned relatively to the wire speed of the welding step (GH%I), the real
speed is shown for information in grey tint, and is directly tunable with the  mode: wire speed (m/min) B%C%D.
-1,'05


This menu allows refining of the tuning of the welding step.
-()&A:
Once you’ve chosen the mode, the main welding parameters are actualized. t is then possible to tune the parameters of each mode directly from
the main welding tuning page.
,<)0.-,-J2-0.-& ( + )
Sequence the welding phase in two regimes 1 and 2, which can have different arc transfers: Flat or Pulsed.
The arc transfer of the regime 1 is the one selected on the synergy bar of the main welding tuning page.
Variables :
Arc transfer regime 2: Transfer2
Main welding parameters of the regimes 1 and 2
The timing of regimes 1 and 2 are independent and allow tuning of a dissymmetrical cycle. T(s) B%C%D
Transit time T(s) B%%%C%%D
06-&('66-06(/,- ( )
The welding is made intermittently by a succession of times ON and times OFF.
Variables :
Main welding parameters
The timings of step ON and OFF are independent and allow tuning a dissymmetrical cycle. T(s) B%C%%D
-()&A:
You can choose to realize the hotstart only on the first time ON in the menu:Configuration > Installation > Cycle.
6-4(/,- ( ) 
Bearing change by a short press on the trigger
Variables :
Step number [2 ; 4]
Main welding parameters of every step
&/5&)(.)11,2&'053-1,'05 ( )
Once you activate this option, you can call programs with the trigger while you’re welding. See §
4.3. page
23
. Program Management.
-()&A:
You can activate the program call out of welding in the menu: Configuration > Installation > Cycle


        

&)6-&:'11-&


The crater fill phase allows filling up of the crater at the end of the weld for a good finish of
welding. t is made by decreasing the arc regime at the end of the weld (downslope), then
maintaining a low level of the wire speed for a defined timing (Craterfiller step).
Variables :
Step time : T(s) B%%C%%%D
downslope : T(s) B%%C%%%D
Main welding parameters of the Craterfiller step

-()&A :
With the  mode, the wire speed of the Crater fill step is tuned relatively to the wire speed of
the welding step (GB%ID), the real speed is shown for information in grey tint, and is directly
tunable with the  mode: wire speed (m/min) B%C%D.
You can activate the option Shorten down slope control in the menu:
Configuration > Installation > Cycle.

"
2&0=).A

Evite le collage du fil dans le bain en décalant l’arrêt du fil et l’arrêt de la puissance Variables :
Manual – Burn back time (ms) B%8%%D
Automatic – Burn back fine tuning (ms) B%%C%%D



7)&4-0'0567&-),

You can set 3 parameters:
7)&4-0'0567&-), : The Post Retract Spray allows ejecting the drop at the end of the wire after the welding
62.A3'&-6-+6: Test if the wire is stuck in the weld pool at the end of welding
26/()6'.20+6'.A'05: if the test indicates that the wire is stuck, a power impulsion will automatically burn back the wire, and then will
check it. 
/+6

5)K

Timing of gas output after the end of welding in order to prevent oxidation while the bead is still
hot.
Variables : T
(
s)

B%%

C

%%D


     










Pre
-
gas


Slow wire inch [forward]


Hotstart


Welding
phase


Crater
fill
er



Burnback



Affûtage fil



Post
-
gas
LM

The striking adjustment is accessible in the menu SETUP of the M G page.
Note: the striking is the 2 phase of the welding cycle.
The striking of every synergy is by default optimal in most of the application cases. However, in few very specific application cases, the user may want to
modify the striking characteristics.
Tuning parameters of striking:
K = Variable coefficient de -10 / 0 / +10
)(-/:67-4)&)(-6-&

-+.&'46'/0

Striking low wire advance K Allows modifying the low wire advance before striking.
Striking current K Allows tuning the striking current energy.
Striking transition energy K
Allows tuning the arc energy during the transit between the arc striking and the first
regime of the welding cycle.

The user is responsible for the eventual dysfunction which a modification of the striking parameters may cause.















%        

The User Synergies Menu is accessible from the homepage. This function of the power source allows the user to create their own synergies from the
existing ones.
From the synergy bar, lo
cated on the top of the screen as in the M G menu, choose an existing synergy by selecting the following parameters: metal,
diameter, gas, arc transfer. Choose those parameters as close as possible from the user synergy you want to create.
Once the parameters are selected, press the button User Synergy Creation:
1. The first step is the selection of the synergy points that will serve as support for the new synergic curves. Select at least 2 points, then validate.
2.
The second st
ep is the modification of the selected points, the addition of new points or the suppression of existing points.
Select a point among the list, press on “edit”. See below the settable parameters:
-Wire speed (m/min) : to create a new point, change this value and press the add point button.
-Arc length
-Fine tuning
-Thickness (mm)
- (A)
-U (V)
-Striking adjustment
The tuning of those parameters allows you adjusting the User Synergy according to your needs.
On this schematic example of a synergic cur
ve, 4 points are
selected in order to create the user synergy.
The user added 3 points on the 4 support points by
setting the adjustable parameters for new values of the
wire speed.