Saf-Fro DVU W500 Installation instructions

DVU W500
EN
INSTRUCTIONS FOR OPE
RATION AND MAINTENAN
CE
FR
INSTRUCTION D'EMPLOI ET D'ENTRETIEN
ES
INSTRUCCIONES DE FUN
CIONAMIENTO Y MANTEN
IMIENTO
IT
ISTRUZIONI PER IL FU
NZIONAMENTO E LA MAN
UTENZIONE
PT
INSTRUÇÕES D
E UTILIZAÇÃO E DE MA
NUTENÇÃO
NL
BEDIENINGS
-
EN ONDER
HOUDSINSTRUCTIES
RO
INSTRUCŢIUNI PRIVIND
OPERAREA ŞI ÎNTREŢI
NEREA
EL
Ο ΗΓΙΕΣ ΑΣΦΑΛΕΙΑΣ ΚΑ
ΤΑ ΤΗ ΧΡΗΣΗ ΚΑΙ ΤΗ Σ
ΥΝΤΗΡΗΣΗ
RU
РУКОВОДСТВО ПО ЭКСПЛ
УАТАЦИИ И ТЕХНИЧЕСКО
МУ ОБСЛУЖИВАНИЮ
Cat n°: 8695-1215
Rev : G
Date : 02/2018
Contact :
www.SAF-FRO.com

DVU W500
EN INSTRUCTIONS FOR OPERATION AND MAINTENANCE
Cat n°: 8695-1215
Rev : G
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. Please ensure you read the operating manual carefully
before use.

3
EN CONTENTS
1 - GENERAL INFORMATION.........................................................................................................................................................................................................................4
1.1. PRESENTATION OF INSTALLATION............................................................................................................................................................................................... 4
1.2. WELDING SET CONSTITUENT........................................................................................................................................................................................................ 4
1.3. TECHNICAL SPECIFICATIONS........................................................................................................................................................................................................ 4
1.4. DIMENSIONS AND WEIGHT............................................................................................................................................................................................................. 4
2 - SETTING UP................................................................................................................................................................................................................................................5
2.1. PRECAUTIONS.................................................................................................................................................................................................................................. 5
2.2. ASSEMBLY OF OPTIONS................................................................................................................................................................................................................. 5
2.3. WIRE FEED UNIT CONNECTION..................................................................................................................................................................................................... 5
2.4. POSITIONNING THE WIRE............................................................................................................................................................................................................... 6
3 - INSTRUCTIONS FOR USE.........................................................................................................................................................................................................................7
3.1. PRESENTATION AND SETTING UP ................................................................................................................................................................................................ 7
3.2. WELDING PARAMETERS SETTING ................................................................................................................................................................................................ 8
3.3. PREVIEW ANS WELDING MEASUREMENT ................................................................................................................................................................................. 12
3.4. PROGRAMS MANAGEMENT.......................................................................................................................................................................................................... 13
3.5. WIRE FEEDER CONFIGURATION ................................................................................................................................................................................................. 14
4 - OPTIONS...................................................................................................................................................................................................................................................16
5 - MAINTENANCE.........................................................................................................................................................................................................................................17
5.1. WIRE ROLLERS AND GUIDES....................................................................................................................................................................................................... 17
5.2. WIRE-FEED PLATE WEAR PART ................................................................................................................................................................................................. 17
5.3. RECYCLING..................................................................................................................................................................................................................................... 18
5.4. SPARE PARTS ................................................................................................................................................................................................................................ 18

EN
4
1 - GENERAL INFORMATION
1.1. PRESENTATION OF INSTALLATION
The Wirefeeder DVU W500 has been specially developed for high standard applications that have particular requirements for the power source range of
DIGIWAVE II, an expert range for manual applications
Its optimized design makes it easy to use in a harsh environment whether for rolling (workshop trolley in option) or against exterior aggressive conditions
(wet, dust, projections, etc…)
The DVU W500 will allow you to achieve high quality welds with a nice appearance.
The wire feeder can only be used in the DIGIWAVE II range.
Optimum use of the system requires full knowledge of this manual; it is important to follow all the instructions described in this document.
1.2. WELDING SET CONSTITUENT
The welding-set is comprise of :
a wire feeder,

A
n adapter for ecological spool,
User instruction
Safety instruction
1.3. TECHNICAL SPECIFICATIONS
DVU W500 - REF. W000372327
Roller plate 4 galets / 4 rollers
Wire feed speed 1 to 25 m / mn
Wire speed regulation Numerical
Wire dia. usable 0.6 to 1,6 mm
Designed to fit through a manhole yes
Protection index IP 23 S
Insulation class H
Standard EN 60974 - 5 / EN 60974 - 10
Torch connection European type
Duty cycle 60% at t=40°C 500 A
NOTE: This wirefeeder cannot be used in falling rain or snow. It may be stored outside, but it is not designed for use without protection during raining.
Degrees of protection provided by the covering
Code letter IP Equipment protection
First number 2 Against the penetration of solid foreign bodies with Ø ≥12,5 mm
Second number 1 Against the penetration of vertical drops of water with harmful effects
3 Against the penetration of rain (inclined up to 60° in relation to the vertical) with harmful effects
S
Indicates that the protection test against detrimental effects due to water penetration has been done
with all parts of the equipment at rest.
1.4. DIMENSIONS AND WEIGHT
Dimensions
(L×W×h)
Net weight Packed weight
Wire feeder DVU W500
603 X 262 X 446 17.5 kgs
(without trolley option)
20 kgs
This wire feeder isn’t designed for automatic applications, and is only applicable for manual installations.
While welding in MIG, the tension is present on the MMA connection. In the same way, while welding in MMA, the tension is
present on the MIG torch connection and on the wire and the contact tube of the MIG torch if this one is still connected.
Avoid any contact of these connections with you or any other element: risk of electric arc (burning, dazzling, deterioration of
material)

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

EN
6
For slinging the wire feeder, you must use the metal hook at the base of the handle.
2.4. POSITIONNING THE WIRE
I1 Wire Feed unit I5 Wire speed setting
I2 Pin of the shaft of the reel locator I6 Gas purge button
I3 Spool axle nut I7 Lever locker of the idlers
I4 Flow meter option I8 Idlers
Open the door of the wire-feed unit (I1) and ensure that it cannot fall.
Unscrew the spool axle nut. (I3).
Insert the spool of wire on the axis. Make sure that the locating pin of the shaft (I2) is properly located into the reel locator
Screw the spool nut (I3) back on to the shaft, turning it clockwise.
Lower the lever (I7) in order to free the idler rollers (I8):
Take the end of the wire of the spool and cut the distorted end piece.
Straighten the first 15 centimetres of wire.
Insert the wire via the inlet wire-guide of the plate.
Lower the idlers (I8) and raise the lever (I7) in order to immobilise the idlers.
Adjust the pressure of the idlers (I8) on the wire to the correct tension.

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

EN
8
Manual wire speed advance :
To activate the wire speed advance, press and hold the button of manual wire speed advance. (I5).
The wire speed is displayed and can be set with the left encoder (2) up to the limit of 12.5
m/min.
The wire is fed with the lowest speed for 1s and then increases progressively up to the reference speed value.
Purge gas :
To activate the gas purge, press the button gas purge (I6). The gas flows during the defined
timing. The timer is displayed:
A
re-press on the button (I7) stops the gas flow
The purge gas timing can be modified with the right encoder (4), the modification is taken into account during the next purge.
3.2. WELDING PARAMETERS SETTING
Setting interface presentation :
1 Line 2 of the LCD screen that displays the parameters being adjusted
2 Left encoder for setting the parameter displayed on the left
3 Scroll button ± of displayed parameters
4 Right encoder for setting the parameter displayed on the right
The wire feeder enables you to set the main welding parameters (wire speed, arc voltage, dynamism…) and the trigger mode. The other settings are
configured on the power source. See the User instructions of the power source.
Modifications made on the wire feeder (or the power source) are updated at the same time on the power source (or the wire feeder).

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

EN
10
Specific case of the step mode :
Go to the appropriate line for access to the parameters you want to set, and turn the right encoder to select the step you want to set:
line 1
Working mode (SYN, MAN FREE)
A
rc transfer and step mode activated Trigger mode
line 2
Last welding current measure Post welding
Last welding voltage measure
line 3
Réglage épaisseur Courant de soudage
line 4
Wire speed
Select the step to be set with the right
encoder
line 5
Hauteur d’arc
/ Arc length Select the step to be set with the right
encoder
line 6
Dynamism
Select the step to be set with the right
encoder
line 7
Number of activated steps
Specific case of the « ADVANCED SEQUENCER »
The mode Advanced Sequencer enables the operator to sequence the welding into two distinct regimes. The display is then adapted to allow setting the
same parameter for the regime 1 at the left and the regime 2 at the right.
line 1
Working mode (SYN, MAN FREE)
A
rc transfer of the regime
1 and 2
Trigger mode
line 2
Last welding current measure Post soudage
Last welding voltage measure
line 3
On regime 1
Wire speed On regime 2
line 4
On regime 1
A
rc length On regime 2
line 5
On regime 1
Regime time On regime 2

EN
11
line 6
On regime 1
Dynamism On regime 2
line 7
Transit time
Potentiometer settings
The wire feeder may be connected to:
The potentiometer remote command
The potentiometer torch
The compatible push pull torch with potentiometers
To be considered, the potentiometers must be configured into the power source (for more details see the power source instruction manual ). You have to
specify the number of used potentiometers.
The potentiometers tune:
Potentiometer 1 Wire speed
Potentiomete
r
2
A
rc Voltage
The setting range of the potentiometers depends on the working mode or on the program
limitations.
Only one peripheral with a potentiometer can be connected to the installation.
When the potentiometers are connected and activated, the corresponding parameters are not adjustable by digital interfaces
(wire feeder, generator and RC job)
MIG welding
In welding, the interface is automatically adapted and only the main welding parameters can be changed:
Wire speed, Arc length, Dynamism, Current, Voltage.
MMA welding
For more information about the setting of the MMA process, see the power source instruction manual.
line 1
Welding current MMA Process
Dynamism setting
line 2
Setting of the arc striking dynamism
line 3
Last welding current measure Post soudage
Last welding voltage measure
During welding, the interface is similar to the MIG process.

EN
12
TIG welding
For more information about the setting of the TIG process, see the power source instruction manual § 3.4.1.
line 1
TIG Process
Trigger mode
line 2
Last welding current measure Post soudage
Last welding voltage measure
line 3
welding current
line 4
End of welding current
Downslope timing
3.3. PREVIEW ANS WELDING MEASUREMENT
Presentation ot the interface pf measurement display :
5 Left measurement display
6 Indicator light of the left parameter displayed
7 Selection button of the left parameter
8 Indicator light of the installation status
9 Right measurement display
10 Indicator light of the right parameter displayed
11 Selection button of the right parameter

EN
13
The displayed values depend on the installation status:
State Displayed values on (5) and (9) Indicator (8)
Ajustement in Progress No values, these are replaced by dashes Off
Out of welding Instructions or theoretical values Off
In welding Direct measurements Blinks
Post welding Last welding measures Fixed
Notes : The post welding time is configurable on the power source. The last measures are still available on the power source (see the power source
instruction manual).
Definition of serigraphy symbols:
Symbol Function Unit Symbol Function Unit
Amperage A Voltage V
Wire speed m/min
Arc length
Thickness mm
Fine tuning/dynamism
3.4. PROGRAMS MANAGEMENT
Presentation
12 The number, the name and the status of the current program
are displayed on line 1 of the LCD.
13 Button (-) to select the previous program
14 Button (+) to select the next program
15 Button (OK) to access to the program management

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

EN
15
Fault list description :
Code Message LCD Signification
E03 Over max pw Exceeding the maximum allowed power from the current source
–
check that the welding program
parameters do not exceed the characteristics of the current source (including Free mode)
E07 Overvoltage pw Over voltage of the 3 phase power supply of the power source of (tolerance 400V - 3 ~ 15 %/-20 %) -
Verify the characteristics of the power supply
E07 Undervoltage pw Under voltage of the 3 phase power supply of the power source of (tolerance 400V - 3 ~ 15 %/-20 %) -
Verify the characteristics of the power supply
E15 Max aver current Overtaking of the maximum average current authorized by the power source - verify that the parameters of
the program of welding do not exceed the characteristics of the power source (Free mode in particular)
E16 Max strikcurrent Overtaking of the maximum instant current authorized by the power source - verify that the parameters of
the program of welding do not exceed the characteristics of the power source (Free mode in particular)
E25 Over duty cycle Overtaking of the duty cycle of the power source
–
wait for the cooling of the power source
E30 Missed striking
A
utomatic mode only
Time out of 3 seconds after the welding launch without detecting striking
E32 Broken arc
A
utomatic mode only
Detection of arc break
E33 Program problem Call of a non authorised or non existing program
E33 Incompat. prog. The program is not compatible with this software version. Please upgrade the software version of the
power source.
E33 Incompat. conf. The configuration is not compatible with this software version. Please upgrade the software version of the
power source.
E33 Corrupted prog.
A
program is corrupted. This program is visible in the programs management page of the power source. A
removal of the program is required.
E33 Corrupted conf. The installation configuration is corrupted. Please configure again the installation.
E33 Corrupted list
A
program list is corrupted. Please configure again the program lists.
E42 Device reset
A
peripheral has been reset. Please restart the power source.
E42 Unstable pow sup The power supply is unstable. Please check the electrical wiring.
E44 Calibration Impossible to achieve the automatic calibration
Check that the procedure of calibration displayed on the screen is well respected
E45 Instant stop Immediate request from user to stop the welding
E49 Check device cnt No communication with a peripheral.
Check the peripheral connection.
It is imperative to connect and disconnect the wire feeder when the installation is out of power.
E50 Cooling problem Flow problem of the cooling
unit
E52 Stuck electrod MMA only
Detection of the sticking of the electrode with the workpiece. Unstick the electrode
E53 Stuck wire MIG only
Detection of the sticking of the wire with the workpiece. Cut the wire
E63 Motor torque Excessive torque of the wire feeder motor.
Check that the wire sheathing is clean and that nothing is blocking the motor advance or the wire feeding
movement
Check that the tightness of the rollers is not too important
E72 Not present Syn Launching of a welding program where user synergy is not present in the generator
–
import or define the
user synergy corresponding to the current program
E80 I min control Overtaking of the low threshold of welding current monitoring defined by the user
E81 I max control Overtaking of the high threshold of welding current monitoring defined by the user
E82 U min control Overtaking of the low threshold of welding voltage monitoring defined by the user
E83 U max control Overtaking of the high threshold of welding voltage monitoring defined by the user
E84 Wf I motor max Overtaking of the low threshold of wire feeder motor current monitoring defined by the user
E85 Wf I motor min Overtaking of the high threshold of wire feeder motor current monitoring defined by the user
E86 Missing software Software is missing for a dedicated peripheral. Please perform again a software upgrade.
E90 Error CAN bus The communication with a peripheral is highly disturbed. Please check the peripheral connection.
It is imperative to connect and disconnect the wire feeder when the installation is out of power

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4 - OPTIONS
Gas flow controller, ref. W000275905
Wire feeder trolley, ref. W000275908
Simple remote control, ref. W000275904
RC-job II remote control ref. W000371925
Torchs évoluées
DIGITORCH 2 E 341 – 4m, ref. W000373831
DIGITORCH 2 E 341W – 4m, ref. W000373832
DIGITORCH 2 E 441W – 4m, ref. W000373833
Potentiometers torchs
DIGITORCH P 341 – 4m , réf. W000345014
DIGITORCH P 341W – 4m, réf. W000345016
DIGITORCH P 441W – 4m, réf. W000345018
PUSH-PULL Card, ref. W000257907
ADAPTATOR TIG, ref. W000379466

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

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5.3. RECYCLING
The presence of the following components requires a specific end of life management (recycling):
Electronic board of the front panel
LCD screen on the electronic board of the front panel
5.4. SPARE PARTS
(see fold-out FIGURE 1 at the end of the manual)
Rep REF. SAF
Designation
W000372327 DVU W500
Front panel
1 W000374095 Front panel W500
2 W000265988 Blu buttons kit
W000373633 Plastic hood
Internal parts
W000278017 Valve
W000277985 Harness wiring + socket
W000277986 RC wiring
10 W000241668 Male plug 500 A ¼T
11 W000148911 Female plug 500 A ¼T
W000277987 European Connection
Chassis
W000278019 Harness fixing plate
21 W000277976 Handle
22 W000277977 Plastic parts
23 W000278020 Equipped door
24 W000277978 Right panel with screws
25 W000278021 Hinges with screws
a W000278730 Swivel front wheel
b W000277990 Fixed rear wheel
Base plate
30 W000277988 Complete motor and encoder
31 W000277989 Roler’s cover
32 W000278018 Setscrew
W000277338 Wheel adapter
Harness
W000278022 Couplers for harness
Trolley option
W000147072 Front wheel
W000147075 Rear Wheel
Push pull option
W000277991 Push-pull wiring

DVU W500
FR INSTRUCTION D'EMPLOI ET D'ENTRETIEN
Cat n°: 8695-1215
Rev : G
Date : 02/2018
Contact :
www.SAF-FRO.com