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.