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1 / DIGI@PULS MIG/MAG welding installations with digital control provided with the latest technology inverter. Aim for digital precision! Awarded by the French Welding Institute

2 / DIGI@PULS, technology at the service o The new DIGI@WAVE and DIGI@PULS installations have been developed in response to customer requests for the best welding characteristics combined with excellent reliability and unequalled ease of use. Air Liquide Welding has used the most advanced technology available in the group and designed these products in direct collaboration with a selection of European industrial customers with the objective of giving the Products designed to satisfy the demanding environment of t Reduction of noise and pollution and ease of use and operation for improved welding conditi increase in the power available for difficult applications and the assurance of having available by reloading the software directly from a workstation Food industry and chemical equipment Transport/naval/rail Digital setting with total control of the waveform Storage and printing of programs Great versatility of use manually and automatic

3 f high-quality welding best response to market expectations. The introduction of digital control for all parameters provides exceptional arc stability and extremely accurate reproduction of welding parameters. The synergic rules have been produced by the best European welders of the group making them a truly one-button operation thus making the unit easy to adjust. oday s modern enterprise: ons, the latest technological developments Automobile manufacture Heavy metalwork/nuclear Air Liquide Welding processes for all the customer s requirements Power calibrated to industrial requirements Modular configuration for all workshop/site requirements 3

4 / DIGI@PULS, a range adapted to new in DIGI@WAVE has been designed for all applications requiring very high quality welding for all thicknesses and all materials used in the main industrial sectors. A wide graphic screen allows the operator to navigate easily around a menu bar for adjusting the various parameters of the unit. User-friendliness and high level performance make the DIGI@WAVE the ideal partner for your manual, automatic and robotic welding. DIGI@WAVE installation D I A B C D E F Welding power source Wire feeder Connection harness 2/5/10 & 15 m Welding torch Workshop trolley Wire feed trolley G A Communication by BUS CAN G Main power on/off switch H I Torch connector Slinging rings C DIGI@WAVE interface E H B F a 1c 1b 1d 1 Graphic screen, parameter pre-selection a - Menu g - Gas b - Programme no. h - Transfer mode c - Presets i - Setting mode d - Pre-display j - Welding mode e - Wire grade k - Locking f - Wire diameter e 1f 1g 1h 1i 1j 1k Parameter print button Help button Selection validation button Return to previous menu button Screen navigation button Setting button Main characteristics DIGI@WAVE 280 A Compact air 400 A Separate water* 500 A Separate water* Remote control Standard interface Expert (graphic screen, extended setup) Main applications Uses Processes Automobile construction and repair. Rail, road and naval construction. Metalwork, infrastructures, energy. Food industry. Manual/Automatic and Robotic at A1, A2, A3 levels. Electrodes, Short arc regimes smooth current MIG/MAG, Speed Short arc and Spray arc, Pulsed and Low Noise Pulsed, MODULE in Spray-MODAL regime. g a f b e c d Synergic laws available (wire/gas combinations) Number of welding and storable programs * Separate air cooler upon request a b c d e f g Programme selector Display Programme selector Entry validation Arc height setting Wire speed setting Display selection +

5 dustrial requirements has the same welding performance as The front panel is simplified to give direct access to the welding parameters. Parameter optimization is carried out after selection of the wire grades and diameter, the gas and the material thickness. It is provided with most of the advanced processes (Pulsed, Speed Short Arc (SSA ), etc. (see table on pages 14 and 15). installation D I A B C D Welding power source Wire feeder Connection harness 2/5/10 & 15 m Welding torch Direct access to parameters E F Workshop trolley Wire feed trolley G A G H Main power on/off switch Torch connector C I Slinging rings DIGI@PULS interface E H B F Welding voltage and setup parameter display Welding current or wire speed or thickness display Mode and welding cycle selection LEDs Process choice selector Gas selector Wire grade selector Wire diameter selector Scrolling of setup parameters Parameter setting Selector for wire speed or thickness display Main characteristics Standard interface Main applications Uses Processes Synergic laws available (wire/gas combinations) Number of welding and storable programs DIGI@PULS 320 A Separate air 320 A Separate water 420 A Separate water 520 A Separate water Easy (2 displays 7 segments, restricted setup) Traditional rail, road and naval construction. Metal construction, steel and stainless steel metalwork, infrastructures Manual/Automatic and Robotic at A1 level Electrodes, Short arc regimes smooth current MIG/MAG, Speed Short arc and Spray arc, pulsed current

6 / DIGI@PULS, tools and options which m Although it is true that welding performance is linked to the technology of the current source and the correct regulation of the wire speed, the welding torch makes an equally important contribution. The parameters sent by the current source must be very accurately transferred by the torch in the arc. Air Liquide Welding torches have been developed specifically for use with DIGI@WAVE and DIGI@PULS installations to optimize performance. PROMIG conventional torches Complete range of manual MIG-MAG torches which are innovative, powerful and suited to quality applications in the various market sectors. Torches comply with the EN standard and use European standard connections PROMIG NG W 441 W 450 W Duty 60 % 250 A 320 A cycle with Ar+CO2 100 % A 400 A 450 A Wire diameter mm mm mm mm mm range Standard 3, 4 and 5 m 3, 4 and 5 m 3, 4 and 5 m 3, 4 and 5 m 3, 4 and 5 m lengths Options Stick-out setting. High-current alum. wear conduit. Stick-out setting. High-current alum. wear conduit Tip + high-current contact tube. Stick-out setting. High-current alum. wear conduit Tip + high-current contact tube. Stick-out setting. High-current alum. wear conduit. Stick-out setting. High-current alum. wear conduit. P E Digital torches with integral settings These high-level torches use advanced digital technology to obtain system miniaturization in order to fit the maximum number of possibilities for settings and parameters into the smallest possible space. The DIGI@TORCH range meets the challenge of making the torch as small and easy to handle as a conventional torch with, in addition, the inclusion of almost complete remote control functionality Wire speed setting Arc length setting 2 DIGI@TORCH E for DIGI@WAVE: integrated setting and displays Type W 441 W Duty 60 % 250 A 320 A - - cycle with Ar+CO2 100 % A 400 A Wire diameter range 0.8-1,0 mm possible (1.2) mm mm possible (0.8 and 1.6) possible (0.8 and 1.6) mm DIGI@TORCH advantages Setting direct on torch Adjustment during welding Parameter reading (on DIGI@TORCH E) Ease of use Cooling air air water water DIGI@TORCH P for DIGI@PULS: integrated setting Type W 441 W Duty cycle with Ar+CO2 60 % 320 A % A 400 A Wire diameter range mm possible (0.8 and 1.6) mm possible (0.8 and 1.6) mm Cooling air water water R Push-pull torches and guns Several push-pull systems are available for use with DIGI@WAVE and DIGI@PULS. The ALUTORCHE and DIGI@TORCH PP ranges offer great operational conditions due to the miniaturization of the wire drive system in line with the push-pull wire feeding axis. These torches and guns give an excellent wire feeding quality, and therefore an excellent weld quality and are particularly recommended for aluminium applications or usage with small diameter wires. They can be easily adapted with a push-pull kit.

7 eet all your requirements and wire feeders are provided with digital setting incorporating an optic encoder which guarantees precision and consistency of feeding even at very slow speeds. The double-disconnectable ducted harnesses with quick connectors are instantly interchangeable. The reel cover with half-shell opening gives easy access to the reel which is in a semi-inclined position to obtain an improved wire. Wire feeding precision DIGI@WAVE DV 500 CDR wire feeder DIGI@PULS DV 400 CDR and DV 400 WKS wire feeder a R R b c e d f g a b c d e f g Reel cover Double-disconnectable harness Display Parameter settings Torch connector Coolant connections CAD connector e f d g Harnesses Steel air Length 2 m - 5 m - 10 m Wire feed Wire speed Diameter 1-25 m/min. Steel water Alu water 2 m - 5 m - 10 m - 15 m 2 m - 10 m - 15 m - 25 m Steel Stainless steel Aluminium mm mm mm Wire feeder options Wire feed trolley Wire feed pivot Wire feed suspension cradle for DV 400 and 500 CDR Flowmeter for DV 400 WKS

8 and new methods of transfer Provided with the latest digital technology, the and power sources offer new welding methods that respond perfectly to the technical developments taking place in industry. These innovative processes guarantee the quality and productivity levels demanded by modern welding applications. Short Arc The Short Arc has a low spatter rate with good wetting and is suited to welding thin steel plate, working in position and penetration passes This regime is characterized by alternating short circuits and light arc. Speed Short Arc (SSA ) The Speed Short Arc allows a high travel speed due to a rigid arc and a cold regime. It is very effective for welding thin steel plates, working in position and in closed angle and filling bevels. The SSA is used for short circuit welding though the normal globular regime travel speed domain. SSA advantages Increase in travel speed Reduced distortion (thin steel sheets) Suited to welding in position Tolerance and usability New Main applications of SSA : Earth Moving Plant Infrastructure Agricultural machines, Trailers Pulsed The pulsed system is recommended for welding stainless steel and aluminium. It guarantees the mechanical characteristics of the joint and limits spatter. The pulsed regime is a waveform which forces the drops of metal to become detached, the hot period projects the drop and the cold period allows the weld pool to cool. 8 Soft Silence Pulse (SSP )* The Soft Silence Pulse is a quieter pulsed mode mainly intended for stainless steel welding applications. The SSP produces a softer but very stable arc with good wetting of the weld bead. This waveform significantly reduces spatter and gives a very fine appearance to the weld bead. SSP advantages Reduction of noise Good wetting of the weld bead Reduction of spatter Good weld bead appearance New Main applications of SSP : Tanks, containers Boiler making Foodstuff and chemical equipment * Soft Silence Pulse and Spray-MODAL are only available on DIGI@WAVE

9 for total weld quality Soft Silence Pulse Cold Double Pulse Spray-MODAL Cold Double Pulse (CDP ) Cold Double Pulse produces very high quality welds on thin material while avoiding distortion. CDP gives a TIG appearance to the weld and is very effective on very thin aluminium or stainless steel sheet (< 2mm). The operating technique is made easier due to good control of the weld pool even on badly-prepared sheets. This sequencer mode automatically chains hot arc and cold arc regimes together. Main applications of CDP : Naval Rail Fine metalwork CDP advantages Effective on thin sheets Reduces distortion Easy operating technique TIG appearance weld bead New MIG Brazing MIG Brazing is extremely effective on thin sheets and accepts large joint tolerances. This process is widely used in the automobile industry as it gives good mechanical characteristics and conserves the coating of galvanized sheets. It is an advantageous replacement for flame brazing processes with the productivity of semi-automatic welding. MIG Brazing advantages Effective on thin coated sheets Reduces distortion Large joint tolerance Good mechanical characteristics Main applications of MB: Automobile, heavy vehicles Metal furniture. Air conditioning Spray-MODAL (SM )* Spray-MODAL is a process that strongly reduces micro porosity and increases penetration. It can be used in all positions and is particularly effective on aluminium sheets greater than 3 mm. Spray- MODAL uses a low-frequency modulated current which has the effect of removing most hydrogen bubbles from the weld pool before solidification. Spray-MODAL advantages Reduces porosity Increases penetration All-position welding Higher travel speed Main applications of SM : Naval Rail Boiler making 9

10 and perfect manual and auto and power sources are designed to be ideal for use with manual, automatic or robotized applications. A1, A2 and A3 automation levels adapt the installation for use with a simple or more advanced automatic machines along with robots with wire or field bus communication. Optional tools enable backup to a USB key or PC, connection of stations to a network, management of special peripherals or retrofit. Automation A1 The A1 automation level allows direct connection of a DIGI@PULS or DIGI@WAVE to an automatic welding machine as standard. A robot wire feeder is recommended, but these installations can also operate with a manual wire feeder. This level of synchronization does not require an additional card. Auto A1 applications: Earth Moving Plant Infrastructure Agricultural machines Trailers Auto A1 advantages: Simple interfacing without options "Chain" program facility * Parameter control by instructions * 10 programs on DIGI@PULS with RC-JOB option Auto wire feeder DV-R 400 DVR400 Automation A2 The A2 automation level with the AUTO-CARD option allows a DIGI@WAVE to be interfaced with a robot or automatic welding machine. This controlled process works by program calls or by instructions for adjusting the parameters. These installations require a DV-R 500 or DV-R 600 HD robot wire feeder for applications with a very high duty cycle. The PC-TOOL option enables download and backup on a USB key. Auto A2 applications: Tanks, containers Boiler making Foodstuff and chemical equipment 10 Auto A2 advantages: 100 programs and backups on USB key Monitoring of parameters by process control Auto options are easily integrated onto a manual welding machine Auto wire feeder DV-R 500 DVR500 ** Backup and printing of parameters with PC-TOOL option

11 matic versatility Automation A3 The A3 automation level with the AUTO-CARD and AUTO-BUS options allows a DIGI@WAVE to be interfaced to a robot with a field bus link. This controlled process works with an advanced protocol. These installations require a DV-R 500 or DV-R 600 HD robot wire feeder for applications with a very high duty cycle. The PC-TOOL option enables download and backup on a USB key. Auto A3 applications: Automobile, heavy vehicles Equipment manufactures Auto A3 advantages: Field bus communication with advanced protocol Multiplexer for the management of special peripherals*** Special wire feeder with very high duty cycle*** *** Optional equipment Automation levels Automation level Manual wire feeder DV 400 CDR DV-R 400 robot wire feeder Manual wire feeder DV 500 CDR DV-R 500 robot wire feeder DV-R 600 HD robot wire feeder AUTO-CARD auto card AUTO-BUS auto card PC-TOOL option RC-JOB Remote control Auto wire feeder DV-R 600 HD DIGI@WAVE DIGI@PULS W 500 W 320 (W) A1 A1 A1 A2 A2 A3 A3 A1 A1 A2 A2 A3 A3 A1 A1 A1 A1 A1 A1 Recommended configuration Required equipment Optional equipment

12 / DIGI@PULS, welding à la carte DIGI@WAVE and DIGI@PULS installations have been designed with the same objective to satisfy welding performance. The DIGI@WAVE has a wider range of processes and one-button laws, and much wider communication possibilities especially with regard to automation. The DIGI@PULS is designed for small and Configuration Compact air Separate air Separate water Processes DIGI@WAVE DIGI@PULS on request Electrode Smooth current MIG Speed Short Arc (SSA ) MIG Pulsed MIG Soft Silence Pulse (SSP ) MIG Spray-MODAL (SM ) MIG Cold Double Pulse (CDP ) MIG MIG brazing Base synergic laws Mild steel 0.6/0.8/1.0/ /1.0/1.2/ /1.0/1.2/ /0.8/1.0/ /1.0/1.2/ /1.0/1.2/1.6 Stainless steel 0.6/0.8/1.0/ /1.0/1.2/ /1.0/1.2/ /1.0/ /1.0/1.2/ /1.0/1.2/1.6 Pure aluminium (series 1000) 1.0/ / / / /1.6 Pure silicon (series 4000) 1.0/ / / / /1.6 Aluminium magnesium AG3 (series 5000) 0.8/1.0/ /1.2/ / / /1.2/ /1.6 Aluminium magnesium AG5 (series 5000) 0.8/1.0/ /1.2/ /1.2/ / /1.2/ /1.2/1.6 Cupro aluminium 1.0/ / / / / /1.2 Cupro silicon 1.0/ / / / / /1.2 SAFDUAL ZN 1.0/ / / / /1.2/ /1.2 SAFDUAL / /1.2/ /1.2/ / /1.2/ /1.2/1.6 SAFDUAL / /1.2/ /1.2/ / /1.2/ /1.2/1.6 SAFDUAL / / / /1.6 Additional equipment Workshop trolley DV 400 CDR wire feeder DV 500 CDR wire feeder DV 400 WKS wire feeder DV-R 400, 500 and 600 HD wire feeder Wire feed trolley Wire feed pivot Wire feed suspension cradle Double-disconnectable air harnesses Double-disconnectable water harnesses (1) 12 Double-disconnectable water harnesses (1) (1) For version 320 W

13 medium-sized businesses who want to increase their productivity and weld quality while at the same time having a product which is easy to install and use. Although simple to use, the DIGI@PULS can also be integrated into a simplified automatic installation or onto a robot. Basic prewiring Auto A1 connector Graphic display source 7-segment display source Enclosed wire feed Wire feed display Gas purge Wire feed inch Remote control connector Push-pull prewiring DIGI@TORCH E prewiring DIGI@TORCH P prewiring DIGI@WAVE DIGI@PULS Automatic prewiring (A1) (A1-A2-A3) (A1-A2-A3) (A1) (A1) (A1) PC-TOOL link prewiring Basic functions Wire speed setting (empty) Wire speed setting (welding) (RC-JOB) Arc length setting (empty) Arc length setting (welding) (RC-JOB) End setting (empty) End setting (welding) (RC-JOB) Spot 2T / 4T / cycle Hot start Soft start Fading Hot start Spray end Synergic mode Semi- synergic mode Manual mode (free) Staged mode Parameter blocking Parameter limitation Parameter saving (RC-JOB) (RC-JOB) (RC-JOB) Display calibration Assisted calibration Software update Error messages Clock Maintenance configuration Language choice (RC-JOB) (RC-JOB) (RC-JOB) 13

14 Technical data Primary Three-phase power supply Consumption Secondary Open circuit voltage 400 V - 50/60 Hz 45 % A - 60 % A 44.5 A A 44.5 A 100 % 31.4 A 29.8 A 39 A 25.9 A 29.8 A 39 A Welding current 20 A A 20 A A 20 A A 20 A/320 A 20 A/420 A 20 A A Duty cycle MIG 280 A/28 V 350 A/31.5 V 450 A/36.5 V 320 A/30 V 350 A/31.5 V 450 A/36.5 V at 100 % EE 280 A/31.2 V 350 A/34 V 450 A/38 V 320 A/32.8 V 350 A/34 V 450 A/38 V Duty cycle MIG A/34 V 500 A/39 V A/35 V (45%) 500 A/39 V at 60 % EE A/36 V 480 A/39.2 V A/36.8 V (45%) 480 A/39.2 V Measurements Dimensions (L x w x h) with trolley and feeder* 845 x 380 x 855 mm 106 V x 750 x mm* Net weight 76 kg 107 kg 90 kg air 107 kg water Standards EN / EN Protection class IP 23 S Cooling Fan V single-phase 230 V single-phase Pump V single-phase 400 V single-phase Maximum pressure - 4 bar 4 bar Maximum flow rate l/min. 4.5 l/min. 107 kg Options RC-JOB Remote control Auto A1 Auto A2 Auto A3 PC-TOOL Push-pull torch Push-pull gun DIGI@TORCH E torch DIGI@TORCH P torch Anti-dust filter 14

15 To order Current sources: P/N 280 Compact air cooled W Separate water cooled W Separate water cooled W DIGI@PULS 320 Compact air cooled W Separate water cooled W Separate water cooled W Separate water cooled W Wire feeder: DV 400 CDR DIGI@PULS manual W DV 500 CDR DIGI@WAVE manual W DV 400 WKS DIGI@WAVE manual W DV-R 400 DIGI@PULS robotic W DV-R 500 DIGI@WAVE robotic W DV-R 600 HD DIGI@WAVE HD robotic W Harnesses (for use with steel): Length 2 m 5 m 10 m 15 m 25 m Air cooling W W W Water cooling W W W W Harnesses (for use with aluminium): Water cooling W W W W Add-ons: Workshop trolley for power source W Pivot stand (requires wire feeder trolley) W Workshop trolley for wire feeder for DV 400 and 500 CDR W Workshop trolley for DV 400 WKS W Wire feed suspension support W Options: Manual push-pull card (PP-CARD) W RC-JOB Remote control W Socket on power source (CAD-plug) W Automatic/robotic interface card (auto-card A2) W Retrofit automatic/robotic multiplexer box (MUXAL) W Communication card (USB-TOOL) W Flowmeter kit W Panel with filter W Torches: 3 m 4 m 5 m PROMIG NG 241 W W W PROMIG NG 341 W W W PROMIG NG 341 W W W W PROMIG NG 441 W W W W PROMIG 450 W W W W DIGI@TORCH E 241 W W DIGI@TORCH E 341 W W DIGI@TORCH E 341 W W W DIGI@TORCH E 441 W W W DIGI@TORCH P 341 W W DIGI@TORCH P 341 W W W DIGI@TORCH P 441 W W W Push-pull torches: 8 m 8 m (straight) 8 m (curved 45 ) 10 m ALUTORCHE DG W ALUTORCHE DG 441 W W DIGI@TORCH PP 352 W DIGI@TORCH PP 451 W - W W

16 Contacts BELGIUM AIR LIQUIDE WELDING BELGIUM SA Z.I. West Grijpen - Grijpenlaan TIENEN Tel.: Fax: CHINA SAF SHANGHAI REP. OFF. Rm Pine City Hotel 777 Zhao Jia Bang Lu - SHANGHAI Tel.: Fax: CZECH REPUBLIC AIR LIQUIDE WELDING CZ S.R.O. Podnikatelská Areál SVUM PRAHA 9 - Bûchovice Tel.: Fax: FRANCE AIR LIQUIDE WELDING FRANCE 13, rue d Épluches - BP Saint-Ouen l'aumône CERGY PONTOISE Cedex Tel.: Fax: HUNGARY AIR LIQUIDE WELDING HUNGARY - Kft Krisztina krt. 39/b - H-1013 Budapest Tel.: Fax: ITALY AIR LIQUIDE WELDING ITALY Via Torricelli 15/A VERONA Tel.: Fax: LUXEMBOURG AIR LIQUIDE WELDING LUXEMBOURG S.A. 5 rue de la Déportation - BP L-1415 LUXEMBOURG Tel.: Fax: MALAYSIA SAF-OERLIKON MALAYSIA SDN BHD No 10, Jalan TPP 5/1 - Taman Perindustrian Puchong PUCHONG, SELANGOR Tel.: Fax: NETHERLANDS AIR LIQUIDE WELDING NETHERLANDS Rudonk 6 B - NL 4824 AJ BREDA Tel.: Fax: POLAND AIR LIQUIDE WELDING POLSKA - SP. Z.o.o UL. Porcelanowa KATOWICE Tel.: Fax: PORTUGAL AIR LIQUIDE SOLDADURA LDA Rua Dr. António Loureiro Borges, 4-2 Arquiparque Miraflores ALGÉS Tel: Fax: ROMANIA DUCTIL Aleea Industriilor Nr BUZAU Tel.: Fax: RUSSIA AIR LIQUIDE WELDING 17 Vorontsovskaya Str MOSCOW Tel.: Fax: SLOVAKIA AIR LIQUIDE WELDING CENTRAL EUROPE S.R.O. Prazska NITRA Tel.: Fax: THAILAND AIR LIQUIDE WELDING THAILAND Co Ltd 40 Moo 6 - Ramindra Road Km. 9.5 KHANNAYAO, BANGKOK Tel.: Fax: U.A.E. AIR LIQUIDE WELDING MIDDLE EAST FZE Jebel Ali free zone warehouse No. FZS1AH05 P.O. BOX Jebel Ali - DUBAI Tel.: +971(0) Fax: +971(0) UKRAINE AIR LIQUIDE WELDING UKRAINE, Llc. 1 rue Proskura - bureau 106A KHARKOV Tel.: Fax: Air Liquide Welding France reserves the right to modify its equipment without prior notice. The illustrations, descriptions and characteristics are provided for information purposes only and are not binding on the manufacturer. For other countries please contact our Export departments ALW Export Department Italy Via Torricelli15/A VERONA Tel: Fax: export.alwitaly@airliquide.com ALW Export Department France 13, rue d'epluches BP Saint Ouen l'aumône CERGY-PONTOISE Cedex Tel: Fax: export.alwfrance@airliquide.com ALWF - W Compliant New Offer QB: S 02 Ed. 2 Photos: JSR - AREVA Founded in 1902, Air Liquide is the world leader in industrial and medical gases and related services. The company has offices in 75 countries and employs a work force of 40,000. Drawing on constantly renewed technologies, Air Liquide develops groundbreaking solutions used in making countless everyday products and in helping to preserve life.