The Oerlikon DMU W500 is a wire feeder unit specifically designed for high-standard MIG/MAG welding applications, particularly those requiring the CITOWAVE II power source range. It is optimized for manual applications and is not intended for automatic use. Its robust design allows for use in harsh environments, whether for workshop trolley mobility (optional) or against aggressive external conditions like wetness, dust, or projections. The DMU W500 aims to deliver high-quality welds with a clean finish.
Important Technical Specifications:
- Roller Plate: Equipped with 4 rollers for stable wire feeding.
- Wire Feed Speed: Adjustable from 1 to 25 m/min.
- Wire Speed Regulation: Numerical for precise control.
- Usable Wire Diameter: Compatible with wires from 0.6 to 1.6 mm.
- Manhole Compatibility: Designed to fit through a manhole, indicating a compact form factor.
- Protection Index: IP 23 S, meaning it is protected against solid foreign bodies with a diameter of 12.5 mm or more, and against vertically falling water drops with harmful effects. The 'S' indicates that the water penetration test was performed with the equipment at rest. It is not designed for use in falling rain or snow, though it can be stored outdoors without protection during rain.
- Insulation Class: H.
- Standard Compliance: EN 60947-5 / EN 60947-10.
- Torch Connection: "European type."
- Duty Cycle: 60% at 40°C, delivering 500 A.
- Dimensions (LxWxH): 603 x 262 x 446 mm.
- Net Weight: 17.5 kg (without trolley option).
- Packed Weight: 20 kg.
Usage Features:
The DMU W500 features a user-friendly interface for setting welding parameters.
- Wire Feed Interface: The LCD screen displays various settings and measurements. It shows the software version and wire feeder number upon startup.
- Manual Wire Speed Advance: Activated by pressing and holding a dedicated button (I5). The wire speed is displayed and can be adjusted with the left encoder (2) up to 12.5 m/min. The wire feeds at the lowest speed for 1 second, then gradually increases to the set reference speed.
- Gas Purge: Activated by pressing the gas purge button (I6). Gas flows for a defined duration, displayed by a timer. The purge gas timing can be modified with the right encoder (4).
- Welding Parameters Setting: The interface allows adjustment of main welding parameters like wire speed, arc voltage, dynamism, and trigger mode using encoders (2 and 4) and a scroll button (3). Other settings are configured on the power source.
- Preview and Welding Measurement: The display shows real-time measurements during welding (current, voltage, wire speed, arc length, thickness, dynamism) and the last welding measures after the process.
- Programs Management: Users can select, restore, and save welding programs. The display shows the program number, name, and status (modified or locked).
- Wire Feeder Configuration: The unit displays warning messages in case of faults, showing the fault number and associated text.
Maintenance Features:
Regular maintenance is crucial for optimal performance and longevity.
- General Inspection: Twice a year, or more frequently depending on usage, inspect the cleanliness of the wire feeder and the electrical and gas connections.
- Cleaning: Always disconnect the unit from the mains before cleaning or repairing. Remove wire feeder panels and vacuum dust and particles using a plastic nozzle to prevent damage. Electronic circuits should be vacuumed carefully.
- Troubleshooting: In case of malfunction, check electrical connections (power, control, supply circuits), insulation, cables, and lines before attempting further diagnosis.
- Startup Checks: Before each startup and any service operation, verify that power terminals are tightened, connections are correct, gas flow is adequate, torch condition is good, and the wire type and diameter are appropriate.
- Wire Rollers and Guides: These components are designed for long service life. However, sticky deposits can cause premature wear or clogging. Regularly check and clean the plate to minimize this risk. The motor reducing gear set is maintenance-free. An adapter (ref. W000277338) is required for mounting rollers.
- Wire-Feed Plate Wear Parts: The wearing parts that guide and advance the welding wire must be adapted to the wire type and diameter. Replace them if wear affects welding results. Specific part numbers are provided for different wire types (steel, flux-cored, aluminum) and diameters.
- Recycling: Certain components, such as the electronic board of the front panel and the LCD screen, require specific end-of-life management and recycling.
- Spare Parts: A comprehensive list of spare parts with their reference numbers and descriptions is provided, including front panel components, internal parts, chassis elements, base plate components, harness, and optional accessories like trolleys and push-pull wiring.
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