The WF 3000 CLASSIC-SMART is a mobile wire feed unit designed for MIG/MAG welding, compatible with URANOS 3200-4000-5000 GSM, PME, and MSE generators. It connects to the generator via a variable-length cable bundle, offering a compact design with a fully protected and electrically insulated wire spool compartment, safeguarding it from dust and debris. The wire feed mechanism is driven by a robust 120W motor with 2/4 rollers, controlled by an optical encoder. A powerful microprocessor enables comprehensive control over all welding functions, making the system suitable for various MIG/MAG processes, including Pulsed-MIG and Double Pulsed-MIG.
Technical Specifications
Wire Feeder:
- Motor: SL4R-2T(v.2R)
- Rated Power: 120W
- Number of Rolls: 2 (4)
- Standard Wire Diameter / Roller: 1.0-1.2 mm
- Tractable Wire Diameters: 0.6-1.6 mm solid wire, 0.8-1.6 mm aluminum wire, 1.2-2.4 mm flux-core wire
- Gas Test Button: Yes
- Wire Feed Button: Yes
- Wire Backward Push Button: No
- Wire Feed Speed: 0.5-22 m/min
Electrical:
- Power Supply Voltage U1: 48Vdc
- Max. Input Current I1max: 4.5A
Duty Factor (40°C):
- (x=50%): 500A
- (x=60%): 470A
- (x=100%): 420A
Duty Factor (25°C):
- (x=80%): 500A
- (x=100%): 470A
External Devices:
- RC (Remote Control): Yes
- Connector for Push-Pull Torch: Yes (optional)
- Communication Bus: DIGITAL
Physical:
- Coil Diameter: Ø 200/300mm
- Front Wheels Ø: 63/125mm (optional)
- Rear Wheels Ø: 63/125mm (optional)
- IP Protection Rating: IP23S
- Dimensions (LxWxH): 660x280x390mm
- Weight: 20.3kg
Manufacturing Standards:
- EN 60974-5:2014
- EN 60947-10:2015 Class A
Usage Features
The WF 3000 CLASSIC-SMART offers a comprehensive control panel for managing welding operations.
Front Control Panel (WF 3000 Classic):
- VRD (Voltage Reduction Device): Indicates controlled no-load voltage.
- General Alarm: Signals intervention of protection devices (e.g., thermal protection).
- Power On: Indicates voltage presence at output connections.
- 7-Segment Display: Displays general parameters, settings, current/voltage readings, and alarm codes.
- Main Adjustment Handle: Continuously adjusts MMA welding current, allows access to setup, parameter selection/setting, and continuous wire feed speed adjustment. It also regulates welding current and sets workpiece thickness.
Front Control Panel (WF 3000 Smart):
- Power Supply: Indicates connection to mains.
- General Alarm: Signals intervention of protection devices.
- Power On: Indicates voltage presence at output connections.
- 7-Segment Display: Displays general parameters, settings, current/voltage readings, and alarm codes.
- LCD Display (3.5"): Displays general parameters, settings, current/voltage readings, alarm codes, and all operations instantaneously.
- Main Adjustment Handle: Allows access to setup, parameter selection/setting.
- Processes/Functions: Selects various system functions (welding process, mode, current pulse, graphic mode).
- Synergy: Selects preset welding programs by choosing wire type, gas type, and wire diameter.
- Programs: Stores and manages 64 customizable welding programs.
- Inductance: Electronically regulates series inductance for the welding circuit, affecting arc reactivity and spatter.
Main Screen (WF 3000 Smart):
- Heading: Displays important information about the selected process, including synergic curve, filler metal type, wire diameter, gas type, welding current, part thickness, corner bead, and welding voltage.
- Welding Parameters: Allows selection and adjustment of specific welding parameters with icons, values, and units of measurement.
- Functions: Configures key process functions and welding methods, including MMA, TIG DC, MIG/MAG, and Pulsed MIG.
Setup (WF 3000 Smart):
- Save and Quit / Reset: Saves changes or resets parameters to default values.
- Hot Start (MMA): Adjusts initial arc striking current (percentage of welding current).
- Welding Current (MMA/TIG): Regulates welding current in Amperes.
- Arc Force (MMA): Adjusts dynamic response to facilitate welding.
- Dynamic Power Control (MMA): Selects desired V/I characteristic (constant current or falling characteristic with adjustable slope).
- Arc Detachment Voltage (MMA): Sets voltage for forced arc switch-off.
- Graphic Interface Selection: Chooses between Easy (XE), Advanced (XA), or Professional (XP) modes.
- Lock/Unlock: Locks control panel settings with a security password.
- Buzzer Tone: Adjusts buzzer volume.
- Adjustment Step: Sets parameter variation step for up-down keys.
- External Parameters (CH1, CH2, CH3, CH4): Manages external parameter settings.
- U/D Torch: Manages external parameter (CH1) settings.
- Current/Voltage Reading: Displays real-time welding current/voltage and allows setting display method.
- Guard Limits: Sets warning and alarm limits for welding current, voltage, and automation movement.
Synergic Curves Screen (WF 3000 Smart):
- Manual/Synergic Welding Method: Selects between manual parameter adjustment or preset synergic curves based on filler metal type, gas type, and wire diameter.
Programs Screen (WF 3000 Smart):
- Program Storage/Retrieval/Cancellation: Manages up to 64 customizable welding programs, allowing for naming, saving, retrieving, and deleting.
Interface Personalization (WF 3000 Smart):
- 7-Segment Display Personalization: Configures which parameters are displayed on the 7-segment display.
External Controls Management (WF 3000 Smart):
- RC Remote Control Output: Manages external control parameters (Min-Max-parameter) for RC remote controls.
Guard Limits (WF 3000 Smart):
- Warning/Alarm Limits: Sets and adjusts limits for welding current, voltage, and automation movement, with visual signals for warnings and immediate blockage for alarms.
Alarms Screen:
- Alarm Icon/Code/Type: Displays alarm information and provides important indications for troubleshooting.
Maintenance Features
The WF 3000 CLASSIC-SMART requires routine maintenance as per manufacturer instructions, to be performed by qualified personnel.
General Maintenance:
- Safety: All access doors and covers must be closed and secured during operation. Unauthorized modifications are strictly forbidden.
- Cleaning: Prevent accumulation of metallic dust near ventilation grilles. Disconnect from power supply before any intervention.
- Periodic Checks: Clean the generator interior with low-pressure compressed air and soft brushes. Check electrical connections and cables.
- Torch Components: For maintenance or replacement of torch components, electrode holders, and earth cables, check component temperature to ensure they are not overheated.
- Personal Protection: Always use regulation gloves, appropriate wrenches, and tools.
- Warranty: Failure to perform routine maintenance invalidates all warranties.
Troubleshooting:
- Qualified Personnel: All repairs or replacements must be carried out by qualified technical personnel. Unauthorized repairs void the product warranty.
- No Power On: Diagnoses and solutions for issues like no mains voltage, faulty plug/cable, blown fuse, faulty on/off switch, or faulty electronics.
- No Output Power: Diagnoses and solutions for issues like faulty torch trigger, overheating, open side cover/faulty door switch, incorrect earth connection, out-of-range mains voltage, or faulty electronics.
- Incorrect Output Power: Diagnoses and solutions for issues like incorrect welding process selection, incorrect parameter/function settings, faulty potentiometer/encoder, out-of-range mains voltage, or missing input mains phase.
- Blocked Wire Feeder: Diagnoses and solutions for issues like faulty torch trigger, incorrect/worn rollers, faulty wire feeder, damaged torch liner, no power supply to wire feeder, tangled wire on spool, or melted torch nozzle.
- Irregular Wire Feeding: Diagnoses and solutions for issues like faulty torch trigger, incorrect/worn rollers, faulty wire feeder, damaged torch liner, or incorrect spindle clutch/misadjusted rolls.
- Arc Instability: Diagnoses and solutions for issues like insufficient shielding gas, humidity in welding gas, incorrect welding parameters, or incorrect welding mode.
- Excessive Spatter: Diagnoses and solutions for issues like incorrect arc length, incorrect welding parameters, incorrect arc dynamics, insufficient shielding gas, or incorrect welding mode.
- Insufficient Penetration: Diagnoses and solutions for issues like incorrect welding mode, incorrect welding parameters, incorrect electrode, incorrect edge preparation, incorrect earth connection, or oversized workpieces.
- Slag Inclusions: Diagnoses and solutions for issues like poor cleanliness, oversized electrode diameter, or incorrect edge preparation.
- Tungsten Inclusions: Diagnoses and solutions for issues like incorrect welding parameters, incorrect electrode, or incorrect welding mode.
- Blowholes: Diagnoses and solutions for issues like insufficient shielding gas.
- Sticking: Diagnoses and solutions for issues like incorrect arc length, incorrect welding parameters, or incorrect welding mode.
- Undercuts: Diagnoses and solutions for issues like incorrect welding parameters, incorrect arc length, or incorrect welding mode.
- Oxidations: Diagnoses and solutions for issues like insufficient gas protection.
- Porosity: Diagnoses and solutions for issues like grease/varnish/rust/dirt on workpieces/filler metal, humidity in filler metal/welding gas, or incorrect arc length.
- Hot Cracks: Diagnoses and solutions for issues like incorrect welding parameters, grease/varnish/rust/dirt on workpieces/filler metal, or incorrect welding mode.
- Cold Cracks: Diagnoses and solutions for issues like humidity in filler metal or particular joint geometry.
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