DINSEO DIX CM 653.M User manual

DIX CM 653.M
DIX CM 589.M
BA-0106
Cooling modul
SCHWEISSEN WELDING WELDINGSCHWEISSEN SCHWEISSEN
Keepinsecureareaforfuturereference!
Operations manual

2
ENGLISH
EN
Introduction 2
Description 2
Technical data 2
Usage limits (IEC 60974-2) 3
Installation 3
Usage norms 3
Electrical wiring of the welding cooling device 3
Hydraulic connection between the equipment and
the welding unit 4
Start-up / drainage 4
Maintenance 4
Wiring diagram 6
Hydraulic diagram 6
Meaning of graphic symbols on machine 7
Introduction
Thank you for buying our product.
In order to get the best performance out of the plant and ensure
the maximum lifespan of its parts, the use and maintenance
instructions contained in this manual must be read and strictly
complied with, as well as the safety instructions contained
in the relevant folder. If repairs to the plant are required, we
recommend that our clients contact our service centre work-
shops, as they have the necessary equipment and personnel
that are specifically trained and constantly updated.
All our machines and equipment are constantly developed and
so changes may be made in terms of their construction and
features.
Description
The device, particularly suited for cooling by means of water
circulation utilised in particularly heavy welding operations, is
composed in its essential parts of:
• Asingle-phase electric pump.
• Aplastic tank.
• Aradiator.
• Apressure switch.
• Aprotection fuse.
The cooling module is particularly compact and lightweight. It
is designed as part of a welding power source. For other appli-
cations, please contact your DINSE consultant.
Technical data
The general technical data of the system are summarized in
table 1.
Table 1
Model CM653.M - CM 589.M
Single-phase input V400
Frequency Hz 50/60
Max power supply kW 0,3
Max current absorbed A0,9
Delayed fuse A1,6
Coolant 20%-30% antifreeze 70%-80% distilled
water
CoolingpowerΦ1kW 0,95
Capacity with 4 m TIG torch l/min 1,6
Capacity with 4 m MIG/MAG
torch l/min 1,4
Capacity with 4 m MIG/MAG
torch + 10 m extension cable l/min 1,15
Max pressure bar 4,3
Standards IEC 60974-2
Protection class IP 23
Insulation class F
Tank capacity l 5
Dimensions mm 670-235-305
Weight kg 16
Weight with liquid kg 21
Copyright © 2018 DINSE G.m.b.H., Hamburg.
These instructions or excerpts there of shall not be duplicated, transla-
ted or reproduced, nor shall they be stored, processed, transmitted or
distributed by any electronic means without the prior written permission
of DINSE G.m.b.H.
DINSE G.m.b.H.
Tarpen 36 • D-22419 Hamburg
Tel. [phone]
Fax [phone]
[email protected] – www.dinse.eu

3
Usage limits (IEC 60974-2)
The cooling device is sized for cooling by means of water cir-
culation in the welder in a continuous manner.As a work cycle,
it is considered at 100%.
Installation
WARNING: CM653.M or CM 589.M may only be installed hor-
izontally.
The installation site for the system must be carefully chosen in
order to ensure its satisfactory and safe use.
The user is responsible for the installation and use of the sys-
tem in accordance with the producer’s instructions contained
in this manual.
Before installing the system the user must take into consider-
ation the potential electromagnetic problems in the work area.
In particular, we suggest that you should avoid installing the
system close to:
• Signalling, control and telephone cables.
• Radio and television transmitters and receivers.
• Computer and control and measurement instruments.
• Security and protection instruments.
Persons fitted with pace-makers, hearing aids and similar
equipment must consult their doctor before going near a ma-
chine in operation. The installation environment of the device
has to be in conformance with the protection degree of the
carcass, which is equivalent to IP 23 (publication IEC 60529),
which means that the device may be used in closed environ-
ments as well as outdoors. This system is cooled by means of
the forced circulation of air, and must therefore be placed in
such a way that the air may be easily sucked in and expelled
through the apertures made in the frame.
Usage norms
CONTROL APPARATUS (Fig. A)
Pos. 1 Cap for filling tank.
Pos. 2 Level indicator for presence of coolant in the tank (the
level of the liquid must never be inferior to the notch
indicated).
Pos. 3 Luminous two-pole switch.
Pos. 4 Protection fuse.
Pos. 5 CM 589.M: Blue and red quick couplings for connect-
ing the torch.
Pos. 6 CM653.M: Blue and red quick couplings for connect-
ing the torch.
Pos. 7 Cable for electric connection of the device to the gen-
erator cooling device.
Electrical wiring of the
welding cooling device
The cooling device cannot function in an autonomous manner,
therefore it must be connected electrically, in order to operate,
to the welder, making the coupling between the male connec-
tor in the cooling devise and the corresponding female on the
welder (Fig. B).
Prior to beginning, the operator has to assure that close at hand
there is both the welder (example: DIX PI 3506.M) and the cool-
ing device (example: CM 589.M) and that both are working at
the same feed voltage of 400 V.
Upon final connection, even the pressure switch will be con-
nected. The pressure switch has a protective function. It does
not allow the device to emit voltage in case the water pres-
sure and therefore the cooling capacity, is inferior to the cali-
bration value.
FIG. A
FIG. B

4
Hydraulic connection between the
equipment and the welding unit
With separate wire feeder
The hydraulic connection between the cooling system and the
generator must be formed using the connection cable. The de-
livery (blue coloured) and return (red coloured) water tubes,
used for cooling the torch of the welding machine, are part of
the interconnection cable and should be connected as follows:
• Interconnection cable on generator side: connect up tubes
to their rapid couplings (blue and red coloured) at the back
of the coolant system (Fig. C1).
With built-in wire feeder (compact)
The hydraulic connection between the cooling system and the
generator must be formed using the water-cooled torch.
The delivery (blue) and return (red) water hoses are part of the
water-cooled torch, and these are used to cool the welding set
torch and must be connected to the respective (blue and red)
quick couplings on the front of the cooling unit (Fig. C2).
Start-up / drainage
Before connecting the equipment to the utilities check the
rating plate to make sure the voltage and frequency of the
mains correspond and check that the main circuit break-
er on the equipment is turned to “O”.
Upon the first usage following a period of extended inactivity
of the device or in the case in which the electropump does not
go under pressure (slight whistle), it is necessary to undertake
drainage in order to eliminate all the air bubbles present with-
in the hydraulic circuit.
Carry out the following operations following the assembly in-
structions indicated here (Fig. D) :
A) Unscrew the tank’s cap and, using a funnel, fill it with dis-
tilled water. In case of particularly rigid climates with air
temperature near to 0° C it is necessary to add antifreeze
to the cooling distilled water. Do not use antifreeze con-
taining propylene because it could provoke blockage of
the electropump.
B) Connect the hose supplied to the blue quick coupling and
insert the other end of the hose into a receptacle that con-
tains the water.
C) Switch the welding machine on by turning the main switch
to position 1 and switch on the cooling system using the
relevant switch. Then wait about 30 seconds to allow the
cooling system to circulate the liquid.
D) Wait for the exit of the liquid. The operation will be termi-
nated when the liquid exits in a constant way and without
any traces of air bubbles.
E) Once the operation has been completed switch off the
welding machine and the cooling system.
F) Then tighten the cap on the tank again before starting work.
Maintenance
WARNING: Prior to undertaking any kind of inspection within
the machine, unplug the device from feed.
• Periodically check the level of the cooling fluid.
•
Add fluid whenever it drops below the minimum level indi-
cated.
•
Add antifreeze when the room temperature is below 2°C (ta-
ble 2).
• Make sure all joints are tight and that there areno leaks
• Periodically clean the radiator with compressed air to elimi-
nate the dust that reduces the cooling capacity.
IMPORTANT: Original spare parts have been specially de-
signed for our equipment. The use of non-original spare parts
may cause variations in performance or reduce the foreseen
level of safety. We decline all responsibility for the use of non-
original spare parts.
Table 2
Distilled
water Antifreeze External temperature
0°C -10°C -15°C -20°C
80% 20%
75% 25%
70% 30%
65% 35%

5
FIG. C1 FIG. C2
FIG. D

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Wiring diagram
Key to the electrical diagram
•CA Power supply connector •F Fuse •IL Power supply switch •M Electric pump •W Pressure switch
Colour key
•Bc White •Bl Blue •Gg Grey •GV Yellow Green •Mr Brown •Nr Black
Hydraulic diagram
Key to hydraulic diagram
•IL Depth gauge •IN Torch outlet (red) •M Electric pump •OUT Torch intake (blue) •R Radiator •RP Divider •S Tank •V Fan •W Pressure switch

7
Meaning of graphic symbols on machine
Fuse
Cold water outlet
Hot water intake for cooling in the unit
Grounding
Warning!
Before using the equipment you should
carefully read the instructions included in
this manual
Product suitable for free circulation in the
European Community
Power supply switch
Special disposal
Water cooling