Dinseo Dix go 1206.m c User manual

DIX GO 1206.M C

BA-0120

TIG Welding Power Source

SCHWEISSEN WELDING WELDINGSCHWEISSEN SCHWEISSEN

Keepinsecureareaforfuturereference!

Operations manual

Introduction 2

Description 2

Technical data 2

Usage limits (IEC 60974-1) 3

How to lift up the machine 3

Open the packaging 3

Installation 3

Connection to the electrical supply 3

Usage norms 4

MMAelectrode welding (Fig. B) 4

TIG welding (Fig. C) 5

Maintenance 6

The pointing out of any difficulties and their elimination6

Procedure for welding power source assembly and

disassembly 6

Deactivating the VRD device 6

Introduction

Thank you for purchasing one of our products. Please read in-

structions on use in this manual as well as the safety rules giv-

en in the attached booklet and follow them carefully to get the

best performance from the plant and be sure that the parts have

the longest service life possible. In the interest of customers, you

are recommended to have maintenance and, where necessary,

repairs carried out by the workshops of our service organisation,

since they have suitable equipment and specially trained person-

nel available. All our machinery and systems are subject to con-

tinual development. We must therefore reserve the right to modify

their construction and properties.

Description

DIX GO is the latest evolution in inverter technology generators

for welding. The most advanced materials and components have

been used to design and produce it such as:

•

VRD (Voltage Reduction Device), which makes it possible to use

the machine in environments where the risk of electric shock or

electrocution caused by arc welding is enormously increased by

the presence of water, humidity, or heat, and particularly where

the ambient temperature exceeds 32°C. This device can be ex-

cluded by means of settings on the electronic board that controls

the inverter (see the “Deactivating the VRD device” paragraph).

• Main planar transformer with extremely low load loss.

• Electronic auxiliary feeder.

•

Voltage doubler ensuring precision striking, constant arc and

very low electrical input from the main supply by the welding

power source.

•

Extremely high frequency power INVERTER with very latest type

of IGBT to reduce switching losses to a minimum.

•

The inverter resists ample current variations (MAX 290V) and

can be utilized with very long electric cables (MAX 100 m).

• Selector with 3 weld procedures:

Basic and “cellulosic” electrodes with “Hot Start” and “Arc

Force” devices.

Stainless steel electrodes with special characteristics for a

soft arc.

TIG welding with thermal controlled (TCS) “Lift” type striking

reducing tungsten inclusions to a minimum and allowing to

also strike on sharp edges.

•

The generator also conforms to all European Union standards

and directives in force.

Technical data

The general technical data of the system are summarized in ta-

ble 1.

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. +49 (0)40 658 75-0

Fax +49 (0)40 658 75-200

[email protected] – www.dinse.eu

Usage limits (IEC 60974-1)

The use of a welding power source is typically discontinuous, in

that it is made up of effective work periods (welding) and rest pe-

riods (for the positioning of parts, the replacement of wire and

underflushing operations etc. This welding power source is di-

mensioned to supply a I2max nominal current in complete safety

for a period of work of 20% of the total usage time. The regula-

tions in force establish the total usage time to be 10 minutes. The

work cycle is considered to be 20% of this period of time. If the

permitted work cycle time is exceeded, an overheat cut-off occurs

to protect the components around the welding power source from

dangerous overheating. Intervention of the overheat cut-off is in-

dicated by the lighting up of yellow thermostat LED. After several

minutes the overheat cut-off rearms automatically (and the yellow

LED turns itself off) and the welding power source is ready for use

again. This generator is constructed in compliance with the IP23 S

protection level, meaning:

• That it is protected against the penetration of solid foreign bod-

ies with diameters in excess of Ø 12 mm.

•

That it is protected against water spray hitting the surface with

an angle of incidence up to 60°.

•

That the welding power source has been tested for withstanding

harmful effects due to water getting in when the moving parts on

the equipment are moving.

How to lift up the machine

This welding power source has a handle for picking it up and car-

rying it by hand.

NOTE: These hoisting and transportation devices conform to Eu-

ropean standards. Do not use other hoisting and transportation

systems.

Open the packaging

The system essentially consists of:

• DIX GO 1206.M C

• weld unit.

Upon receiving the system:

• Remove the welding generator and all relative accessories and

components from the packaging.

•

Check that the weld machine is in good condition, if not report

any problems immediately to the seller-distributor.

•

Make sure all ventilation grilles are open and that no foreign bod-

ies are blocking the air circulation.

Installation

The installation site for the system must be carefully chosen in or-

der to ensure its satisfactory and safe use.

The user is responsible for the installation and use of the system

in accordance with the producer’s instructions contained in this

manual.

Before installing the system the user must take into consideration

the potential electromagnetic problems in the work area. In particu-

lar, we suggest that you should avoid installing the system close to:

• Signalling, control and telephone cables.

• Radio and television transmitters and receivers.

• Computers and control and measurement instruments.

• Security and protection instruments.

Persons fitted with pace makers, hearing aids and similar equip-

ment must consult their doctor before going near a machine in

operation. The equipment’s installation environment must comply

to the protection level of the frame i.e. IP 23 S (IEC 60529 publi-

cation). The system is capable of working in environments where

working conditions are particularly hard. 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.

Connection to the electrical supply

Before connecting the welding power source to the electrical

supply, check that the machine’s plate rating corresponds to

the supply voltage and frequency and that the line switch of

the welding power source is in the “O” position.

This system has been designed for nominal voltage 230 V - 50/60

Hz. It can however work at 220 V and 240 V - 50/60 Hz without

any problem. Connection to the power supply must be carried out

using the tripolar cable supplied with the system, of which:

•

2 conducting wires are needed for connecting the machine to

the supply.

• The third, which is YELLOW GREEN in colour is used for mak-

ing the “EARTH” connection.

Connect a suitable load of normalised plug (2p + e) to the

power cable and provide for an electrical socket complete

with fuses or an automatic switch. The earth terminal must

be connected to the earth conducting wire (YELLOW-GREEN)

of the supply.

Table 2 shows the capacity values that are recommended for fus-

es in the line with delays.

NOTE 1: Any extensions to the power cable must be of a suitable

diameter, and absolutely not of a smaller diameter than the spe-

cial cable supplied with the machine.

NOTE 2: It is not advisable to plug up the welding power source

to motor-driven generators, as they are known to supply an un-

stable voltage.

Table 1

Model DIX

GO 1206.M C

Single-phase power supply 50/60 Hz V230

Mains supply: Zmax (*) Ω0,26

Power input @ I2Max kVA 11,3

Delayed fuse (I2@ 100%) A20

Power factor / cosφ 0,55 / 0,99

Maximum efficiency degree η0,74

Open circuit voltage (max) V105

Open circuit voltage (resting) V≤12

vrd - Intervention time at end of welding s≤0,3

vrd - LST LED indication

green

red V

VU2 > 35

U2≤35

Current range A5 ÷ 180

Duty cycle @ 100% (40°C) A100

Duty cycle @ 60% (40°C) A120

Duty cycle @ 20% (40°C) A180

Usable electrodes Ø mm 1,6 ÷ 4

Standards IEC 60974-1

IEC 60974-10

Insulation class IP 23 S

Protection class F

Dimensions mm 390-300-135

Weight kg 6,5

(*) Mains supply Zmax: maximum impedance value allowed for the grid

according to the EN/IEC 61000-3-11 standard.

WARNING: This equipment does not comply with EN/IEC 61000-3-12.

If it is connected to a public low voltage system, it is the responsibil-

ity of the installer or user of the equipment to ensure, by consultation

with the distribution network operator if necessary, that the equipment

may be connected.

Table 3

WELDING THICKNESS (mm) Ø ELECTRODE (mm)

1,5 ÷ 3

3 ÷ 5

5 ÷ 12

≥12

2,5

3,25

Table 4

Ø ELECTRODE (mm) CURRENT (A)

1,6

2,5

3,25

30 ÷ 60

40 ÷ 75

60 ÷ 110

95 ÷ 140

140 ÷ 190

Usage norms

CONTROL APPARATUS (Fig. A)

Pos. 1 Supply switch. In the “O” position the welding power

source is off.

Pos. 2 Rapid connection attachments of the electrode holder

and earth holder gripper.

Pos. 3 Yellow THERMOSTAT LED. When this LED switches on

it indicates that the trip switch has tripped because you

are working beyond the work cycle. Wait for a few min-

utes before starting to weld again.

Pos. 4 Welding current adjust potentiometer.

FIG. B

FIG. A

Pos. 5 Two-colour LED (red - green) signalling the presence of

voltage at the welding clamps (LST).

LED colour Voltage at the welding

clamps

Red U2 > 35

Green U2≤35

Pos. 6 Selector 3 weld procedures:

•

ELECTRODE - For welding using basic and “cellu-

lose” electrodes with a “Hot Start” and “Arc Force”

device.

•

Cr-Ni ELECTRODE - For stainless steel welding with

special soft-arc characteristics.

•

TIG - For TIG welding with thermal controlled (TCS)

“Lift” type striking reducing tungsten inclusions to a

minimum and allowing to also strike on sharp edges.

MMA electrode welding (Fig. B)

Electrode welding is used for welding most metals (various types

of steels, etc.) using rutilic, basic, and cellulosic electrodes with

diameters from 1.6 mm to 4.0 mm.

1) Connecting the welding cables:

Disconnect the machine from the mains power supply and con-

nect the welding cables to the output terminals (Positive and

Negative) of the welding power source, attaching them to the

clamp and earth with the polarity specified for the type of elec-

trode being used (Fig. B). Always follow the electrode manu-

facturer’s instructions. The welding cables must be as short

as possible, they must be near to one another, positioned at

or near floor level.

2) Adjust the welding current using the potentiometer (Pos. 4,

Fig.A).

3) Turn the process selector (Pos. 6, Fig.A) to the ELECTRODE

position (for welding using basic and “cellulose” electrodes

with a “Hot Start” and “Arc Force” device) or Cr-Ni ELEC-

TRODE (for welding stainless steel with special characteris-

tics to achieve a softer arc).

4) Start the welding power source by selecting position 1 on the

line switch (Pos. 1, Fig. A).

5) The green LED (Pos 5, FigA) shows that the VRD function is

active.

6) To “deactivate” the VRD device and therefore start to weld,

follow this simple procedure: First touch the workpiece with

the electrode, then detach it and ignite the arc within a MAX

of 0,3 seconds, otherwise if this time is exceeded the VRD de-

vice starts and prevents welding.

Strike the arc to melt the electrode, the coating of which forms

a protective residue. Then continue welding by moving the

electrode from left to right, inclining it by about 60° compared

with the metal in relation to the direction of welding.

During welding the VRD LED may turn RED, which does not

indicate any malfunction on the welding power source, but that

the VRD device has been deactivated to allow welding.

PART TO BE WELDED

The part to be welded must always be connected to earth in order

to reduce electromagnetic emission. Much attention must be af-

forded so that the earth connection of the part to be welded does

not increase the risk of accident to the user or the risk of damage

to other electric equipment. When it is necessary to connect the

part to be welded to earth, you should make a direct connection

between the part and the earth shaft. In those countries in which

such a connection is not allowed, connect the part to be welded

to earth using suitable capacitors, in compliance with the nation-

al regulations.

WELDING PARAMETERS

Table 3 shows some general indications for the choice of elec-

trode, based on the thickness of the parts to be welded. The val-

ues of current to use are shown in the table with the respective

electrodes for the welding of common steels and low-grade alloys.

These data have no absolute value and are indicative data only.

For a precise choice follow the instructions provided by the elec-

trode manufacturer.

The current to be used depends on the welding positions and the

type of joint, and it increases according to the thickness and di-

mensions of the part.

The current intensity to be used for the different types of welding,

within the field of regulation shown in table 4 is:

• High for plane, frontal plane and vertical upwards welding.

• Medium for overhead welding.

•

Low for vertical downwards welding and for joining small pre-

heated pieces.

A fairly approximate indication of the average current to use in

the welding of electrodes for ordinary steel is given by the follow-

ing formula: I = 50 × (Øe – 1)

Where:

I = intensity of the welding current

Øe = electrode diameter

Example:

For electrode diameter 4 mm

I = 50 × (4 – 1) = 50 × 3 = 150A

TIG welding (Fig. C)

TIG welding melts the metal of the workpiece, using an arc struck

by a tungsten electrode.

The fusion bath and the electrode are protected by gas (Argon).

This type of welding is used to weld thin sheet metal or when el-

evated quality is required.

1) Connecting the welding cables:

•

Connect one end of the gas hose to the gas connecter on

the TIG torch and the other end to the Argon cylinder and

open it.

• With the machine switched off:

Connect the earth cable to the snap-on connector marked

+ (positive).

Connect the relative earth clamp to the workpiece or to the

workpiece support in an area free of rust, paint, grease,

etc..

Connect the TIG torch power cable to the snap-on con-

nector marked - (negative).

2) Adjust the welding current using the potentiometer (Pos. 4,

Fig.A).

3) Turn the process selector (Pos. 6, Fig. A) to the TIG position.

4) Start the welding power source by selecting Pos. 1 on the line

switch (Pos. 1, Fig.A).

5) The two-tone LED (Pos 5, Fig A) will turn GREEN, which

means that the VRD function is active.

6) Adjust the gas flow by manually turning the valve on the TIG

torch.

7) To “deactivate” the VRD device and therefore start to weld, fol-

low this simple procedure: First touch the workpiece with the

electrode, then detach and ignite (see Fig D).

8) Carry out TIG welding. During welding the VRD LED may turn

RED, which does not indicate any malfunction on the welding

power source, but that the VRD device has been deactivated

to allow welding.