DINSEO DIX TIG G O 1406.M HF Pro User manual

BA-0136
TIG Welding Power Source
SCHWEISSEN WELDING WELDINGSCHWEISSEN SCHWEISSEN
Keepinsecureareaforfuturereference!
Operations manual
DIX TIG G O 1406.M HF Pro

2
Introduction 2
Description 2
Features 2
Usage limits (IEC 60974-1) 3
Technical data 3
How to lift up the welding power source 3
Open the packaging 3
Serial number 3
Installation 3
Connection to the electrical supply 4
Instructions for use 4
TIG welding 4
Electrode welding (MMA) 5
Maintenance 6
Optional 6
The pointing out of any difficulties and their elimination7
Procedure for welder assembly and disassembly 7
Digital interface PCB replacement 7
Meaning of graphic symbols on welding power source 8
Wiring diagram 8
Description
DIX TIG GO 1406.M HF Pro with digital control represents the very
latest evolution in direct current weld generators with INVERTER
technology. This powerful 100 KHz generator, based on the latest
generation IGBT, fitted with a planar transformer, makes it pos-
sible to TIG weld any metal except for aluminium and its alloys.
DIX TIG GO 1406.M HF Pro, also excellent for electrode welding,
with its lightness and compactness and first-rate welding charac-
teristics, is ideal for using for maintenance, erection and light steel
structural works.
Features
Main features are:
• Innovative and compact design.
• Compact size and light weight for easy transportation.
• Load-bearing structure with panels made of impact-resistant fi-
bre.
• Robust handle integrated into the chassis.
• Control panel protected against accidental impact.
•
Sloping front control panel, easy to read and adjust and highly
visible from any direction.
• IP 23 S protection class and dust-proof electronic components,
thanks to the innovative “Tunnel” fan cooling system, allow their
use in the toughest work environments.
•
Digital control, regulation and monitoring of all welding param-
eters.
• Digital display for pre-setting welding parameters.
•
Digital ammeter with saving of the latest value (Hold function)
is standard fitted.
•
Feature that makes it possible to save and call up personal-
ised welding programs (only adjustable with the control panel).
• Self-diagnosis device.
• Overheating thermostatic protection.
•
Automatic compensation for mains voltage fluctuations within
±20%.
• Safety barrier against excess voltage from mains.
•
Electromagnetic disturbance is reduced due to high frequency
being involved only during the arc ignition phase.
• “Energy Saving” function that starts ventilation of the generator
only when necessary.
• TIG
- Excellent TIG welding characteristics.
- High frequency arc striking of TIG welding, precise and effi-
cient even from long distance.
- Using special TIG torches allows remote adjustment of weld-
ing current directly from the torch.
- Standard built-in pulsation with provision for entering the SYN
Pulse function.
• MMA
- The VRD (Voltage Reduction Device) can be activated, which
reduces voltages to below 12 V, which means that the weld-
ing power source can be used in ambient conditions in which
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 instruc-
tions contained in this manual must be read and strictly complied
with, as well as the safety instructions contained in the rele-
vant folder. If repairs to the plant are required, we recommend that
our clients contact our service centre workshops, as they have the
necessary equipment and personnel that are specifically trained
and constantly updated.
All our welding power sources and equipment are constantly de-
veloped and so changes may be made in terms of their construc-
tion and features.
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
there is a high electrical risk, thereby providing maximum op-
erator safety.
- Arc Force to select the best dynamic characteristics of the
welding arc.
- Hot Start to improve ignition with particularly difficult elec-
trodes.
- Anti-sticking function to avoid the electrodes sticking.
Usage limits (IEC 60974-1)
The use of a welder is typically discontinuous, in that it is made up
of effective work periods (welding) and rest periods (for the posi-
tioning of parts, the replacement of wire and underflushing opera-
tions etc. This welder is dimensioned to supply a I2max nominal
current in complete safety for a period of work of X% of the total us-
age time. The regulations in force establish the total usage time to
be 10 minutes. The work cycle is considered to be X% of this period
of time. If the permitted work cycle time is exceeded, an overheat
cut-off occurs to protect the components around the welder from
dangerous overheating.Activation of thermal protection is signaled
by “t° C” flashing on control panel display (for further information
see the control panel manual).After several minutes the overheat
cut-off rearms automatically and the welder is ready for use again.
Technical data
The general technical data of the system are summarized in ta-
ble 1.
How to lift up the welding power source
The weld welding power source has a strong handle all in one
with the frame, used for transporting the welding power source
manually only.
NOTE: These hoisting and transportation devices conform to Eu-
ropean standards. Do not use other hoisting and transportation
systems.
Open the packaging
Upon receiving the system:
•
Remove the welding generator and all relevant accessories-
components from their packaging.
• Check that the weld welding power source 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.
Serial number
The welding power source’s serial number is shown on the unit’s
data plate.
The serial number provides the key to tracing the production lot
applicable to the product. The serial number may be essential with
ordering spare parts or planning maintenance.
Installation
The installation site for the system must be carefully chosen in or-
der to ensure its satisfactory and safe use. The user is responsi-
ble for the installation and use of the system in accordance with
the producer’s instructions contained in this manual. Before install-
ing the system the user must take into consideration the potential
electromagnetic problems in the work area. In particular, we sug-
gest 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 welding pow-
er source in operation. The environment in which the equipment
is installed must be suitable for the casing’s protection level. 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.
The welding unit is characterised by the following levels:
•
Protection level IP 23 S indicates that the equipment can be used
both indoors and outdoors.
Table 1
Model DIX TIG GO 1406.M HF Pro
TIG DC MMA
Single-phase power supply 50/60 Hz V1~230 ±20%
Mains supply: Zmax (*) Ω0,19
Power input @ I2Max kVA 8,5 9,0
Delayed fuse (I2@ 100%) A20
Power factor / cosφ 0,67 / 0,99
Maximum efficiency degree η0,82 0,84
Open circuit voltage V88
Current range A5÷200 5÷160
Duty cycle @ 100% (40°C) A120 110
Duty cycle @ 60% (40°C) A140 130
Duty cycle @ X% (40°C) A200 (25%) 160 (30%)
Standards IEC60974-1•IEC60974-3•IEC60974-10
Insulation class IP 23 S
Protection class F
Dimensions mm 390-300-135
Weight kg 7,5
(*) 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 responsibility
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.

4
• Use class means that the equipment can be used in condi-
tions subject to heightened electrical shock.
Connection to the electrical supply
Before connecting the welder to the electrical supply, check
that the welding power source’s plate rating corresponds to
the supply voltage and frequency and that the line switch of
the welder is in the “O” position.
Connection to the power supply must be carried out using the trip-
olar cable supplied with the system, of which:
•
2 conducting wires are needed for connecting the welding pow-
er source 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 recommended load values for retardant sup-
ply fuses.
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 welding power source.
NOTE 2: It is not advisable to plug up the welder to motor-driv-
en generators, as they are known to supply an unstable voltage.
Instructions for use
COMMAND AND CONTROL UNITS (Fig. A)
Pos. 1 command and control panel.
Pos. 2 Positive pole quick connection.
Pos. 3 Fast coupling TIG torch gas tube.
Pos. 4 TIG weld auxiliary control connector (torch button, re-
mote controlpedal, etc.).
Pos. 5 Negative pole quick connection.
Pos. 6 Power supply switch.
In the “O” position the welder is off.
Pos. 7 Mains cable.
Pos. 8 Weld gas inlet coupling.
TIG welding
In the TIG process welding is achieved by melting the two metal
pieces to be joined, with the possible addition of material from the
outside, using an arc ignited by a tungsten electrode. The molten
bath and the electrode are protected by and inert gas (e.g.Argon,
and a flow rate of around 8-14 litres per minute). If necessary, to
complete the welded joint, suitable additional material is added.
The type of additional material and welding current are determined
according to the type of thickness of the base material, the shape
of the joint, and the position of the weld.
1) Connecting the welding cables (Fig. B):
• Connect the gas hose to theArgon cylinder.
• With the welding power source switched off:
- Connect the ground cable to the snap-on connector
marked + (positive).
FIG. A
Table 2
Model DIX TIG GO 1406.M HF Pro
TIG DC MMA
Power input @ I2Max kVA 8,5 9,0
Duty cycle @ X% (40°C) A200 (25%)* 160 (30%)*
Supply connection cable
Length
Section m mm22,5
2,5
Earth cable
Section mm225
* Factor of efficiency

5
- Connect the relative ground 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).
- Connect the torch gas tube to the connection (Pos. 3,
Fig.A).
- Insert the torch button connector in the 6 poles holder
(Pos. 4, Fig.A).
2) Switch the welding power source on by moving the power sup-
ply switch to I(Pos. 6, Fig.A).
3) Make the adjustments and select the parameters on the con-
trol panel.
TIG WELDING WITH “Lift” TYPE STRIKING
4a) Open the gas cylinder and flow regulator (8-14 l/min).
5a) Put the electrode at the point at which welding is to begin, put
the TIG torch at an angle so that the edge of the gas nozzle
is not on top of the piece to be welded, keeping contact be-
tween the point of the electrode and the piece to be welded
(Fig. C-1).
6a) Press the torch button.
7a) The “Lift” function strikes the arc when the TIG torch electrode
comes into contact with the workpiece and is then removed
(Fig. C-2)
8a) Carry out TIG welding (Fig. C-3).
To end welding:
• Lift the torch slowly, at a certain point the welding current
decreases, and then stop.
•
The welding power source follows an automatic down slope
along with extinguishing of the arc.
9a) When finished welding remember to shut off the gas cylinder.
TIG WELDING WITH HIGH FREQUENCY STRIKING (HF)
4b) Open the gas cylinder and flow regulator (8-14 l/min).
5b) Put the electrode at the point at which welding is to begin, put
the TIG torch at an angle so that the edge of the gas nozzle is
not on top of the piece to be welded, keeping a 2-3 mm gap
between the point of the electrode and the piece to be weld-
ed (Fig. D-1).
6b) Press the torch button.
7b) The voltaic arc strikes even without contact between the TIG
torch electrode and the workpiece (Fig. D-2).
8b) To continue welding put the torch back in its normal position
(Fig. D-3).
9b) When finished welding remember to shut off the gas cylinder.
IMPORTANT: The high frequency switches off automatically af-
ter switching on.
PART TO BE WELDED
The part to be welded must always be connected to ground in or-
der to reduce electromagnetic emission. Much attention must be
afforded so that the ground connection of the part to be welded
does not increase the risk of accident to the user or the risk of dam-
age to other electric equipment. When it is necessary to connect
the part to be welded to ground, you should make a direct con-
nection between the part and the ground shaft. In those countries
in which such a connection is not allowed, connect the part to be
welded to ground using suitable capacitors, in compliance with the
national regulations.
WELDING PARAMETERS
Table 3 shows the currents to use with the respective electrodes
for TIG welding.This input is not absolute but is for your guidance
only; read the electrode manufacturers’ instructions for a specific
choice. The diameter of the electrode to use is directly proportion-
al to the current being used for welding.
Table 3
Ø ELECTRODE (mm) CURRENT (A)
1,2
1,6
2,4
3,2
4,0
10 ÷ 80
70 ÷ 150
140 ÷ 250
225 ÷ 400
300 ÷ 500
Before use, sharpen the tungsten electrode, forming a tip about
1,5 times its diameter.
2000HA73 2000HA72
FIG. C FIG. D
FIG. B
α
FIG. E
If the electrode comes into contact with the work-
piece, the point must be formed again.
The point on the electrode must be shaped as
shown in the figure.
α (°) CURRENT (A)
30
60 ÷ 90
90 ÷ 120
0 ÷ 30
30 ÷ 120
120 ÷ 250

6
Electrode welding (MMA)
The welding electrode is used to weld most metals (various types
steel, etc.),for which rutilic and basic electrodes are used.
1) Connecting the welding cables (Fig. F):
Disconnect the welding power source from the mains power
supply and connect the welding cables to the output terminals
(Positive and Negative) of the welding power source, attaching
them to the clamp and ground with the polarity specified for the
type of electrode being used (Fig. F). Always follow the elec-
trode manufacturer’s instructions.The welding cables must be
as short as possible, they must be near to one another, posi-
tioned at or near floor level. Do not touch the electrode clamp
and the ground clamp simultaneously.
2) Switch the welding power source on by moving the power sup-
ply switch to I(Pos. 6, Fig.A).
3) Make the adjustments and select the parameters on the con-
trol panel.
4) Carry out welding by moving the electrode to the workpiece.
Strike the arc (press the electrode quickly against the met-
al and then lift it) 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° com-
pared with the metal in relation to the direction of welding.
PART TO BE WELDED
The part to be welded must always be connected to ground in or-
der to reduce electromagnetic emission. Much attention must be
afforded so that the ground connection of the part to be welded
does not increase the risk of accident to the user or the risk of dam-
age to other electric equipment. When it is necessary to connect
the part to be welded to ground, you should make a direct con-
nection between the part and the ground shaft. In those countries
in which such a connection is not allowed, connect the part to be
welded to ground using suitable capacitors, in compliance with the
national regulations.
WELDING PARAMETERS
Table 4 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 table 5 with the respective
electrodes for the welding of common steels and low-grade al-
loys. These data have no absolute value and are indicative data
only. For a precise choice follow the instructions provided by the
electrode manufacturer.
Table 4
MATERIAL THICKNESS (mm) Ø ELECTRODE (mm)
1,5 ÷ 3
3 ÷ 5
5 ÷ 12
≥12
2
2,5
3,2
4
Table 5
Ø ELECTRODE (mm) CURRENT (A)
1,6
2
2,5
3,2
4
30 ÷ 60
40 ÷ 75
60 ÷ 110
95 ÷ 140
140 ÷ 190
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 5 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.
FIG. F
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

7
Maintenance
ATTENTION: Before carrying out any inspection of the inside of
the generator, disconnect the system from the supply.
SPARE PARTS
Original spare parts have been specially designed for our equip-
ment. 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.
GENERATOR
In order to maintain proper operation, please carry out the follow-
ing maintenance work at regular intervals:
•
Periodic removal of accumulated dirt and dust from the inside
of the generator, using compressed air. Do not aim the air jet
directly onto the electrical components, in order to avoid dam-
aging them.
• Make periodical inspections in order to individuate worn cables
or loose connections that are the cause of overheating.
Optional
DIX TIG GO 1406.M HF Pro welding power sources can be fitted
with various remote control devices and accessories.
The remote controls can be only used in the 2-STROKE and
4-STROKE welding modes.
MANUAL REMOTE CONTROL
WARNING: When using the welding power source for TIG welding
it is OBLIGATORY to use the kit for simultaneously use.
Weld current can be measured at a distance by connecting up this
control. The display will show the previous maximum weld current
value set on the welder. The remote control will adjust welding cur-
rent from the minimum to this value. Just turn the adjustment knob
on the welder to change the maximum output value.
FOOT SWITCH DIX RC 1
The foot switch replaces the torch button and the welding current
setting knob. The display will show the previous maximum weld
current value set on the welder. The pedal will adjust the welding
current from the minimum to this value. Just turn the adjustment
knob on the welder to change the maximum output value.
NOTE:
•
To use the pedal control correctly, set the “welding mode” to
2-STROKE and then the welding parameters SLOPE UP time
to 0 sec., SLOPE DOWN time to 0 sec.
•
When using the welding power source for TIG welding the op-
erator can use the torch button to start the weld and the pedal
to regulate the welding current remotely, provided the simulta-
neous use kit is used.
AIR AND/OR WATER-COOLED TORCH UP/ DOWN
The up/down torch replaces the current setting knob on the front
of the welder. Press right (+) and left (-) button to adjust the ac-
FIG. G
tive parameter. With this kind of torch, it is also possible to scroll
the saved programmes by pressing the two (+) and (-) buttons.
NOTE: The value shown on the display during welding represents
the effective current output with all types of control.
The digital control unit of the welding power source is fitted with a
control recognition device which allows it to identify which device
is connected and take action accordingly. To allow the command
recognition device to work correctly, connect (with the welding
power source switched off) the required accessory to the relative
connector and then switch on the welding power source with the
on/off switch.
When the welding power source is doing a programmed weld, if a
remote control command is activated (and the self-recognition pro-
cedure is carried out), it exits programming automatically.
The pointing out of any difficulties
and their elimination
The supply line is attributed with the cause of the most common
difficulties. In the case of breakdown, proceed as follows:
1) Check the value of the supply voltage
2) Check that the power cable is perfectly connected to the plug
and the supply switch
3) Check that the power fuses are not burned out or loose
4) Check whether the following are defective:
• The switch that supplies the welding power source.
• The plug socket in the wall.
• The generator switch.
NOTE: Given the required technical skills necessary for the repair
of the generator, in case of breakdown we advise you to contact
skilled personnel or our technical service department.
Procedure for welder assembly
and disassembly
Proceed as follows (Fig. G):
• Unscrew the 4 screws holding the front and back panels.
• Unscrew the 2 screws holding the handle.
• Proceed the other way round to re-assemble the welder.
Digital interface PCB replacement
Proceed as follows:
• Unscrew the 4 screws fastening the front rack panel.
• Remove the adjustment knob.
• Extract wiring connectors from digital interface PCB.
• Remove digital interface PCB by lifting it out of its supports.
• Proceed vice versa to assemble new digital interface PCB.

8
Meaning of graphic symbols on welding power source
Power supply switch
System for use in environments with increased
risk of electroshock
Product suitable for free circulation in the Euro-
pean Community
Danger! High voltage
Grounding
Positive pole snap-in connector
Negative pole snap-in connector
Connector for the remote control
Warning!
Fast coupling TIG torch gas tube
Before using the equipment you should carefully
read the instructions included in this manual
MMAwelding
TIG welding
Special disposal
Key to the electrical diagram
•1 Capacitors •2 Remote control •3 TIG torch connector •4 Secondary diode
•5 Primary circuit rectifier •6 Digital display •7 DOWN button •8 Encoder •9
Gas solenoid valve •10 Pedal control potentiometer •11 Microswitch •12
Mains switch •13 Fan •14 Remote current potentiometer •15 Pedal con-
trol •16 TIG torch button •17 Primary IGBT circuit •18 Membrane keyboard
•19 EMC filter PCB •20 High frequency (HF) PCB •21 Digital interface PCB
•22 Primary Inverter PCB •23 Secondary circuit PCB •24 Secondary circuit
thermostat •25 HF transformer •26 TIG torch •27 Up / Down TIG torch •28
Main transformer •29 UP button
Colour key
Ar Orange
Az Sky Blue
Bc White
Bl Blue
Gg Grey
Gl Yellow
GV Yellow-Green
Mr Brown
Nr Black
Ro Pink
Rs Red
Vd Green
Vl Violet
Wiring diagram
•1•2•3•4•5•6•7•8•9
C11-12-13-24 CD 6 CT D1-2 D8-12 DD DW ED EVG
•10 •11 •12 •13 •14 •15 •16 •17 •18 •19
FPP FPS IL MV PD PSR 7 PT Q1-2-3-4 RF SF
•20 •21 •22 •23 •24 •25 •26 •27
SHF S-INT DIG S-INV SS THS THF TORCH TORCH UP/DOWN
•28 •29
TP UP

9

10
Introduction
This manual describes the functions on and how to use the fol-
lowing control panels:
Control panel
WELDING PARAMETERS
WELDING PROCESS
PULSE
DISPLAY WELDING MODE
ENCODER KNOB
VRD
■ENCODER KNOB
This is used to regulate and change the welding parameters, ac-
cording to which LED is switched on and the value shown on the
DISPLAY, which is necessary for the machine to work correctly.
■DISPLAY
Displays the selections made using the various keys (with corre-
sponding LED on or flashing) and regulated using the ENCOD-
ER knob.
■VRD
The Voltage Reduction Device (VRD) is a safety device that re-
duces the voltage. It prevents voltages forming on the output ter-
minals that may pose a danger to people.
Two-tone LED (off - red - green) indicates enabling of the VRD
device.
The standard, preset settings for the firm do not activate the VRD
function on the welding machine and so this LED is normally off.
To activate the VRD device, see the relevant paragraph.
Introduction 10
Control panel 10
Displaying the software version installed 12
Electrode welding (MMA) 12
TIG welding 12
TIG welding with the SPOT WELDING function on 13
TIG welding - Welding parameters 13
Creating and memorising automatic welding points 16
PROGRAMMED and/or MANUAL welding 16
Calling up saved programs 17
Viewing the parameters set 17
Activating the VRD device 17
Auxiliary functions 18
Factory default 18
Error and protection conditions 18