Dinseo Dix tig g o 1406.m hf pro User manual

BA-0136

TIG Welding Power Source

SCHWEISSEN WELDING WELDINGSCHWEISSEN SCHWEISSEN

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Operations manual

DIX TIG G O 1406.M HF Pro

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.

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

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.

•

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

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

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)

60 ÷ 90

90 ÷ 120

0 ÷ 30

30 ÷ 120

120 ÷ 250

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.