Dinseo Dix tig go 1806.m ac/dc User manual

BA-0112

Welding Power Source

SCHWEISSEN WELDING WELDINGSCHWEISSEN SCHWEISSEN

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Operations manual

DIX TIG GO 1806.M AC/DC

DIX TIG GO 2506.M AC/DC

Introduction 2

Description 2

Features 2

Usage limits (IEC 60974-1) 3

Technical data 3

Open the packaging 4

Installation 4

Connection to the electrical supply 4

Instructions for use 4

Interfacing accessories (optional) 5

TIG welding 6

Electrode welding (MMA) 7

Maintenance 7

Optional 8

The pointing out of any difficulties and their elimination8

Digital interface PCB replacement 8

Meaning of graphic symbols on machine 9

Adjustment of electronic circuit board 9

Wiring diagram (DIX TIG GO 1806.MAC/DC) 10

Wiring diagram (DIX TIG GO 2506.MAC/DC) 12

Key to the electrical diagram 14

Colour key 14

Description

DIX TIG GO 1806.M AC/DC

Powerful, compact and easily represents the

DIX TIG GO 1806.M AC/DC the most innovative, powerful and

technically latest inverter welding power source with single-phase

power supply for TIG welding. The PFC (Power Factor Correc-

tion) device fitted optimises absorption of energy from the mains,

means that these high power welding power source can be con-

nected to power supply systems with 16Afuses without any prob-

lem. The user friendly digital control and advanced functions

ensure complete stability of all welding parameters, guaranteeing

high quality TIG welding for all metals, aluminium, and its alloys,

as well as MMAwelding with any type of electrode.

The DIX TIG GO 1806.MAC/DC units are the ideal solution for all

professional welding applications and for maintenance work that

calls for power and portability.

DIX TIG GO 2506.M AC/DC

Using the most modern IGBT based inverter technology, the three-

phase TIG welding power source DIX TIG GO 2506.MAC/DC with

high frequency ignition, comes with an innovative digital control for

all welding parameters.

Technologically cutting-edge, robust, easy to use with both direct

and alternating current, fitted with high potential digital control, this

welding power source can be used for high quality TIG welding

of all metals including aluminium and alloys. This means that the

machine is particularly suitable for specific uses in industry and

the maintenance sector.

It also guarantees excellent performance for MMA welding, even

when using particularly difficult cellulosic and basic electrodes.

Features

The characteristics found in all welding machines are:

• Innovative and compact design.

• Compact size and light weight for easy transportation.

• Metallic main structure with shock-proof plastic front panel.

• Protective visor on the control panel.

• Robust handle integrated into the chassis.

•

Digital control, regulation and monitoring of all welding param-

eters.

• Digital display for pre-setting welding parameters.

• Digital ammeters and voltmeters are standard fittings, with pre-

setting of welding current and saving of the latest value (Hold-

function).

• DIX ARC COOL SPOT function in TIG HF DC. Innovative spot

welding device to achieve precise and safe joining with a minimal

thermal input. “Multi-DIXARC COOLSPOT” function grants cold

spotting in a rapid sequence, thus further widening the benefits

of the single spot. Thanks to “Perfect-Point” function, DIXARC

COOLSPOT allows to obtain the most precise spot positioning.

• Feature that makes it possible to save and call up personalised

welding programs.

• 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 to operate the power source cooling

fan andthe torch water cooling only when necessary.

• Low absorbed current consumption.

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 machines and equipment are constantly developed and so

changes may be made in terms of their construction 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

• 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.

The diameter of the electrode used is set to allow greater con-

trol of the ignition and dynamics of the arc.

Standard built-in pulsation (from 0,5 to 2000 Hz) with provi-

sion for entering the SYN Pulse function.

Square, mixed, sinusoidal, or triangular wave shape selector.

Square welding wave frequency balancing / regulation and

“Balance Plus”.

• MMA

The VRD (Voltage Reduction Device) can be activated, which

reduces voltages to below 12 V, which means that the weld-

ing machine can be used in ambient conditions in which there

is a high electrical risk, thereby providing maximum opera-

tor safety.

“Arc Force” adjustable to select the best dynamic character-

istics for the welding arc.

- “Hot Start” adjustable to improve ignition with particularly dif-

ficult electrodes.

- Anti-sticking function to avoid the electrodes sticking.

DIX TIG GO 1806.M AC/DC

•

The PFC device makes the wave form of the current absorbed si-

nusoidal, which results in no harmonic disturbance on the mains

and optimisation of absorption, which allows you to use the weld-

ing power source’s full power with a 16Afuse, as well as ensur-

ing greater protection of the welding machine against fluctuations

in the power supply voltage.

DIX TIG GO 2506.M AC/DC R

• Suitable for use on all robotic systems.

• Optional robot interface that handles all process start/ stop sig-

nals, regulation of the principal welding parameters, and also

acts as a flexible, efficient interfacing system that meetsallAna-

logue / Digital connection requirements.

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.

Table 1

Model DIX TIG GO 1806.MAC/DC DIX TIG GO 2506.MAC/DC

TIG MMA TIG MMA

Power supply 50/60 Hz V1~ 230 ±20% 3~ 400 ±20%

Power supply: Zmax Ω(*) 0,092

Input power @ I2Max kVA 6,5 7,0 9,6

Delayed fuse (I2@ 100%) A16 10

Power factor / cosφ 0,99 / 0,99 0,95 / 0,99

Efficiency degree η0,77 0,76 0,81

Open circuit voltage V100 100

Current range A5÷220 10÷180 5÷300 10÷250

Duty cycle @ 100% (40°C) A140 120 210 190

Duty cycle @ 60% (40°C) A180 150 250 220

Duty cycle @ X% (40°C) A220 (30%) 180 (30%) 300 (35%) 250 (40%)

Usable electrodes mm 1,2÷2,4 1,6÷4,0 1,2÷4,0 1,6÷5,0

Standards IEC60974-1•IEC60974-3•IEC60974-10

IEC60974-1•IEC60974-3•IEC60974-10

Protection class IP 23 S IP 23 S

Insulation class F F

Dimensions mm 465 - 390 - 185 495 - 390 - 185

Weight kg 15,5 19

IMPORTANT:

These systems, tested in accordance with the requirements of the EN/IEC 61000-3-3 standard, satisfy the requirements laid down by the EN/

IEC 61000-3-11 standard.

DIX TIG GO 1806.M AC/DC

(*) This equipment meets the requirements laid down in the EN/IEC 61000-3-12 standard on harmonic currents.

DIX TIG GO 2506.M AC/DC

This equipment complies with EN/IEC 61000-3-12 provided that the maximum permissible system impedance Z

max

is less than or equal to 0,092

at the interface point between the user’s supply and the public 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 is connected only to a supply with maximum permissible

system impedance Zmax less than or equal to 0,092.

How to lift up the machine

The weld machine has a strong handle all in one with the frame,

used for transporting the machine manually only.

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 TIG GO 1806.M AC/DC or DIX TIG GO 2506.M AC/DC

weld unit.

• Separately:

- Welding TIG torches (optional).

- Neck strap (optional DIX TIG GO 1806.MAC/DC).

- Ground cable, complete with rapid coupling (optional).

- Coolant unit for welding torch (optional).

- trolley for transportation (optional).

- analogue / digital robot interface (optional this interface must

only be used for automatic / robotised equipments).

- Welding power source interconnection cable - robot interface

(optional - this interface must only be used for automatic / ro-

botised equipments).

Upon receiving the system:

• Remove the welding welding power source and all relevant ac-

cessories-components from their 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 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 machine in op-

eration. 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 ex-

pelled 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.

• Use class “S” means that the equipment can be used in condi-

tions subject to heightened electrical shock.

Connection to the electrical supply

Connection of the machine to the user line (electrical current)

must be performed by qualified personnel.

Before connecting the welding machine to the mains pow-

er supply, make sure that rated voltage and frequency corre-

spond to those provided by the mains power supply and that

the welding machine’s power switch is turned to “O”.

DIX TIG GO 1806.M AC/DC • Single-phase power supply

Use the welder’s own plug to connect it up to the main power sup-

ply. Proceed as follows if you have to replace the plug:

•

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 “GROUND” connection.

DIX TIG GO 2506.M AC/DC • Three-phase power supply

The four-pole cable supplied with the system must be used for the

connection to the mains power supply. This cable is made up of:

•

Three conductors that are used to connect the machine to the

power supply.

•

The fourth, which is YELLOW-GREEN, is used to form the

“GROUND” connection.

Connect a suitable load of normalised plug (3p+t) to the pow-

er cable and provide for an electrical socket complete with

fuses or an automatic switch. The ground terminal must be

connected to the ground 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: 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.

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 shield 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 Shield gas connection.

Table 2

Model DIX TIG GO 1806.MAC/DC DIX TIG GO 2506.MAC/DC

TIG MMA TIG MMA

Input power @ I2Max kVA 6,5 7,0 9,6

Delayed fuse (I2@ 100%) A16 10

Duty cycle @ X% (40°C) A220 (30%) 180 (30%) 300 (35%) 250 (40%)

Mains cable

Length

Section m

mm23,5

2,5 4

2,5

Ground cable

Section mm225 35

Interfacing accessories (optional)

analogue / digital robot interface

Fitted on the back of the DIX TIG GO 2506.M AC/DC R welding

machine (Pos. 1, Fig. B).

analogue / digital robot interface connection cable -

Cutting robot or for automatic equipment

Connect the cable to the analogue / digital interface as shown in

figure (Pos. 2, Fig. B).

To connect the other end of this cable see the diagram in the man-

ualfor the analogue / digital robot interface.

IMPORTANT: Do not keep the analogue / digital robot interface

connected to the welding power source, unless it is also powered

by the automatic system.

FIG. B

FIG. A

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 (for exam-

ple, Argon). This type of welding is used to weld thin sheet metal

or when elevated quality is required.

1) Connecting the welding cables (Fig. C):

• Connect the shield gas hose to theArgon cylinder.

• With the machine switched off:

Connect the ground cable to the snap-on connector

marked + (positive).

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 machine on by moving the power supply

switch to I(Pos. 6, Fig.A).

3) Make the adjustments and select the parameters on the con-

trol panel (for further information see the control panel manu-

al).

TIG WELDING WITH “Lift” TYPE STRIKING

4a) Open the shield gas cylinder and flow regulator.

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. D-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. D-2)

8a) Carry out TIG welding (Fig. D-3).

To end welding:

•

Lift the torch slowly, at a certain point the welding current

decreases, and then stop.

•

The welding machine follows an automatic down slope

along with extinguishing of the arc.

9a) When finished welding remember to shut off the shield gas

cylinder.

TIG WELDING WITH HIGH FREQUENCY STRIKING (HF)

4b) Open the shield gas cylinder and flow regulator.

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. E-1).

6b) Press the torch button.

7b) The voltaic arc strikes even without contact between the TIG

torch electrode and the workpiece (Fig. E-2).

8b) To continue welding put the torch back in its normal position

(Fig. E-3).

IMPORTANT: The high frequency switches off automatically af-

ter switching on.

FIG. F

2000HA73

2000HA72

FIG. D FIG. E

FIG. C

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

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 machine from the mains power supply and con-

nect the welding cables to the output terminals (Positive and

Negative) of the welding machine, attaching them to the clamp

and ground with the polarity specified for the type of electrode

being used (Fig.F). Always follow the electrode manufactur-

er’s instructions.The welding cables must be as short as pos-

sible, they must be near to one another, positioned at or near

floor level. Do not touch the electrode clamp and the ground

clamp simultaneously.

2) Switch the welding machine on by moving the power supply

switch to I(Pos. 6, Fig.A).

3) Make the adjustments and select the parameters on the con-

trol panel (for further information see the control panel manu-

al).

4) Carry out welding by moving the torch to the workpiece. Strike

the arc (press the electrode quickly against the metal and then

lift it) to melt the electrode, the coating of which forms a protec-

tive 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.