Lincoln Electric DIX WD 300 Mounting instructions

WIRE FEEDER
DIX WD 300
SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE
DEVICE N° W000315522
EDITION : EN Instructions for use REF : 8695 5601
REVISION : D
DATE : 07-2019 Original instructions

Thank for the trust you have expressed by purchasing this equipment, which
will give you full satisfaction if you follow its instructions for use and
maintenance.
Its design, component specifications and workmanship comply with
applicable European directives.
Please refer to the enclosed CE declaration to identify the directives
applicable to it.
The manufacturer will not be held responsible where items not recommended
by themselves are associated with this product.
For your safety,there follows a non-restrictive list of recommendations or
requirements, many of which appear in the employment code.
Finally we would ask you kindly to inform your supplier of any error which
you may find in this instruction manual.

8695 5601
TOPTIG I
CONTENTS
A - SAFETY INSTRUCTIONS............................................................................................................1
1 - SERVICING.........................................................................................................................1
2 - PERSONAL PROTECTION................................................................................................1
B - TECHNICAL SPECIFICATIONS..................................................................................................2
C - STARTING UP..............................................................................................................................3
1 - INSTALLING THE REEL HOLDER.....................................................................................3
2 - CONTROLS ........................................................................................................................4
3 - DIX WDW 100 COOLING KIT.............................................................................................4
4 - WDA 303 TIG BUNDLE CONNECTING KIT ......................................................................5
5 - OTHER ELEMENTS ...........................................................................................................6
6 - ADAPTATION TO WIRE DIAMETER.................................................................................7
7 - WIRE LOADING..................................................................................................................8
D - MAINTENANCE AND TROUBLESHOOTING.............................................................................9
1 - MAINTENANCE..................................................................................................................9
2 - TROUBLESHOOTING........................................................................................................10
3 - WIRING DIAGRAM.............................................................................................................11
4 - SPARE PARTS...................................................................................................................13
PERSONAL NOTES ..........................................................................................................................16

8695 5601
II TOPTIG
REVISIONS
REVISION B 07/06
DESIGNATION
PAGE
To change logos
-
REVISION C 07/17
DESIGNATION
PAGE
Complete update
-
REVISION D 07/19
DESIGNATION
PAGE
To change logos
-

8695 5601 / D
TOPTIG A-1
A - SAFETY INSTRUCTIONS
ELECTROMECHANICAL EQUIPMENT USED AS THE SUBASSEMBLY OF AN
INSTALLATION.
This equipment can be associated with a
welding installation, in which case it is covered by
safety instructions described in the instructions for the
welding installation
If this equipment is used in other cases, a
minimum of instructions must be respected, in
particular :
1 - SERVICING
Check often that the insulation and connections of
the electrical equipment and accessories are in
good condition: plugs, cables, flexible cables,
sheaths, connectors, extension cables, workpiece
clamps, electrode holders or torches...
Maintenance and repair work on insulating
sheaths and covers should never be carried out in
a makeshift manner.
Have defective accessories repaired by a
specialist or, better still, replace them.
Periodically check that electrical connections are
properly tightened and do not overheat.
2 - PERSONAL PROTECTION
RISK OF EXTERNAL INJURY
The operator must be properly dressed and
protected for the work he is carrying out
Ensure that no part of the operator's body or of his
assistant's body can come in contact with metal
parts and workpieces which are energized or
which could accidentally become energized
and/or which are moving.
Do not wrap electrical cables around your body.

8695 5601 / D
B-2 TOPTIG
B - TECHNICAL SPECIFICATIONS
Welding process
TIG or plasma, welding and brazing.
Wire feed speed
0 - 20m/min
Wire diameter
0.8/1.0/1.2/1.6mm
Welding metal
Steel alloys and non alloys, high-alloy steels, aluminium alloys,
magnesium alloys, copper alloys and nickel alloys
Max. welding current.
500 A 60% (ambient temperature 40 °C)
400A 100%
Welding voltage
see welding station
Max. no-load voltage
Uo = 113 V (peak value)
Max. connecting voltage
42 V / 50 Hz
Capacity
100 VA
Degree of protection
IP 23
Sound level
< 70 dB (A)
Dimensions
275/ 220/ 259 - (L/W/H in mm)
Weight
7.2 kg
Reel holder
DIX WDS 300 (reel Ø 300 mm)
Ambient operating temperature
-10 °C to +40 °C
Ambient transport and storage
temperature
-10 °C to +55 °C

8695 5601 / D
TOPTIG C-3
C - STARTING UP
1 - INSTALLING THE REEL HOLDER
The DIX WD 300 and reel holder are assembled with the help of the DIX WDV 100 connecting kit
Connecting kit
Installing the reel
Drive pin
When you put in place the wire reel, make sure that the
reel drive hole rests on the core drive pin.
Adjusting the reel brake
The reel core has a braking screw, which must be adjusted so that the reel of wire stops moving when it is stopped.
Female 5-mm hex key.
Protect the brake from
impurities!
Applying the brake excessively will stop continuous feeding (movement in jolts), with a risk of overloading the drive
motor.
If the braking force is not sufficient, the stopped wire reel could continue to turn due to inertia and the wire may get
entangled or come off.
Use a female 5-mm hex
key.
Released
Applied

C - STARTING UP 8695 5601 / D
C-4 TOPTIG
2 - CONTROLS
The main controls are on the front.
Wire feed pushbutton
Torque adjustment potentiometer
(wire feed force)
3 - DIX WDW 100 COOLING KIT
The rapid union system is used to automatically lock the connection when the homologous element of the coupler
is pushed home. Unlocking is by sliding the bush towards the unit.
Front
Rear
Water out
Water return
Water out
Water return

8695 5601 / DC - STARTING UP
TOPTIG C-5
4 - WDA 303 TIG BUNDLE CONNECTING KIT
Bundle connecting kit:
DIX WDA 300 - (CI77500.280)
with welding current

C - STARTING UP 8695 5601 / D
C-6 TOPTIG
5 - OTHER ELEMENTS
1. Reel nut
for opening and closing the reel holder
cover.
2. Cover lock
closing the unit cover.
Rear connection
A1
Connection to wire feeder
A2
Connection to power source
A3
Torch impact safety output
A4
Primary power supply
A5
Support plate A5
Fastening the intermediate bundle
Pull-relief for the connecting bundle.

8695 5601 / DC - STARTING UP
TOPTIG C-7
6 - ADAPTATION TO WIRE DIAMETER
Identification
The corresponding wire diameter is provided on the front of the drive rollers :
Steel wire
Example : DIX DV –04 –12 / 12 T
Ø 1,2 mm
Replacing the wire drive rollers
- Open the wire feeder door.
- Clear the spring blade from the pressure screw and lift the compression clamp.
- Loosen the drive rollers with a 4-mm hex socket key, turning to the left.
- Remove the screws entirely, take out the rollers and replace with others.
- During assembly, fasten the screws with the key till the rollers turn as well.
Feed direction
Pressure screw
Spring blade
Compression clamp
Drive roller
Inlet bush

C - STARTING UP 8695 5601 / D
C-8 TOPTIG
7 - WIRE LOADING
- Connect the bundle to the feeder.
- Connect the power cable to the feeder.
- Take care that all the connections are made correctly. Loose links could damage the connections and affect the
welding performance.
- Important note while loading the wire! - The motor heats during this operation. That is normal and has no effect
on the life of the motor.
Loading
- Load the wire through the feeder inlet taper and feed it through the rollers and insert it into the wire guide sheath.
- While loading, make sure that the wire does not come off the reel or get entangled.
Tension
- Lower the compression clamp and set the spring blade under the pressure screw.
Pressure
- Set the pressure on the rollers with the red pressure screw so that the wire is not deformed and does not slip.
PRESSURE FORCE
Decrease Increase
1. Pressure screw
Loosen
2. Wing nut
The wing nut sets the pressure
screw adjustment position. Before
adjusting the pressure, you need
to unfasten the wing nut.
Tighten
- Close the cover of the wire feeder and the reel holder and fasten the reel nut carefully!
- Always use the pushbutton to load the wire.
- Caution! There is a hazard when the wire comes out of the bundle!
Torque (wire feeding force)
- Use the potentiometer to adjust the torque.
- Keep engaged only till the wire reaches the rollers of the other feeder safely.
- To lock the wire reel, the rollers must not move and the drive unit must be immobile!
- Adjust the reel brake adjustment if required

8695 5601 / D
TOPTIG D-9
D - MAINTENANCE AND TROUBLESHOOTING
Before any work, the welding equipment must be stopped
1 - MAINTENANCE
Because it uses high-quality components, the wire feeder requires virtually no
maintenance.
Users are advised to perform regular inspections to ensure trouble free service. The
frequency of each inspection and the maintenance operations will depend on the
conditions of use of the wire feeder. Each user must therefore identify their own
maintenance plan.
Imperatively remove the mains plug before any inspection or maintenance operation!
Make sure that nobody can reconnect the power supply during maintenance operations!
The following work is to be performed regularly to ensure correct operation:
- Overall visual inspection of the wire feeder to check it for damage or traces of wear.
- Check if the removable connections are secured.
- Remove any residues of material that may be deposited in the unit, e.g. by vacuuming them
up. Important : Eye protection must be used imperatively for this operation!
- Periodically blow clean the wire inlet hose of the torch (depending on the quality of the wire
and the quantity carried).
Important: Eye protection must be used imperatively for this operation!
- Visual inspection of the connecting cables, intermediate hoses and torches to check for any
damage.
- Keep the pressure and driving rollers clean.
- The groove of the drive roller and the point of the inlet bush must be aligned with each
other, both vertically and horizontally. Otherwise, the wire may undergo excess wear.
- Check if the reel holder core and braking system in the reel holder are fouled.
Gas protection
Prevent gas leaks by regularly checking if the gas pipe and connection are tight!
Cooling liquid
Top up with cooling liquid after each torch change. See TOPTIG torch instructions.

D - MAINTENANCE 8695 5601 / D
D-10 TOPTIG
2 - TROUBLESHOOTING
All the products undergo stringent inspections during and after manufacturing. If any operating fault does occur,
please check the wire feeder with help of the table below.
FAULT
POSSIBLE CAUSE
REMEDY
The wire is fed in
jolts
THE WIRE REEL USED IS NOT
CORRECTLY WOUND
Replace the wire reel
The wire reel is deformed or broken
Replace the wire reel
The wire reel brake is applied too
tightly
CORRECT THE REEL BRAKE
ADJUSTMENT
The drive rollers are not adapted to
the wire diameter
Compare the wire diameter
indicated on the drive rollers with
that of the selected wire
Wire guide spiral locked or damaged
Clean or replace
Contact point hole too small
Use a contact point that is suited
to the wire diameter
No control signal
Connect the control unit to the
feeder
The welding torch is
heating
The cooling liquid pipes are not
connected
Connect the cooling liquid pipes to
the cooling unit
Cooling liquid level not sufficient
Top up with cooling liquid
Leak in the cooling circuit
Remove the leak and top up with
cooling liquid
Cooling liquid polluted
Replace! Dispose of the used
cooling liquid in accordance with
the regulations.

8695 5601 / DD - MAINTENANCE
TOPTIG D-11
3 - WIRING DIAGRAM

D - MAINTENANCE 8695 5601 / D
D-12 TOPTIG

8695 5601 / DD - MAINTENANCE
TOPTIG D-13
4 - SPARE PARTS
How to order
The photos or sketches identify nearly every part in a machine or an installation
The descriptive tables include 3 kinds of items:
those normally held in stock: 
articles not held in stock: 
those available on request: no marks
(For these, we recommend that you send us a copy of the page with the list of parts duly
completed. Please specify in the Order column the number of parts desired and indicate the
type and the serial number of your equipment.)
For items noted on the photos or sketches but not in the tables, send a copy of the page
concerned, highlighting the particular mark.
For example:

normally in stock

not in stock
on request
Item
Ref.
Stock
Order
Designation
1
W000XXXXXX


Machine interface board
2
W000XXXXXX


Flowmeter
3
9357 XXXX


Silk-screen printed front panel

D - MAINTENANCE 8695 5601 / D
D-14 TOPTIG
Drive system

normally in stock

not in stock
on request
Item
Ref.
Stock
Order
Designation
1


Screws presser roller assembly / 719070401
2


Wire pipe / 650103006
3


Wire guide block / 71901030016
4


Nut / 659902103
5


Wire inlet guide / 629363005
6
W000260942


Ø 0,8mm steel wire roller / DIX DV - 04
W000263425


Ø 1.0mm steel wire roller / DIX DV - 04 - 10/10 T
W000260943


Ø 1.2mm steel wire roller / DIX DV - 04 - 12/12 T


Ø 1.6mm steel wire roller / DIX DV - 04 - 16/16 T

8695 5601 / DD - MAINTENANCE
TOPTIG D-15
DV AP 0300 CI80060.200 drive motor

normally in stock

not in stock
on request
Item
Ref.
Stock
Order
Designation
1

Motor unit / DV - 01 - P
2

Drive motor / DV - 02 - P
3

Roller support / DV - 03 - P
4

Drive roller / DV - 04 - 12/12 S
5

Roller locking screw / DV - 05 - S
6

Upper roller cover assembly / DV - 06 - P
7

Upper cover pin / DV - 07 - S

D - MAINTENANCE 8695 5601 / D
D-16 TOPTIG
PERSONAL NOTES
Lincoln Electric France S.A.S.
Avenue Franklin Roosevelt 76120 Le Grand Quevilly
76121 Le Grand Quevilly cedex
www.lincolnelectriceurope.com