BA-0110
Operations manual
Welding Power Source
DIX GO 1206.M
Keep in secure area for future reference!
SCHWEISSEN WELDING
WELDINGSCHWEISSEN SCHWEISSEN
Introduction 1
Description 1
Technical data 2
Usage limits (IEC 60974-1) 2
How to lift up the machine 2
Open the packaging 2
Installation 2
Introduction
Thank you for purchasing one of our products. Please read instructions 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 personnel available. All our machinery and systems are subject to continual development. We must therefore reserve the right to modify
their construction and properties.
Connection to the electrical supply 2
Usage norms 3
MMA electrode welding (Fig. B) 3
TIG welding (Fig. C) 4
Maintenance 5
The pointing out of any difficulties and their elimination 5
Procedure for welder assembly and disassembly 5
DINSE G.m.b.H.
Tarpen 36 • D-22419 Hamburg
Tel. +49 (0)40 658 75-0
Fax +49 (0)40 658 75-200
info@dinse.eu – www.dinse.eu
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:
• 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 welder.
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).
Table 1
Model
Single-phase power supply 50/60 Hz V 230
Mains supply: Z
Power input @ I
Delayed fuse (I
Power factor / cosφ 0,66 / 0,99
Maximum efficiency degree η 0,79
Open circuit voltage (max) V 88
Open circuit voltage (resting) V -
Current range A 5 ÷ 150
Duty cycle @ 100% (40°C) A 100
Duty cycle @ 60% (40°C) A 120
Duty cycle @ 30% (40°C) A 150
Usable electrodes Ø mm 1,6 ÷ 4
Standards
Insulation class IP 21 S
Protection class F
Dimensions
Weight kg 4,2
(*) Mains supply Z
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.
(*) Ω 0,21
max
Max kVA 7,6
2
@ 100%) A 16
2
mm 340-260-115
: maximum impedance value allowed for the grid
max
DIX.GO 1206.M
≤24
IEC 60974-1
IEC 60974-10
Copyright © 2018 DINSE G.m.b.H., Hamburg.
These instructions or excerpts there of shall not be duplicated, translated 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.
2
• Selector with 3 weld procedures:
- Basic electrodes with “Hot Start” and “Arc Force” device.
-
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.
• 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 equipment 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 21 S (IEC 60529 publication). 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.
T echnical data
The general technical data of the system are summarized in table 1.
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 positioning of parts, the replacement of wire and underflushing operations etc. This welder is dimensioned to supply a I2 max nominal
current in complete safety for a period of work of 30% of the total usage time. The regulations in force establish the total usage
time to be 10 minutes. The work cycle is considered to be 30% 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. Intervention of the overheat
cut-off is indicated 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 welder is ready for use again.
How to lift up the machine
This welding machine has a handle for picking it up and carrying
it by hand.
NOTE: These hoisting and transportation devices conform to European standards. Do not use other hoisting and transportation
systems.
Open the packaging
•
Upon receiving the system:
Remove the welding generator and all the relative accesso-ries-
•
components from the pack and the case (if present).
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 order 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 particular, we suggest that you should avoid installing the system close to:
• Signalling, control and telephone cables.
Connection to the electrical supply
Before connecting the welder 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 welder is in
the “O” position.
Use the welder’s own plug to connect it up to the main power supply. 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 making the “EARTH” connection.
DIX GO 1206.M works with circuit breaker or fusible power switches.
Table 2 shows the capacity values that are recommended for fuses 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 special cable supplied with the machine.
NOTE 2: It is not advisable to plug up the welder to motor-driven generators, as they are known to supply an unstable voltage.
Usage norms
CONTROL APP ARA TUS (Fig. A)
Pos. 1 Supply switch. In the “O” position the welder is off.
Pos. 2 Welding current adjust potentiometer.
Pos. 3 Selector 3 weld procedures:
Model
Power input @ I
Delayed fuse (I
Duty cycle @ 30% (40°C) A 150
Mains supply connection cable
Length
Section
Earth cable
Section mm
• ELECTRODE - For basic electrode welding with “Arc
Force” and “Hot Start” device.
Cr-Ni ELECTRODE - For stainless steel welding with
•
special soft-arc characteristics.
Table 2
DIX GO 1206.M
Max kVA 7,6
2
@ 100%) A 16
2
m
mm
2
2
2,2
2,5
16
3
FIG. A
•
TIG - For TIG welding with thermal controlled (TCS)
“Lift” type striking reducing tungsten inclusions to a
Pos. 4 Rapid connection attachments of the electrode holder
Pos. 5 Yellow THERMOST AT LED. When this LED switches on
Pos. 6 DIX GO 1206.M - Green POWER SUPPL Y LED. When
minimum and allowing to also strike on sharp edges.
and earth holder gripper.
it indicates that the trip switch has tripped because you
are working beyond the work cycle. Wait for a few minutes before starting to weld again.
this LED is on, it means that the power supply to the
welding machine is on, and it is ready to work.
MMA electrode welding (Fig. B)
Electrode welding is used to weld most metals (different types of
steel, etc.) using coated rutilic and basic electrodes with diameters
ranging from Ø 1.6 mm to Ø 4 mm.
1) Connecting the welding cables:
Disconnect the machine from the mains power supply and
connect the welding cables to the output terminals (Positive
and Negative) of the welding machine, attaching them to the
clamp and earth with the polarity specified for the type of electrode being used (Fig. B). Always follow the electrode manufacturer’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. 2,
Fig. A).
3) Turn the process selector (Pos. 3, Fig. A) to the ELECTRODE
position (for welding using basic electrodes with an “Arc Force”
and “Hot Start” device) or Cr-Ni ELECTRODE (for welding
stainless steel with special characteristics to achieve a softer
arc).
4) Start the welding machine by selecting position 1 on the line
switch (Pos. 1, Fig. A).
5) DIX GO 1206.M - The green LED (Pos. 6, Fig. A) shows that
the power supply to the welding machine is on, and it is ready
to work.
WELDING P ARAMETERS
Table 3 shows some general indications for the choice of electrode, based on the thickness of the parts to be welded. The values 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 electrode manufacturer.
The current to be used depends on the welding positions and the
type of joint, and it increases according to the thickness and dimensions 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 following 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
FIG. B
4
Table 3
WELDING THICKNESS (mm) Ø ELECTRODE (mm)
1,5 ÷ 3
3 ÷ 5
5 ÷ 12
≥12
Ø ELECTRODE (mm) CURRENT (A)
1,6
2
2,5
3,2
4
2
2,5
3,2
4
Table 4
30 ÷ 60
40 ÷ 75
60 ÷ 110
95 ÷ 140
140 ÷ 190
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 elevated 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-
2) Adjust the welding current using the potentiometer (Pos. 2,
3) Turn the process selector (Pos. 3, Fig. A) to the TIG position.
4) Start the welding machine by selecting Pos. 1 on the line
5) DIX GO 1206.M - The green LED (Pos. 6, Fig. A) shows that
6) Adjust the gas flow by manually turning the valve on the TIG
nector marked - (negative).
Fig. A).
switch (Pos. 1, Fig. A).
the power supply to the welding machine is on, and it is ready
to work.
torch.
FIG. C
2000HA41
P ART T O BE WELDED
The part to be welded must always be connected to earth in order
to reduce electromagnetic emission. Much attention must be afforded 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 national regulations.
FIG. D
2000HA39
5
FIG. E
Maintenance
WARNING: Before carrying out any inspection of the inside of the
generator, disconnect the system from the supply.
SP ARE PARTS
Original spare parts have been specially designed for our equipment. 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
As these systems are completely static, proceed as follow:
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 damaging them.
• Make periodical inspections in order to individuate worn cables
or loose connections that are the cause of overheating.
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 machine.
• 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. E):
• 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.
6
IT
Schema elettrico
FR
Schéma électrique
ES
Esquema eléctrico
PT
Esquema eléctrico
EN
Wiring diagram
DE
Schaltplan
NL
Elektrisk skema
2101F634
7
•1 •2 •3 •4 •5 •6 •7 •8 •9 •10 •11 •12 •13 •14 •15 •16 •17 •18
BP BS DB IB IC IL LA LT MV POT1 RP RS SF SW1 TP TRP TRS VR
DE
Schaltplan-Legende
•1 Primäre Trafospule •2 Sekundäre Trafospule •3 Vervielfältiger-Karte •4 INVERTER-Leistungskarte •5 INVER TER-Steuerkarte •6 Leitungschalter •7 DIX
GO 1206.M: Grüne LED VERSORGUNG •8 Gelbe LED Auslösen Thermoschutz •9 Belüfteter Motor •10 Strompotentiometer •11 Primärer Gleichrichter
•12 Sekundärer Gleichrichter •13 Karte mit Frontsteuerungen •14 Verfahrenumschalter •15 Leistungstrafo •16 Thermostat primärer Gleichrichter •17
Thermostat sekundärer Gleichrichter •18 Varistor
EN
Key to the electrical diagram
•1 Primary transformer coil •2 Secondary transformer coil •3 Doubler card •4 INVERTER power card •5 INVERTER control card •6 Supply switch •7 DIX
GO 1206.M: Green POWER SUPPLY LED •8 Yellow LED for overheat cutofft •9 Blower •10 Current potentiometer •11 Primary rectifier •12 Secondary
rectifier •13 Front controls card •14 Process switch •15 Power transformer •16 Primary rectifier thermostat •17 Secondary rectifier thermostat •18 Varistor
ES
Leyenda esquema eléctrico
•1 Bobina primaria transformador •2 Bobina secundaria transformador •3 T arjeta duplicador •4 Tarjeta potencia INVERTER •5 Tarjeta control INVERTER
•6 Interruptor de línea •7 DIX GO 1206.M: LED verde ALIMENTACIÓN •8 LED amarillo de señalación intervención protección termostática •9 Motor
ventilador •10 Potenciómetro corriente •11 Enderezador primario •12 Enderezador secundario •13 Tarjeta mandos frontal •14 Conmutador de proceso
•15 Transformador de potencia •16 Termostato enderezador primario •17 Termostato enderezador secundario •18 V aristor
DE
Farbenlegende
Ar Orange
Bl Blau
Gl Gelb
GV Gelb Grün
Nr Schwarz
Rs Rot
Vd Grün
EN
Colour key
Ar Orange
Bl Blue
Gl Yellow
GV Yellow Green
Nr Black
Rs Red
Vd Green
Ar Anaranjado
Bl Azul
Gl Amarillo
GV Amarillo Verde
Nr Negro
Rs Rojo
Vd Verde
8
ES
Leyenda colores
1
3
4
5
6
7
82
9
DE
Bedeutung der grafischen Symbole auf der Maschine
•1 Schalter EIN/AUS •2 Umschalter Schweißverfahren •3 Skala des Schweißstromes •4 DIX GO 1206.M: Grüne LED Netzkontrolle •5 Gelbe LED Auslösen
Thermoschutz •6 Möglicher Gebrauch der Anlage in Umgebung mit erhöhter Gefahr elektrischer Schläge •7 Gefährliche Spannung •8 Schutzerde •9
Erdung •10 Schnellanschluß Pluspol •11 Schnellanschluß Minuspol •12 Achtung! •13 Vor der Anwendung der Anlage sind die Gebrauchsanweisungen
des vorliegenden Handbuches sorgfältig zu lesen •14 Für den freien Warenverkehr in der EU zugelassenes Produkt
EN
Meaning of graphic symbols on machine
•1 On/off switch •2 Welding process switch •3 Welding current scale •4 DIX GO 1206.M: Green LED for power •5 Yellow LED for overheat cutoff •6 System
for use in environments with increased risk of electroshock •7 Danger! high voltage •8 Grounding protection •9 Grounding •10 Positive pole snap-in
connector •11 Negative pole snap-in connector •12 Warning! •13 Before using the equipment you should carefully read the instructions included in this
manual •14 Product suitable for free circulation in the European Community
ES
Significado de los símbolos gráficos referidos en la máquina
•1 Interruptor conectado/apagado •2 Comutador proceso de soldadura •3 Escala corriente de soldadura •4 DIX GO 1206.M: LED verde de señalación
presencia alimentación de red •5 LED amarillo de señalación intervención protección termostática •6 Instalación que puede ser utilizada en ambientes
con grande riesgo de descargas eléctricas •7 Tensión peligrosa •8 Tierra de protección •9 Tierra •10 Toma rápida polo positivo •11 Toma rápida polo
negativo •12 Atención! •13 Antes de utilizar la instalación, es necesario leer atentamente las instrucciones contenidas en este manual •14 Producto apto
para circular libremente en la Comunidad Europea
10
11
12
13
14
15
16
9
DE
Bedeutung der grafischen Symbole auf dem Datenschild
•1 Name und Anschrift des Herstellers •2 Bezeichnung der Anlage •3 Einphasiger INVERTER-Generator •4 Anlage Elektrodenschweissen •5
Gleichstrom Schweißen •6 Möglicher Gebrauch in Umgebung mit erhöhter Gefahr elektrischer Schläge •7 Netzspeisung und Phasenanzahl •8 Nennwert
Versorgungsfrequenz •9 WIG-Schweißen •10 Sekundär-Leerlaufspannung •11 Umluftkühlung •12 Isolationsklasse •13 Versorungsspannung •14 Höchstwert
des zugeführten Nennstromes •15 Gehäuse-Schutzgrad •16 Für den freien Warenverkehr in der EU zugelassenes Produkt •17 Sonderentsorgung •18
Höchstwert des tatsächlich zugeführten Stromes •19 Nennwert Ladespannung •20 Aussetzungsverhältnis •21 Nennwert Schweißstrom •22 Min. und
Max. Schweißstrom und Schweißspannung •23 Referenznormen •24 Seriennummer
EN
Meaning of graphic symbols on rating plate
•1 Name and address of manufacturer •2 Name of system •3 Single-phase INVERTER generator •4 Electrode welding equipment •5 Continuous welding
current •6 Welder usable in environments with enhanced risk of electroshock •7 Mains power supply and number of phases •8 Nominal supply frequency
•9 TIG welding •10 Secondary no-load voltage • 11 Forced air cooling •12 Insulation class •13 Supply voltage •14 Maximum value of rated supply current
•15 Degree of protection of casing •16 Product suitable for free circulation in the European Community •17 Special disposal •18 Maximum value of
effective input current •19 Nominal load voltage •20 Duty cycle •21 Nominal welding current •22 Mimimum and maximum current and welding voltage
•23 Reference standards •24 Serial number
ES Significado de los símbolos referido en la chapa datos
•1 Nombre y dirección del constructor •2 Denominación sistema •3 Generador de INVERTER monofásica •4 Equipo de soldadura con electrodo •5
Corriente de saldadura continua •6 Soldadora utilizable en lugares con riesgo acrecido de choques eléctricos •7 Alimentación de red y número de
las fases •8 Frecuencia nominal de alimentación •9 Soldadura TIG •10 Tensión secundaria en vacío •11 Refrigeración por aire forzado •12 Clase de
aislamiento •13 Tensión de alimentación •14 Máximo valor de la corriente nominal de alimentación •15 Grado de protección de la caja •16 Producto
apto para circular libremente en la Comunidad Europea •17 Eliminación especial •18 Máximo valor de la corriente efectiva de alimentación •19 Tensión
nominal de la carga •20 Relación de intermitencia •21 Corriente nominal de soldadura •22 Corriente y tensión de soldadura mínimas y máximas •23
Normas de referencia •24 N° de matrícula
DIX.GO 1206.M
10
DE
Einstellung der INVERTER-Steuerkarte
RT1 Einstellung des Höchstschweißstromes
RT2 Einstellung des Mindestschweißstromes
RT4 Einstellung des „Hot Start“
RT5 Regelung des Steuerstromes beim WIG - Schweißen mit
„Lift“ - Zündung
EN
Adjustment of INVERTER control card
RT1 Adjustment of the maximum current
RT2 Adjustment of the minimum current
RT4 “Hot Start” adjustment
RT5 Adjustment of the striking current in TIG welding with the
“Lift” ignition
ES
Regulación tarjeta control INVERTER
RT1 Regulación de la corriente máxima
RT2 Regulación de la corriente mínima
RT4 Regulación de “Hot Start”
RT5 Regulación de la corriente de ejecución de la soldadura
TIG con ignición “Lift”
RT1RT2
RT4
RT5
11
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