Operating Instructions Safeguard for future use! Options according to range of application Sample application Checking jig DIX PV 100/150 DIX PV 200/250 Aligning module DIX JM 100 DINSE Inc. 830 Dillon Drive Wood Dale, IL 60191 USA Phone: 517 416 5294 Fax: 888 896 4871 sales@dinse-us.com www.dinse-us.com
Copyright 2011 DINSE G.m.b.H., Hamburg. These instructions or excerpts thereof 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. GB-PV-100-200-JM-100-BA-L11 Änderungen vorbehalten!
Read these operating instructions without fail before commissioning, to make sure that you use the DINSE product safely. The owner must make available these operating instructions to the operator and make sure that the operator reads and understands the instructions. Preserve the operating instructions in a safe place for future reference. Display a note prominently in the working area specifying the place where the instructions are kept. Technical standards and accident prevention regulations: Always observe the technical standards and accident prevention regulations mentioned below during any set-up, installation, operation or maintenance. BGR 500 Chapter 2.26 - Operating of equipment - Welding, cutting and related procedures 3
Inhaltsverzeichnis 1. Introduction 5 2. Safety 6 2.1 For your safety 6 2.2 Signs used 6 2.3 Proper use 6 2.4 Safety instructions and tips 7 2.5 Permitted operators 7 2.6 Warranty claim 7 2.7 Transportation and packaging 8 2.8 Recycling/disposal 9 3. Technical data 10 4. Installation 11 4.1 Description 11 4.2 Elements 13 4.3 Tools 14 4.4 Testing 15 4.5 Alignment 16 4.6 Disassembly 27 5. Maintenance instructions 31 4
1. Introduction You have purchased a quality product from Dinse Inc. Thank you for your confidence in our products. This carefully manufactured product is under constant supervision during production. Each system is tested for proper functionality before and after mounting. Tests during production, precisely matched materials and manufacture on spezial high-grade production machines characterize this technically sophisticated welding accessory. Please contact us if you have any questions or requests concerning accessories or equipment. Our application engineers will be glad to assist you. 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 5
2. Safety 2.1 For your safety All DINSE-products are equipped with safety devices. They are manufactured using the latest technology and approved safety regulations. Any improper or unauthorised use could lead to the following risks: Life and body of the operator The product and other property of the owner The efficient work of the product It concerns your safety! 2.2 Signs used The following signs are used in these operating instructions: CAUTION! Reference to possible dangerous situations. Non-observance can result in serious injuries! I N F O Technical information and tips Warning - Hand injuries! - Non-observance can result in serious hand injuries! 2.3 Proper use The checking jig and the aligning module exclusively serve for testing and aligning standard torch heads. Arbitrary conversions and changes of the checking jig and the aligning module are not permitted due to safety reasons. 6
2. Safety 2.4 Safety instructions and tips Observe the following safety regulations: I N F O For using in the open air, the checking jig and the aligning module are not intended! The checking jig must be placed on an even (max. incline 15 ) firm and stable ground! The checking jig may not be carried at the fixing/gauge support! Warning - Hand injuries! - Do not put the fingers into the spindle guide or the prism. 2.5 Permitted operators The checking jig and the aligning module may be operated only by persons trained by DINSE Inc., and who are aware of the relevant safety instructions! 2.6 Warranty claim The suitability of the checking jig and the aligning for specific applications must be determined by the user and is not subject to the product liability by the manufacturer. The warranty claim is applicable only for: Proper use Operation according to regulations Use of original DINSE Inc. components and spare parts. Compliance with the safety instructions 7
2. Safety 2.6 Warranty claim Ensure that repairs are generally carried out only by DINSE Inc.! In case of basic complaints during the warranty period, send the complete checking jig and the aligning module to DINSE Inc. without making any modifications. Product liability and warranty lapse on unauthorised tampering! 2.7 Transportation and packaging The checking jig and the aligning module has been checked and carefully packed before shipment, however damages may occur during shipping and this product should be carefully inspected prior to use. In case of damage, contact DINSE Inc. immediately and return the entire checking jig and the aligning module at your expense to: 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 IN THE EVENT YOUR DINSE CHECKING JIG AND THE ALIG- NING MODULE NEEDS TO BE RETURNED: 1. Please be sure to carefully pack the checking jig and the aligning module in a suitable container with sufficient packing material in order to avoid causing any damages during shipping. 2. Please include a note describing the problem(s) with sufficient detail. This will help our service department to determine the cause of the problem sooner, and can reduce the time it takes to repair the checking jig and the aligning module. 8
2. Sicherheit 2.8 Recycling/disposal Only applies to EU countries. Do not discard electrical tools with ordinary waste! As per EU directive 2002/96/EC regarding old electrical and electronic equipment and as implemented in national law, used electrical tools must be collected separately and recycled in an eco-friendly manner. Some of the TIG- torch set s materials can be reused. Reusing some parts of raw materials from used products is an important way of helping to protect the environment. Contact your local authority in the event that you require information on local collection points. 9
3. Technical data Individual parts Weight (kg) Base plate DIX PVB 100 7,4 Base plate DIX PVB 200 11,5 Support-set: DIX PVS 100 Fixing support 1,7 gauge support 1,0 Set up pin (106) DIX PVL 106 0,3 (108) DIX PVL 108 0,3 Torch adapter DIX PVP 100 0,2 SAS adapter DIX PVA 100 0,8 SASS adapter DIX PVA 1000 0,9 SASS adapter DIX PVA 2000 1,3 Aligning tool DIX JW 100 1,2 Aligning bracket DIX JH 100 0,5 Aligning socket DIX JB 100 0,4 Aligning set DIX JS xxx 0,6 10
4.1 Description Functions The checking jig and the aligning module provide quality assurance in welding production. They are long-lasting, precision testing aids made of a high-quality aluminum alloy for controlling the position of the TCP. Aligning and testing standard torch heads for parallelism and centre of contact tip. Hole pattern of the checking jig with standard positions for torch heads (angle 0 /22 /45 ). Aligning module for separately aligning the inner and outer part of the torch head. Checking jig DIX PV 100/150 45 22 0 Options according to range of application DIX JM 100 Aligning sets for standard torch heads and checking jig DIX PV 100: DIX JS 350/520 DIX MET(Z) 35(x)/52(x) DIX JS 540 DIX METZ 54(x) DIX JS 560 DIX METZ 56(x) Aligning set for standard torch heads and checking jig DIX PV 150: DIX JS 390/590 DIX MET(Z) 39(x)/59(x) Aligning set DIX JS 350/520 11
4.1 Description Functions Testing of torch systems with standard torch heads for parallelism and centre of contact tip. Bore pattern of the checking jig with standard positions for torch heads (angle 0 /22 /45 ). Checking jig DIX PV 200/250 Torch system, singly separable, torch bracket, fixed and shock sensor DIX SAS 100 (application sample) Torch system, doubly separable, torch bracket, PUSH-PUSH/ PUSH-PULL and shock sensor DIX SAS 200 (application sample) Accessories: Checking jig ror torch systems Torch adapter DIX PVP 100 SAS adapter DIX PVA 100 SASS adapter DIX PVA 1000 SASS adapter DIX PVA 2000 12
4.2 Elements 1 2 3 4 5 6 7 8 9 10 11 1 Fixing support 2 Aligning bracket 3 Holding plate 4 Aligning pin H 5 Aligning socket 6 Aligning pin W 7 Aligning tool 8 Aligning spindle 9 Gauge support 10 Base plate 11 Set up pin 12 Prism Aligning tool DIX JW 100 A B C D E Aligning cylinder Clamp nut Aligning adapter Clamp nut Aligning gauge Aligning set DIX JS 350/520 13
4.3 Tools These tools are required for assembly / disassembly of the checking jig and the aligning module: Alan key SW 6 Wrench SW 12 / SW 14 Hook spanner DIX SLAT 4 I N F O Use only tools that are grease-free and not worn. Always observe relevant accident protection regulations at the assembly site. CAUTION! No external use of force! (Use hammer, etc.) Neither the keys nor directly on the checking jig or the adjusting module. The checking jig, in particular the adjusting module is a precision tool to aligning, examining and adjusting the torch head. If used improperly, we can not guarantee accurate measurement results. 14
4.4 Testing Testing the torch heads Checking jig DIX PV 100/150 Mounting the fixing support (1) and gauge support (9) on the base plate (10). (if not already mounted) 1 9 10 Checking jig DIX PV 200/250 Preparation for testing the torch heads without torch brecket and SAS (shock sensor) Remove the SAS adapter DIX PVA 100 from the fixing support (1) SAS adapter DIX PVA 100 45 22 0 Reposition the fixing support (1) on the base plate. The pins of the torch adapter DIX PVP 100 introduced into the holes provided on fixing support (1) and screwing. Torch adapter DIX PVP 100 15
4.5 Alignment Mounting the torch head Insert the aligning pin H/W - (4)/ (6) and tighten it using an openended wrench (WS 14 - torque 25 Nm) 4 pieces allen wrench M8x30 mm (WS 6 - torque 20 Nm) tighten if using an allen wrench 2 pieces aligning pin H (4), short 4 4 pieces allen wrench M8 x 30 mm (WS 6 - torque 20 Nm) tighten if using an allen wrench 2 pieces aligning pin W (6), long 6 11 Install the torch head without the gas nozzle and tighten it using the DIX SLAT 4 hook spanner Slide the set up pin (11) with the tip into the outlet of the contact tip. If there is a deviation, an aligning must be made. 16
4.5 Alignment Mounting the aligning module Place the aligning bracket (2) on the torch head Pull up the holding plate (3) Slide the aligning bracket(2) over the aligning pins H (4) as far as the stop Push down the holding plate (3) 2 3 4 Fix the aligning bracket(2) with the knurled nuts of the aligning pins H (4) 17
4.5 Alignment Mounting the aligning tool Slide the aligning tool (7) over the torch head as far as the aligning bracket (2) Loosen the clamp nut using the open-ended wrench (WS 12mm) on the torch head Remove the contact tip Then tighten the clamp nut again by hand 2 7 18
4.5 Alignment Mounting the aligning tool Screw the aligning adapter (C) to the thread of the torch head by hand C Slide the aligning cylinder (A) onto the aligning adapter (C) as far as the stop C A Pull up the holding plate (3) Center the prism (12) Slide the aligning tool (7) over the aligning pins W(6) as far as the stop 6 3 12 7 19
4.5 Alignment Mounting the aligning tool Push down the holding plate (3) Fix the aligning tool (7) using the knurled nuts of the aligning pins W (6) 7 3 6 Check deviation A 11 Slide the tip of the set up pin (11) in the direction of the aligning cylinder (A) to determine the deviation. 20
4.5 Alignment Aligning the outer part (torch head) A Pivoting the aligning spindle (8) to the axis of the deviation. Align the torch head by rotating the tri-star handle of the aligning spindle (8) (left/right), taking a slight overbend into consideration. Release the aligning spindle (8). Check the position of the tip of the aligning cylinder (A) with the tip of the set up pin (11). Turn the set up pin (11) and slide it over the tip of the aligning cylinder (A) to check the parallelism. If necessary, repeat the procedure! 8 11 21
4.5 Alignment Aligning the inner part (torch head) Remove the knurled nuts of the aligning pins W (6) Pull up the holding plate (3) Slide the aligning tool (7) to the aligning bracket (2) Remove the aligning cylinder (A) 2 6 3 7 A 22
4.5 Alignment Aligning the inner part (torch head) Insert the aligning gauge (E) into the clamp nut Tighten by using the open-ended wrench (WS 12 - torque 10 Nm) E Check deviation Slide the tip of the set up pin (11) in the direction of the aligning gauge (E) to determine the deviation. 23
4.5 Alignment Aligning the inner part (torch head) Pull up the holding plate (3) Center the prism (12) Slide the aligning tool (7) over the aligning pin W (6) as far as the stop Push down the holding plate (3) Fix the aligning tool (7) by using the knurled nuts of the aligning pins W (6) 6 3 12 7 24
4.5 Alignment Aligning the inner part (torch head) Positioning the aligning socket (5) over the torch head in order to fix the outer part of the torch head 5 Insert the aligning socket (5) into the slot and lock it counterclockwise Slot 25
4.5 Alignment Aligning the inner part (torch head) E Pivoting the aligning spindle (8) to the axis of the deviation. Align the torch head by rotating the tri-star handle of the aligning spindle (8) (left/right), taking a slight overbend into consideration. Release the aligning spindle (8). Check the position of the tip of the aligning gauge (E) with the tip of the set up pin (11). Turn the set up pin (11) and slide it over the tip of the aligning gauge (E) to check the parallelism. If necessary, repeat the procedure! 8 11 26
4.6 Disassembly Removing the aligning tool Release and remove the aligning socket (5) clockwise 5 Remove the knurled nuts of the aligning pins W (6) Push up the holding plate (3) 6 3 27
4.6 Disassembly Removing the aligning tool Slide the aligning tool (7) to the aligning bracket (2) 2 7 Loosen and remove the aligning gauge (E) by using an openended wrench (WS 12mm) E 28
4.6 Disassembly Removing the aligning tool Remove the aligning adapter (C) from the thread of the torch head C Remove the aligning tool (7) 29
4.6 Disassembly Removing the torch head Remove the knurled nuts of the aligning pins H (4) Push up the holding plate (3) Remove the aligning bracket (2) 2 3 4 Screw off the tested and aligned torch head Using the DIX SLAT 4 hook spanner 30
5. Maintenance instructions The checking jig and the aligning module is nearly maintenancefree because of the use of high-grade components. Conduct regular inspections to guarantee problem-free operation. The frequency of single inspections and maintenance work is focussed on the conditions for using the checking jig and the aligning module. Therefore, each user must define a separate maintenance schedule. To guarantee trouble-free function, the following tasks must be carried out at regular intervals: General visual inspection of the checking jig and the aligning module for damages or indications of wear. Check that all connections are fit correctly. Visual inspection of the aligning sets for damage. After using the elements of the aligning sets sort correctly! Also observe the maintenance instructions of the torch heads. I N F O Use only Original components and spare parts from the DINSE Inc.! 31