Koike Sanso Kogyo IK-12 NEXT, Operation Manual

Page 1: ...OPERATION MANUAL KOIKE SANSO KOGYO CO LTD For every person who will be engaged in operation and maintenance supervision It is recommended to read through this manual before any operations so as to pe...

Page 2: ...efer to it as necessary Do not use the machine carelessly without following the instructions in the manual Use the machine only after you have completely understood the contents of the manual If an ex...

Page 3: ...perators must ground the equipment using the safety grounding terminal Pull out the power plug from the outlet Operators must unplug the power plug from the outlet when a failure occurs or when there...

Page 4: ...fety Measures before Starting Work 37 5 5 Ignition and flame adjustment 38 5 6 Cutting and piercing method 38 5 7 Procedures for starting cutting operation and extinguishing the flame 38 5 8 Safety me...

Page 5: ...d fully understand the following important safety information 1 1 1 Machine safety 1 The machine casing is mainly made of aluminum alloy to reduce weight For this reason be careful not to drop a heavy...

Page 6: ...ouch the rail 11 To prevent the torch holder from dropping fix it with the wing bolt BS 6x22 on the torch slide 12 Be sure to hold the handle when carrying the machine 13 Be sure to remove the machine...

Page 7: ...ockimpact at carriage or if mounting screw of handle is loose 1 1 7 Machine noise 1 Volume of at the time of driving the machine is less than 70dB 1 1 8 About external environment 1 Never use the mach...

Page 8: ...ee from heat sparks slag and naked flame 6 Contact the distributor if the container valves will not open Never use a hammer wrench or other tools to forcibly open container valves 1 2 4 Safety precaut...

Page 9: ...tened still more making it difficult to remove the tip Avoid damaging the taper of the tip since this may cause backfire 7 Check with soapsuds for any leakage of gas from the connection part of the di...

Page 10: ...e damaged shading plate broken glasses goggles helmet 3 Please warn other people in the workplace to wear eyeglasses goggles helmets 4 We recommend that you can install protective screens and curtains...

Page 11: ...ilator to protect workers from fumes and gases discharged during arc cutting 3 If ventilation is inadequate please use an effective gas mask 1 3 6 Prevention of toxic fume Fumes generated during cutti...

Page 12: ...st 10 m away from the cutting place 3 Always be sure to cool beforehand if you place a newly cut metal or heated metal near the combustible material 4 Do not cut containers containing flammable substa...

Page 13: ...rly If you see damaged parts such as fatigue and wear please replace it immediately 1 3 11 Ground of cutting surface plate 1 Make sure to connect the ground cable directly from the cutting member or s...

Page 14: ...ure or cause serious accidents By the skilled repair technician repair please check 3 Never use pressure regulators that have leaks or malfunctions 4 Do not use regulators with oil or grease 1 3 15 Sa...

Page 15: ...acemaker in his heart shall not approach the welding machine in operation or the welding space unless he has obtained doctor s permission For safety leave the installation maintenance inspection and r...

Page 16: ...machine with the welding machine case or coser removed Be sure to cover the input and output terminals before use Do not use broken or wet gauntlets Never fail to use a life line when working in high...

Page 17: ...s high wear a noise proofing protector CAUTION Use protective gear to protect you and others from fumes and gas generated by welding Welding generates fumes and gas Inhalation of such fumes and gas ca...

Page 18: ...as cylinders only for specified purposes DO not apply oil or grease to the valve on gas cylinders When the valve on gas cylinders is hard to open contact the dealer CAUTION Strictly observe the follow...

Page 19: ...tered spatters will be in contact with inflammables Do not do welding in a place near inflammable gas Do not bring hot base metal right after welding close to inflammables Welding on ceilings floors a...

Page 20: ...and labels for correct operations are stuck to the machine Carefully read labels before operation and follow the instructions decried on them Never peel off the labels Keep them clean and legible at a...

Page 21: ...on 5 Pressing a button instantly switches to slow travel to help to prevent uncut material being left at the start and finish ends when cutting thick material 6 The incorporated arc coupling function...

Page 22: ...ail 1 8M 2 Circle rail 3 Circle cutting attachment 4 S 100 torch set 5 S 200 torch set 6 SP 100 torch set 7 SP 200 torch set 8 SR 100 torch set 9 SR 200 torch set 10 SPR 100 torch set 11 SPR 200 torch...

Page 23: ...isk of short circuit due to tearing of insulation covering Kindly weld below the rated current and usage rate of torch to prevent dielectric breakdown due to overheating Kindly place power cable and t...

Page 24: ...Treatment position When the switch ot the welding power supply which is to be connected to the welding machine is set in the Self Holding or Crater Treatment position the welding arc will not stop ev...

Page 25: ...WU 3R make sure Turn Off the Power When the power is on if it gets connected there is a possibility of failure 3 Operation panel The detail is shown below 4 Heat insulating plate It prevents heat from...

Page 26: ...input voltage within 10 for power supply input to input plug Kindly use input voltage in the range of AC100V AC240V There is risk of short circuit due to failure of printed board on operation panel In...

Page 27: ...rection selection switch has been operated while this switch is flipped to the MANUAL side turn the power OFF and back ON Multi function selector switch This switch is used to select each parameter an...

Page 28: ...detecting welding current 012 Encoder selection error 013 Unit configuration unsuitable error 014 Weld movement distance during tack operation error 016 Servo driver error This is an error that occurs...

Page 29: ...of the carriage can be changed by turning the volume switch while the carriage is stopped and while it is traveling To increase the speed turn it clockwise and to decrease the speed turn it countercl...

Page 30: ...it is traveling To increase the speed turn it clockwise and to decrease the speed turn it counterclockwise Operation Panel Indication Digital Display Setting Range Default Value 40 2400 mm min 2400mm...

Page 31: ...ING SPEED starts weaving as an independent operation No arc is generated in independent operation This is not used when no weaving unit is connected When WU 3R connected Operation Panel Indication Dig...

Page 32: ...rts weaving as an independent operation No arc is generated in independent operation This is not used when no weaving unit is connected When WU 3R connected Operation Panel Indication Digital Display...

Page 33: ...e carriage is stopped and the multi function selector switch is set to TIMER LEFT starts weaving as an independent operation No arc is generated in independent operation This is not used when no weavi...

Page 34: ...r the arc stabilization time is in progress This may cause the carriage to operate unexpectedly In order to weld for the arc stabilization time with the initial arc current an initial arc setting has...

Page 35: ...ting is self latching crater filling supported If the value above is set and the arc is frequently interrupted set the value to 0 1 In this case the signal will remain in the ON state up until the arc...

Page 36: ...h respect to the speed indicated at the digital display Actual speed speed displayed This parameter value Not used Model Selection Setting 0 WH MULTI NEXT 1 IK 12NEXT After setting this parameter swit...

Page 37: ...omes like the following time chart Example1 Parameter settings Central torch stop time 0sec Left torch stop time 0sec Right torch stop time 0sec Weaving swing width 10mm 0 39inch Example2 Parameter se...

Page 38: ...IK 12 NEXT 34 Weaving swing width swing speed is the numerical value of at a distance 100mm from the center of rotation Rotation center Swing speed Swing width Origin position...

Page 39: ...rm Pipe arm 500L Pipe arm 500L Arm holder Distributor Double distribution with valves Triple distribution with valves Torch holder Profiling system Profiling system Bevel attachment For cutting V For...

Page 40: ...tal receptacle is fitted with screws Be sure to tighten the screws in order to prevent the plug coming out while the unit is traveling When turning on the power supply after turning off the unit body...

Page 41: ...n Use a power outlet with an opening to receive the ground pin 5 4 2 Operating the direction selection switch The direction selection switch is used to switch between forward and reverse travel The ne...

Page 42: ...steel plate before cutting 3 Drill a hole before cutting Piercing method 1 Ignite and adjust the flame 2 Thoroughly preheat the cut in point until it is white hot 3 Open the cutting oxygen valve to pi...

Page 43: ...lightly open the preheating oxygen valve and then ignite the oxygen with an ignition lighter Then fully open the gas valve and make the flame neutral by controlling the preheating oxygen 4 Adjust the...

Page 44: ...2 Attach pivot pin and weight to radius bar Please attach weight as close to the center as possible 3 Free the guide wheel and pull the machine so that it describes a natural arc and tighten the guid...

Page 45: ...cut 2 Set Multi function selector switch to SPEED 3 When putting the clutch into START and tilting the direction change switch to forward or reverse an arc occurs only when the arc changeover switch...

Page 46: ...able to use this unit in the best condition at all times 8 1 Daily Inspections 1 Wipe off the dirt on the unit with a clean cloth especially the pipe arm key slots and rack parts 2 Lubricate the axles...

Page 47: ...continuty check by tester while electric supply is turned OFF Since above mentioned 2 and 3 checking are to be carried out while control power supply is ON professional engineer having enough knowledg...

Page 48: ...t carriage travel fails to stop when the direction selection switch is returned to neutral during travel 1 Printed circuit board failure 9 The travel speed of the carriage does not change when the CRE...

Page 49: ...e lubrication shortage 15 High level of vibration or noise 1 Foreign object trapped in the gears 2 Wear of gears 3 Motor failure 4 Speed reducer failure 16 Knocking occurs 1 Gear wear 2 Play between t...

Page 50: ...IK 12 NEXT 46 10 Wiring diagram...

Page 51: ...IK 12 NEXT 47 11 Assembly drawing of IK 12 NEXT 215mm 8 465inch 220mm 8 661inch 432mm 17 008inch...

Page 52: ...IK 12 NEXT 48 012 Parts list 12 1 Main body and inside parts...

Page 53: ...lever shim 0 5 1 20506245 32 10 Gear head 1 61007942 IG 43 KS5 1 49 15 Screw 4 6C500510 SF 5 12 32 11 Motor 1 61007939 With the pinion 16 Clutch lever base 1 20506242 32 12 Spring washer 4 6D510040 WS...

Page 54: ...IK 12 NEXT 50 12 2 Outside parts...

Page 55: ...54 Hexagon socket head cap screw 4 6C450515 BC 5 15 WS WF 55 Chip support assembly 1 60035003 Accessories 56 Universal wheel assembly 1 20506418 56 1 Spacer 1 20506235 56 2 Washer 1 60030211 56 3 U n...

Page 56: ...IK 12 NEXT 52 12 3 Electrical parts 103...

Page 57: ...20506481 MD CN6 Receptacle assembly 80 12 Receptacle assembly 1 20506464 Harness plaiting A Harness plaiting C 99 Harness plaiting D 4P 4P 1 20506478 MD CN3 SW CN2 Receptacle 1 64000510 NCS 255 R squ...

Page 58: ...750 680 102 D7 HIGH SPEED For Acetylene PLATE THICKNESS mm TIP SIZE CUTTING SPEED mm min PRESSURE kg c Mpa FLOW RATE H OXYGEN ACETYLENE CUTTING OXYGEN PREHEATING OXYGEN ACETYLEN 5 10 0 750 680 7 0 0...

Page 59: ...0 1 180 310 10 15 1 625 550 0 2 0 02 2 400 1 180 310 15 30 2 550 475 0 25 0 025 3 600 1 370 360 30 40 3 475 425 0 25 0 025 4 800 1 370 360 40 50 4 425 350 0 3 0 03 5 600 1 860 490 106 D7 HIGH SPEED Fo...

Page 60: ...IK 12 NEXT OPERATION MANUAL Date of issue Sep 2018 2nd Nov 2018 3rd Dec 2018 KOIKE SANSO KOGYO CO LTD Printed in Japan...