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Koike Sanso Kogyo IK-12 NEXT Operation Manual

Portable automatic gas cutter
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Portable Automatic Gas Cutter
BCG00B02
OPERATION MANUAL
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
permit
optimum operation of this machine.
KOIKE SANSO KOGYO CO.,LTD.

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  • Page 1 Portable Automatic Gas Cutter BCG00B02 OPERATION MANUAL For every person who will be engaged in operation and maintenance supervision, It is recommended to read through this manual before operations, permit optimum operation of this machine. KOIKE SANSO KOGYO CO.,LTD.
  • Page 2 INTRODUCTION Thank you very much for purchasing this product. Read this instruction manual thoroughly to ensure correct, safe and effective use of the machine. Read the manual first to understand how to operate and maintain the machine. Cooperation between colleagues in the workplace is essential for safe, smooth operation.
  • Page 3 Symbol Title Meaning General General caution, warning, and danger. Be careful not to get your Possible injury to fingers if caught in the insertion fingers caught. port. Caution: Electric shock! Possible electric shock under special conditions. Ground this equipment. Operators must ground the equipment using the safety grounding terminal.

  • Page 4: Table Of Contents

    8.4 About the Warranty --------------------------------------------------------------------------- 42 9. Trouble shooting -------------------------------------------------------------------------------------- 43 10. Wiring Diagram --------------------------------------------------------------------------------------- 46 11. Assembly drawing of IK-12 NEXT ---------------------------------------------------------------- 47 12. Parts list ------------------------------------------------------------------------------------------------ 48 12.1 Main body and inside parts --------------------------------------------------------------- 48 12.2 Outside parts --------------------------------------------------------------------------------- 50 12.3 Electrical parts ------------------------------------------------------------------------------- 52...

  • Page 5: Safety Information

    IK-12 NEXT 1 Safety information Many accidents are caused by operation, inspection, and maintenance which disregard the basic safety rules. Carefully read, understand, and master the safety measures and precautions described in this instruction manual and on the machine before operating, inspecting and maintaining the machine.
  • Page 6 IK-12 NEXT 1.1.2 Safety clothing 1. Be sure to wear protectors gauntlets, goggles, helmet, and safety shoes during operation. 2. Avoid operating the machine with wet clothes or hands in order to prevent electric shock. 1.1.3 Operation and handling safety precautions 1.
  • Page 7 IK-12 NEXT 1.1.6 About the transport of the machine 1. Be sure to hold the handle when carrying the machine. 2. Be sure to remove the machine from the rail when moving the rail. 3. Do not lift the carriage by holding its Handle. There is risk of falling off carriage while holding carriage by handle, if there is shockimpact at carriage or if mounting screw of handle is loose.

  • Page 8: Gus Cutting Safety Precautions

    IK-12 NEXT 1.2 Gas cutting safety precautions Strictly observe the safety rules and precautions to ensure the safety of gas cutting operations. Operators and supervisors MUST keep safety in mind. 1.2.1 Prevention of explosion 1.Never cut pressurized cylinders or hermetically sealed containers.

  • Page 9: Plasma Cutting Safety Precautions

    IK-12 NEXT 1.2.6 Safety precautions for skin burns Observe the safety precautions to prevent skin burns. Ignoring heat, spatter, and sparks during operation could cause a fire or burned skin. Do not perform cutting near flammables. (Move flammables well away from the sparks.) Do not cut containers filled with flammables.
  • Page 10 IK-12 NEXT 1.3 Plasma cutting safety precautions In order to carry out plasma cutting safely, it is important to observe precautions and rules for safety, and to keep in mind safety as a daily practice. In plasma cutting, in particular, or damage the eye by an arc light, it burns due to high fever member will occur.
  • Page 11 IK-12 NEXT 5. When you press the start button will cause the pilot arc immediately. Be sure to separate the body from the torch and cut it. 6 .When touching the torch, wait until the surface of the torch cools and perform the work.
  • Page 12 IK-12 NEXT 3. When cutting galvanized metal, wear a mask correctly and use a proper ventilator. 4. Container or the like that contains the substance that contains toxic substances Please do not cut. 1.3.7 Explosion fire accident prevention If you cut a container that is under pressure, it may explode. Please be careful.
  • Page 13 IK-12 NEXT 1.3.10 Electric shock prevention The plasma system uses high voltage when arcing occurs. Please be aware of the following points when operating. 1. Please dry your body and clothes. 2. Please do not stand or touch the wet floor when cutting the plasma.
  • Page 14 IK-12 NEXT 1.3.14 Pressure regulator 1. Please use under the condition that all pressure regulators operate properly. 2. Defective regulator can rupture or cause serious accidents. By the skilled repair technician, repair, please check. 3. Never use pressure regulators that have leaks or malfunctions.

  • Page 15: Welding Safety Precautions

    IK-12 NEXT 1.4 Welding safety precautions WARNING Strictly observe the following to prevent accidents resulting in serious injury or death. ■This welding machine is designed and manufactured by taking safety into consideration. However, never fail to observe the warning and precautions described in this instruction manual, otherwise accidents leading to serious injuly or death can result.
  • Page 16 IK-12 NEXT WARNING Strictly observe the following to prevent electric shock. ■Do not touch the charged section; otherwise fatal electric shock or burns can result. When the power on the input side is turned on, the Input circuit and the inside of the welding machine are charged.
  • Page 17 IK-12 NEXT CAUTION Use protective gear to protect you and others from arc light, scattered spatters/slugs, and noise. ■ The arc light includes harmful ultraviolet rays and infrared rays, causing Inflammation of eyes or burns. ■Scattered spatters and slugs can damage your eyes and cause burns.
  • Page 18 IK-12 NEXT CAUTION Strictly observe the following to prevent gas cylinders from falling or bursting. ■Gas cylinders, when they fall, can cause accidents leading to death or injury. ■High-pressure gas is contained in gas cylinders. Improper handling of gas cylinders can cause a burst or emission of high-pressure gas, causing accidents that lead to death or injury.
  • Page 19 IK-12 NEXT CAUTION Strictly observe the following to prevent fire, explosion, or burst. ■Spatters and hot base metal right after welding can cause tire. ■Imperfect connection of cables or imperfect contact on the route of the electric current on the steel bar and other base metal can cause fire because of heating due to resistance.

  • Page 20: Location Of Safety Labels

    IK-12 NEXT Location of Safety labels Safety labels 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 all times.

  • Page 21: Overview Of The Unit

    IK-12 NEXT Overview of the Unit 3.1 Features of the Unit 1）It offers excellent operability. 2）It can travel over a wide speed range, from 40～2400 mm/min/1.575～94.488 inch/min. 3）It incorporates a motor equipped with an encoder and the actual speed is displayed on a digital meter.

  • Page 22: Specifications

    IK-12 NEXT 3.2 Specifications Weight (body): 8.5Kg/18.74lb Machine size: 432mm/17inch Machine width 220mm/8.66inch Wheel width 160mm/6.3inch Power source: AC100～240V±10％ 1.1～0.7A 50-60Hz Motor: DC24V motor with an encoder 23W 5600rpm Transmission Dial acceleration formula、Variable speed Traveling speed 40～2400mm/min/1.57～94.49inch Creep speed 40～300 mm/min/1.57～11.81inch...

  • Page 23: Method Of Operation

    IK-12 NEXT Method of operation Kindly take care about following things to avoid getting an electric shock. WARNING  Kindly remove input plug from outlet while checking, dis-assembling or repairing and turn OFF the control source while leaving. If it is...

  • Page 24: Name Of Each Parts

    IK-12 NEXT CAUTION Set the welding power switch in the "No Self-Holding (or No Crater 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 even if the welding operation is stopped.
  • Page 25 IK-12 NEXT (1) Receptacle Kindly connect power cable to this receptacle. WARNING Never fail to ground the clip. ■ The grounded clip prevents short circuits or electtic shock which results from a short circuit in the carriage, etc. Ground wire position (No.3)

  • Page 26: Operation Panel

    IK-12 NEXT Operation panel V4.02 Kindly take care about following things to avoid getting an electric WARNING shock. ■ Kindly remove input plug from outlet while checking, dis-assembling or repairing and turn OFF the control source while leaving. If it is...
  • Page 27 IK-12 NEXT 4.2.1 Explanation of the Operation Panel Indication Name Function This switch is used to start, or stop, travel of the carriage. On flipping the switch while the multi-function selector switch is set Direction to any of the SPEED (1) to (3) positions, the carriage will travel selection switch in the direction of the arrow flipped to.
  • Page 28 IK-12 NEXT <About error numbers> Error indications are three-digit numbers that start with “E.”. Example indication Error Error details Cause Corrective action number There may be a contact failure Check for cable disconnections, and for in the wiring between electrical...
  • Page 29 IK-12 NEXT 4.2.2 About the multi-function selector switch With IK-12 NEXT, various operations can be set by selecting individual modes and parameters with the multi-function selector switch. The individual modes and parameters are as follows. Operation Panel Digital Display Setting Range...
  • Page 30 IK-12 NEXT Operation Panel Digital Display Setting Range Default Value Indication 40～2400 mm/min 500mm/min 1.574～94.488 inch/min 19.685 inch/min Function Travel mode (2) Travel. Select this mode to make the carriage When the direction selection switch is flipped while this mode is selected, the carriage will start traveling in the direction of the arrow.
  • Page 31 IK-12 NEXT Operation Panel Digital Display Setting Range Default Value Indication 400～1500 mm/min 400mm/min 15.748～59.055 inch/min 15.748 inch/min Function When WU-3R not connected Weaving Oscillation Speed Setting ウ Select this mode to set the oscillation speed during weaving operation. The digital meter displays the oscillation speed value while the carriage is stopped and while it is traveling.
  • Page 32 IK-12 NEXT Operation Panel Digital Display Setting Range Default Value Indication 0～10.0 s Function When WU-3R not connected Right Torch Stop Time Setting Select this mode to set the right torch stop time during weaving operation. The digital meter displays the right torch stop time value while the carriage is stopped and while it is traveling.
  • Page 33 IK-12 NEXT Operation Panel Digital Display Setting Range Default Value Indication 0～10.0 s Function When WU-3R not connected Left Torch Stop Time Setting Select this mode to set the left torch stop time during weaving operation. * The left torch stop time in the tack travel mode is also set here.
  • Page 34 IK-12 NEXT Operation Panel Digital Display Setting Range Default Value Indication 0～10.0 s Function Arc Stabilization Time Setting Select this mode to set the arc stabilization time during traveling mode. This is the time between flipping the direction selection switch and the carriage starting to travel.
  • Page 35 IK-12 NEXT Parameter Number Details Parameter number Explanation Unintended input prevention setting Parameter editing is enabled when the value of this parameter is If it is any other value, input is possible only for this parameter. Use this to prevent unintended input.
  • Page 36 IK-12 NEXT Not used Not used Not used Not used Torch switch signal minimum time setting Setting range: 0.4～1.5 s At shipment from factory: 0.7 s Sets the time to guarantee the ON/OFF state of the torch switch. Reducing this value may mean that the welding power source is unable to receive a signal, so care is required.
  • Page 37 IK-12 NEXT Travel mode (3) * This is the same as the SPEED (3) setting made with the multi-function selector switch. Use the SPEED (3) setting on the multi-function selector switch. Weaving movement time chart 4.2.3 The weaving movement at the time of the weaving welding becomes like the following time chart.
  • Page 38 IK-12 NEXT ※Weaving swing width, swing speed is the numerical value of at a distance 100mm from the center of rotation. 回転中心 Rotation center 振り速度 Swing speed 振り幅 Swing width Origin position 原点位置 - 34 -...

  • Page 39: Gas Cutting Operation

    IK-12 NEXT 5 Gas cutting operation 5.1 Standard composition of gas epuipment 1) Composition of gas equipment for linear and parallel cutting Composition F-type single torch set F-type two torch set E-type single torch set E-type two torch set Pipe arm...

  • Page 40: Assembling The Unit (For A Single Torch Set)

    IK-12 NEXT 5.2 Assembling the Unit (for a Single Torch Set) 1. Take the unit body out of the packing box. 2. Fit the primary hose to the gas distributor. • Blue hose (oxygen) • Red or orange hose (acetylene or LPG) 3.

  • Page 41: Safety Measures Before Starting Work

    IK-12 NEXT 5.3.4 Installing the rails 1. Place the rails parallel to a scribed line, and check that they are parallel either by making the carriage travel along them by hand, or by using a jig. In addition, when considering the thermal effects on the rails, ideally the distance between the rails and the scribed line should be at least 100 mm.

  • Page 42: Ignition And Flame Adjustment

    IK-12 NEXT 5.5 Ignition and flame adjustment ・Adjust the gas pressure according to the Cutting Data. The data shows the pressure when all the valves are open. Readjust the pressure after ignition. ■Flame adjustment method 1. Open the fuel gas valve 1/4～1/2 a tum, and light the torch with an igniter.

  • Page 43: Safety Measures Against Backfire And Flashback

    IK-12 NEXT 5.8 Safety measures against backfire and flashback 5.8.1 Prevention of backfire Backfires may cause serious accidents or fires. Be careful to prevent such disaster. When a backfire occurs, find the cause and inspect and maintain the machine correctly before using the machine again.
  • Page 44 IK-12 NEXT 5.9.2 In bevel cutting In case of bevel cutting, tilt torch to the desired angle. Depending on the combination of tip, it is possible to cut as shown in the figure. Welding V bevel cutting Welding Y bevel cutting...

  • Page 45: Plasma Cutting Operation

    17 Welding Work 7.1 Preparation for Work 1. Attach welding holder to IK-12 NEXT. 2. Connect the welding power cable to the main unit. 3. Connect the cord side receptacle (plug) to the main unit side receptacle (receptacle). Before connecting, check that foreign matter, dust, etc. are not contained.

  • Page 46: Welding Work

    IK-12 NEXT 7.2 Welding Work 1. Align the wire tip with the welding position. 2. Set the multi-function selector switch to any of the SPEED (1) to (3) positions. 3. The arc will be generated only while the arc selection switch is set to ON with the clutch at START and the direction selection switch is flipped to forward or reverse.

  • Page 47: Trouble Shooting

    IK-12 NEXT Trouble shooting Defects Cause/check position 1) No power supply voltage to outlet 2) Cable is disconnected Kindly take care about following things WARNING to avoid getting an electric shock. ● Since above mentioned 1) and (1)No electric power...
  • Page 48 IK-12 NEXT 1)ARC OFF option is selected in Arc mode changing over switch. 2) No welding current. Flipping direction 3) Metal outlet for torch switch is not connected. selection switch 4) Kindly verify whether there is short circuit between ①-②...
  • Page 49 IK-12 NEXT 1) Connecting bar and lever pins not connected 2) Failure of the spring / ball plunger (loose) (14) Clutch malfunction 3) Failure of the clutch wheel / worm wheel 4) Clutch wheel and the axle lubrication shortage 1) Foreign object trapped in the gears...

  • Page 50: Wiring Diagram

    IK-12 NEXT Wiring diagram - 46 -...

  • Page 51: Assembly Drawing Of Ik-12 Next

    IK-12 NEXT Assembly drawing of IK-12 NEXT 215mm=8.465inch 220mm=8.661inch 432mm=17.008inch - 47 -...

  • Page 52: Parts List

    IK-12 NEXT Parts list 12.1 Main body and inside parts - 48 -...
  • Page 53 IK-12 NEXT Main body and inside parts ITEM STOCK ITEM STOCK PART NAME REMARKS PART NAME REMARKS Cover 20506249 DU bush 6D710607 MB0607-12FDU Hexagon socket head Hexagon socket head 6C450510 6C450625 BC-5×10(WS,WF) BC-6×25(WS,WF) cap screw cap screw Hexagon socket head...

  • Page 54: Outside Parts

    IK-12 NEXT 12.2 Outside parts - 50 -...
  • Page 55 IK-12 NEXT Outside parts ITEM STOCK ITEM STOCK PART NAME REMARKS PART NAME REMARKS Heat insulating plate 20506234 Heat insulating plate 20506334 spacer Hexagon socket head 6C411020 BH-10×20(WF) cap screw Stand 60030204 Hexagon socket head 6C450515 BC-5×15(WS,WF) cap screw Chip support assembly...

  • Page 56: Electrical Parts

    IK-12 NEXT 12.3 Electrical parts - 52 -...
  • Page 57 IK-12 NEXT Electrical parts ITEM STPCK ITEM STOCK PART NAME REMARKS PART NAME REMARKS Operation board Push button switch ～ switch harness 20506436 20506474 assembly assembly plaiting 80-1 Operation name plate 20507065 Push button switch 60036249 SB-221 80-2 Screw 89 Screw 6C570308 SP-3×8(WS,WF)

  • Page 58: Cutting Data

    IK-12 NEXT 13 Cutting Data Cutting hole diameter（ｍｍ） TIP SIZE TYPE STANDARD D5 type D7 type 102(STANDARD SPEED) For Acetylene PRESSURE FLOW RATEＬ/H PLATE CUTTING (kg/c ㎡) / (Mpa) THICKNESS SPEED SIZE CUTTING PREHEATING (mm) (mm/min) OXYGEN ACETYLENE ACETYLEN OXYGEN OXYGEN 3～5...
  • Page 59 IK-12 NEXT 106(STANDARD SPEED) For Propane PRESSURE FLOW RATEＬ/H PLATE CUTTING (kg/c ㎡) / (Mpa) CHIP THICKNESS SPEED SIZE CUTTING PREHEATING (mm) (mm/min) PROPANE PROPANE OXYGEN OXYGEN OXYGEN 3～5 700～660 1.5 / 0.15 0.2 / 0.02 1,180 5～10 660～550 2.0 / 0.2 0.2 / 0.02...
  • 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...

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