Koike Sanso Kogyo WEL-HANDY COMPACT Operation Manual

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Portable Automatic Welding Carriage for fillet welding

BUV00B00

WEL-HANDY

COMPACT

OPERATION MANUAL

For every person who will be engaged in

operation and maintenance supervision, It is

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Page 1 Portable Automatic Welding Carriage for fillet welding BUV00B00 WEL-HANDY COMPACT 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 3 WEL-HANDY COMPACT 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 4 WEL-HANDY COMPACT 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. part. Caution: Electric shock! Possible electric shock under special conditions. Ground this equipment.
Page 5: Table Of Contents
7. Wiring diagram-------------------------------------------------------------------------------------------- 24 7.1 Electrical diagram --------------------------------------------------------------------------------- 24 7.2 Assembly drawing of circuit board ------------------------------------------------------------ 25 8. Assembly drawing of WEL-HANDY COMPACT -------------------------------------------------- 26 9. Parts list ---------------------------------------------------------------------------------------------------- 27 9.1 Main body and inside parts --------------------------------------------------------------------- 27 9.2 Holder relationship ------------------------------------------------------------------------------- 29 9.3 Arm relationship ----------------------------------------------------------------------------------- 31...
Page 6: Safety Information
WEL-HANDY COMPACT Safety information Most accidents are caused by negligence of basic safety regulations during operation, inspection, and maintenance. Carefully read, understand, and master the safety precautions and preventive measures written in this manual or on the machine before operation, inspection, and maintenance of the machine.
Page 7: Safety Precautions
WEL-HANDY COMPACT 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 8 WEL-HANDY COMPACT resuming operation. ■Do not use cables with Insufflcient capacity or damaged cables whose conductors are exposed. ■firmly tighten and insulate cable connections. ■Firmly connect the welding cable on the base metal side at a location as close as possible to the base metal.
Page 9 WEL-HANDY COMPACT 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 can damage your health. ■Welding operation in a smell space causes deficiency of oxygen, which is very likely to cause suffocation.
Page 10 WEL-HANDY COMPACT CAUTION Strictly observe the following to prevent injury due to rotary section. ■ Do not bring your hands, hair, or clothes close to the cooling fan of the welding power supply or the feeder roller of the wire feeder; otherwise you can be caught in them.
Page 11 WEL-HANDY COMPACT About the transport of the machine 1. Be sure to hold the handle when carrying the machine. 2. Do not pull the carriage up with a crane, lift, etc. hanging on its Handle for transferring or storing. 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 12: Location Of Safety Labels
WEL-HANDY COMPACT 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 13: Features And Specifications
WEL-HANDY COMPACT Features and specifications 4.1 Features The WEL-HANDY COMPACT has been developed to allow even unskilled operators to successfully do horizontal fillet welding (bottom steel plate traveling type) in a simple manner. Major features are as follows: Compact, Light weight, Durable and Low gravity.
Page 14: Specification
WEL-HANDY COMPACT Specifications Item Specifications Model WEL-HANDY COMPACT Rubber roller 4 wheeler driving (permanent magnet absorption type) Driving method (Lower plate traveling system, traveling surface is steel plate) Traveling speed 100~550mm/min / 3.9~21.7inch/min Swept forward angle/sweep back angle：5°/4° Horizontal angle：45°...
Page 15: Method Of Operation
WEL-HANDY COMPACT 5 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 necessary to...
Page 16: Name Of Each Part
WEL-HANDY COMPACT 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 17 WEL-HANDY COMPACT ① Slide unit assembly The arc point can be adjusted toward UP/DOWN or FRONT/REAR. ② Torch holder Insert the exclusive use torch mounting section into the torch holder to secure it. WARNING Secure the insulated section of the torch when mounting it.
Page 18 WEL-HANDY COMPACT The height of the guide rollers can be adjusted by changing the attaching method. The height can be adjusted in the range of 5mm(0.197inch) ~ 19mm(0.748inch) and 90mm(3.543inch) ~ 105mm(4.134inch) from the contact patch of a tire. =0.197inch 19mm =0.748inch...
Page 19 WEL-HANDY COMPACT ⑦ Driving wheel (Rubber roller) Rubber wheels for driving. ⑧ Torch angle adjusting bolt Used to set the torch angle. Loosen the bolt and swing the torch for setting within the range of 35-55 degrees. ⑨ Grip handle A grip handle for carrying the carriage.
Page 20 WEL-HANDY COMPACT WARNING Please use the grip handle with caution. (Be careful not to drop it.) ■ It is possible to change the length of the handle from 2 to 1, but if it is 1, the part to hold will be shorter, making it difficult to hold.
Page 21: Operation Panel
WEL-HANDY COMPACT selected, and blinks when right traveling is selected. Blinks when the carriage is moving. The faster the speed, the shorter the blinking interval. 5.1.2 Operation panel V2.00 WARNING Kindly take care about following things to avoid getting an electric shock.
Page 22 WEL-HANDY COMPACT ① Traveling direction changing over switch It is possible to select traveling direction of carriage. ② Traveling speed adjustment switch Kindly turn carriage in clockwise direction to increase speed of carriage and turn it in anti-clock wise direction to reduce speed of carriage.
Page 23: Preparation And Procedure For Welding
WEL-HANDY COMPACT 5.2 Preparation and procedure for welding Conduct welding in the following manner, while referring to the Fig. 6 “System connection diagram” and the operation procedure in item 5.1. WARNING Strictly observe the following to prevent electric shock. ■Turn OFF the control power and welding power, and then conduct operations from (1) to (4) shown below.
Page 24: System Connection Diagram
WEL-HANDY COMPACT (13) Welding can be stopped by means of the stop switch or Limit switch. (While the carriage stops, arcs stop at the same time.) 5.3 System connection diagram Signal plug ＊溶接トーチ Torch Wire feeder ワイヤー供給装置 Electrical plug Receptacle ＡＣ１００Ｖ...
Page 25: Maintenance
WEL-HANDY COMPACT 6 Maintenance For correct operation of the machine for an extended period of time without trouble, the daily maintenance is indispensable. (Refer to 6.1 "Maintenance and inspection.") When trouble occurs, refer to 6.3 "Trouble and corrective measures." 。...
Page 26: Monthly Inspection
WEL-HANDY COMPACT 6.1.2 Monthly inspection (1) Check the locking screws of the torch holder, tracing arm, handle, grip handle, carriage bottom plate, etc. for looseness. (2) heck cables (torch and control) for twisting or broken sheathing. (3) Confirmation of the operation of auto stop limit switch.
Page 27 WEL-HANDY COMPACT Defects Cause/check position 1) Defect, disconnection of traveling speed adjustment switch * Kindly verify conduction between Variable resister and DMDU-C board by tester when power supply is turned OFF. ・When it is conducting Kindly verify whether resistance value between variable resister terminals is changed by tester.
Page 28: Warranty
This is thoroughly inspected and tested before leaving the factory, and guaranteed for 12 months from the date of purchase against defective workmanship and material. Should any trouble develop, return the complete equipment prepaid to KOIKE Sanso Kogyo Co., Ltd. Authorized KOIKE Distributor.
Page 29: Wiring Diagram
WEL-HANDY COMPACT 7 Wiring diagram 7.1 Electrical diagram - 24 -...
Page 30: Assembly Drawing Of Circuit Board
WEL-HANDY COMPACT 7.2 Assembly drawing of circuit board DMDU-C board - 25 -...
Page 31: Assembly Drawing Of Wel-Handy Compact
WEL-HANDY COMPACT WEL-HANDY COMPACT Assembly drawing of Guide roller height 90~150 Guide roller height 5~19 Clearance with the moving surface =0.197inch 19mm =0.748inch 90mm =3.543inch 110mm =4.331inch 150mm =5.906inch 200mm =7.874inch 230mm =9.055inch 245mm =9.646inch 255mm =10.039inch - 26 -...
Page 32: Parts List
WEL-HANDY COMPACT 9 Parts list 9.1 Main body and inside parts - 27 -...
Page 33 WEL-HANDY COMPACT Main body and inside parts ITEM STOCK ITEM STOCK PART NAME REMARKS PART NAME REMARKS Body bearing plate 20521497 27-4 Worm gear 20521405 COM Gear box bearing Gear cover 20521498 27-5 20521496 plate Limit switch mounting 20521499 27-6 Motor...
Page 34: Holder Relationship
WEL-HANDY COMPACT 9.2 Holder relationship - 29 -...
Page 35 WEL-HANDY COMPACT Holder relationship ITEM STOCK ITEM STOCK PART NAME REMARKS PART NAME REMARKS 50 Slide unit bracket 20521430 64-4 Washer 6D500060 WF-6 51 Handle 20521546 64-5 Screw 20521574-Y M6×16 52 Grip handle 20521547 64-6 Clamp assembly 20523296 53 Holder bracket...
Page 36: Arm Relationship
WEL-HANDY COMPACT 9.3 Arm relationship - 31 -...
Page 37 WEL-HANDY COMPACT Arm relationship ITEM STOCK ITEM STOCK PART NAME REMARKS PART NAME REMARKS 70 Arm link A 20523297 With DU bush 71 Arm link B 20521501 72 Arm link shaft 20521503 73 Lock spring 20521507 74 Arm rotating shaft...
Page 38: Electrical Parts(1)
WEL-HANDY COMPACT 9.4 Electrical parts(1) 105-3 105-2 105-1 - 33 -...
Page 39 WEL-HANDY COMPACT Electrical parts ITEM STOCK ITEM STOCK PART NAME REMARKS PART NAME REMARKS Arc switch and volume 100 Operation board cover 20521560 1 20522390 DMDU-CN5 assembly 101 Screw 6C570410 Toggle switch 1 6N110009 M-2029L/B 4×10(WS,WF) RV24YN20SB10 102 Toothed washer...
Page 40 WEL-HANDY COMPACT 9.5 Electrical parts(2) Install so that there is no gap between it and the cover. ITEM STOCK ITEM STOCK PART NAME REMARKS PART NAME REMARKS Operation board heat 20521561 shield 111 Screw 20523666-Y SP-4×15(WS,WF) Hexagon socket head 6C450410 BC-4×10 （WS,WF）...
Page 41: About The Use Of Commercial Torches
WEL-HANDY COMPACT About the use of commercial torches When using a commercially available torch, it can be used if the shape of the torch is as shown in the figure. Torch hold position 115 or less 115 or More - 36 -...
Page 42 ＜MEMO＞...
Page 44 WEL-HANDY COMPACT OPERATION MANUAL Date of issue: Feb.2021 KOIKE SANSO KOGYO CO.,LTD. Printed in Japan...