Koike IK-72T W2 Operation Manual

Portable automatic welding carriage for fillet welding

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Portable Automatic Welding Carriage for fillet welding

T89002425

IK-72T W2

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 T89002425 IK-72T W2 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 ENGINEERING TANGSHAN CO.,LTD.
Page 2 IK-72T W2 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 IK-72T W2 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. Operators must ground the equipment using the Ground this equipment.
Page 4: Table Of Contents
8.3 Maintenance and inspection........................- 35 - 8.4 Warranty..............................- 38 - 9 Wiring diagram............................- 39 - 10 Assembly drawing of IK-72T W2....................- 40 - 11、Part List..............................- 41 - 11.1 Main and Driving units.......................... - 41 - 11.2 Torch holder............................- 43 - 11.3 Limiting device............................
Page 5: Safety Information
1 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 6: Safety Precautions
IK-72T W2 2 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 7 IK-72T W2 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 8 IK-72T W2 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 9 IK-72T W2 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 10 IK-72T W2 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 11: Equipment Outline
IK-72T W2 3 Equipment outline The outline dimensions of the equipment are as follows - 8 -...
Page 12: Features And Specifications
IK-72T W2 4 Features and specifications 4.1 Features This machine ‘IK-72T W2’is a welding carriage equipped with a weaving unit WU-5R. Vertical and horizontal weaving welding is enabled by simple operation. 1. Compact, Light weight, Durable and Low gravity. 2. The high-quality track （1D/3D） greatly improves the reliability and traction of the equipment, thus ensuring the driving stability.
Page 13: Specifications
IK-72T W2 4.3 Specifications Item Specifications Model IK-72T W2 Input power supply AC100-240V ±10% Weight 10kg Carriage dimensions L295×W218×H327mm(Includes torch holder) L11.6×W8.58×H12.87inch(Includes torch holder) Speed control Dial operation Cutting speed 150–700 mm/min Cutting thickness 5–30 mm (by standard accessories cutting tip) Bevel angle 0–45 degree...
Page 14: Method Of Operation
IK-72T W2 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 15: Operation Panel
IK-72T W2 5.1 Operation panel V3.33 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...
Page 16: Explanation About Operation Unit Functions
IK-72T W2 5.1.1 Explanation about operation Unit functions Display Name Function It is used at the time of start/stop of travelling of carriage. Moreover, there are cases where this function is used to set parameters START/STOP ※When an error occurs, the error display is reset when you press the Button START / STOP switch .
Page 17 IK-72T W2 <Regarding Error number> Error contents Dealing method Error number Please confirm whether an encoder line isn’t connected to Encoder line MD-CN10. Connection error If it is connected, connect it to MD-CN5. Kindly verify whether there is load on motor or motor DC line or Motor deviation over error encoder line is slipping off.
Page 18: Regarding Select Switch
IK-72T W2 5.1.2 Regarding SELECT SWITCH In IK-72T W2, it is possible to carry out continuous welding and TACK welding operation by selecting each mode and each parameter by SELECT SWITCH Regarding each mode and each parameter it is given as below.
Page 19 IK-72T W2 Operation Digital display Setting range Factory default unit display 0～10.0s Function Right torch stop time setting Selecting when setting the right torch stop time during weaving operations. TIMER Right torch stop time of tack/stitch driving mode also set here.
Page 20 IK-72T W2 Operation Digital display Setting range Factory default unit display －－ Function Origin position adjustment setting During the carriage stopped or carriage traveling by turning the DATA DIAL you can adjust the position of the origin of the torch.
Page 21 IK-72T W2 Weaving tack/stitch driving mode and welding distance setting Carriage is selected by you when weaving tack/stitch run is done, also you select welding distance at the time of tack/stitch run. Press the START/STOP button while selecting this mode starts the running of the carriage in the direction of the arrow.※...
Page 22 IK-72T W2 Parameter number details Parameter number Function Input prevent erroneous settings Parameter values enables you to edit the parameters at the time of In other value becomes an input of only this parameter. Please use for the erroneous input prevention.
Page 23 IK-72T W2 Setting range :-0.1～1.0s Torch switch ON output time setting (crater Process) Factory default：0 Set the torch switch output ON time during welding start-up to the welding power source. ・ If the setting of a welding power source is Mu self-holding of (crater non-compliant), this parameter Please to 0 the data.
Page 24 IK-72T W2 Setting range Welding return distance setting Factory default 0～39.4inch ：0～999.9mm ：0mm 0inch This mode is selected to set welding return distance at the time of continuous travelling mode and TACK/STITCH travelling mode. It operates after completion of welding return waiting time.
Page 25: Metric, Inch Switch Over Method
IK-72T W2 Metric Metric, Inch switch over settings Inch ：： The displayed set value of speed and distance can be switched in metric and inches. Refer to "switch over method of metric and inch" for method to switch. ※ The factory default is the metric specifications.
Page 26 IK-72T W2 Arc stability time Welding return waiting time ※In the weaving tack driving at the time of the operation, the weaving operation will be done.At the time of sky transmission distance, the weaving operation is not done. ※Stop work by START / STOP button or limit switch, the running and welding can be stopped.
Page 27 IK-72T W2 Welding distance In case of normal operation (“Without” ARC changing over switch Preliminary feeding distance Transition of toggle switch ARC MANUAL “No” switch ARC ON operation ARC OFF In case of extended operation (“With” ARC changing over switch...
Page 28: Weaving Movement Time Chart
IK-72T W2 5.1.5 Weaving movement time chart The weaving movement at the time of the weaving welding becomes like the following time chart. Example1) Parameter settings Central torch stop time 0sec Left torch stop time 0sec Right torch stop time...
Page 29: Tack/Stitch Running Motion Time Chart
IK-72T W2 5.1.6 tack/stitch running motion Time chart Crater (self-holding)”OFF” setting A Arc stability waiting time B Welding return waiting time 0s C Welding return distance 0mm(0inch) Start Stop START/STOP Button Limit Switch Welding distance Welding distance Empty run distance...
Page 30 IK-72T W2 Crater (self-holding)”OFF” setting A Arc stability waiting time 1.0s B Welding return waiting time 1.0s C Welding return distance 5mm(0.19inch) Stop Start START/STOP Button Limit Switch Welding distance Empty run distance Welding distance Truck operations Arc signal Main current...
Page 31: Preparation Operation
9. IK-72T W2 on which M6 eye bolt (with nut) is installed. 10. IK-72T W2 to which handle that is attached to the 90 ° direction installed in changing state. 11. Insert weaving unit cable metal plug into IK-72T W2 operation panel receptacles.
Page 32: Trouble And Corrective Measures
IK-72T W2 6.3 Trouble and corrective measures The machine will not move (the motor will not run) 1） Reasons of Failures Inspection Troubleshooting 1) The Power is turned Check the power; Check the plug. 2) The power cables are Use a detector to test the Fix the broken cables.
Page 33 IK-72T W2 4) The device is not operating properly. Reasons of Inspection Troubleshooting Failures 1) too fast as to Voltage is not normal. Check voltage. the speed 2) no low speed 1) Speed control resistor Replace with a new resistor.
Page 34: Welding Operation
IK-72T W2 7 Welding operation 7.1 Preparation and procedure for welding Conduct welding in the following manner, while referring to the Fig 3“System connection diagram” and the operation procedure in item 8.1. WARNING Strictly observe the following to prevent electric shock.
Page 35: System Connection Diagram
IK-72T W2 (7) Turn the handle of the slide unit assembly (UP/DOWN or FRONT/REAR) for torch position alignment. Origin position of the torch can be adjusted by turning the DATA DIAL to fit the SELECT SWITCH according to ORG. ( 8) Select each parameter by SELECT SWITCH and set parameter value by DATA DIAL.
Page 36: Applicable Welding Machine And Signal Adaptor
IK-72T W2 7.3 Applicable welding machine and signal adaptor This welding machine is to be used in combination with a semi-automatic (CO2, MAG) welding machine (power supply and feeder) available on the market. The signal cable plug is D25-2P (connectable to wire feeders made by Matsushita or Daihen). Plugs for connection to wire feeders of other manufacturer are also available as options.
Page 37: Maintenance And Inspection
IK-72T W2  Do not use welding equipment without case or cover.  Kindly use power outlet with earth pin outlet since input plug has earth pin. It is connected to main body of carriage in operation panel.  Kindly use input voltage within ±10%for power supply input to input plug (Kindly use input voltage in the range of AC100-240V) There is risk of short circuit due to failure of printed board on operation panel.
Page 38: Recommended Spare Parts
IK-72T W2 8.2 Recommended spare parts (1) Side gear assembly (2) Track（1D/3D） (3) Auto stop switch (4) Printed circuit board 8.3 Maintenance and inspection Defects Cause/check position 1) Guide gear is not rotating. 2) Cable is stuck in and it is blocking smooth traveling of carriage.
Page 39 IK-72T W2 1) Limit switch at carriage traveling direction side is pressed. (4) No welding operation and  Carriage starts traveling by pressing Limit switch which no traveling of carriage at is at opposite side of carriage traveling direction. the pressing of...
Page 40 IK-72T W2 (11) There is stopping of welding operation but no stopping of traveling of 1) Defective printed board carriage at pressing of Limit switch (12)Absorption force is not 1) Fault of Rotating Shaft of Track (1D/3D) Magnet weaken even at drawing *If the rotating shaft broken it must be changed.
Page 41: 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 42: Wiring Diagram
IK-72T W2 9 Wiring diagram - 39 -...
Page 43: Assembly Drawing Of Ik-72T W2
IK-72T W2 10 Assembly drawing of IK-72T W2 - 40 -...
Page 44: 11、Part List
IK-72T W2 11、Part List 11.1 Main and Driving units - 41 -...
Page 45 IK-72T W2 Main and driving units ITEM PART NAME Q’TY STOCK NO. REMARKS PART NAME Q’TY STOCK NO. REMARKS Machine base T60031674 Side gear assembly T60031611 Drive shaft assembly T60031606 Screw T6C530514 SP-5×14 Clutch shaft T60038839 102L. Hexagon bolt T6C030530 BC-5×30...
Page 46: Torch Holder
IK-72T W2 11.2 Torch holder - 43 -...
Page 47 IK-72T W2 Torch holder ITEM ITEM PART NAME Q’TY STOCK NO. REMARKS PART NAME Q’TY STOCK NO. REMARKS Bracket T61001700 Fixing holder T61000597 Hexagon blot T6C440512 BC-5x12 Hexagon blot T6C450516 BC-5x16 Hexagon blot T6C450625 BC-6x25 Slide unit assembly T61000645 56-1 Slide base...
Page 48: Limiting Device
IK-72T W2 11.3 Limiting device 801 802 - 45 -...
Page 49 IK-72T W2 Limiting device ITEM ITEM PART NAME Q’TY STOCK NO. REMARKS PART NAME Q’TY STOCK NO. REMARKS T89000399 Cover T89000400 Limited right 61006497 Limited left 61006470 Screw T6C520306 SP-3x6 Wash T6D510030 WS-3 Wash T6D500030 WF-3 Screw T6C520410 SP-4x10 Wash...
Page 50 IK-72T W2 11.4 Electrical parts - 47 -...
Page 51 IK-72T W2 Electrical parts STOCK STOCK REMARK ITEM ITEM No. PART NAME REMARKS No. PART NAME Operation panel assembly 1 61007880 41-30 Terminal resistance 61006520 DSP-CN5 (5P) 41-1 Panel board 61006484 41-31 Extension harness ass’y 1 61006506 Moter line 41-2 Power blacket 61006512 41-32 Extension harness ass’y 1...
Page 52 IK-72T W2 IK-72T W2 OPERATION MANUAL Version T89002425 Date of issue: June.2019 KOIKE ENGINEERING TANGSHAN CO., LTD. - 49 -...