Koike WU-5R Operation Manual

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Supporting equipment for WU-5R

WU-5R

OPERATION MANUAL

For every person who will be engaged in

operation and maintenance supervision, It is

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Summary of Contents for Koike WU-5R

Page 1 Supporting equipment for WU-5R WU-5R 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. part. 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
5.1.4 Weaving tack/stitch running motion pattern diagram 5.1.5 Weaving movement time chart 5.1.6 tack/stitch running motion time chart 6. Preparation of work if you have purchased un WU-5R unit 6.1 Package contents (WU-5R unit) 6.2 Machine Assembly 7. WU-5R Weaving unit Wiring diagram...
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
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 Foreign materials can cause short-circuits or melt the connector. ■ In case if you get connected WU-5R, make sure to Turn Off the Power. Caution: When the power is on if it gets connected there is a possibility of failure.
Page 8 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. ■Noise can cause hearing difficulties.
Page 9 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 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: Locations Of Safety Labels
3 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 12: Features And Specifications
4 Features and specifications 4.1 Features This machine, weaving unit WU-5R is an optional unit to realize weaving welding with easier operations. By introducing this unit, various types of welding machine can easily get a weaving function. The main features as below.
Page 13: Specifications
4.3 Specifications 4.3.1 Weaving unit WU-5R body Item Specifications Model Weaving unit WU-5R DC24V 1.2A Input power supply (supplied from WEL-HANDY MULTIⅡ TACK/STITCH) Weight 2kg / 4.4lb Carriage dimensions L125×W91×H185mm(Includes torch holder) L4.9×W3.6×H7.3inch(Includes torch holder) 2 phase excitation stepping motor Drive motor Step angle 1.8degrees...
Page 14: Method Of Operation
 Kindly use input voltage within ±10%for power supply input to input plug (Kindly use input voltage in the range of AC100V~AC240V to the welding carriage). WU-5R is operated with DC24V supplied from the welding carriage. There is risk of short circuit due to failure of printed board on operation panel.
Page 15: Operation Panel
■Kindly use input voltage within ±10%for power supply input to input plug (Kindly use input voltage in the range of AC100V~AC240V to the welding carriage). WU-5R is operated with DC24V supplied from the welding carriage.
Page 16: Explanation About Operation Unit Functions
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 Motor overload error Please make sure the load is not applied to the motor. Trduck backup err Please make sure the truck and the WU-5R is not OFF the （parameter） power while fine-tuning move in operation or limit switch . After...
Page 18: Regarding Select Switch
5.1.2 Regarding SELECT SWITCH It is possible to carry out continuous welding and tack welding operation by selecting each mode /stitch and each parameter by SELECT SWITCH Regarding each mode and each parameter it is given as below. Operation Digital display Setting range Factory default unit display...
Page 19 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. RIGHT During the stop in the digital meter, right torch stop time value is displayed.
Page 20 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. Turn the DATA DIAL clockwise, the torch moves to the left. Turn in the counter-clockwise direction, the torch moves to the right.
Page 21 Operation Digital display Setting range Factory default unit display 0～999.9mm 20.0mm 0～39.4inch 0.8inch Function Preliminary feeding distance settings (It shows length of the portion not to be weld) This mode is selected to set preliminary feeding distance at the time of tack/stitch travelling mode.
Page 22 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. ：0000～9999 Setting range ：0114 Factory default...
Page 23 Welding return waiting time settings Setting range：0～999.9s Factory default：0s This mode is selected to set welding return waiting time at the time of continuous travelling mode and TACK/STITCH travelling mode. It displays welding return waiting time value while stopping on the digital meter. It is possible to change the welding return waiting time by turning DATA DIAL during stopping of carriage.
Page 24 Welding return speed settings Setting range：50～1500mm/min 2.0~59.0inch/min Factory default:200mm/min 7.9inch/min This mode is selected to set welding return travelling speed at the time of continuous travelling mode and TACK/STITCH travelling mode. It displays welding return speed value during stopping of carriage on digital meter.
Page 25: Metric,Inch Switch Over Method
5.1.3 Metric, Inch switch over method 1.Turn ON the electric supply. 2.Select “PAM” in selection switch and turn ON the START/STOP switch for once. 3.Turn the DATA DIAL and select , then turn ON START/STOP switch for once. 4.Select and then turn ON the START/STOP switch for once. : Metric specification (mm) : Inch specification (inch) 5．Turn OFF the electric supply.
Page 26: Weaving Tack/Stitch Running Motion Pattern Diagram
5.1.4 Weaving tack/stitch running motion pattern diagram Example 1) Weaving tack/stitch welding parameter setting Operation Movement sequence Welding distance 70mm / 2.76inch Welding movement Welding return distance 30mm / 1.18inch Welding return Sky transmission distance 40mm / 1.57inch distance Welding return waiting time 1sec preliminary feeding distance Arc stability time...
Page 27 Further, “Welding distance”, “Preliminary feeding distance”, “Welding return distance” can be changed by operating “Arc changing over switch” during weaving tack/stitch welding operation. Kindly operate by referring to below mentioned settings while changing distance during weaving tack/stitch welding operation. Welding distance In case of normal operation (“Without”...
Page 28: Weaving Movement Time Chart
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 0sec Weaving swing width 10mm / 0.39inch Weaving swing width Origin position...
Page 29: Tack/Stitch Running Motion Time Chart
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) Stop Start START/STOP Button Limit Switch Welding distance Empty run distance Welding distance Truck Arc signal Main current Main current Welding current...
Page 30 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) Start Stop START/STOP Button Limit Switch Welding distance Welding distance Empty run distance Truck Arc signal Main current Main current Welding current Crater (self-holding)”ON”...
Page 31: Preparation Of Work If You Have Purchased Un Wu-5R Unit
16. Instruction manual, Warranty card --------------------------------------------------------------- 1pc 6.2 Machine Assembly Following Assembly, the top purchase WU-5R alone, when assembled to IK-72 tack/stitch will need work. Remove the Panel name plates from IK-72 TACK/STITCH with the weaving unit attached to the bracket, slide unit, fixed holders, arm, Control Panel.
Page 32 10. IK-72 TACK/STITCH on which M6 eye bolt (with nut) is installed. 11. Insert weaving unit cable metal plug into IK-72W TACK/STITCH operation panel receptacles. In case if you get connected WU-5R, make sure to Turn Off the Power. CAUTION ■...
Page 33: Wu-5R Weaving Unit Wiring Diagram
7. WU-5R Weaving unit Wiring diagram -29-...
Page 34 -30-...
Page 35: Weaving Unit Parts
8. Weaving unit parts straight torch curved torch -31-...
Page 36 Weaving unit parts ITEM STOCK ITEM STOCK PART NAME REMARKS PART NAME REMARKS Insulating plate Weaving unit assembly 61006521 40-3 (1) 60038148 (for curved torch) Insulating collar 38-1 Weaving cover A 61006498 40-4 (2) 60038149 (for curved torch) 38-2 Weaving cover B 61006499 40-5 Clamp knob (1) 60038166...
Page 37 WU-5R WEAVING UNIT OPERATION MANUAL KOIKE SANSO KOGYO CO.,LTD. -33-...