Koike Sanso Kogyo WEL-HANDY MINI User manual

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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
Wel-Handy-MINI_Cover_1.fm Page 1 Tuesday, April 2, 2002 11:59 AM

BOEKNAAM
1 KOIKE Europe B.V. in Zaandam The Netherlands provides a 1 year guarantee on the devices, from the day of
delivery. In case the buyer also agreed on an installation contract, the guarantee starts on the date the products
are supplied.
2 The activities involving guarantee will only be conducted by people employed by, or specifically contracted by
Koike Europe b.v.
3 a The guarantee comprises repairs free of charge or replacement of (parts of) the devices in case of material
and/or manufacturing faults. The guarantee does not include the supply and/or replacement of
consumables.
b The parts that are being replaced as a result of the guarantee will automatically become the property of Koike
Europe b.v.
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1 KOIKE Europe B.V. te Zaandam verstrekt garantie op de zaken gedurende 1 jaar, te rekenen vanaf de datum van
aflevering. Indien de koper tevens een installatieovereenkomst voor de zaken is aangegaan, zal de garantie
worden verleend vanaf de datum dat de zaken zijn opgeleverd.
2 De werkzaamheden onder garantie worden alleen verricht door mensen in dienst van of specifiek aangewezen
door Koike Europe b.v..
3 a De garantie omvat kosteloze reparatie dan wel vervanging van (onderdelen van) de zaken in geval van
materiaal en/of fabricagefouten. De garantie omvat niet de levering en/of vervanging van verbruiksartikelen.
b De onderdelen die ingevolge de garantie worden vervangen, worden automatisch eigendom van Koike
Europe b.v.
1 KOIKE Europe B.V. in Zaandam The Netherlands gewährt 1 Jahr Garantie ab Lieferdatum auf das Gerät. Sollte der
Käufer auch einen Installationsvertrag unterzeichnet haben, beginnt der Garantiezeitraum mit dem Lieferdatum
der Produkte.
2 Alle unter Garantie ausgeführten Arbeiten dürfen nur von Personen ausgeführt werden, die bei Koike Europe b.v.
beschäftigt sind oder von ihr speziell beauftragt wurden.
3 a Die Garantie umfasst kostenlose Reparaturen oder Austauschteile für die Geräte, oder Teilen davon, im Falle
von Material und/oder Konstruktionsfehlern. Die Garantie schließt nicht die Lieferung und/oder den Ersatz
von Verbrauchsmaterial.
b Teile, die innerhalb der Garantie ausgetauscht wurden, werden automatisch Eigentum der Koike Europe b.v.
Wel-Handy-MINI_Cover_1.fm Page 2 Tuesday, April 2, 2002 11:59 AM

BOEKNAAM
4 In folgenden Fällen erlischt die Garantie:
a bei Reparaturen, Ersatz oder Erweiterungen der Geräte, die von Personal ausführt wurde, das nicht zur Koike
Europe b.v. gehört, oder ohne ihre Zustimmung;
b wenn die Geräte verwahrlost sind oder in Zuwiderhandlung der Vorschriften von Koike Europe b.v.
unprofessionell eingesetzt, behandelt und/oder gewartet wurden;
c wenn die Typnummern und/oder Seriennummer beschädigt, entfernt und/oder verändert wurden;
d wenn die Fehler als Folge von unsachgemäßem Anschluß und/oder Bedienung und/oder Installation der
Geräte auftreten;
e wenn die Fehler als Folge von ungeeigneten Raumbedingunen auftreten, insoweit diese angegeben wurden;
f wenn die Fehler als Folge von äußeren Einflüssen auftreten;
g wenn eventuell vorhandene Versiegelungen aufgebrochen wurden.
4 De garantie vervalt indien:
a reparaties, vervangingenof uitbreidingen aan de zaken is verricht door anderen dan Koike Europe b.v. zonder
haar toestemming;
b de zaken naar het oordeel van Koike Europe b.v. verwaarloosd dan wel onvoorzichtig en/of ondeskundig zijn
gebruikt, behandeld en/of onderhouden;
c typenummers en/of serienummers zijn beschadigd, verwijderd en/of veranderd;
d defecten zijn ontstaan door het niet volgens de voorschriften aansluiten en/of bedienen en/of installeren van
de (goedgekeurde) zaken;
e defecten zijn ontstaan ten gevolge van afwijkende omgevingscondities, voor zover dergelijke condities zijn
aangegeven;
f defecten zijn ontstaan door overige oorzaken komend van buitenaf;
g de verzegeling van de zaken, voorzover aanwezig, is verbroken.
4 The guarantee expires in case:
a repairs, replacements or expansions regarding the devices have been conducted by others than Koike
Europe b.v. without its consent;
b the devices were neglected or applied, treated and/or maintained carelessly and/or unprofessionally
according Koike Europe b.v.;
c type numbers and/or serial numbers are damaged, removed and/or altered;
d defects have come into being as a result of connecting and/or operating and/or installing the (approved
devices) without following the instructions;
e defects have come into being as a result of deviating ambient conditions, as far as such conditions were
indicated;
f defects have come into being as a result of other external causes;
g the sealing of the devices, as far as present, is broken.
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CONTENTS
1 Safety information ......................................................................................... 5
1.1 Introduction ............................................................................................ 5
1.2 General machine safety precautions ..................................................... 6
1.2.1 Machine safety ............................................................................ 6
1.2.2 Safety clothing ............................................................................. 6
1.2.3 Electrical system precautions ...................................................... 7
1.3 General Welding safety precautions ...................................................... 8
1.3.1 Rotary section precautions .......................................................... 9
1.3.2 Prevention of explosion ............................................................... 9
1.3.3 Pressure regulator safety precautions ......................................... 9
1.3.4 High pressure gas cylinder safety precautions .......................... 10
1.3.5 Safety precautions for fire, explosion or burst ........................... 10
2 Locations of safety labels ............................................................................ 13
3 Outline of machine ...................................................................................... 15
3.1 Features of machine ............................................................................ 15
3.2 Name and function of each section .....................................................16
3.2.1 Main unit of welding carriage ..................................................... 16
3.2.2 Operation panel ......................................................................... 19
3.3 Specifications ...................................................................................... 21
4 Preparation and procedure for operation .................................................... 23
4.1 Contents of package ............................................................................ 23
4.2 Preparation and procedure for welding ............................................... 24
4.3 System connection diagram ................................................................ 26
4.4 Applicable welding machine and signal adaptor .................................. 26
4.5 Operational precautions ...................................................................... 27
5 Maintenance ................................................................................................ 29
5.1 Maintenance and inspection ................................................................ 29
5.1.1 Daily inspection ......................................................................... 29
5.1.2 Monthly inspection ..................................................................... 29
5.2 Recommended spare parts ................................................................. 30
6 Troubleshooting .......................................................................................... 31
7 Wiring diagram ............................................................................................ 35
8Parts list ......................................................................................................... 37
8.1 Main body and inside parts ............................................................ 37
8.2 Outside parts ....................................................................................... 40
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PREFACE
Introduction
Thank you very much for purchasing this product. This manual is intended
for operators and maintenance personnel. Read the operation manual
thoroughly to ensure correct, safe and effective use of the machine.
Make sure you read, understand and take all the necessary safety
precautions.
Safety precautions
This product is designed to be safe, but it can cause serious accidents if
not operated correctly. Those who operate and repair this machine must
read this manual thoroughly before operating, inspecting and maintaining
the machine. Keep the manual near the machine so that anyone who
operates, inspects or maintains the machine can refer to it if necessary.
• Do not use the machine carelessly without following the instructions
in the manual.
• Use the machine only after you completely understood the contents
of the manual.
• If an explanation in the manual is difficult to understand, contact our
company or sales service office.
• Keep the manual near by at all times and read it as many times as
necessary for a complete understanding.
• If the manual becomes lost or damaged, place an order with our
company or sales service office for a new one.
• When transferring the machine to a new owner, be sure to hand over
this instruction manual as well.
Qualifications for machine operator
Operators and repair staff of this machine must completely understand
the contents of the instruction manual and they must be qualified and
educated to handle this equipment.
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Explanation of symbols
In this manual safety signs (symbols) are used to indicate safety
messages and signal words to indicate the degree or level of hazard. The
safety indicators are explained in the table below.
table 2 - 1
Symbol Title Meaning
Safety alert symbol This symbol is applied to indicate general
caution, warning and danger messages.
Be careful not to get your fingers
caught. Possible injury to fingers if caught in the insertion point.
Caution: Electric shock! Possible electric shock under special
conditions.
Ground this equipment. Operators must ground the equipment using the
safety grounding terminal.
Caution against bursting. Possible bursting under certain conditions.
Caution: Hot! Possible injury due to high temperature under
certain conditions.
Caution: Ignition! Possible ignition under certain conditions.
Pull out the power plug from the
outlet. Operators must unplug the power plug from the outlet when a failure occurs or when there is a
danger of lightning.
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1 Safety information
1.1 Introduction
Operation, inspection, and maintenance that disregard the basic safety
rules cause many accidents. Carefully read, understand, and master the
safety measures and precautions described in this operation manual and
on the machine before operating, inspecting, and maintaining the
machine.
The safety messages used in this manual are classified as indicated on
the machine safety labels.
Danger
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury. The safety label on the machine
is positioned at places that can cause injury or serious accident.
Warning
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury. The safety label on the
machine is positioned at places that could cause injury or serious
accident.
Caution
Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury or machine damage.
Note:
Indicates an additional explanation for an element of information.
The serious injury mentioned above refers to loss of eyesight, injury, burns
(high/medium temperature), electric shock, bone fracture, poisoning
which leave an aftereffect or require hospitalization or regular treatment at
a hospital far an extended period of time.
The injury refers to a wound, burn, or electric shock which do not need
hospitalization or regular treatment at a hospital for an extended period of
time. The physical damage refers to damage to assets and extensive loss
due to damage to the machine.
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1.2 General machine safety precautions
1.2.1 Machine safety
Warning
Strictly obeserve the following to prevent accidents resulting in
serious injury or death.
• Keep people out of the space around the welding machine and
working area.
• The welding machine generates a magnetic field around itself. Such
a magnetic field affects certain types of sensors and clocks. For the
same reason, any person who have a pacemaker 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 repair
of the machine to a person who has thorough knowledge about
welding machines or to a quafified operator.
• For safety, leave the operation of the machine to a person with
complete knowledge of the instruction manual and sufficient skill.
• Do not use this machine for any purpose other than arc welding
described in the instruction manual.
• Do not remodel the machine.
• Check the safety around the machine before operation to prevent
accidents.
• Be sure to hold the handle when carrying the machine.
• Wear leather gauntlets when touching the machine during welding
or right after operation. Do not touch the welded surface until it has
cooled.
1.2.2 Safety clothing
Caution
Use protective gear to protect you and others from arc light,
scattered spatters/slugs and noise as well as from fumes and gas
generated by welding.
1 The arc light includes harmful ultraviolet rays and infrared rays,
causing Inflammation of eyes or burns.
2 Scattered spatters and slugs can damage your eyes and cause
burns.
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3 Noise can cause hearing difficulties.
4 Wear light-shielding goggles or hand shield, which blocks light
sufficiently, for welding operation or monitoring welding.
5 Wear protective goggles to protect your eyes from spatters and
slugs.
6 Install a protective curtain around the welding site so that arc light
will not reach the eyes of people around the site.
7 Wear protective gear such as leather gauntlets. clothes with long-
sleeves, leg cover, leather apron, helmet, and safety shoes.
8 When the noise level is high, wear a noise-proofing protector.
9 Welding generates fumes and gas. Inhalation of such fumes and gas
can damage your health.
10 Welding operation in a small space causes deficiency of oxygen,
which is very likely to cause suffocation.
11 When the welding space is small, ventilate the space sufficiently or
wear an inhaler. Have a trained watchman monitor welding.
12 Welding zinc plated steel sheets or other coated steel sheets will
generate harmful fumes. Remove the coating before welding, or
wear an inhaler before operation.
1.2.3 Electrical system precautions
Strictly observe the following to prevent electric shock.
1 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.
Even if the input power is turned off, the capacitor may have been
charged. When the welding power is output, the electrode and base
metal, as well as the metal portion in contact with these, are
charged.
2 Never touch charged sections.
3 The welding power supply case and base metal, as well as jigs
electrically connected to them, shall be grounded in conformity with
the law (Technical Standard for Electric Equipment) by a qualified
electric engineer.
4 Turn off all power supplies on the input side by means of switches in
the switch boxes before installation, maintenance, and inspection.
The capacitor will not discharge completely right after the input
power is turned off. Check that no voltage is remaining before
maintenance or inspection.
5 Periodically conduct maintenance and inspection. Repair damaged
parts before resuming operation.
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6 DO not use cables with Insufflcient capacity or damaged cables
whose conductors are exposed.
7 Firmly tighten and insulate cable connections.
8 Firmly connect the welding cable on the base metal side at a
location as close as possible to the base metal.
9 Do not use the machine with the welding machine case or coser
removed.
10 Be sure to cover the input and output terminals before use.
11 Do not use broken or wet gauntlets.
12 Never fail to use a life-line when working in high places.
13 Turn of power switches of all devices and input-side power supply
when the machine is not used.
14 Do not wear wet clothes.
15 Do not stand on or touch the wet floor.
16 Do not use the machine outdoors when it is raining.
17 Do not leave the machine outdoors after use.
18 Be sure to install a fuse or breaker on the input power supply side.
19 Check the supply voltage of the machine before use.The tolerance
for the input supply voltage is plus or minus 10% of the rating. Use
of the machine out of this range is prohibited.
20 The metal receptacle (plug) on the tough-rubber sheath cable is
threaded.Tighten it firmly.
21 Be sure to ground the tough-rubber sheath cable of the machine.
22 Turn off the power and stop operation in the following cases, and
ask an engineer with special knowledge of electricity to repair.
a Broken or worn-out cables
b Damage due to water leakage or other liquid
c Malfunction of the machine inspire of operation in conformity
with the instruction manual.
d Breakdown of the machine.
e Abnormal performance of the machine which requires tune-up.
23 Ask an engineer with expertise to maintain, inspect, or repair the
machire.
1.3 General Welding safety precautions
Strictly observe the safety rules and precautions to ensure the safety of
welding operations. Operators and supervisors MUST keep safety in
mind.
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1.3.1 Rotary section precautions
Caution
Strictly observe the following to prevent injury due to rotary section
1 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.
2 Do not bring your head near the end of the welding torch during wire
inching; otherwise the wire may stick in your eyes.
3 When the spool of wire is released, you can get hurt.
4 Do not use the welding machine with its case or cover removed.
5 Ask a trained person who has thorough knowledge of welding
machines or a qualified person to remove the case for maintenance,
inspection, or repair. Install a protective fence around the welding
machine to prevent people from getting near carelessly.
6 DO not bring your hand, fingers, hair, or clothes close to the rotating
cooling fan or the roller of the feeder.
7 Secure the end of the wire with the wire stopper on the spool when
storing or moving the spool of wire or when setting it in the wire
feeder.
8 When inserting the spool of wire into the wire guide on the wire
feeder, firmly hold the wire so that it will not be released.
1.3.2 Prevention of explosion
1 Never weld pressurized cylinders or hermetically sealed containers.
2 Ensure sufficient ventilation for welding to prevent the air from
becoming stale.
1.3.3 Pressure regulator safety precautions
1 Before starting operation, check that all pressure regulators are
operating correctly.
2 Ask a skilled repair engineer to perform maintenance and inspection
service.
3 Do not use pressure regulators from which gas is leaking, nor
malfunctioning pressure regulators.
4 Do not use pressure regulators smeared with oil or grease.
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1.3.4 High pressure gas cylinder safety precautions
Caution
Strictly observe the following to prevent gas cylinders from falling or
bursting.
1 Never use broken cylinders or cylinders from which gas is leaking.
2 Install cylinders upright and take measures to prevent them from
falling.
3 Use cylinders only for specified purposes.
4 Do not smear container valves with oil or grease.
5 Install cylinders in a place free from heat, sparks, slag, and open
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.
7 Never generate arcs on gas cylinders. Do not hook the welding torch
on gas cylinders, or do not allow electrodes to touch gas cylinders.
8 Do not bring your head close to the discharge port when opening
the valve on the gas cylinder.
9 Attach a protective cap to gas cylinders when they are kept unused.
10 Use a gas flow rate controller made or recommended by a welding
machine manufacturer.
11 Read the instruction manual for the gas flow rate controller before
use, and strictly observe the precautions.
1.3.5 Safety precautions for fire, explosion or burst
Caution
Strictly observe the following o prevent fire, explosion or burst.
1 Spatters and hot base metal right after welding can cause fire.
2 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.
3 Arcs generated on the container of gasoline or other inflammables
can cause explosion.
4 Welding of sealed tanks or pipes can cause bursts.
5 Do not do welding in a place where scattered spatters will be in
contact with inflammables.
6 Do not do welding in a place near inflammable gas.
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7 Do not bring hot base metal right after welding close to
inflammables.
8 Welding on ceilings, floors, an walls may cause fire on the hidden
side. Remove inflammables from the hidden side.
9 Firmly tighten cable connections, and firmly connect the welding
cable on the base metal side at a location as close as possible to the
base metal.
10 Do not weld gas pipes filled with gas.
11 Do not weld sealed tanks or pipes.
12 Provide a fire extinguisher near the welding place to prepare for the
worst.
13 Do not weld a container that has inflammables inside.
14 Do not have a lighter, matches, or other inflammables with you
during welding.
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2 Locations of safety labels
Safety labels and other labels for correct operation are affixed to the
machine. Carefully read the labels and follow the instructions on them
when operating the machine.
Never remove the labels. Keep them clean and legible at all times.
figure 2 - 1
WARNING
ELECTRIC
SHOCK
WARNING
BEWARE
OF MAGNETIC
FORCE
WARNING
NO LIFTING
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3 Outline of machine
3.1 Features of machine
The WEL-HANDY MULTI 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.
• The powerful magnet has dramatically enhanced the tracing
reliability and tractive force, thereby ensuring stable traveling.
• It is possible to operate multiple machine by improved tracing
reliability and automatic stopping function.
• The direction changeover switch permits rightward/leftward
traveling.
• The height of the tracing roller can be changed in three stages.
The above features are expected to exhibit their effects in terms of
"welding efficiency" and "operation by unskilled workers."
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3.2 Name and function of each section
3.2.1 Main unit of welding carriage
figure 3 - 1
1 Slide unit assembly
The arc point can be adjusted toward UP/DOWN or FRONT/REAR.
The each stroke is 45 mm.
1. Slide unit assembly
2. Torch holder
3. Guide roller and arm
4. Auto stop switch
5. Operation panel
6. Welding torch
7. Metal socket
8. Driving wheel (Rubber roller)
9. Torch angle adjusting bolt
10. Handle
11. Magnet lever
1
34
5
7
2
8
6
9
11
10
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Warning
Secure the insulated section of the torch before mounting it.
When the conductive section is secured, a short circuit and/or electric
shock can result.
2Torchholder
Insert the exclusive use torch mounting section into the torch holder
to secure it.
3 Guide roller and arm
Press them against the vertical plate for welding by tracing.
Three positions can be selected. (The dimension shows in mm.)
4 Auto stop switch
These are provided on both sides of the carriage, serving as
(welding) stop button.
Caution
Do not apply impact to the auto stop switch
When impact is applied to the auto stop switch, it can be broken. When
the auto stop switch is broken, the automatic stopping function will not
work, resulting in contineous traveling and arcs welding.
5 Operation panel
The detail is shown in figure 3-2.
6Weldingtorch
Insert the exclusive use welding torch into the torch holder (2).
7 Metal socket
The cable is plugged into this socket. The cable is connected
between the control panel and the wire feeder, as well as power
supply. (The cable is divided in the middle into one for the wire
feeder and another for the input power.)
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