Portable Automatic Gas Cutter

Transcription

1 Portable Automatic Gas Cutter BHA00B20 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.

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. Make sure you read, understand and take all 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 operates the machine can refer to it as necessary. Do not use the machine carelessly without following the instructions in the manual. Use the machine only after you have 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 to hand at all times and read it as many times as is 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 have either of the following qualifications: 1. Gas welding foremen s license 2. Completion of gas welding training course 3. Approval by the Minister of Labor

3 Symbol Title Meaning General General caution, warning, and danger. Be careful not to get your fingers caught. Possible injury to fingers if caught in the insertion port. Caution: Electric shock! Possible electric shock under special conditions. Ground this equipment. Operators must ground the equipment using the safety grounding terminal. 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 damage. Caution against bursting Possible bursting under certain conditions. General General warning. Caution: Hot! Possible injury due to high temperature under certain conditions. Caution: Ignition! Possible ignition under certain conditions.

4 CONTENTS 1. Safety Information General machine safety precautions Gas cutting safety precautions 3 2. Locations of safety labels 5 3. Outline of machine Features of machine Name and function of each section Specifications 7 4. Preparation for operation Contents of package Function of each section Machine assembly Preparation for operation Cutting operation Safety measures prior to operation Ignition and flame adjustment Cutting and piercing method Safety measures against backfire and flashback Cutting operation Precautions in diagonal web cutting with an ST torch Maintenance and inspection Daily inspection Periodical inspection Maintenance and inspection of quick cock Trouble shooting Wiring diagram Assembly drawing of MINIMANTIS Ⅱ Parts list Body unit Torch slide unit Gas distributor operation plate unit Rail Straight head type torch unit Cutting Data 35

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11 MINIMANTIS-Ⅱ 3.3 Specifications Weight: 20Kg (incl. rail) Body: 15Kg Rail: 5Kg Motor: Web side DC motor (1/30 gear assembly) 15W Flange side DC motor (1/750 gear assembly) 15W Power source: ±10% Speed control: Dial operation Cutting speed: 100~700 mm/min (4 ~27.5 ) Drive: Web side Function roller Flange side Rack and pinion Cutting thickness: 5~30 mm (0.2 ~1.18 ) Tip: 102 (for acetylene) or 106 (for propane) # 0, 1, 2 one each Gas: Oxygen, acetylene gas, or LPG gas Rail length (600 rail): 1100 mm (43.3 ) Cutting dimensions and cutting method 1) Right-angle cutting A= mm (6 ~24 ) B= mm (6 ~16 ) 2) Diagonal web cutting 35 at 400 mm (16 ) maximum diagonal web cutting 35 maximum diagonal web cutting 3) Bevel cutting 35 for both web and flange 4) Flange diagonal cutting 30 at 300mm (12 ) maximum diagonal flange dimension 30 maximum diagonal flange cutting Standard accessories TIP 102 (for acetylene) or 106 (for propane) No. 0, 1, 2 1pc each Power cable: 1 set Tip cleaner: 1 set Spanner (A, B, C): 1 set Screw driver: 1 pc Hose band: 1 set Fuse (1A): 2 pcs Center: 1 set Torch up/down unit (Selective) ST-400, ST-700 Rail (Selective) 600 rail, 900 rail, 1500 rail -7-

12 MINIMANTIS-Ⅱ 4 Preparation for operation 4.1 Contents of package The contents of the standard package are shown below. Check them carefully before assembling the machine. Body... 1 set Gas distributor (quick cock)... 1 set Torch holder... 1 set Torch... 1 pc Hose Distributor hose (2 pcs set: 1900 L)... 1 set Distributor hose (1 pc: 400L)... 1 set Power cable (3P 5M)... 1 pc TIP 102 (for acetylene) or 106 (for propane)... 1 pc each Tip cleaner... 1 set Screw driver... 1 pc Spanner (A,B,C)... 1 set Fuse (1A)... 2 pcs Hose band... 1 set Center... 1 set 4.2 Function of each section Quick cock (gas distributor) Adjust the preheating flame and axially flame (pilot burner) once, and the lever operation ensures the same flame conditions at all times. -8-

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17 MINIMANTIS-Ⅱ 900 rail 600 rail Mounting position Web dimensions (mm) 1 152~300 Mounting position Web dimensions (mm) 2 245~ ~ ~ ~ ~ ~ ~ ~ ~

18 MINIMANTIS-Ⅱ Caution when using 1500 rail The web dimension that can be mounted on the 1500rail is 900~1500mm. When using the 1500 rail, the range that can be cut off of the flange differs from when using the 600 rail and 900 rail. 600 rail 900 rail ST ~400 ST ~ rail 150~ ~

19 MINIMANTISⅡ The ground pin is attached to the rubber plug of a cabtyre cord. Please use a power receptacle with a ground pin opening

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31 MINIMANTISⅡ 8 Wiring diagram NCS-253-R 9 Assembly drawing of MINIMANTISⅡ

32 MINIMANTISⅡ 10 Parts list 10.1 Body unit

33 MINIMANTISⅡ Body unit ITEM No. PART NAME QTY STOCK No. REMARKS ITEM No. PART NAME QTY STOCK No. REMARKS 1 Main unit case With BC PCS 33 Screw 1 6C SP Pipe arm(a) Screw 2 6C SF Gear box With DU bush 35 Spring pin 1 6B PR Motor (DC24V) W 5000r.p.m With Pinion 36 Screw 3 6C SP Spacer Screw 1 6C Gear assembly Hexagon bolt 1 6C With Nut SP-5 25 With Nut 2PCS BH Bearing 1 6A ZZ 39 Spring pin 1 6B PR Washer Washer 3 6D WF-5 11 Bearing retainer Hex,socket head screw 3 6C BC Clutch lever plate Screw 3 6C SF Bearing 1 6A ZZ 43 Screw 1 6C SSS Collar Washer 1 6D WF Worm wheel Nut 1 6D NH Drive wheel shaft Spring pin 1 6B PR Bearing 1 6A ZZ 47 Steel ball TB-1/4 18 Casing Screw 2 6C SP Bearing retainer Washer 2 6D WF-5 20 Drive roller Spring pin 1 6B PR Roller assembly ZZ With stop ring 22 Guide roller shaft Gear box fitting shaft Casing Spring Clutch lever Lever spring Clutch shaft holder Clutch shaft Taper pin 1 6B PT Screw 4 6C With WS SP Screw 3 6C SP

34 MINIMANTISⅡ 10.2 Torch slide unit

35 Torch slide unit ITEM No. PART NAME QTY STOCK No. REMARKS 1 Torch and holder assembly Except USA,KE ITEM No. PART NAME QTY MINIMANTISⅡ STOCK No. 34 Crank handle M8x25 Torch and holder assembly USA only 35 Crank handle M8x20 Torch and holder assembly KEonly 36 Cross feed handle assembly Torch Except USA,KE 37 φ 50 Handle Torch USA only 38 Pinion metal Torch KE only 39 Pinion REMARKS 3 Tip fixing nut Screw 1 6C SS-12x10 4 Torch holder Wing bolt 1 6C BS-6x12 5 Collar Screw 2 6C SP-4x25 With Nut 6 Spring Wing bolt 1 6C BS-4x10 7 Lock nut Screw 4 6C SP-4x15 With WS 8 Slide bar ST400/LT Screw 3 6C SP-3x20 Slide bar (1) ST700/LT Screw 4 6C SP-4x16 9 Angle gradation ring With SS-3x5 47 Washer 4 6D WF-5 10 Upper stopper assembly Nut 4 6D NH-5 11 Lower stopper assembly Screw 2 6C SP-4x4 12 Stopper Screw 4 6C SP-3x20 13 Limit shaft Screw 2 6C SP-4x14 14 Hose hanger Washer 1 6D WF-8 15 Guide roller holder With screw 53 Spring pin 1 6B PR-2.5x16 16 Motor (DC24V) w 5000rp 54 Metal plug 1 6N P 20 Gear assembly / Spring Bearing 1 6A ZZ 56 Washer 1 6D WF-6 22 Bearing adjusting metal Guide roller shaft (A) Guide roller assembly Guide roller collar Guide roller shaft (B) Saddle Spacer Limit switch Switch cover Guide roller holder bracket M5x16 With Nut 32 Key Rotary shaft

36 MINIMANTISⅡ 10.3 GAS distributor operation plate unit

37 Gas distributor operation plate unit ITEM No. PART NAME QTY STOCK No. REMARKS 1 Solenoid valve(ox) Except USA,KE Solenoid valve(ox) V USA,KE ITEM No. PART NAME QTY MINIMANTISⅡ STOCK No. REMARKS 23 Switch ass y Switch S-1A 2 Nipple Except USA 23-2 Nut for dust protector S-1A only Nipple USA only 25 Cap for dust protector Elbow Neon lamp 1 6N AC100V-AC120V 4 Nipple Except USA 28 Fuse holder Nipple USA only 29 Fuse A 5 Solenoid valve fitting plate Printed card Distributor Except USA,KE 31 Resistor Distributor USA only 32 Relay Except USA,KE Distributor KE only Relay USA,KE 7 Valve for Jet oxygen Except KE 33 Printed card fitting bar Valve for Jet oxygen KE only 34 Terminal P 8 Valve for Preheat oxygen Except KE 35 Metal socket 1 6N P Valve for Preheat oxygen KE only 36 Metal socket 1 6N P 9 Valve for Gas Cabtyre cord ass y(3p) Hose for Jet oxygen 1 Except USA ST-400,LT-400 Hose for Jet oxygen 1 USA only ST-400,LT Hose for Jet oxygen 1 Except USA ST-400 Hose for Jet oxygen 1 USA only ST-400 Hose for Jet oxygen 1 Except USA ST-700 Hose for Jet oxygen 1 USA only ST Hose for Preheat oxygen 1 Except USA ST-400 Hose for Preheat oxygen 1 USA only ST-400 Hose for Preheat oxygen 1 Except USA ST-700 Hose for Preheat oxygen 1 USA only ST Hose for Gas (Red) 1 Except USA ST-400 Hose for Gas 1 USA only ST-400 Cabtyre cord ass y(3p) For transformers Cabtyre cord ass y(3p) CEtype Metal plug 1 6N P 39 Cabtyre cord(5m) For transformers KE only Cabtyre cord(5m) CEtype KE only 40 Rubber plug Operation panel ass y 1 Except KE,USA For 100V Operation panel ass y KE,USA For 120V 42 screw 4 6C SP screw 6 6C SM Screw 2 6C SP Controller Hose for Gas (Orange) (1) ST Screw 2 6C SP-3 10 Hose for Gas (Red) 1 Except USA ST-700 Hose for Gas 1 USA only ST Isolation washer WP-1 50 Spacer 2 6R EP-5 Hose for Gas (Orange) (1) ST Screw 1 6C SF Screw (SP-5 12) 2 6C M5 12 With WS 52 Spacer EM Operation panel Screw 2 6C SP Direction switch Transformer For 100,120V 20 Push button switch Bracket Variable resistor Bracket Handle With Screw

38 MINIMANTISⅡ 10.4 Rail Straight head type torch unit

39 MINIMANTISⅡ Rail Straight head type torch unit ITEM No. PART NAME QTY STOCK No. REMARKS ITEM No. PART NAME QTY STOCK No. REMARKS 1 Rail (ST TYPE) For 600 mm 26 Pinion metal(a) Rail (ST TYPE) For 900 mm 27 Pinion(A) Rail (LT TYPE) For 600 mm 28 Torch holder base Rail (LT TYPE) For 900 mm 29 Collar(A) Set plate spacer For 600 mm 30 Spring Set plate spacer For 900 mm 31 Collar(B) With Set screw 3 Set base assembly Spring Set base Hose for Jet oxygen Set shaft Hose for Jet oxygen Base plate Except USA LT-400 USA only LT Slide base assembly Hose for Jet oxygen 1 Except USA LT Slide base Hose for Jet oxygen 1 USA only LT-700 HOSI Except USA 9 Fixing bolt Hose for Preheat oxygen LT Hex socket head screw 10 6C BC-5 15 For WF,WS,NH Hex socket head screw 12 6C BC-5 15 For WF,WS,NH Hose for Preheat oxygen Hose for Preheat oxygen Wing bolt 2 6C BS Hose for Preheat oxygen Nut 4 6D NH Hose for Gas (Red) Washer 2 6D WF-10 Hose for Gas USA only LT-400 Except USA LT-700 USA only LT-700 Except USA LT-400 USA only LT Hex socket head screw 2 6C With WS Hose for Gas (Orange) (1) LT Hexagon bolt 2 6C Hose for Gas (Red) Stabilizer LT Type Hose for Gas Except USA LT-700 USA only LT Hexagon bolt (LT TYPE) 6 6C With WS,NH Hose for Gas (Orange) (1) LT Straight head type torch unit Except USA 36 Screw 2 6C SP-5 20 Straight head type torch unit USA only 37 Spring Pin 1 6B PR Straight head type torch Except USA 38 Steel ball 1 6F TB-1/4 Straight head type torch USA only 39 Washer 1 6D AW-12 Straight head type torch KE only 40 Nut 1 6D NL Tip fixing nut Wing bolt 1 6C BS Rack for torch With Screw 42 Screw 1 6C SP-6 15 With NH Straight head type torch holder assembly 23 Torch holder Pinion assembly φ40 Handle

40 MINIMANTISⅡ 11 Cutting data 102(STANDARD SPEED) For Acetylene CUTTING OXYGEN PRESSURE FUEL GAS TIP SPEED (kg/c m2 ) / (Mpa) PRESSURE SIZE (mm/min) CUTTING PREHEAT (kg/c m2 ) / (Mpa) / / / / / / / / / / / / / / / / / / / / / / / / PLATE THICKNESS (mm) KERF WIDTH (mm) 102-D7(HIGH SPEED) For Acetylene CUTTING OXYGEN PRESSURE FUEL GAS TIP SPEED (kg/c m2 ) / (Mpa) PRESSURE SIZE (mm/min) CUTTING PREHEAT (kg/c m2 ) / (Mpa) / / / / / / / / / / / / / / / / / / / / / / / / PLATE THICKNESS (mm) KERF WIDTH (mm) NOTE 1) All pressures are torch inlet pressures. 2) Oxygen purity is minimum of 99.7%. 3) Depending on the surface condition of the steel plate (scale, paint) either increase the fuel gas pressure or decrease the cutting speed. Also, when precision cutting is required, adjust all data

41 106(STANDARD SPEED) For Propane PLATE THICKNESS (mm) MINIMANTISⅡ CUTTING OXYGEN PRESSURE FUEL GAS TIP SPEED (kg/c m2 ) / (Mpa) PRESSURE SIZE (mm/min) CUTTING PREHEAT (kg/c m2 ) / (Mpa) / / / / / / / / / / / / / / / / / / / / / / / / KERF WIDTH (mm) 106-D7(HIGH SPEED) For Propane CUTTING OXYGEN PRESSURE FUEL GAS TIP SPEED (kg/c m2 ) / (Mpa) PRESSURE SIZE (mm/min) CUTTING PREHEAT (kg/c m2 ) / (Mpa) / / / / / / / / / / / / / / / / / / / / / / / / PLATE THICKNESS (mm) KERF WIDTH (mm) NOTE 1) All pressures are torch inlet pressures. 2) Oxygen purity is minimum of 99.7%, propane is minimum of JIS Grade 3. 3) Depending on the surface condition of the steel plate (scale, paint) either increase the fuel gas pressure or decrease the cutting speed. Also, when precision cutting is required, adjust all data

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44 MINIMANTISⅡ (H-Shape Steel Cutter) OPERATION MANUAL Date of issue Feb nd Dec rd Jan th May th Nov th Dec th Apr th Jan th May th Jun th Jul th Dec th Oct th Nov th Feb th Jan th Feb th Mar th Sep th Dec th Apr th Nov.2017 KOIKE SANSO KOGYO CO., LTD. Printed in Japan