Semiautomatic Gas Cutting machine Operating instruction

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1 KOIKE CUTTING & WELDING INDIA PVT., LTD. Semiautomatic Gas Cutting machine Operating instruction 一 Characteristics and Application of Semiautomatic Gas Cutting Machine The oxygen cutting is widely used because of its simplicity, low price and easy operation. It is a main method for cutting carbon steel plate and low alloy metal steel plate, especially for middle thick steel plate. The surface cutting roughness could reach to 12.5 and needless to cutting processing further on common occasion. The IK-12 Elite (single cutting torch and double cutting torches) semiautomatic gas-cutting machine produced are

2 multi-use machine with Ethane as its flame gas. It can do linear cutting but also circle, slide cutting as well as V shape beveling. What s more, if more facilities added, it can even be used for quench and plastic welding. 二 Technical parameters This product is produced based on JB/T standard. Its main technical parameters are as following: 1. Technical parameter IK-12 Elite Single Torch IK-12 Elite Double Torches Steel plate thickness mm mm Cutting speed mm /min mm /min Cutting thickness Power AC 240V,50Hz AC 240V,50Hz Machine body dimension Weight Small vehicle 18 kg, guide rail 12 kg Small vehicle 24 kg, guide rail 12 kg 2. The Chart below is part specifications for GO2 (ethane) isobaric pressure cutting mouth (30 ) Note: 1. This machine can use G03 cutting mouth with propane as its flame gas. 2. This machine can also use high-speed cutting mouth GK1 (ethane), GK3 (propane) for cutting with 20-30% faster than before. Shape diagram of IK-12 Elite semiautomatic gas cutting machine 1

Table 1 Technical parameter for steel plate cutting 三 Structure of gas cutting machine The gas-cutting machine is consisted in small vehicle, torch system, guide, radius bar and electric gas control.

3 Table 1 Technical parameter for steel plate cutting 三 Structure of gas cutting machine The gas-cutting machine is consisted in small vehicle, torch system, guide, radius bar and electric gas control. Please see picture Small vehicle The vehicle body is made through casting of high strength aluminum ingot with speed redactor box and electric box inside. There are indication light, power switch, and speed adjustment switch and clutch handle. A. Speed redactor The vehicle body is made of high-strengthen aluminum ingot with speed redactor box and electric box inside. There are indication light, power switch, and speed adjustment switch and clutch handle. B. Electric gas control Please see picture 5 for the electric gas control of gas cutting machine. The motor all adjustment by the sleeplessness is realized through controlling transistor pipe angle. The cutting speed can be sleeplessly adjusted with the scope of mm/min simply through moving the electric level device switch (with meters) 2. Torch system The torch system is consisted in torch, cutting mouth, gas pipe, arrangement device, movable bar, vertical lifted rod, clamping device, hand wheel. The torch direction can be adjusted through the movement of wheel and its fittings to meet the requirement of different cutting situation. Besides, the torch can be adjusted within ±45 O (see picture 2) to meet the special requirements, such as, slide cutting and V shape cutting. 3. Guide Two protruding guides with outlet can use prolonged one if needed. Installation and testing 1. Installation and testing of vehicle and torch system When open the box, firstly, please check the vehicle and its fastening parts. Make small repair if there are problems and install them with reference to picture1 and the cover picture. A. Fix the bar on the vehicle fixed support with the lifted rod on the left, the same side as the protection 2

4 board is fixed, and the balance hammer IK-12 ELITE on the right and fix well. B. Put the arrangement device in the fixed support and fasten the screw; Insert the cutting mouth into the torch, make it right and fasten the screw. Check the gas to prevent gas-leaking situation. Finally, fix the torch on the lifted rod-clamping device. Caution: 1. Before installation, please make sure that there is no small useless materials, serious copper stain in the torch and damaged in the torch cutting mouth surface. If the faces between torch and torch cutting mouth are inconsistent with each other well enough, it can arouse gas leakage and poor cutting performance. The sealing with torch can be ensured only on when you use the torch cutting mouth produced by our company. 2.The torch shall be installed on the same side as protection board is fixed at and shall keep certain distance from the protection board. C. The gas pipes from oxygen bottle and ethane bottle shall be fixed on the joints of oxygen and ethane inlet pipe of arrangement device. Please refer to picture3 (60 o inverted angle in the screw center and left turning screw line). Adjust the ethane valve (black gas pipe) to control the ethane flow quantity, i.e., the flame frequency. One part input oxygen will be adjusted by preheating oxygen valve (green pipe) and burn through mixing with the ethane. The steel plate shall be preheated to the iron element burning point temperature. The other part oxygen will be adjusted by cutting oxygen valve (red pipe) to support the iron element burning and exempting the oxygenized material, melted slag. Caution: 1. Before you joint the gas valve to with the arrangement device, please make sure that there shall be no useless materials for example, foams in the valve and its joint. Otherwise, it will seriously impact the cutting thickness and even cannot be used. 2. Make sure that the oxygen pipe and ethane pipe are well installed and no gas leakage at joint part. D. Insert one side of connector of three-core power wire into the small vehicle plug and other side into three-hole power plug with single-phase ground wire (220V). The indication light will be lighting. Adjust the power switch and the small vehicle will go ahead and back. The out shell of vehicle is without current. Caution: 1. Shell of vehicle is connected to earth; If earth wire of power receptacle connect the wrong position. Sunken groove of power wire s receptacle isn t aim at protruding angle of vehicle s receptacle. Then enforce to carry out, the shell of vehicle maybe carry electricity and be electric shocked. 2. Turn on power switch still power is off. Otherwise, it will damage the current motor. 2. Check and install guide rail Is there damage during transportation? Rectify seriously change shaped guide rail. Place guide rail on cutting steel plate or earth but the slop couldn t surpass 3, It will influent moving stability that seriously deformed, big slop or mass on the protruding and concave surface of guide rail. As a result, it will reduce cutting quality. 3. Preparation and installment round-shaped (fan- shaped) A. Take a 60 fixed hole processed on the surface of steel plate as the center of circle. B. Install radius bar on vehicle; Put the fixed pin into fixed hole, Adjust the position of fixed bar according to cutting radius. Tighten fixed screw, turn fixed pin, raise radius bar make the rolling wheel that is leave steel plate. Tighten screw and fix the height of fixed pin. C. When the radius is small, radius bar should be placed at the same side with cutting torch. When radius is big, radius should be placed at the side of opposite to cutting torch. D. Loosen the fixed screw of all directions wheel and take away one fixed screw that is at the same side with radius. E. Process a hole at the cutting starting point. If cutting starting point isn t at the edge of steel plate. Otherwise, it maybe damages steel plate. F. Connect the power; vehicle rotates around the center of circle. Cut round-shape or fan-shaped sittings. 3

5 Cutting 1. Choice of Cutting Technical Parameter A. Choose Cutting Mouth Choose the specification of cutting mouth according to the width of steel plate, diagram 1.You make the best efficient, only choosing right cutting mouth. B. Adjust verticality of Cutting Torch For the common cutting, cutting torch (slightly adjust direction through moving bar) and steel plate become vertical. Adjust cutting torch from left to right if cutting inclined plane, use IK-12 ELITE double-torch cutting machine to make V shaped groove. C. Height of Cutting Mouth Adjust cutting torch, the distance of ending of cutting mouth and surface of steel plate are following: GO2, GO3 cutting mouth, mm GK1, GK3 cutting mouth, 5-10 mm D. Pre-heating Flame Use middle flame,high temperature, high efficient. The more wider cutting steel plate, the more higher efficiency of pre-heating flame. E. Cutting Oxygen Drung Adjust the oxygen drung to suitable point. Make the best cutting efficiency, when the flame wind line is the longest and the clearest. F. Cutting Speed Cutting speed is relates with steel plate s width, flame s efficiency and required cutting quality., the high quality requires slow speed, the common quality require fast speed. It s the normal speed, when the spark is vertical, slightly inclined or forward. G. Surface of Steel Plate. Must make the steel plate flat before cutting and clean the oxidizing surface, brass, point and other mass to cutting quality. 2. Cutting A. Turn on power switch, vehicle move; the track of cutting mouth must match with cutting line. Otherwise, must adjust guide or steel plate. B. Open the ethane valve, after light a fire, open pre-heating oxygen valve. Adjust flame s efficiency and type. When the temperature of steel plate reach 970, open cutting oxygen valve. After adjust drung, turn on power switch or clutch. Caution: Open ethane valve, must light a fire at once. Keep from the danger of leaking flammable gas or entering body machine. C. At the ending of cutting. Must orderly close cutting oxygen valve, pre-heating oxygen valve, ethane valve and power switch or clutch. Caution and maintain avowal 1. Forbid to using cutting machine on easy burning and exploding place. Forbid to using gas-cutting machine on open air on rainy day. Otherwise easy to get electric shock or short circuit. 2. Well manage and use oxygen bottle and ethane bottle according to rule. 3. Before light a fire, must check gas pipe, joint of gas pipe, gas valve, cutting torch.. Make sure those are no gas leak. 4. Make the habit of close power switch conveniently,. When operator takes a rest or leave, operator must close power switch in order to prevent from damage electrical machinery. 5. Special person uses maintain and regularly checks machine. Speed redactor should be added lubricating oil 4

every year. 6. Gas cutting machine should be placed no abrasive gas and dry room, keep from moisture. 7. From the date of sale, we guarantee six months according to invoice.

It is not the scope of guarantee: the damage are led by transportation, unsuitable keeping or operating is not according to instruction.

6 every year. 6. Gas cutting machine should be placed no abrasive gas and dry room, keep from moisture. 7. From the date of sale, we guarantee six months according to invoice. Factory repairs or changes machine if it shows some fault phenomenon that are led by manufacture. 8. It is not the scope of guarantee: the damage are led by transportation, unsuitable keeping or operating is not according to instruction. Random document and enclosure 1) Product instruction and certificate of goods inspection every one copy 2) 1 #,2 #,3 # cutting mouth (buy other specification cutting mouth) every one copy Electric Principle Drawing Elements table (Kindly note, no special notification if some elements changed) 5

7 Code Name Spec Quantity M Permanent magnetic DC ZYT261,110V,24W,3600r/min 1 T1 Power voltage transformer 220V/110V/6.3V 1 T2 Pulse voltage transformer E193 Input voltage transformer 1 S1 S2 Knob switch KN3 3A/250V 2 H Indictor light XDX1-H-6.3V 1 F Fuse RF1-20-2A 1 V1 V2 Second electrode silicon pipe 1N4004,1A/400V 2 V3 Transistor control pipe KP5A/400V 1 C1 Capacitor CJ30 1uf/500v 1 C2 Capacitor CD15 10uf/400v 1 C3 Capacitor CD11 33Uf/400v 1 R1 Resistance RJ 12Ω/1W 1 R2 Resistance RJ 1.5KΩ/0.5W 1 R3 Resistance RJ 4.7KΩ/0.5W 1 R4 Resistance WX KΩ/0.5W 1 Power wire YQ-3 0.5/10m,connector plugs CF A/250V Knob K Common problems and settlement No Problems Proper causes Settlement 1 No power on the 1. No current for the power supply 1. Check and repair the circuit, close switch, to small vehicle receptacle make it supply power after power is supplied 2. The fuse was burned 3. The wires in receptacle, plug or switch 2. Change the fuse 3. Fix the disconnected wire 2 The electric pressure is regular after power supplied 3 The vehicle speed can t be adjusted after power supplied were disconnected 1. The contact between motor s receptacle and plug is irregular or the wire is disconnected. 2. The motor s electric brash card is bad 3. The magnet goes off the motor and jammed the electric circuit. Ill connection for the slide piece of speed adjustment electric level device 1. Tightly weld the disconnected wire and well joint the motor s receptacle and plug. Repair the connector piece if needed. 2. Get out the electric brash and brash its outlet to make it more reliable. 3. Change the motor Repair the slide piece to make it more reliable or change the electric level device directly. 1 6

8 4 Leak gas with flame in the joint of torch and torch cutting mouth. 1. The fire outlet molt hasn t been strengthened, leak gas 2. There is copper stain or useless materials on the surface of torch, which make bad cooperation and gas leakage 3. The bigger outlet of torch cutting mouth was stuck with some useless materials or was damaged. 1. Tighten the molt 2. Softly grind the torch cone with small sand paper to clean out the verdigris 3. Clean the useless materials on the cutting mouth. Softly grind the surface with small sand paper. Change the cutting mouth if it is badly damaged. 5 The fire flame goes out as soon as open the cutting oxygen valve 6 The steel plate can t be cut through 7 The linear cutting is not straight enough. The cutting oxygen was leaked into the preheating oxygen area 1. Copper stain or useless materials on the inner part of torch 2. The smaller cone of torch cutting mouth was stuck with some useless materials or was damaged. 1. The torch cutting mouth is too small. 2. The fire flame frequency is not strong enough 3. Low pressure for cutting oxygen 4. The hole channel of cutting mouth may be jammed 5. The cutting oxygen is not pure enough. 6. The cutting oxygen was leaked into the preheating oxygen hole channel. 1. The steel plate was not put well enough or was deformed. 2. The flame wind line was not straight. 3. Uneven guide channel of small vehicle 4. The torch was ill fixed and can be moved around 1. Softly grind the most inner part of cutting mouth with small sand paper to clean out the verdigris 2. Softly grind the smaller part surface of cutting mouth. Change the cutting mouth if it is serious damaged. 1. Choose the cutting mouth spec according to the cutting thickness. 2. Increase flame frequency properly. 3. Properly increase the cutting oxygen s drung to ensure the enough flow speed and motivation of cutting oxygen. 4. Clean the useless materials in the torch cutting mouth with cutting pin. 5. Use the oxygen with more than 95% purity. 6. Clean the useless materials on the cutting mouth and torch, repair the damaged surface and change cutting mouth if needed. 1. Well put the steel plate and calibrate it before cutting. 2. The torch should have an 90 o angle with the steel plate and tightly fixed. Clean the useless materials in the torch cutting mouth with cutting pin. 3. Calibrate the guide of the small vehicle 4. Tighten the papilionaceous screw and make the bar, rod and clamper well fixed. 7

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