ESAB | Railtrac™ B42V | Instruction manual | ESAB Railtrac™ B42V User manual

ESAB Railtrac™ B42V User manual
Railtrac™ B42V
Instruction manual
0463 465 101 GB 20181123
Valid for: 1634 xxxx
TABLE OF CONTENTS
1
SAFETY .......................................................................................................
4
1.1
Meaning of symbols ...............................................................................
4
1.2
Safety precautions .................................................................................
4
2
INTRODUCTION ..........................................................................................
7
3
TECHNICAL DATA ......................................................................................
11
4
INSTALLATION............................................................................................
12
4.1
Connections............................................................................................
12
4.2
Assembly ................................................................................................
12
OPERATION ................................................................................................
14
5.1
Preheat ....................................................................................................
14
5.2
Remote control for digital wire feeder..................................................
14
5.3
Electronic – Carriage .............................................................................
15
5.4
Remote control .......................................................................................
17
5.5
Installation of wire feeder ......................................................................
17
MAINTENANCE ...........................................................................................
18
ORDERING SPARE PARTS ........................................................................
ORDERING NUMBERS .......................................................................................
ACCESSORIES ...................................................................................................
19
20
21
5
6
7
Rights reserved to alter specifications without notice.
0463 465 101
© ESAB AB 2018
1 SAFETY
1
SAFETY
1.1
Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
NOTE!
For product operation instructions please refer to the supplied USB memory stick.
1.2
Safety precautions
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1.
2.
3.
Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
The workplace must:
○ be suitable for the purpose
○ be free from drafts
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1 SAFETY
4.
5.
Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
•
•
•
•
Install and ground the unit in accordance with instruction manual.
Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
Insulate yourself from work and ground.
Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
•
•
•
Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
Exposure to EMF may have other health effects which are unknown.
Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
•
•
Keep your head out of the fumes.
Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
ARC RAYS - Can injure eyes and burn skin
•
•
Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
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1 SAFETY
MOVING PARTS - Can cause injuries
•
•
•
Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
Stop engine before installing or connecting unit.
Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
•
•
Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation
in accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be
disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.
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© ESAB AB 2018
2 INTRODUCTION
2
INTRODUCTION
Railtrac™ B42V is a system of components that can be configured to create the optimal
solution for your mechanized welding application. To minimise problems associated with
harsh environments, most mechanical parts are constructed in aluminium or stainless steel.
Railtrac™ B42V is designed for horizontal and vertical joints (up, and down, when
applicable).
Features Railtrac™ B42V
•
•
•
•
•
•
•
•
•
•
42 V AC or battery driven with standard Makita® 18 V system.
High speed and low speed in one unit.
Micro process controlled electronics package in a single onboard housing.
Stepper motor both for drive and weaving function.
Only one cable to the wire feeder (not needed if using the battery) and one cable to the
remote control (if used) but can be run without any remote control.
The unit can be programmed and run directly from the controls on the Railtrac™
machine if the remote control is lost-damaged or not preferred.
Dual high-visibility screens for easy viewing in any orientation.
The remote is programmable for weave patterns and travel speed and is capable of
controlling voltage and wire feed speed in up to 5 standard programs.
IP44 environmental rating on both the Railtrac™ and the remote control.
Choose between welding on left side or right side for remote to correspond to carriage
movement.
Direct connection to all new modern ESAB wire feeders
Railtrac™ B42V can be easily connected to most ESAB wire feeders with no major
modification. Remote adapters have to be mounted in wire feeders (Aristo® Feed 3004,
Aristo® Feed 4804, Origo™ Feed 304, Origo™ Feed 484 and Warrior™ Feed 304).
Five programs can easily be stored
As many as five different programs can be stored. Each program is individual and can be
retrieved from the control on the main unit or the remote control.
Remote control of welding parameters and immediate program shift
Both welding current (wire-feed speed) and voltage can be adjusted (in %) during welding.
Stepping up or down between the alternative motion programs is also easy, depending on
welding position.
Resilient programming units with great potential
Straightforward, logically-designed programming units are used to set the values for five
different programs. All speeds are calibrated in millimetre (mm), for the greatest possible
precision and welding quality.
Remote control for the harshest environments
Using the robust and lightweight remote control that comes with the Railtrac™ B42V, the
operator can access and control every function without lifting the welding visor. Individually
shaped buttons for:
•
•
•
•
•
•
Start and stop
Shift program
Travel or welding direction (cutting direction)
Travel or welding speed (cutting speed)
Weaving width
Zero-line displacement
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2 INTRODUCTION
•
•
Welding current (wire-feed speed)
Welding voltage
Joint rail system for stiff or flexible rail applications
The extendable Railtrac™ combi-rail enables the same tractor to run on a flexible rail or the
same rail stiffened with a stiffener bar. The stiffener-bar rail fits into the existing holes in the
rail. This makes it possible to weld straight as well as curved surfaces (min 1600 mm in
diameter). The combi-rail is clean, without a rack for driving the tractor. If longer rails are
needed it is easy to joining several rails.
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© ESAB AB 2018
2 INTRODUCTION
1. Slide height adjustment
2. Support wheel holder
3. Bracket for coarse adjustment in/out and
height
4. Universal torch holder
5. Protection plate
6. Drive wheel ×2
0463 465 101
7. Locking wheel
8. Locking screw
9. Electronics
10. Battery holder
11. Weaving movement
12. Weaving movement connection
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© ESAB AB 2018
2 INTRODUCTION
Dimensions
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© ESAB AB 2018
3 TECHNICAL DATA
3
TECHNICAL DATA
Supply voltage
24 - 70 V DC
20 - 50 V AC
18 V battery (optional)
Power consumption
max 50 W
Battery running time
3 - 4 h (5 Ah)
Weight
8 kg (17.63 lb.)
Carriage measurements (L×W×H)
210 × 360 × 270 mm (8.26 × 14.17 × 10.62
in.)
Min bending diam. rail
Ø 1600 mm (62.99 in.)
Max temp. magnet/vacuum att.
70 °C / 90 °C (158 °F / 194 °F )
Max pay load
10 kg (22.04 lb.)
Max pay load with battery
5 kg (11.02 lb.)
High adjustment slide
+/- 45 mm (± 1.77 in.)
Speed carriage
0.4 - 25 mm/s (0.01 - 0.98 in./s)
Rapid speed carriage
30 mm/s (1.18 in./s)
Rapid speed battery
25 mm/s (0.98 in./s)
Welding length - auto return
10 - 9999 mm. Tolerance ±1 mm (0.39
- 393.66 in. Tolerance ±0.04 in.)
Weaving speed
10 - 50 mm/s (0.39 - 1.97 in./s)
Weaving pattern
3
Weaving width
0 - 30 mm (0 - 1.18 in.)
0-line adjustment
± 30 mm (± 1.18 in.)
Mechanical adj. in/out
± 40 mm (± 1.57 in.)
Tot. movement weaver
80 mm (3.15 in.)
Dwell time weaving
0.0 - 5.0 s
Programs
5
Remote control Wire Feed Speed and V
(separate adj. on each program)
ESAB 0 - 10 V
Safety Class
DIN40050
Enclosure class
IP44
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© ESAB AB 2018
4 INSTALLATION
4
INSTALLATION
The installation must be carried out by a professional.
4.1
Connections
Information and drawings from ESAB.
4.2
Assembly
Follow these steps to assemble brackets, carriage, torch holder and for connection of the
control box.
1.
Assemble the magnet brackets on the aluminium rail.
Optional: Attach the stiffener bar.
1. Flip magnet
2. Assembly screws
2.
3. Flex rail
4. Stiffener (optional)
Adjust the rail parallel to the joint.
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© ESAB AB 2018
4 INSTALLATION
3.
Put the carriage on the rail.
4.
Tighten the locking screw (1).
5.
Connect the remote control to the carriage and the control cable to ESAB wire feeder.
Use the battery when not using ESAB wire feeder.
Mount the torch and adjust for correct position (2).
Secure the rail from falling down by way of a wire or the like.
6.
7.
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5 OPERATION
5
OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
5.1
Preheat
The first menu in service is Preheat. Start delay carriage after start welding.
WFS = Wire Feed Speed
1.
2.
3.
Press Stop for 6 seconds for access to
service menu A.
Release Stop when the display shows
Service Menu A .
The electronics will stay in the service menu
5 seconds after last button press.
The default setting is 300 ms.
Press + or - to adjust the setting.
5.2
Remote control for digital wire feeder
It is possible to adjust the maximum value on the remote control output (0-10 V) both for wire
feed speed and volt. The maximum value is 0.5 V lower than Vin (10 V) due to the voltage
drop in the opto driver.
Set Wire Feed Speed (WFS)
1.
2.
Press Menu once.
The display shows: DigF max WFS
Press + or - to adjust the setting.
Scale value: 1 - 40
Higher value gives higher output.
Set Voltage (V)
1.
2.
Press Menu until DigF max V is shown in the
display.
Press + or - to adjust.
Scale value: 1 - 40
Higher value gives higher output.
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
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© ESAB AB 2018
5 OPERATION
5.3
Electronic – Carriage
One press: Start left without welding
1 Start left
Double press: Start left with welding
Press 2 seconds: Start with fast move left
One press after start: Speed carriage -
2 Menu/Stop
Before start: Selector for programming
parameters. Blinking display indicates
progamming modus. Adjust parameters with
the buttons + and -.
After start: Stop carriage and welding.
If function Length: Press for 3 seconds to set
start position. Display shows 0.
One press: Start right without welding
3 Start right
Double press: Start right with welding
Press 2 seconds: Start with fast move right
One press after start: Speed carriage +
Menus
Program
P1 to P5 Railtrac™ can store 5 different programs.
Speed Carriage
0.4 – 25 mm/s (0.01 - 0.98 in./s)
Speed weaving
10 – 50 mm/s (0.39 - 1.97 in./s)
Weaving width
0 – 30 mm (0 - 1.18 in.)
Pattern
3
Hold time out
0.0 – 5.0 s
Hold time in
0.0 – 5.0 s
WFS
Wire Feed Speed 1 – 99% (Only for ESAB wire feeders)
Volt
1 – 99% (Only for ESAB wire feeders)
Length
10 – 10000 mm (0.39 - 393.70 in.) – Set welding length. At the end
the carriage make a return with rapid speed back to start pos. 0 mm
(0 in.) = function off.
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© ESAB AB 2018
5 OPERATION
1.
2.
3.
4.
Software version / Running hours
Connected wire feeder
4 settings. Use button Start right to select
Default: Program number / RS = welding
on right side
5. Default: Speed Carriage / Weaving width,
Weaving speed
6. Menu 1: Program number
7. Menu 2: Speed carriage
9. Menu 4: Weaving width
10. Menu 5: Weaving pattern
11. Menu 6: Weaving hold time (hold out)
12. Menu 7: Weaving hold time (hold in)
13. Menu 8: Wire feed speed
14. Menu 9: Volt
15. Menu 10: Welding length. 0 mm >
length/auto return off
8. Menu 3: Speed weaving
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© ESAB AB 2018
5 OPERATION
5.4
Remote control
1
Shift
2
Stop
3
Weaving width -
WFS-
4
One press: Start up
Volt +
Double press: Start up with arc
Press 2 seconds: Start with fast
move up
One press after start: Speed +
5
0-line in
6
One press: start down
Volt -
Double press: Start down with
arc
Press 2 seconds: Start with fast
move down
One press after start: Speed -
5.5
7
Program -
Menu -
8
Program +
Menu +
9
0-line out
10
Weaving width +
WFS+
Installation of wire feeder
The installation must be carried out by a professional.
Railtrac™ B42V can be connected to one of the following wire feed units: Aristo® Feed 3004,
Aristo® Feed 4804, Origo™ Feed 304, Origo™ Feed 484 and Warrior™ Feed 304.
For necessary adaptation between Railtrac™ B42V and the used wire feed unit (including
choice of control cable), see the "ACCESSORIES" appendix to this manual.
Universal feeder connection
For the operation of Railtrac™ B42V from other wire feeders (none ESAB), use transformer
unit and control cable according to the "ACCESSORIES" appendix.
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© ESAB AB 2018
6 MAINTENANCE
6
MAINTENANCE
NOTE!
All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
Daily
• Check that all cables and plugs are intact.
• Clean the magnet, vacuum cups and air hoses and check for damage.
• Check that the rail is not damaged.
• Clean the carriage and the torch holder.
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© ESAB AB 2018
7 ORDERING SPARE PARTS
7
ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Railtrac B42V is designed and tested in accordance with the international and European
standard EN 60974-10 Class A. On completion of service or repair work, it is the
responsibility of the person(s) performing the work to ensure that the product still complies
with the requirements of the above standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. When ordering, please state product type, serial number, designation and spare
part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.
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© ESAB AB 2018
ORDERING NUMBERS
ORDERING NUMBERS
Ordering no.
Denomination
Product
0398 146 016
Welding tractor
Railtrac™ B42V
0463 467 001
Spare parts list
Railtrac™ B42V
Notes
Technical documentation is available on the Internet at: www.esab.com
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© ESAB AB 2018
ACCESSORIES
ACCESSORIES
1. 0457 360 880 Control cable (12p- 23p) Railtrac™ - MEK
2. 0457 360 886 Universal connection cable 12-pin plug
3. 0457 467 880 Transformer 230/36 V AC with 12-pin plug
0457 467 882 Transformer 115 V AC
The work piece tractor is mounted on the rail. The light flexible aluminium rail can be used
on objects that are flat, curved or round and can be fitted to the surface in different ways. It
is supplied in standard 2.5 metre lengths and can be extended to any required length. The
rail can be mounted permanently on the work object or temporarily fixed with magnets or
vacuum fixtures. It may also be attached to the outside or inside of a tube. A stiffener bar
may be used to stiffen the flexible rail.Rails for tubes can be purchased at ESAB
distributors.
0398 146 115
Flexible alu rail 2.5 metres
0398 146 119
Flexible alu rail 5 metres
0398 146 112
Flexible alu rail 2.5 metres with 8 magnets
(FlipMag)
0398 146 113
Flexible alu rail 2.5 metres with vacuum
attachments
0398 146 116
Stiffener bar 2.5 metres
0398 146 100
Flip magnetic attachment at least 8 pcs per
2.5 metres
0398 146 104
Vacuum attachment 90°, at least 4 pcs per
2.5 metres
0398 146 105
Vacuum attachment 200°, at least 4 pcs per
2.5 metres
0398 146 114
Screw attachment for stiffened rail at least
8 pcs per 2.5 metres
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© ESAB AB 2018
ACCESSORIES
0398 145 211
Floating welding head
A floating welding head holds the torch of the
welding or cutting equipment at a constant
height above the surface during the work.
To enable correct weaving motions even in
troublesome positions the weaving unit can
be fitted with supports for turning and tilting.
0398 145 106
Torch holder universal Ø15-30 mm
System features different torch holders for
different torches and applications. Railtrac™
B42V comes with a universal torch holder
(Ø10-22 mm) and adjusters as standard.
0398 145 101
Torch holder for ESAB PSF torches
0398 145 202
Tilt bracket Railtrac™ B42V
The tilt bracket enables the Railtrac™ to
weave when welding fillet joints. It is mounted Release in November 2016
between drive and weaving unit. The weaving
unit can be tilted from 0 to 60 degrees.
0398 145 203
Turning bracket B42
The turning bracket is used to change the
Release in November 2016
angle of the weaving unit at ±22 degrees from
travel direction.
0398 145 211
Floating head
This component helps maintain constant
stick-out at the welding torch or cutting torch.
0457 467 880
Transformer 230 V AC
0457 467 882
Transformer 115 V AC
0457 360 880
Connection cable ESAB, 12 + 23-pin
0457 360 886
Connection cable universal, for start/stop
wire feeder, only with 12-pin
0398 146 120
Quick-extension bracket for flexible rail
The quick-extension bracket facilitates rapid
mounting and dismounting when using two
rails.
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© ESAB AB 2018
ACCESSORIES
0457 468 074
Battery 18 V / 5 Ah Makita®
0457 468 072
Battery charger 230 VAC Makita®
For local purchase at hardware store Makita®
196673-6
BL1850
18 V
18 V 5.0 Ah Li-ion.
195585-0
DC18RC
14,4 V - 18 V
Charger for 14,4 V - 18 V batteries.
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© ESAB AB 2018
ACCESSORIES
Cable key function diagram
0463 465 101
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© ESAB AB 2018
ACCESSORIES
0463 465 101
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© ESAB AB 2018
For contact information visit esab.com
ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com
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