ESAB Railtrac BV2000 User manual

Instruction manual

0463 629 001 GB 20181029 Valid for: serialno.1801xxxx

Railtrac™ BV2000

TABLE OF CONTENTS

0463 629 001 © ESAB AB 2018

1SAFETY ....................................................................................................... 4

1.1 Meaning of symbols ............................................................................... 4

1.2 Safety precautions ................................................................................. 4

2INTRODUCTION.......................................................................................... 7

3TECHNICAL DATA ...................................................................................... 11

4INSTALLATION............................................................................................ 12

5OPERATION ................................................................................................ 14

5.1 Electronic – Carriage ............................................................................. 14

5.2 Programs................................................................................................. 16

5.3 Remote control ....................................................................................... 17

5.3.1 Remote control functions...................................................................... 17

5.4 Preheat .................................................................................................... 18

5.5 Remote control for digital wire feeder.................................................. 19

5.6 Installation of wire feeder ...................................................................... 19

6MAINTENANCE........................................................................................... 20

7ORDERING SPARE PARTS ........................................................................ 21

DIAGRAM ............................................................................................................ 22

ORDERING NUMBERS....................................................................................... 23

ACCESSORIES ................................................................................................... 24

Rights reserved to alter specifications without notice.

1 SAFETY

0463 629 001 -4- © ESAB AB 2018

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).

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. 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

2. 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

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

1 SAFETY

0463 629 001 -5- © ESAB AB 2018

4. 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

5. 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.

1 SAFETY

0463 629 001 -6- © ESAB AB 2018

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.

2 INTRODUCTION

0463 629 001 -7- © ESAB AB 2018

2 INTRODUCTION

Railtrac™ BV2000 is a system of components that can be configured to create the optimal

solution for a mechanized welding application. Railtrac™ BV2000 is designed for horizontal

use and it covers most proven and globally applied welding patterns for repair of rail and rail

components in all steel types and casting grades. To minimise problems associated with

harsh environments, most mechanical parts are constructed in aluminum and stainless steel.

Equipment

The welding tractor Railtrac™ BV2000 is supplied with:

• Remote control

• Slides and torch holder

• 1x 2 m rail BV2000

• 2x Rail Bracket

• 2x Alignment brackets

• Storage box

Features Railtrac™ BV2000

• 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™

BV2000 if the remote control is lost-damaged or not preferred.

• Dual high-visibility screens for easy viewing in any orientation.

• The remote control is programmable for weave patterns and travel speed and is

capable of controlling voltage and wire feed speed in up to 6 standard programs.

• IP44 environmental rating on both the Railtrac™ and the remote control.

• Choose between welding on left side or right side for remote control to correspond to

carriage movement.

Direct connection to all new modern ESAB wire feeders

Railtrac™ BV2000 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).

Six programs can easily be stored

As many as six 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 six

different programs. All speeds are calibrated in millimetre (mm), for the greatest possible

precision and welding quality.

2 INTRODUCTION

0463 629 001 -8- © ESAB AB 2018

Remote control for the harshest environments

Using the robust and lightweight remote control that comes with the Railtrac™ BV2000, 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

• Welding current (wire-feed speed)

• Welding voltage

2 INTRODUCTION

0463 629 001 -9- © ESAB AB 2018

1. Slide height adjustment 7. Locking wheel

2. Support wheel holder 8. Locking screw

3. Bracket for coarse adjustment in/out and

height

9. Electronics

4. Universal torch holder 10. Battery holder

5. Protection plate 11. Weaving movement

6. Drive wheel ×2 12. Weaving movement connection

2 INTRODUCTION

0463 629 001 - 10 - © ESAB AB 2018

Dimensions

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