Valid for serial no. 735-xxx-xxxx0777 167 001 110921
Railtrac
F1000/ FR1000
Instruction manual
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Rights reserved to alter specifications without notice.
ENGLISH 3..............................................
ENGLISH
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TOCe
1 DIRECTIVE 4........................................................
2SAFETY 4...........................................................
3 INTRODUCTION 6...................................................
3.1 General 6..................................................................
3.2 Control box 7...............................................................
3.3 Tecnical data 7.............................................................
4 INSTALLATION 8....................................................
4.1 General 8..................................................................
4.2 Connections 8..............................................................
4.3 Mounting 12.................................................................
4.4 Mounting start/stop brackets (Only for Railtrac FR) 14.............................
5 OPERATION 15.......................................................
5.1 General 15..................................................................
5.2 Control box 15...............................................................
5.3 Start/Stop 16................................................................
6 MAINTENANCE 17....................................................
6.1 General 17..................................................................
7 ACCESSORIES 17....................................................
8 ORDERING OF SPARE PARTS 17......................................
ASSEMBLY INSTRUCTIONS 18...........................................
SPARE PARTS LIST 19..................................................
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1 DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guaran-
tee that automatic welding machine F1000/FR1000 from serial number 735 complies
with standard EN 60292, in accordance with the requirements of directive
(89/392/EEC) and addendum (93/68/EEC), and with standard EN 50199, in accord -
ance with the requirements of directive (89/336/EEC) and addendum (93/68/EEC).
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Laxå 2000--01--03
Anders Birgersson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
2SAFETY
Users of ESAB welding 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 welding 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 welding
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 welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no-one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from draughts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves.
S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER'S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS' HAZARD DATA.
ELECTRIC SHOCK - Can kill
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
S Keep your head out of the fumes.
S 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.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with s uitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
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.
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3 INTRODUCTION
3.1 General
Railtrac 1000 is a series of equipment for mechanisation offering increased
efficiency and better working environment when welding and cutting.
The equipment can be used for both horizontal and vertical joints.
Railtrac F1000 (Flexi) and Railtrac FR1000 (Flexi Return adjustable start, stop and
return functions) are two machines which can weld along curved objects.
Each equipment consists of a travel carriage, a rail and a control box.
The rail is made of extruded aluminium and can easily be extended, shortened or
stiffened. As the rail does not contain any racks the risk of service interruption due to
spatter from the weld is minimised.
The flexible rail can be bent down to a diameter of three meters without being
deformed. For diameter s between three and one meter the rail will be permanently
deformed. For smaller diameters specially rolled rings are used.
The rail is attached to the ground by way of magnetic brackets or vacuum brackets.
For secure attachment each vacuum holder consists of one ejector and two vacuum
suction cups.
1. Cable support
2. Vertical slide
3. Horizontal slide
4. Carriage
5. Torch holder
6. Esab PSF (Option)
7. Universal
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3.2 Control box
The control box has memory for 5 pre-programmed
welding schedules.
All values on the display are true values in mm, cm or
seconds.
By means of the control box the machine can be
started and stopped with or without welding, the
welding direction be selected, the welding speed
adjusted and machine set for rapid speed.
3.3 Tecnical data
Railtrac F1000/FR1000
Power supply 30-46 VAC / 36-60 VDC
Power consumption 30 W
Weight (excluding rail) 7Kg
Dimension rail 50x60 mm
Min. bend diameter Ø 3000 mm
Slide vertical adjustment ±22 mm
Slide horizontal adjustment ±28 mm
Max. temperature machine/magnet 70° C
Max. temperature vacuum brackets 100° C
Welding speed 100 - 1500 mm/min
Quick transport speed 1500 mm/min
Interval welding 10 - 990 mm
Preheat 0.0 -9.9 s
Crater filling time 0.0 - 9.9 s
Backfill 0-99mm
Torch holder Ø12 - 36 mm
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4 INSTALLATION
4.1 General
The installation must be executed by a professional.
Railtrac F / FR can be connected to m ost of ESAB's feed units.
For connection to older feed units, please contact your nearest ESAB retailer.
Railtrac F / FR can also be powered by other welding power sources via a separate
transformer, see page 11.
For connection of the wire feed unit to Railtrac F/ FR, use control cable acc. to
Accessories, on page 17.
4.2 Connections
Railtrac F / FR ! Origot Feed
Railtrac F / FR is to be connected directly to the remote control socket.
No intervention in the feed unit is necessary.
Origot Feed 304/ 484 with M 12 con t rol panel.
It is not possible to adjust the voltage
from Railtrac F/ FR.
Origot Feed 304/ 484 with M 13 con t rol panel.
It is not possible to adjust the voltage
from Railtrac F/ FR.
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Railtrac F / FR ! Origot Feed 3004/4804 and Aristot F eed 3004/4804 with
control panel fitted
S Dismount the door and fit the sticker (1).
S Mount the switch with the cabling (2).
S Open the socket for remote control connection (3).
S Fit the cabling (4).
S Fit the remote control socket on the front panel (5).
S Connect the cabling with the printed circuit boards (6).
S Fit the printed circuit board at the bottom and then fit the door (7).
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Railtrac F / FR ! Aristot Feed 3004/4804 with U8
S Dismount the door (1).
S Open the socket for remote control connection (2).
S Fit the cabling (3).
S Fit the remote control socket on the front panel (4).
S Mount the switch with the cabling on the printed circuit board (5).
S Connect the cabling with the printed circuit boards (6).
S Fit the printed circuit board at the bottom and then fit the door (7).
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Railtrac F / FR ! oth er feed unit makes
When connecting Railtrac F/ FR to other feed units, use the transformer and the
control cable you find under Accessories on page 17.
10 kohm
F – G = Start / Stop function
J = Reference +
K = Reference welding voltage
L = Reference 0
M = Reference wire feed speed
A – B = Voltage feed
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4.3 Mounting
Follow the instructions below for the mounting of brackets, carriage, torch holder and
for connection of the control box.
S Mount the m agnet brackets on the
aluminium rail.
If necessary, attach the stiffener bar.
S Adjust the rail parallel to the joint.
S Put the carriage on the rail.
S Tighten the locking screw (1).
Mount the torch holder (2).
1
2
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S Connect the control box.
S Mount the torch and fix the hose
package.
S Adjust the welding gun for correct
position.
S Secure the rail from falling down by
way of a wire or the like.
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4.4 Mounting start/stop brackets (Only for Railtrac FR)
1. Start position 2. Stop position 3. Fast return after stop
1. Magnet loosen screw 2. Start/ Stop bracket 3. Magnet bracket
1. Sensor
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5OPERATION
5.1 General
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
5.2 Control box
1 Program selection The unit can store 5 different programmes, P1-P5.
2 Select Select menus for programming welding speed, crater-/ filling time,
backfill and intermittent welding
3 Speed The display shows the programmed welding speeds in cm/min.
4 100+ Indicates when the display shows speeds above 100cm/min.
5 Crater filling time The time for which the machine stands still and the wire feeders built-in
crater filling function is activated.
6 Backfill Backfill can be used for the crater filling if the power unit does not
incorporate the crater fill feature. The carriage reverses a short distance
(adjustable 0-9,9 cm) at the end of each weld in order to fill the crater.
7 Interval LED is blinking. Interval 1 - 99 cm between each weld.
8 Weld length LED is blinking. Weld length is 1 -99 cm.
9 Weld ON/OFF Red LED indicates weld on. No LED indicates off.
10 Intermittent or
continuos welding
The green LED indicates that the machine is set for interval welding.
11 Welding direction To be selected before carriage is started.
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5.3 Start/Stop
S Start (green push-button)
S Stop (red push-button)
S If Crater filling time or Backfill have been
pre-programmed you have to stop the welding
with the push-button for Start (green)
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6 MAINTENANCE
6.1 General
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
S Check that all cables and plugs are intact.
S Clean the magnet, vacuum cups and air hoses and check for damage.
S Check that the rail is not damaged.
S Clean the carriage and the torch holder.
7 ACCESSORIES
Origot
Feed 302
Origot
Feed 484
Origot
Feed 3004
Origot
Feed 4804
Aristot
Feed 3004
Aristot
Feed 4804
Control cable 23-p
0457 360 880
x x x x x x
Remote adapter
0459 681 880
x x x x
MEK 4 MEK 4SP MEK 4C MEK 44C MED 44A
Control cable 23-p
0457 360 880
x x x x x
Cable kit, remote control
socket 23-p
0457 462 880
x x x x x
MEH 30 MEH 44 MED44B MEK 2 Universal
Control cable 4-p, 12-p
0457 360 883
x x
Cable kit
0443 341 880
x x x x
Control cable 4-p
0457 360 882
x x
Control cable
0457 360 881
x
Transformer
0457 467 880
x
Floating weld in g h ead 0398 145 211
A flo ating welding head holds the torch of the welding or cutting equipment at a
constant height above the surface during the work.
8 ORDERING OF SPARE PARTS
Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as desig-
nation and spare part number as shown in the spare parts list on page 19.
This will simplify dispatch and ensure you get the right part.
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ASSEMBLY INSTRUCTIONS
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Start/Stop bracket
SPARE PARTS LIST
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Edition 000131
Ordering no. Denomination Notes
0398 146 002 Carriage for F 1000
0398 146 003 Carriage for FR 1000
0398 145 178 Control box complete
0398 146 112 Flexible alu rail, 8 magnets
0398 146 113 Flexible alu rail, 4 vacuum attachments
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Pos
Item
no.
Ant
Qty
Best nr.
Ordering no.
Benämning
Denomination
Anm.
Notes
0398 146 002 Carriage for Railtrac F1000 (100 1500 mm/min)
0398 146 003 Carriage for Railtrac FR1000 low speed (50 990 mm/min)
1 1 0398 145 501 Cover
2 1 0398 145 502 Motor box
3 1 0398 145 503 Cable release
4 1 0398 145 505 Cable with 12 pin plug
5 1 0398 145 290 Inductive transducer
6 2 0398 145 506 Clamp for torch cable and inductive transducer
7 1 0398 145 507 Holder for torch cable clamp
8 1 0398 146 508 Bearing house short, drive wheel included
9 1 0398 146 509 Bearing house long, drive wheel included
10 1 0398 146 510 Distance, screws included
11 1 0398 146 511 Arm with support wheel
12 1 0398 145 512 Locking screw
13 1 0398 146 513 Bracket for locking screw
14 1 0398 146 514 Mounting plate
15 1 0398 145 515 Motor with gear box (100 1500 mm/min)
16 1 0398 146 516 Drive wheel
17 1 0398 146 517 Drive chain
18 1 0398 146 530 Spring, short, screw included
19 1 0398 146 531 Spring, long
20 1 0398 145 290 Inductive sensor
21 1 0398 145 732 Lever
22 1 0398 146 520 Support bracket with wheel
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