ESAB Railtrac Orbital W User manual

Category
Welding System
Type
User manual
Valid for serial no. 0605--xxx--xxxx0460 521 001 2007--11--07
Railtrac Orbital W
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Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò
Instrukcja obs³ugi
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Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.
Zastrzegamy sobie prawo do wprowadzenia zmian.
SVENSKA 5..............................................
DANSK 23................................................
NORSK 41................................................
SUOMI 59................................................
ENGLISH 77..............................................
DEUTSCH 95.............................................
FRANÇAIS 113.............................................
NEDERLANDS 131.........................................
ESPAÑOL 149..............................................
ITALIANO 167..............................................
PORTUGUÊS 185..........................................
ÅËËÇÍÉÊÁ 203.............................................
POLSKI 222.................................................
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RSÄKRAN OM ÖVERENSSTÄMMELSE
ESAB AB, Welding Equipment, 695 81 Laxå, Sverige, försäkrar under eget ansvar att svetsautomat
Railtrac Orbital W från serienummer 0605 xxx xxxx (2006 v.05) är konstruerad och provad i över-
ensstämmelse med publicerade standarder enligt villkoren i direktiven (98/37/EG) och (89/336/EG).
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OVERENSSTEMMELSEERKLÆRING
ESAB AB, Welding Equipment, 695 81 Laxå, Sverige, forsikrer hermed eget ansvar, at svejseauto-
mat Railtrac Orbital W fra serienummer 0605 xxx xxxx (2006 v.05) er konstrueret og afprøvet i over-
ensstemmelse med kravene i direktiverne (98/37/F) og (89/336/EØF).
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FORSIKRING OM SAMSVAR
ESAB AB, Welding Equipment, 695 81 Laxå, Sverige, forsiker eget ansvar at sveiseautomat
Railtrac Orbital W fra serienummer 0605 xxx xxxx (2006 v.05) er konstruert og kontrollert i samsvar
med publiserte standarder ifølge vilkårene i direktivene (98/37/EF) og (89/336/EF).
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VAATIMUSTENMUKAISUUSVAKUUTUS
ESAB AB, Welding Equipment, SE--695 81 Laxå, Ruotsi, vakuuttaa omalla vastuullaan, että hitsau-
sautomaatti Railtrac Orbital W sarjanumerosta 0605 xxx xxxx (2006 v.05) alkaen on konstruoitu ja
testattu direktiivien 98/37/EY ja 89/336/EY ehtojen pohjalta julkaistujen standardien mukaisesti.
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DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, 695 81 Laxå, Sweden, declares under sole responsibility that the au-
tomatic welding machine Railtrac Orbital W from serial number 0605 xxx xxxx (2006 week 05) is
designed and tested in conformity with the published standards in accordance with the conditions in
the directives (98/37/EC) and (89/336/EC).
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ZULASSUNGSNACHWEIS
ESAB AB, Welding Equipment, 695 81 Laxå, Schweden, bestätigt auf eigene Verantwortung, dass
der Schweißautomat Railtrac Orbital W ab Seriennummer 0605 xxx xxxx (2006 v.05) in Überein-
stimmung mit veröffentlichten Standards gemäß den in den Richtlinien (98/37/EG) und (89/336/EG)
festgelegten Bedingungen konstruiert und geprüft wurde.
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CERTIFICAT DE CONFORMI
ESAB AB, Welding Equipment, 695 81 Laxå, Suède, garantit, sous sa propre responsabilité, que
l’équipement automatique de soudure Railtrac Orbital W à partir du numéro de série 0605 xxx xxxx
(2006 v.05) a été conçu et testé selon les normes publiées répondant aux directives 98/37/CE et
89/336/CE.
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VERKLARING VAN OVEREENSTEMMING
ESAB AB, Welding Equipment, 695 81 Laxå, Zweden, verklaart onder eigen verantwoording dat de
lasmachine Railtrac Orbital W vanaf serienummer 0605 xxx xxxx (5e week van 2006) geconstru-
eerd en getest is in overeenstemming met gepubliceerde normen conform de voorwaarden in de richt-
lijnen (98/37/EG) en (89/336/EG).
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DECLARACIÓN DE CONFORMIDAD
ESAB AB, Welding Equipment, 695 81 Laxå, Suecia, declara bajo su propia responsabilidad que la
soldadora automática Railtrac Orbital W, con el número de serie 0605 xxx xxxx (2006 v.05), ha sido
construida y probada de conformidad con los estándares publicados según las condiciones de las
directivas (98/37/CE) y (89/336/CE).
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DICHIARAZIONE DI CONFORMITA
ESAB AB, Welding Equipment, 695 81 Laxå, Svezia, dichiara sotto la propria responsabilità che la
saldatrice automatica Railtrac Orbital W con numero di serie a partire da 0605 xxx xxxx (2006 sett.
05) è progettata e collaudata in conformità alle norme armonizzate previste dalle direttive 98/37/CE e
89/336/CE.
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DECLARAÇÃO DE CONFORMIDADE
ESAB AB, Equipamentos de Soldadura, 695 81 Laxå, Suécia, assegura à sua responsabilidade que o
autómato de soldadura Railtrac Orbital W do número de série 0605 xxx xxxx (2006 v.05) foi cons-
truído e testado de acordo com as condições das directivas (98/37/EG) e (89/336/EG).
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ÄÇËÙÓÇ ÓÕÌÌÏÑÖÙÓÇÓ
H ESAB AB, Welding Equipment, 695 81 Laxå Óïõçäßá, âåâáéþíåé ìå äéêÞ ôçò åõèýíç üôé ï
áõôüìáôïò óõãêïëëçôéêüò åîïðëéóìüò Railtrac Orbital W áðü ôïí áñéèìü óåéñÜò 0605 xxx xxxx
(2006 v.05) åßíáé êáôáóêåõáóìÝíïò êáé äïêéìáóìÝíïò óýìöùíá ìå äçìïóéåõìÝíá ðñüôõðá ðïõ
áíôáðïêñßíïíôáé óôïõò üñïõò ôùí Ïäçãéþí (98/37/EK) êáé (89/336/EK).
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DEKLARACJA ZGODNO¦CI
ESAB AB, Welding Equipment, 695 81 La, Szwecja, niniejszym za¶wiadcza pod rygorem
odpowiedzialno¶ci, ¿e automat spawalniczy Railtrac Orbital W od numeru seryjnego 0605 xxx xxxx
(2006 t.05) zosta³ zaprojektowany i przetestowany zgodnie z opublikowanymi normami wed³ug wymogów
zawartych w dyrektywie (98/37/EG) oraz (89/336/EG).
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Kent Eimbrodt
Global Director
Equipment and Automation
L
axå 2006--01--31
ENGLISH
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TOCe
1SAFETY 78...........................................................
2 INTRODUCTION 80...................................................
2.1 General 80..................................................................
2.2 Technical data 81............................................................
3 INSTALLATION 82....................................................
3.1 General 82..................................................................
3.2 Other connections 83.........................................................
3.3 Mounting 87.................................................................
4 OPERATION 90.......................................................
4.1 General 90..................................................................
4.2 Front Panel -- Carriage 90.....................................................
4.3 Front Panel -- Weaving Unit 91.................................................
4.4 Remote Control Box 92.......................................................
5 MAINTENANCE 94....................................................
5.1 General 94..................................................................
6 ACCESSORIES 94....................................................
6.1 General 94..................................................................
7 SPARE PARTS 94.....................................................
DIMENSION DRAWING 240................................................
DIAGRAM 241............................................................
SPARE PARTS LIST 243...................................................
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SafE
1SAFETY
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 recommen-
dations 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.
GB
-- 7 9 --
SafE
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 suitable 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!
GB
-- 8 0 --
fta7d1ea
2 INTRODUCTION
2.1 General
Railtrac Orbital W is a mechanisation equipment that enhances efficiency and
improves the work environment for welding. The equipment can be used for orbital,
horizontal and vertical joints with or without weaving.
The equipment consists of a carriage, travel track and control box.
The carriage has two separate drive units which can be angled steplessly for
different travel track diameters. Each drive unit has its own motor, so that one pulls
and one pushes for stable operation for both raising and lowering.
The travel track consists of two rolled halves with spring--loaded / adjustable
supports which can be adjusted +/-- 25 mm for correct alignment against the tube.
The halves are tensioned together with quick--acting locks.
The control box consists of two digital control units (one for the carriage and one for
the weaving unit) as well as a compact remote control which provides the operator
with full control of the carriage. The control box can store 5 different programs which
can also be switched via the remote control during operation. The weaving unit is
synchronised with the movement of the carriage for different weaving patterns.
1. Drive unit
2. Angle bracket
3. Travel track
4. Weaving unit
5. Drive unit
6. Motor cable
7. Remote control
8. Control box
GB
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fta7d1ea
2.2 Technical data
Railtrac Orbital W
Supply voltage: 36--46 V AC / 40 -- 60 V DC
Power consumption: max 90W
Weight: 8kg
Carriage measurements (lxwxh): 312 x 327(± weaving) x 181 mm
Minimum tube diameter: 300 mm
Height adjustment slide: 6”
Height adjustment slide: ± 22 mm
Welding speed: 5–99cm/min
Length / Intermittent welding: 1–99cm
”Backfill” 0–99mm
Weaving speed: 6–60mm/s
Weaving width: 1–30mm
0--line displacement: +/-- 12.5 mm (tot. 25 mm)
Dwell time: 0.0–9.9s
Number of programs: 5
GB
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fta7i1ea
3 INSTALLATION
3.1 General
The installation must be execu ted by a professional.
Railtrac Orbital W can be connected to m ost of ESAB’s feed units.
For connection to older feed units, please contact your nearest ESAB retailer.
Railtrac Orbital W can also be powered by other welding power sources via a
separate transformer, see page 86.
For connection of the wire feed unit to Railtrac Orbital W, u se control cable acc. to
Accessories, on page 94.
GB
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fta7i1ea
3.2 Other connections
Railtrac Orbital W Origot Feed
Railtrac Orbital W is to be connected directly to the remote control socket.
No intervention in the feed unit is necessary.
Origot Feed 302 with control p an el M11.
Railtrac Orbital W cannot be connected to
this feed unit.
Origot Feed 304 an d 484 with M12 control panel.
It is not possible to adjust the voltage
from Railtrac Orbital W.
Origot Feed 304 an d 484 with M13 control panel.
It is possible to adjust both voltage and wire
feed from Railtrac Orbital W.
GB
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fta7i1ea
Railtrac Orbital W ! Aristot Feed 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).
GB
-- 8 5 --
fta7i1ea
Railtrac Orbital W ! Aristot Feed 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).
GB
-- 8 6 --
fta7i1ea
Railtrac Orbital W ! o t h er feed unit makes
When connecting Railtrac Orbital W to other feed units, use the transformer and the
control cable you find under Accessories on page 94.
F G = Start / Stop function
J = Reference +
K = Reference welding voltage
L = Reference 0
M = Reference wire feed speed
A B = Voltage feed
GB
-- 8 7 --
fta7i1ea
3.3 Mounting
Mount the travel track on the tube in accordance with the instructions included with
the travel tr a ck.
Mount the Railtrac Orbital W in accordance with the instructions below.
1. Locking lever
2. Drive wheel module
3. Vertical support wheel x2
4. Travel track
5. Support wheel bracket
6. Horizontal support wheel
7. Locking guide wheel
1
Mount the travel track on the tube. Normally 170
mm from the edge of the rail to the centre of the
joint.
Check that the travel track is parallel with the joint
around the tube.
2 Release the locking levers so that the drive wheel
modules can rotate freely.
(Handling the carriage is easier without slide and
pistol bracket. The pistol bracket can be pulled by
the weaving arm by undoing the locking lever on the
pistol bracket.)
3 Push the locking guide wheel to the side to release
the horizontal support wheel.
GB
-- 8 8 --
fta7i1ea
4 Fold out the horizontal support wheel and set the
carriage on the track.
5 Adjust the angle of the drive wheel modules so that
the vertical support wheels are in contact with the
travel track.
Lock the position with the locking levers.
6 Screw out the Unbraco screws (x 2) so that the
support wheel can be threaded into/out from the
hub.
Adjust the height of the support wheel so that it is in
contact with the lower edge
of the travel track.
Screw in the lock screws.
(1) Lock screws x2 (3 mm Unbraco)
7 Pull the locking guide wheel back over the support
wheel and turn the guide wheel clockwise so that
the support wheel locks the carriage to the travel
track.
8 Connect the motor cable (1) and remote control (2)
to the control box.
Connect 42 V to the control box.
Press the button for centring the weaving unit.
(Bottom right, flashing LED).
9 Run the carriage forward and back on the travel
track.
Precision adjust the support wheel as required to
avoid it scraping on the travel track.
GB
-- 8 9 --
fta7i1ea
10 Fit the slide with pistol bracket.
Fit the welding pistol and adjust in relation to the
weld joint.
11 Enter the required data into the control box (it has
memory for five sets, ”P1”--”P5”).
Set the welding parameters on the welding power
source/feed unit.
GB
-- 9 0 --
fta7o1ea
4 OPERATION
4.1 General
General safety regulations for the handling of the equipment can be found on
page 78. Read through before you start using the equipment!
4.2 Front Panel -- Carriage
1. Program selection: The electronics contain 5 different programs, P1--P5
2. Function selector: Selector for the display of weld speed, craterfill time, backfill distance
or intermittent welding distances. The activated function is indicated
by 1 out of 4 light emitting diodes.
3. Speed: The welding speed is displayed in cm/min.
4. Craterfill time: The time during which the built--in craterfill function of the wire feed
unit is activated and the carriage stands still. Value: 0--9.9 s.
5. Backfill distance: Used as a craterfill alternative. The carriage mmves backwards for a
programmed distance in order to fill the crater. Value: 0--99 mm.
6. Intervals in intermit-
tent welding:
The diode flashes. Displays the distance between the welds in
intermittent welding. Value: 1--99 cm.
7. Weld length in
intermittent welding:
The diode flashes. Displays the welding length in cm in intermittent
welding. Value: 1--99 cm.
8. Welding On/Off: A diode indicates whether the start function is activated or not. Red
diode = Welding On.
9. Intermittent/Continu--
ous welding:
For the selection of intermittent or continuous welding. Green diode =
Intermittent welding.
10. Welding direction/
Backfill:
Green diode indicates the travel direction of the machine or if the
backfill function is used.
GB
-- 9 1 --
fta7o1ea
4.3 Front Panel -- Weaving Unit
1. Weaving speed: Shows the speed of the weaving. Value. 6--60 mm/s.
2. Function selector: Selector to show the width of the weaving, the 0--line setting and the
dwell times. The activated function is indicated by 1 out of 4 light
emitting diodes.
3. Weaving width: Shows the width of the weaving. Value: 0--30 mm.
4. 0--line setting: Shows the centre of the weaving motion in relation to the working
range of the machine. Value: 50 = centre, 00 = 12.5 mm inwards, 99
= 12.5 mm outwards.
5. Dwell time -- left: Dwell time in the left turning position. Value: 0--9.9 s.
6. Dwell time -- right: Dwell time in the right turning position. Value: 0--9.9 s.
7. 0--line adjustment: Automatic adjustment of the centre of the weaving unit. The 0--line is
to be adjusted when the power has been turned on or after a power
failure. A flashing lamp indicates this state. The lamp lights
continuously when the 0--line has been adjusted.
8. Weaving pattern: For selection between 3 different basic patterns. A diode indicates the
selected pattern.
9. Weaving unit On/Off: A red lamp indicates that the weaving unit is activated. The weaving
unit is automatically engaged when the 0--line has been adjusted.
GB
-- 9 2 --
fta7o1ea
4.4 Remote Control Box
Travel in the direction of the arrow:
Click START SPEED + once.
Rapid transport: Hold down for two sec -
onds.
Travel in the direction of the arrow:
Click START SPEED - once.
Rapid transport: Hold down for two sec -
onds.
Weldin g in the direction of the arrow:
Double--click on START SPEED + .
Weldin g in the direction of the arrow:
Double--click on START SPEED - .
STOP
Click STOP.
STOP with Backfill
Hold down NEXT and press STOP.
GB
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ESAB Railtrac Orbital W User manual

Category
Welding System
Type
User manual

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