ESAB Railtrac Orbital W 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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FÖRSÄKRAN 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 på 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/EØF) og (89/336/EØF).

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FORSIKRING OM SAMSVAR

ESAB AB, Welding Equipment, 695 81 Laxå, Sverige, forsiker på 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 CONFORMITÉ

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 Laxå, 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

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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

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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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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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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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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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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

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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

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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

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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

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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

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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

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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

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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

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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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