Service manual
0463 466 001 GB 20201016
Valid for: Railtrac™B42V:serialno.1634xxxx,
Railtrac™BV2000:serialno.1801xxxx
Railtrac™B42V,
Railtrac™BV2000
TABLE OF CONTENTS
0463 466 001 © ESAB AB 2020
READ THIS FIRST
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3
BEFORE STARTING SERVICE
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4
Service aid
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4
INTRODUCTION
.......................................................................................
5
Block diagram
.........................................................................................
6
TECHNICAL DATA
...................................................................................
7
WIRING DIAGRAM
...................................................................................
9
Component description
.........................................................................
9
Diagram carriage
....................................................................................
10
Power board
............................................................................................
11
Diagram weaving unit
............................................................................
12
Diagram remote control
.........................................................................
13
CALIBRATION RAILTRAC B42V AND BV2000
......................................
14
REMOTE ADAPTER KIT
..........................................................................
16
Connceting remote adapter kit
..............................................................
16
Connection instructions
........................................................................
18
Aristo Feed 3004/4804 & Origo Feed 3004/4804................................. 18
Warrior Feed 304/w .............................................................................. 19
Fault indication measurements
............................................................
19
Warrior Feed 304/w .............................................................................. 19
SERVICE MENU
.......................................................................................
21
Units
.........................................................................................................
21
Preheat
....................................................................................................
22
REMOTE CONTROL SETTINGS AND ADJUSTMENTS ANALOG
FEEDER
....................................................................................................
23
Setting of maximum value for wire feed speed and voltage
..............
23
"WFS" = Wire feed speed..................................................................... 23
"V" = Voltage ........................................................................................ 23
Warrior.................................................................................................. 24
TROUBLESHOOTING
..............................................................................
25
SPARE PARTS AND ACCESSORIES
.....................................................
26
Rights reserved to alter specifications without notice.
READ THIS FIRST
0463 466 001
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© ESAB AB 2020
READ THIS FIRST
Maintenance and repair work must be performed by an experienced person, and electrical
work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault-tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit boards
are divided into numbered blocks, which are described individually in more detail in the
description of operation. Component names in the wiring diagram are listed in the
component description.
Use the spare parts list as a guide to where the components are located in the equipment.
The spare parts list is published as a separate document, see the "SPARE PARTS AND
ACCESSORIES" chapter in this manual.
This manual contains details of design changes that have been made up to and including
December 2017.
The manual is valid for:
• Railtrac™B42V / ordering no. 0398146016 / serialno.1634xxxx
• Railtrac™BV2000 / ordering no. 0459990644 / serialno.1801xxxx
NOTE!
The unit is tested by ESAB in a general set-up. The responsibility for safety and
function, of the specific set-up, lies with the integrator.
Railtrac™B42V and Railtrac™ BV2000 are designed and tested in accordance with the
standards stated in the instruction manual for each product. 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 involved standards.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.
BEFORE STARTING SERVICE
0463 466 001
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© ESAB AB 2020
BEFORE STARTING SERVICE
Service aid
ESAB can offer a number of service tools that will simplify the service.
Antistatic service kit
Ordering no. 0740 511 001
The kit makes it easier to protect sensitive
components from electrostatic discharge.
Contents:
• A conductive mat (size 610×610mm /
24×24in)
• A 1.5m (3.28ft) long ground cable with
a crocodile clip
• An adjustable wrist strap and cable with
a built-in protective resistor
Antistatic service kit
INTRODUCTION
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© ESAB AB 2020
INTRODUCTION
Railtrac™B42V and Railtrac™ BV2000 are systems of components that can be configured
to create the optimal solution for your mechanized welding application. Most mechanical
parts in the system are produced from aluminium or stainless steel.
INTRODUCTION
0463 466 001
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© ESAB AB 2020
Block diagram
TECHNICAL DATA
0463 466 001
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© ESAB AB 2020
TECHNICAL DATA
Railtrac™ B42V, Valid from serial no. 1634xxxx
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 (5Ah)
Weight 8 kg (17.63lb.)
Carriage measurements (L×W×H) 210×360×270 mm (8.26×14.17×10.62in.)
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 (22.04lb.)
Max pay load with battery 5 kg (11.02lb.)
Height adjustment slide ± 45 mm (± 1.77in.)
Speed carriage 0.4–25 mm/s (0.01–0.98in./s)
Rapid speed carriage 30 mm/s (1.18in./s)
Rapid speed battery 25 mm/s (0.98in./s)
Welding length – auto return 10–9999 mm. Tolerance ±1 mm
(0.39–393.66in. Tolerance ±0.04in.)
Weaving speed 10–50 mm/s (0.39–1.97in./s)
Weaving pattern 3
Weaving width 0–30 mm (0–1.18in.)
0-line adjustment ± 30 mm (± 1.18in.)
Mechanical adj. in/out ± 40 mm (± 1.57in.)
Tot. movement weaver 80 mm (3.15in.)
Dwell time weaving 0.0–5.0s
Programs 6
Remote control Wire Feed Speed and V
(separate adj. on each program)
ESAB 0–10V
Safety class DIN40050
Enclosure class IP44
Railtrac™BV2000, Valid from serial no. 1801xxxx
Supply voltage 24–60VDC
20–50VAC
18 V battery
Power consumption max 50W
Battery running time 3–4h
Weight 8 kg (17.6lb)
Carriage measurements (L×W×H) 210×350×267mm (8.27×13.78×10.51in.)
Length running rail 2m (2x 1m) (6ft7in.)
TECHNICAL DATA
0463 466 001
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© ESAB AB 2020
Railtrac™BV2000, Valid from serial no. 1801xxxx
Max temp. Carriage
Carriage with battery
80°C (176°F)
60°C (140°F)
Max pay load 10 kg (22 lb)
Height adjustment slide ± 45mm (± 1.77 in.)
Speed carriage 2–150 cm/min (0.79–4ft 11in./min)
Rapid speed carriage 15cm/min (5.91in./min)
Weaving speed 5–40mm/s (0.2–1.57in.)
Weaving width 0–60mm (0–2.36in.)
0-line adjustment ±30mm* (1.18in.*)
Mechanical adj. in/out ±40mm (±1.57in.)
Tot. movement weaver 80mm (3.15in.)
Programs 6
Remote control Wire Feed Speed and V
(separate adj. on each program)
ESAB 0–10V
Safety class DIN40050
Enclosure class IP44
*Depending on weaving width. Max workspace = 80mm (3.15in.)
WIRING DIAGRAM
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© ESAB AB 2020
WIRING DIAGRAM
Railtrac™B42V/Railtrac™BV2000 constitutes function module ???. Does it have a
module number? This section to be updated based on received information! The
names of the circuit boards and components included in the UniversalConnector contains
the number ??? to indicate that they belong to the UniversalConnector. The circuit boards
and components are listed in the component description below.
Wires/cables within modules are marked 100 - 6999.
Wires/cables between modules are marked 7000 - 7999.
Components outside modules - e.g. capacitors - are named such as C1 - C99, connectors
XS1 - XS99 (S = socket), XT1 - XT99 (T = terminal).
Circuit boards within each module have names such as 20AP1 - 20AP99.
20 = module association, 1-69
AP = circuit board
1 = individual identification number, 0-99
Transistors within particular modules have identification numbers such as 15Q1 - 15Q99.
15 = module association, 1-69
Q = transistor
1 = individual identification number, 0-99
Component description
Component Description
X Xxxxxxxxxxx Wire numbers XXX–XXX
XAP? Xxxxxxxxxxxxxx
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.
WIRING DIAGRAM
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© ESAB AB 2020
Diagram carriage
WIRING DIAGRAM
0463 466 001
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© ESAB AB 2020
Power board
New PTC (2,5A) from serial no: 17103187
CAUTION!
STATIC ELECTRICITY can damage circuit boards and
electronic components.
• Observe precautions for handling electrostatic
sensitive devices.
• Use proper static-proof bags and boxes.
WIRING DIAGRAM
0463 466 001
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© ESAB AB 2020
Diagram weaving unit
Pin A: 0V
Pin B: +24V (23-27VDC)
Pin E: Motor dir. Active low (0V) Opto inp. on motor driver. Current reg. via 470
ohm res. to +24V
Pin F: Motor speed Active low (0V) Puls inp. 1 – 5 kHz Current reg. via 470 ohm
res.
WIRING DIAGRAM
0463 466 001
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© ESAB AB 2020
Diagram remote control
CALIBRATION RAILTRAC B42V AND BV2000
0463 466 001
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© ESAB AB 2020
CALIBRATION RAILTRAC B42V AND BV2000
Adjusting motor current
1. Unscrew the driver from motor.
2. Turn it around so that the back side comes forward.
3. Use a small screwdriver and turn switch “1” off (down), as shown in the picture.
4. Measure the voltage on pad “+” & “-“.
Driver carriage: 1,6V
Driver weaver: 1,4V
CALIBRATION RAILTRAC B42V AND BV2000
0463 466 001
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© ESAB AB 2020
5. Adjust if necessary motor current on the small pot.
6. Use a small screwdriver and turn switch “1” on (up).
7. Reinstall the driver on motor.
REMOTE ADAPTER KIT
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© ESAB AB 2020
REMOTE ADAPTER KIT
Connceting remote adapter kit
Remote kit Railtrac/Miggytrac for Aristo Feed 3004/4804 & Origo Feed 3004/4804.
CAN Adapter kit.
Miggytrac / Railtrac 0459 681 880
CAN adapter
The CAN adapter option is used when Miggytrac, Railtrac or a welding gun with pull motor is
connected to the wire feeder.
Connection instructions for the option are included in the delivery. There is a copy of the
instructions in section "Connection instructions".
The adapter board has a software identity, machine ID. The ID defines how the welding
equipment reacts on the commands from the connected equipment. The CAN adapter
options are delivered with correct machine ID. Spare part boards are delivered without
machine ID. To read or change the machine ID you need the ESAT service kit, see chapter
"Software update and configuration".
The CAN adapter board has a built-in terminating resistor. The resistor is disconnected on
delivery of this option. In most operating cases it should be disconnected.
It can be connected by a jumper over terminal J1 on the CAN adapter board. See the
component position diagram in section "Circuit board layout, CAN adapter and filter board".
Can adapter board, filter board and cable set connected to the control board of the wire
feeder.
Adapter option for Miggytrac / Railtrac 04590681880
The adapter board is delivered with machine ID 2.
Switch 13S2 is used for activating / deactivating the external control functions. When the
switch is in position B, the external controls are active and the control panel of the feeder is
inactive. In position A the control panel is active and the external controls inactive.
If the wire feeder is controlled by an U8, switch 13S2 has to be in position B. Then external
or internal control can be selected by the U8-2.
REMOTE ADAPTER KIT
0463 466 001
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© ESAB AB 2020
Circuit board layout, CAN adapter and filter board.
REMOTE ADAPTER KIT
0463 466 001
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© ESAB AB 2020
Connection instructions
Aristo Feed 3004/4804 & Origo Feed 3004/4804
REMOTE ADAPTER KIT
0463 466 001
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© ESAB AB 2020
Warrior Feed 304/w
Fault indication measurements
Warrior Feed 304/w
Instructions for "Fault indication measurements" on Railtrac interface PCBA
0440110880
REMOTE ADAPTER KIT
0463 466 001
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© ESAB AB 2020
Points to be checked if a faulty Railtrac-interface PCBA is expected:
For convenience perform the check with the Wire feeder (containing the Railtrac kit)
connected to a Warrior power source.
• Measure "V-" between CN3:3 and CN2:11 or. (-12V±3V)
• Measure "V-vb" between CN3:1 and CN1:7. (-12V±3V)
• Measure "Vboost" between CN3:2 and CN1:7. (17.5V±1V)
• Set remote control to min setting. "8V" should be shown in the display. Measured value
on "VREF_B" output (CN1:8 to CN1:7) should be approx. <50mV.
• Set remote control to max setting. "44V" should be shown in the display. Measured
value on "VREF_B" output (CN1:8 to CN1:7) should be 14.7V±0.5V. If measured
without Warrior power source output is approx. 15-15.5V due to absence of PS load
resistor.
• All output values for the "VREF_B" output should be within the range of ±0.25V of input
"VREF" (measured between CN2:2 and CN2:3) when swept between min (0V) and max
(~15V) values. If measured without Warrior power source deviation is bigger (<1V) due
to absence of the PS load resistor.
If measurement is failing on one or more points above the Railtrac PCBA needs to be
replaced. (Railtrac kit functionality could work with slightly higher deviations as well but may
be unreliable in performance.)
440110-001:
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ESAB Railtrac™ BV2000 User manual
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