ESAB Railtrac™ BV2000 User manual

Service manual

0463 466 001 GB 20201016

Valid for: Railtrac™B42V:serialno.1634xxxx,

Railtrac™BV2000:serialno.1801xxxx

Railtrac™B42V,

Railtrac™BV2000

TABLE OF CONTENTS

0463 466 001 © ESAB AB 2020

READ THIS FIRST

....................................................................................

3

BEFORE STARTING SERVICE

................................................................

4

Service aid

..............................................................................................

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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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. 0398146016 / serialno.1634xxxx

• Railtrac™BV2000 / ordering no. 0459990644 / serialno.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

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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 610×610mm /

24×24in)

• A 1.5m (3.28ft) 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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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

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Block diagram

TECHNICAL DATA

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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 (5Ah)

Weight 8 kg (17.63lb.)

Carriage measurements (L×W×H) 210×360×270 mm (8.26×14.17×10.62in.)

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 (22.04lb.)

Max pay load with battery 5 kg (11.02lb.)

Height adjustment slide ± 45 mm (± 1.77in.)

Speed carriage 0.4–25 mm/s (0.01–0.98in./s)

Rapid speed carriage 30 mm/s (1.18in./s)

Rapid speed battery 25 mm/s (0.98in./s)

Welding length – auto return 10–9999 mm. Tolerance ±1 mm

(0.39–393.66in. Tolerance ±0.04in.)

Weaving speed 10–50 mm/s (0.39–1.97in./s)

Weaving pattern 3

Weaving width 0–30 mm (0–1.18in.)

0-line adjustment ± 30 mm (± 1.18in.)

Mechanical adj. in/out ± 40 mm (± 1.57in.)

Tot. movement weaver 80 mm (3.15in.)

Dwell time weaving 0.0–5.0s

Programs 6

Remote control Wire Feed Speed and V

(separate adj. on each program)

ESAB 0–10V

Safety class DIN40050

Enclosure class IP44

Railtrac™BV2000, Valid from serial no. 1801xxxx

Supply voltage 24–60VDC

20–50VAC

18 V battery

Power consumption max 50W

Battery running time 3–4h

Weight 8 kg (17.6lb)

Carriage measurements (L×W×H) 210×350×267mm (8.27×13.78×10.51in.)

Length running rail 2m (2x 1m) (6ft7in.)

TECHNICAL DATA

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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 ± 45mm (± 1.77 in.)

Speed carriage 2–150 cm/min (0.79–4ft 11in./min)

Rapid speed carriage 15cm/min (5.91in./min)

Weaving speed 5–40mm/s (0.2–1.57in.)

Weaving width 0–60mm (0–2.36in.)

0-line adjustment ±30mm* (1.18in.*)

Mechanical adj. in/out ±40mm (±1.57in.)

Tot. movement weaver 80mm (3.15in.)

Programs 6

Remote control Wire Feed Speed and V

(separate adj. on each program)

ESAB 0–10V

Safety class DIN40050

Enclosure class IP44

*Depending on weaving width. Max workspace = 80mm (3.15in.)

WIRING DIAGRAM

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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 UniversalConnector contains

the number ??? to indicate that they belong to the UniversalConnector. 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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Diagram carriage

WIRING DIAGRAM

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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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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

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Diagram remote control

CALIBRATION RAILTRAC B42V AND BV2000

0463 466 001

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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

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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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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 04590681880

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

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Circuit board layout, CAN adapter and filter board.

REMOTE ADAPTER KIT

0463 466 001

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Connection instructions

Aristo Feed 3004/4804 & Origo Feed 3004/4804

REMOTE ADAPTER KIT

0463 466 001

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Warrior Feed 304/w

Fault indication measurements

Warrior Feed 304/w

Instructions for "Fault indication measurements" on Railtrac interface PCBA

0440110880

REMOTE ADAPTER KIT

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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, Railtrac™ B42V User manual

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