Page is loading ...
Railtrac
Service Manual
ver.: GB3c 0333
GB
Railtrac Service Manual
- 2-
Contents Contents
DECLARATION OF CONFORMITY 3
SAFETY 3
3 ELECTRICAL BLOCK DIAGRAM 5
3.2 Component description 5
3.3 Wire diagram “FW1000” & “FWL1000” 6
3.4 Wire diagram “FWR1000” 7
3.5 Wire diagram “F1000” & “FL1000” 8
3.6 Wire diagram “FR1000” & “FRL1000” 9
3.7 Wire diagram “W30” 10
3.8 Wire diagram “W80” 11
3.9 Wire diagram “BVR1000” 12
4 FILTER , VOLTAGE SUPPLY 14
4.1 General 14
5 FILTER , REMOTECONTROL “B” 14
5.1 General 14
5.2 Wiring diagram FLT_11 “B” 15
5.3 Component location FLT_11 “B ” 15
5.4 Wiring diagram FLT_12 “B” 16
5.5 Component location FLT_12 “B” 16
6 FILTER , CARRIAGE “C” 17
6.1 General 17
6.2 Wiring diagram FLT_20 “C” 17
6.3 Component location FLT_20 ”C” 18
6.4 Component location FLT_21 ”C” 18
7 CONTROL UNIT, CARRIAGE “D” 19
7.1 General 19
7.2 Component location on main board 19
7.3 Component location, supply board 20
D1 Rectifier, Voltage supply 20
D1.1 + 5V 21
D2 I / O remote control 22
D3 Motor driver 23
D4 Start / Stop power source 24
D5 Stop switch 25
D6 Com. between control units 26
8 CONTROL UNIT - WEAVING “E” 27
8.1 General 27
8.2 E1 Rectifier , Voltage supply 27
8.3 E1.1 + 5V 28
8.4 E1.2 + 24V 28
8.5 E2 I / O Remote control 29
8.6 E3 Motor driver 30
8.7 E4 Encoder input 30
8.8 E6 Communication control units 30
9 TROUBLESHOOTING 31
9.1 Control box not working. 31
9.2 Cannot start welding 31
9.3 Remote control not working 32
9.3 Travel not working 33
9.4 Travel unit stops 33
9.5 Cannot find 0-line 34
10 BASIC PARAMETERS 35
10.1 Speed calibration for travel unit 35
10.2 Travel unit motor cut-out 36
10.3 Pulse time, 0-line position 37
10.4 Manual speed weaving unit 38
11 MAINTANANCE 39
11.1 Daily maintenance 39
11.2 Maintenance 39
12 SPARE PARTS 40
12.1 Carriage “F” and “FW” 40
12.2 Carriage “B” & "BV1000" 41
12.4 Weaving unit 42
12.6 Control box Version. 3 43
12.7 Control box “1000” 44
12.8 Spare parts torch holder 45
We reserve the right to change the specification without notice
ESAB Sverige AB
GB
Railtrac Service Manual
- 3-
DECLARATION OF CONFORMITY
TPS as 3251 Larvik, Norway, gives its unreserved guarantee that Railtrac 1000 having serial
number735xxxx complies with standard EN 50199 in accordance with requirements of directive
89/392 EEC
Larvik 97.08.25
Geir Espedalen
SAFETY
Users of ESAB automatic welding machines have ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions.
The following recommendations should be observed in addition to the standard regulations
that apply to the work place.
All work must be carried out according to the specified instructions by personnel who are
thoroughly familiar with the operation of the welding machine.
Incorrect or unintentional operation of the equipment may lead to a hazardous situation which
can result in injury to the operator and damage to the equipment.
1. Anyone who uses the automatic welding machine must be familiar with:
• its operation
• the location of emergency stops
• its function
• relevant safety precautions
To make this easier each switch, push button or potentiometer is marked with a symbol or
text that indicates its function when activated.
2. The operator must ensure that:
• no unauthorised person is stationed within the working area of the machine when it is
started up.
• that no-one is in a hazardous position when the carriage or slide mechanisms are
operated.
3. The work place must:
• be clear of mechanical components, tools, or other obstructions that could prevent the
operator from moving freely within the working area.
• be organised so that there is free access to the emergency stop.
4. Personal safety equipment
• Always wear recommended personal safety equipment, such as safety glasses, flame-
proof clothing, safety gloves.
• Do not wear loose-fitting items, such as scarves, bracelets, etc., which could become
trapped.
5. General precautions
• Live electrical components are normally shielded from accidental contact.
• Make sure the return cable is connected securely.
• Work on high voltage components may only be carried out by a qualified electrician.
• Appropriate fire extinguishing equipment must be clearly marked and close at hand.
• Lubrication and maintenance must not be carried out on the equipment during its
operation.
GB
Railtrac Service Manual
- 4-
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS.
TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY
PRACTICES WHICH SHOULD BE BASED ON MANUFACTURER’S HAZARD DATA.
ELECTRIC SHOCK - Can kill
• Install and earth the welding unit in accordance with applicable standards.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from earth and the work piece.
• Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to keep fumes and gases from your
breathing zone and the general area.
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby.
NOISE - Excessive noise can damage hearing
• Protect your ears. Use ear defenders or other hearing protection.
• Warn bystanders of the risk.
MALFUNCTION
• Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE OPERATING MANUAL
BEFORE INSTALLING OR OPERATING.
PROTECT YOUR SELF AND OTHERS!
GB
Railtrac Service Manual
- 5-
3 ELECTRICAL BLOCK DIAGRAM
3.2 Component description
No. Description Type
A Filter, voltage supply Mains filter in metal casing
B Filter, remote control FLT_12
C Filter, travel unit FLT_21
D Control unit, travel unit MMC231 and LPW123
E Control unit, weave MMC231 and LPW123
R Remote control
W Carriage unit
SW01 Emergency stop Tele mecanique
XS01 Connector socket, remote control 19-pin Burndy, female
XP01 Connector plug , remote control 19-pin Burndy, male
XS02 Connector plug, power source 12-pin Burndy, female
XP02 Connector socket , power source 12-pin Burndy, male
XS03 Connector socket, carriage 12-pin Burndy, female
XP03 Connector plug , travel unit 12-pin Burndy , male
XS04-12 Connector, cable AMP , Female
XP04-12 Connector, circuit board AMP , Male
GB
Railtrac Service Manual
- 6-
3.3 Wire diagram “FW1000” & “FWL1000”
Control box
Remote control
ESAB
Welding carriage
GB
Railtrac Service Manual
- 7-
3.4 Wire diagram “FWR1000”
Remote control Welding carriage
ESAB
Control box
GB
Railtrac Service Manual
- 8-
3.5 Wire diagram “F1000” & “FL1000”
GB
Railtrac Service Manual
- 9-
3.6 Wire diagram “FR1000” & “FRL1000”
GB
Railtrac Service Manual
- 10-
3.7 Wire diagram “W30”
GB
Railtrac Service Manual
- 11-
3.8 Wire diagram “W80”
GB
Railtrac Service Manual
- 12-
3.9 Wire diagram “BVR1000”
GB
Railtrac Service Manual
- 13-
Notes
GB
Railtrac Service Manual
- 14-
4 FILTER , VOLTAGE SUPPLY
4.1 General
Sections A1 to E5 refer to wiring diagram 4.1
Each unit has its own letter code which is divided into section numbers.
A1 Filter, Voltage supply
A standard filter in a metal casing is used. The filter is bolted to the rear wall of the
electronic controller. To ensure best possible earth the filter is secured to 2 bolts that
are welded to the chassis of the electronic controller. Underneath each nut is a tag
washer that ensures good electrical contact.
Other parts of the electronic controller are earthen by these two bolts. The filter has its
own earth, which is connected to Burndy connector XP02, pin X.
Earlier versions of the electronic controller had a 3-pin Amphenol connector for
connecting to the power source, with the earth connected to pin “B”.
Filters of different makes were used – SAE and Corcom – both designed for 1A.
OutIn
5 FILTER , REMOTECONTROL “B”
5.1 General
The filter is mounted in the left corner of the electronic controller and secured to one
of the voltage supply filter bolts. A nut (M4) can be screwed up or down to adjust the
height of the filter. To ensure the filter is properly earthen, a tag washer is placed
between the nut and the underside of the circuit board.
The filter is supplied with a base voltage (50 - 60 V DC) from the voltage supply board
(terminals 10 and 13 on unit “D”) via a LC filter that consists of L1, L2 and C7 - C9.
The filter inputs (6 of them on FLT_11 and 8 on FLT_12) from the remote control are
filtered via a RC filter, and the voltage is then reduced to around 1.2 V by a voltage
divider. This signal is then input to the LED on the opposite switch and the transistor
output is pulsed (multiplexed) by the microprocessor (port C2 on module “D” and port
C3 on module “E”).
Earlier versions of the electronic controller did not have a Burndy connector for the
remote control cable. The cable was connected directly to the filter and the cable
screen was attached to the filter bolt.
GB
Railtrac Service Manual
- 15-
5.2 Wiring diagram FLT_11 “B”
GREY or
BLACK
YELL
OW
GREEN
BROWN
BLUE
REDPINK or
VIOLET
WHITE
C1
D
1
_2
D1_2
R1 R2
C2
D
1
_
1
D1_1
R3
C3
D
2
_2
D2_2
R4
C4
D
2
_
1
D2_1
R5
C5
D
3
_2
D3_2
R6
C6
D
3
_
1
D3_1
C8
C7
L1
C9
L2
5.3 Component location FLT_11 “B ”
GB
Railtrac Service Manual
- 16-
5.4 Wiring diagram FLT_12 “B”
C8
C7
L1
C9
L2
R1
C1
D1_2
D1_2
R2
C2
D1_1
D1_1
R3
C3
D2_2
D2_2
R4
C4
D2_1
D2_1
R5
C5
D3_2
D3_2
R6
C6
D3_1
D3_1
R8
C10
D4_2
D4_2
R9
C11
D4_1
D4_1
R10
5.5 Component location FLT_12 “B”
GB
Railtrac Service Manual
- 17-
6 FILTER , CARRIAGE “C”
6.1 General
The filter is mounted in the left corner of the electronic controller and secured to one
of the voltage supply filter bolts. A nut (M4) can be screwed up or down to adjust the
height of the filter. To ensure the filter is properly earthen, a tag washer is placed
between the nut and the underside of the circuit board. This is pressed against the
circuit board earth when the board is bolted into position. It is very important that
interference is filtered to earth using a LC filter.
The filter has 2 components, C1 and C2.
C1 24 VDC filter
A 24 V DC voltage is used by the weaving unit’s encoder. Both the supply voltage and
the encoder signal are filtered.
C2 Motor filter
High frequency interference from the motors is filtered to earth by a choke coil in series
and a capacitor to earth.
Capacitors C1 and C2, which are connected between the motor terminals, are
occasionally replaced with a varistor.
6.2 Wiring diagram FLT_20 “C”
4
"X1"
321
0V +24V Inp.
54321
"X4"
C1 C2
C9
C10 C11
4321
"X3"
C5 C6 C7 C8
L1 L4L3L2 L5 L6 L7
C4
C3
4
"X2"
321
Motor A Motor B Inductive Switch
GB
Railtrac Service Manual
- 18-
6.3 Component location FLT_20 ”C”
6.4 Component location FLT_21 “C”
GB
Railtrac Service Manual
- 19-
7 CONTROL UNIT - CARRIAGE “D”
7.1 General
The controller consists of 2 circuit boards, the main board MMC231 and the voltage
supply board LPW123. The circuit boards are mounted in separate aluminium frames
which are bolted together.
These are insulated from each other by plastic washers. It is important to prevent
electric current passing through the chassis to the switch regulator for the voltage
supply board, which is bolted to the aluminium frame.
The main board is bolted through 6 spacers and shimmed with 3.2 mm diameter plastic
washers to give the correct spacing between the switch and the front panel. The 2
central nuts are also insulated using the same type of plastic washers.
LPW123
MMC231
The main board consists of a microprocessor (µP), a drive unit for the display, a display
switch and a drive unit for the motor. The microprocessor is an OTP version and
therefore cannot be reprogrammed. When upgrading to a new program the complete
microprocessor must therefore be replaced.
!
When replacing the microprocessor use the correct tools and
wear a personal earth device.
7.2 Component location on main board MMC231
GB
Railtrac Service Manual
- 20-
7.3 Component location, supply board LPW_123
D1 Rectifier, Voltage supply
K2_1
K1_
13
K1_
12
K1_
11
K2_4
K1_
10
K1_
10
Voltage is supplied to the board via terminals “11” and “12” on terminal block “K1”.
The inputs are protected by a 1.0 “fast” fuse. A 10 ohm NTC resistor (R0) limits the
current when the voltage is switched on.
R1 is a varistor that protects the board against a high input voltage. The varistor short-
circuits at voltages above 50 VAC, the current through the fuse rises sharply and the
fuse blows. Occasionally the varistor may short circuit, with the result that the fuse
blows as soon as you connect the supply voltage again. The varistor is easily replaced
by cutting the legs close to the casing, then unsoldering the legs individually.
The input filter consists of C1, C13, L1 and L2 plus C2 and C12.
The diode bridge, D1 and D7, rectifies the input voltage, which is around 60 VDC at 42
VAC. The voltage from D1 is fed to terminal 13 on terminal block “K1” and to the motor
transistors on the MMC_231 board. D7 supplies the 5 V and 24 V regulators.
/
