ESAB Railtrac W / FW User manual

Railtrac

Service Manual

ver.: GB3c 0333

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Railtrac Service Manual

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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

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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.

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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!

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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

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3.3 Wire diagram “FW1000” & “FWL1000”

Control box

Remote control

ESAB

Welding carriage

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3.4 Wire diagram “FWR1000”

Remote control Welding carriage

ESAB

Control box

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3.5 Wire diagram “F1000” & “FL1000”

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3.6 Wire diagram “FR1000” & “FRL1000”

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3.7 Wire diagram “W30”

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3.8 Wire diagram “W80”

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3.9 Wire diagram “BVR1000”

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Notes

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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.

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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 ”

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5.4 Wiring diagram FLT_12 “B”

C8

C7

L1

C9

L2

R1

C1

D1_2

R2

C2

D1_1

R3

C3

D2_2

R4

C4

D2_1

R5

C5

D3_2

R6

C6

D3_1

R8

C10

D4_2

R9

C11

D4_1

R10

5.5 Component location FLT_12 “B”

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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

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6.3 Component location FLT_20 ”C”

6.4 Component location FLT_21 “C”

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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

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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.

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ESAB Railtrac W / FW User manual

ESAB Railtrac W / FW User manual

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