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Summary of Contents for SteelMax Rail Runner 2
- Page 1 The tools of innovation. OPERATOR’S MANUAL WELDING CARRIAGE 15335 E. Fremont Drive, Centennial, CO 80112 1– 87STEELMAX, FAX 303 – 690 – 9172 www.steelmax.com sales@steelmax.com...
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Page 2: Table Of Contents
Contents 1. GENERAL INFORMATION ....................3 1.1. Application ......................... 3 1.2. Technical data......................4 1.3. Equipment included ....................5 1.4. Dimensions ........................ 6 1.5. Design ........................7 2. SAFETY PRECAUTIONS ....................8 3. STARTUP AND OPERATION ..................10 3.1. Assembling the semi-flexible or rigid track ..............10 3.2. -
Page 3: General Information
1. GENERAL INFORMATION 1.1. Application The Rail Runner 2 is a track carriage designed to cut and to make butt and fillet welds with or without oscillation. The carriage allows MIG/MAG, oxy-fuel, or plasma torches. The track is clamped with magnetic units to ferromagnetic surfaces that are flat or curved. -
Page 4: Technical Data
Oscillation dwell time at center and on ends 0–5 s Maximum oscillator pulling force 100 N (22 lbs) Allowed ambient temperature 0–45°C (32–113°F) Maximum allowed ambient humidity without condensation Protection level IP 23 Weight 10 kg (22 lbs) Rail Runner 2 – Operator’s Manual... -
Page 5: Equipment Included
1 unit 14 3 m (10 ft) remote control cable 1 unit 15 Power supply* 1 unit – Operator’s Manual 1 unit * 230 V, 115 V, or 42 V depending on the order Rail Runner 2 – Operator’s Manual... -
Page 6: Dimensions
Rail Runner 2 1.4. Dimensions 121 mm (4.8″) 470 mm (18.5″) 195 mm (7.7″) Rail Runner 2 – Operator’s Manual... -
Page 7: Design
Carrying handle Passive roller Arc ignition socket 5 m (17 ft) power cable connection Drive clutch knob Install bracket Limit switch Pressing roller Drive gear Pressing lever (pressing rollers are loose in this position) Rail Runner 2 – Operator’s Manual... -
Page 8: Safety Precautions
20. Use the rigid track only on flat surfaces. 21. At heights, protect the carriage and the track from falling. To do this, use chains (not included) to attach the leftmost and rightmost magnetic units of the semi- Rail Runner 2 – Operator’s Manual... - Page 9 29. Do not leave the carriage unattended during work. 30. If you are not going to use the carriage, remove it from the worksite and keep in a safe and dry place. Rail Runner 2 – Operator’s Manual...
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Page 10: Startup And Operation
Put the rack adjustment tool (not included) into the hole (3), and rotate the tool to the left (4) to remove the gap (5) between the racks. Then, tighten the leftmost screw and the rightmost screw of each rack (2). Rail Runner 2 – Operator’s Manual... - Page 11 Rail Runner 2 Fig. 2. Removing the gap between the racks of a semi-flexible track Rail Runner 2 – Operator’s Manual...
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Page 12: Assembling The Ring Track
Next, for all rails, use the 12 mm hex wrench to set the hinge as shown in Fig. 4. Then, put the lock pin through the holes (1), and then rotate the wrench (2) to connect the rails. Rail Runner 2 – Operator’s Manual... - Page 13 (1, Fig. 5). Adjust each support equally to make the track concentric to the workpiece. Lock the supports with the nuts (2) or levers. Fig. 5. Attaching the ring track to the workpiece Rail Runner 2 – Operator’s Manual...
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Page 14: Positioning On A Straight Track
(3). Then, put the carriage so that the install brackets are on the rail (4, 5). Gear retracted Install bracket Install bracket Fig. 6. Putting the carriage on a straight track Rail Runner 2 – Operator’s Manual... - Page 15 (4). However, do not tighten the knob with too much force. Keep some backlash between the gear and rack. Not engaged × Engaged ✓ Fig. 7. Engaging the carriage with the track Rail Runner 2 – Operator’s Manual...
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Page 16: Positioning On A Curved Track
ON (3). Next, move the carriage left or right and make sure that it moves smoothly. Then, tighten the screws (1) and the knob (4). Fig. 8. Rotating the rollers for a curved track Rail Runner 2 – Operator’s Manual... -
Page 17: Preparing And Connecting
(3). Next, connect the power supply to the power source and put the torch and torch cables into the holders. 3 m (10 ft) remote control cable 5 m (17 ft) power cable Fig. 9. Connecting the carriage Rail Runner 2 – Operator’s Manual... -
Page 18: Connecting To The Welding Circuits
Make sure that the arc ignition cable is connected correctly. To do this, turn on the power of the carriage, and then set the arc ignition switch to TEST. This should enable the arc for a while. Rail Runner 2 – Operator’s Manual... -
Page 19: Operating
(TEST / O / I) Arc ignition switch (TEST / O / I) Fig. 11. Control panel with the main screen displayed Tab. 1 explains the symbols shown on the right of the main screen. Rail Runner 2 – Operator’s Manual... - Page 20 Rotate [step: 0.05/0.02] From –2.5 to +2.5 cm Torch height From –1 to +1 in (when the vertical slide Rotate [step: 0.02/0.01] is connected). Unit of measure. inch Rotate in the correct setup screen. Rail Runner 2 – Operator’s Manual...
- Page 21 Stops the arc and travels the carriage back to the initial position from where the move started. To continue after the carriage reaches the initial position, set the travel direction switch to ‘O’. This removes the information symbol. Rail Runner 2 – Operator’s Manual...
- Page 22 0–5 s Crater fill time at weld end (parameter available only Rotate [step: 0.1] when the stitch welding is set to ON). Press, 0–5 s Crater fill time after welding. hold, and [step: 0.1] rotate Rail Runner 2 – Operator’s Manual...
- Page 23 1–10 Loads the configuration saved under the chosen Rotate program number. No. 1 is factory default. Default, Filler, Sample name to describe the loaded configuration. Press, Linear, Root, hold, and Segment, Top rotate Rail Runner 2 – Operator’s Manual...
- Page 24 To stop the travel, set the travel direction switch to ‘O’. After the work is finished, use the power switch to turn off the power. Then, unplug the carriage from the power source. Rail Runner 2 – Operator’s Manual...
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Page 25: Adjusting The Pressure Of Rollers
If the carriage travels smoothly, use the 2.5 mm hex wrench to prevent rotation of each screw (4). Then, use the 8 mm flat wrench to tighten the nuts (3). Fig. 13. Adjusting the pressure of rollers Rail Runner 2 – Operator’s Manual... -
Page 26: Adapting For Seam Tracking (Option)
Make sure that the carriage travels to the direction shown in Fig. 14 to be able to track the seam correctly. Travel direction Fig. 14. Changing the basic configuration to seam tracking configuration Rail Runner 2 – Operator’s Manual... - Page 27 If the vertical slide is not used, connect the sensor to the carriage with the 1 m (3 ft) signal cable. 0.75 m (2.5 ft) signal cable 0.5 m (1.5 ft) signal cable Fig. 15. Connecting the tracking sensor to the carriage Rail Runner 2 – Operator’s Manual...
- Page 28 Install the torch into the torch holder. Then, tilt the rod of the sensor against the workpiece so that there is tension in the rod. Next, put the tip in the welding seam (Fig. 16). Fig. 16. Setting the tracking sensor correctly in the welding seam Rail Runner 2 – Operator’s Manual...
- Page 29 Then, the oscillator, the vertical slide, and the torch, are moved to maintain the correct position above the seam. Fig. 17. Torch moves with small changes in position of the seam Rail Runner 2 – Operator’s Manual...
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Page 30: Troubleshooting
Contact service center for check communication. and repair. Motor overload. Adjust the position of the cables so that they do not block the travel. Remove other objects that block the carriage or the drive gear. Rail Runner 2 – Operator’s Manual... -
Page 31: Maintenance
3. Clean the torch nozzle. Replace if damaged. Monthly: 1. Make sure that the knobs and the switches work as intended. Replace if loose or damaged. 2. Examine cables, cords, and hoses. Replace if damaged. 3. Tighten screws if loose. Rail Runner 2 – Operator’s Manual... -
Page 32: Accessories
Allows the carriage to track the welding seam. Part number: CZJ-0523-07-00-01-1 5.2. Tracking sensor tips Allow seam tracking in various applications. Part number: WSP-0523-07-01-13-0 (rod required for sensor tips) Part number: ADT-0506-40-00-00-0 Part number: ADT-0506-41-00-00-0 Part number: ADT-0506-43-00-00-0 Rail Runner 2 – Operator’s Manual... -
Page 33: Motorized Vertical Slide
Allows the vertical position of the torch to be controlled. Part number: OSK-0523-06-00-01-1 5.4. 0.5 m (1.5 ft) signal cable Required for connecting the motorized vertical slide to the tracking sensor. Part number: PWD-0523-07-01-09-0 Rail Runner 2 – Operator’s Manual... -
Page 34: Semi-Flexible Track
Allows guiding the carriage along a straight line. The length of a single rail is 2 m (6.5 ft). Part number: PRW-0482-47-00-00-0 5.7. Rack adjustment tool Removes the clearance between the racks of two semi-flexible rails that are put on a curve. Part number: PKT-0341-13-00-00-0 Rail Runner 2 – Operator’s Manual... -
Page 35: Contact Block
Use two blocks to close the track and limit the travel path to a section. To install the contact block on a semi-flexible or rigid track, use the 6 mm hex wrench. Part number: ZDR-0523-76-00-00-0 Rail Runner 2 – Operator’s Manual... -
Page 36: Magnetic Units
50% (600 N, 130 lbs) 120°C (248°F) 200°C (392°F) Use the 4 mm hex wrench to attach the unit to a semi-flexible or rigid track as shown in the figures. M6x35 M6x16 M6x20 M6x16 Rail Runner 2 – Operator’s Manual... - Page 37 50% (600 N, 130 lbs) 120°C (248°F) Install the unit in the same way as the magnetic unit is installed. To adjust the angle, use the 6 mm hex wrench and loosen four side screws. Rail Runner 2 – Operator’s Manual...
- Page 38 50% (600 N, 130 lbs) 120°C (248°F) Install the unit in the same way as the magnetic unit is installed. To adjust the spacing, use the 5 mm hex wrench and loosen four side screws. Rail Runner 2 – Operator’s Manual...
- Page 39 Use the 4 mm hex wrench to attach the unit to a semi-flexible or rigid track as shown in the figures. M6x16 M6x35 M6x16 To clamp the unit to the surface, use the 17 mm flat wrench (not included) and set the side screw to ON. Rail Runner 2 – Operator’s Manual...
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Page 40: Semi-Flexible Track Support
5.10. Semi-flexible track support Allows supporting a semi-flexible track by using the support instead of a magnetic unit. Use the 4 mm hex wrench to attach the support to a semi-flexible track. Part number: WSP-0523-12-01-00-1 M6x16 Rail Runner 2 – Operator’s Manual... -
Page 41: Vacuum Track System
Dedicated to clamping the track to non-ferromagnetic surfaces. Part number (vacuum pump with safety reservoir): AGR-0541-24-10-00-0 (115 V US) AGR-0541-24-20-00-0 (230 V CEE) Other parts of the system are described in a related manual. Rail Runner 2 – Operator’s Manual... -
Page 42: Ring Tracks
TRO-0523-78-00-00-0 TRO-0523-20-00-00-0 TRO-0523-21-00-00-0 TRO-0523-23-00-00-0 TRO-0523-24-00-00-0 TRO-0523-25-00-00-0 TRO-0523-26-00-00-0 TRO-0523-22-00-00-0 TRO-0523-28-00-00-0 TRO-0523-29-00-00-0 TRO-0523-30-00-00-0 TRO-0523-31-00-00-0 TRO-0523-32-00-00-0 TRO-0523-33-00-00-0 1000 TRO-0523-34-00-00-0 1000 1050 TRO-0523-35-00-00-0 1050 1100 TRO-0523-36-00-00-0 1100 1150 TRO-0523-37-00-00-0 1150 1200 TRO-0523-38-00-00-0 1200 1250 TRO-0523-39-00-00-0 1250 1300 TRO-0523-40-00-00-0 Rail Runner 2 – Operator’s Manual... - Page 43 TRO-0523-64-00-00-0 2500 2550 TRO-0523-65-00-00-0 2550 2600 TRO-0523-66-00-00-0 2600 2650 TRO-0523-67-00-00-0 2650 2700 TRO-0523-68-00-00-0 2700 2750 TRO-0523-69-00-00-0 2750 2800 TRO-0523-70-00-00-0 2800 2850 TRO-0523-71-00-00-0 2850 2900 TRO-0523-72-00-00-0 2900 2950 TRO-0523-73-00-00-0 2950 3000 TRO-0523-74-00-00-0 3000 3050 TRO-0523-75-00-00-0 Rail Runner 2 – Operator’s Manual...
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Page 44: Ring Track Supports
Rail Runner 2 5.13. Ring track supports 5.13.1. Ring track support with bolts Part number: WSP-0523-14-02-00-0 5.13.2. Ring track support with plastic feet Part number: WSP-0523-14-11-00-0 5.13.3. Ring track support with magnets Part number: WSP-0523-14-12-00-0 Rail Runner 2 – Operator’s Manual... -
Page 45: Torch Clamps
The clip allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Use the 4 mm hex wrench to tighten the torch in the clip. Part number: ZCS-0476-06-01-00-0 5.14.3. 22–35 mm torch clamp Allows using a torch with the diameter of 22–35 mm (0.87–1.38″). Part number: ZRZ-0466-19-00-00-0 Rail Runner 2 – Operator’s Manual... -
Page 46: Rods
Rail Runner 2 5.15. Rods 5.15.1. Short rod Provides a 120 mm (4.7″) reach. Part number: WLK-0476-20-01-00-0 5.15.2. Long rod Provides a 240 mm (9.4″) reach. Part number: WLK-0466-04-10-00-0 Rail Runner 2 – Operator’s Manual... -
Page 47: Torch Holders
5.16.3. Short rod low torch holder with clip The holder allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Use the 4 mm hex wrench to tighten the torch in the clip. Part number: UCW-0476-06-00-00-0 Rail Runner 2 – Operator’s Manual... - Page 48 5.16.5. Long rod torch holder with clip The holder allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Use the 4 mm hex wrench to tighten the torch in the clip. Part number: UCW-0466-22-00-00-0 Rail Runner 2 – Operator’s Manual...
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Page 49: Transport Attachment
(5/8–7/8″). Can work with an optional seam tracking attachment. To work without the attachment, use a 203 mm rod and a clamping clock. Part number: Part number: OSC-0497-24-00-00-0 KLM-0236-00-16-00-0 (203 mm rod) KST-0525-11-00-00-0 (Clamping block) Rail Runner 2 – Operator’s Manual... - Page 50 (8″) rod and a clamping block (1). Then, use the 80 mm (3″) rod to put the oscillator onto the carriage (2). Next, set the switch to the center position (3) and connect the oscillator to the carriage (4). Part number: KLM-0236-00-16-00-0 (203 mm rod) KST-0525-11-00-00-0 (Clamping block) Rail Runner 2 – Operator’s Manual...
- Page 51 To use the oscillator with seam tracking, put the oscillator onto the carriage with the installed seam tracking attachment (1). Next, set the switch to the center position (2) and connect the oscillator to the tracking sensor (3). Rail Runner 2 – Operator’s Manual...
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Page 52: Wiring Diagram
Rail Runner 2 6. WIRING DIAGRAM Rail Runner 2 – Operator’s Manual... - Page 53 Rail Runner 2 Rail Runner 2 – Operator’s Manual...
- Page 54 Rail Runner 2 Rail Runner 2 – Operator’s Manual...
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Page 55: Exploded Drawings And Parts List
POWER SUPPLY – 115V ZSL-0523-97-00-01-0 POWER SUPPLY – 42V ZSL-0523-97-00-02-0 UCW-0476-27-00-00-0 SHORT ROD TORCH HOLDER WITH CLIP ZCS-0476-06-01-00-0 TORCH HOLDER CLAMP ASSY SRB-000087 HEX SOCKET HEAD CAP SCREW M5x25 WLK-0476-20-01-00-0 SHORT ROD ASSY TLJ-0419-04-02-03-0 INSULATION TUBE Rail Runner 2 – Operator’s Manual... - Page 56 REMOTE CONTROL CABLE L=3 M (10 ft) ZDR-0523-76-00-00-0 CONTACT BLOCK ASSY SRB-000098 HEX SOCKET HEAD CAP SCREW M5x8 ZDR-0523-76-02-00-0 CONTACT BLOCK UCW-0523-76-01-00-0 CONTACT BLOCK HOLDER SRB-000140 HEX SOCKET HEAD CAP SCREW M8x12 *not shown in the drawing Rail Runner 2 – Operator’s Manual...
- Page 57 Rail Runner 2 Rail Runner 2 – Operator’s Manual...
- Page 58 CROSS RECESSED PAN HEAD SCREW M3x6 PDK-000013 ROUND WASHER 3.2 TLJ-000051 HEX SLEEVE OSL-0523-03-09-00-0 DISPLAY COVER MDL-0523-03-03-00-0 PANEL MODULE TLJ-000023 SLEEVE M3x10 NKR-000009 HEX NUT M3 MDL-0523-03-11-00-0 CONTROLLER MODULE PLY-0523-03-01-00-0 BOTTOM PLATE CHW-0523-03-07-00-0 PANEL MAGNET HOLDER Rail Runner 2 – Operator’s Manual...
- Page 59 HEX SOCKET HEAD CAP SCREW M4x8 PLY-0523-02-17-00-0 INTERMEDIATE PLATE OSL-0523-02-05-00-0 OSCILLATOR COVER ASSY SRB-000174 HEX SOCKET LOW HEAD BOLT M5x16 PLY-0523-02-04-00-0 MOUNTING PLATE DCS-0523-02-19-00-0 BELT TENSIONER UCW-0523-02-09-00-0 BELT HOLDER SRB-000067 HEX SOCKET HEAD CAP SCREW M4x40 Rail Runner 2 – Operator’s Manual...
- Page 60 ZDR-0523-02-11-00-0 BUMPER SRB-000377 HEX SOCKET HEAD CAP SCREW M3x20 PRW-000067 LINEAR GUIDE DYS-0523-02-16-00-0 SPACER II WZK-0523-02-13-00-0 LEFT LIMIT SWITCH WIRE SET WZK-0523-02-14-00-0 RIGHT LIMIT SWITCH WIRE SET PLY-0523-02-01-00-0 OSCILLATOR PLATE NKR-000035 NUT SHORT M6 Rail Runner 2 – Operator’s Manual...
- Page 61 WKR-000091 HEX SOCKET BUTTON HEAD SCREW M4x8 WKR-000313 HEX SOCKET BUTTON HEAD SCREW M3x8 PNK-000059 POWER SWITCH GNZ-000053 FEMALE SOCKET 6-PIN DLW-000042 CABLE GLAND WITH STRAIN RELIEF OSL-0523-01-05-01-0 TOP COVER NKR-000010 HEX NUT M3 Rail Runner 2 – Operator’s Manual...
- Page 62 PRESSURE ROLLER PDK-000173 SPACER WASHER 8x14x1 PRS-000014 INTERNAL RETAINING RING 22w SRB-000030 FULL THREAD HEX HEAD BOLT M8x30 SRB-000310 HEX SOCKET HEAD CAP SCREW M3x10 ZST-0341-99-01-00-0 GEAR ASSY SRB-0523-01-03-03-0 FEED SCREW SPR-000010 DISC SPRING 6.2x12.5x0.6 Rail Runner 2 – Operator’s Manual...
- Page 63 LIMIT SWITCH WIRE SET 79* BZP-000054 BLADE FUSE 7.5A PDK-000013 ROUND WASHER 3.2 81* WZK-0523-01-10-00-0 ARC IGNITION WIRE SET OSL-0523-01-02-08-0 BOTTOM GEAR COVER WKR-000180 CROSS RECESSED PAN HEAD SCREW M3x5 * not shown in the drawing Rail Runner 2 – Operator’s Manual...
- Page 64 CROSS RECESSED PAN HEAD SCREW M3x5 MDL-0523-09-04-01-0 PRIMARY SIDE MODULE – 230V MDL-0523-09-04-02-0 PRIMARY SIDE MODULE – 115V MDL-0523-09-04-03-0 PRIMARY SIDE MODULE – 42V MDL-0523-09-05-00-0 SECONDARY SIDE MODULE TLJ-000023 SLEEVE M3x10 NKR-000010 HEX NUT M3 Rail Runner 2 – Operator’s Manual...
- Page 65 WZK-0523-09-06-03-0 PRIMARY SIDE WIRE SET – 42V PWD-0461-17-00-00-2 POWER CORD – 230V – AU PWD-0461-17-00-00-3 POWER CORD – 230V – INDIA PWD-0461-17-00-00-4 POWER CORD – 230V – TYPE G DLW-000007 CABLE GLAND WITH STRAIN RELIEF PG11 Rail Runner 2 – Operator’s Manual...
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Page 66: Declaration Of Conformity
• EN 60974-10 and satisfies safety regulations of the guidelines: 2004/108/EC, 2006/95/EC, 2006/42/EC. Person authorized to compile the technical file: Marek Siergiej, ul. Elewatorska 23/1, 15-620 Białystok Białystok, 17 December 2015 ___________________________ Marek Siergiej Rail Runner 2 – Operator’s Manual... -
Page 67: Warranty Card
WARRANTY CARD No..................in the name of Manufacturer warrants the Rail Runner 2 Welding Carriage to be free of defects in material and workmanship under normal use for a period of 12 months from the date of sale. This warranty does not cover rollers as well as damage or wear that arise from misuse, accident, tempering, or any other causes not related to defects in workmanship or material.
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