Related Manuals for SteelMax Rail Runner 2
Summary of Contents for SteelMax Rail Runner 2
- Page 1 The tools of innovation. OPERATOR’S MANUAL WELDING CARRIAGE 15335 E. Freemont 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 hi-flex, semi-flex, and 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 conden- sation 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 Mounting bracket Limit switch Pressing roller Drive gear Pressing lever (pressing roll- ers are loose in this position) Rail Runner 2 – Operator’s Manual... -
Page 8: Safety Precautions
20. Do not bend the hi-flex track to a radius less than 0.75 m (2.5 ft). 21. Do not bend the semi-flex track to a radius less than 5 m (16 ft). 22. Use the rigid track only on flat surfaces. Rail Runner 2 – Operator’s Manual... - Page 9 30. Do not leave the carriage unattended during work. 31. 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
(1, Fig. 2) and of the racks (2). Next, attach the rails, clamp them with levers, and then tighten the connecting plates. Put the rack adjustment tool (not included) into the hole (3), and rotate the tool to the Rail Runner 2 – Operator’s Manual... - Page 11 (4) to remove the gap (5) between the racks. Then, tighten the leftmost screw and the rightmost screw of each rack (2). Fig. 2. Removing the gap between the racks of a semi-flex 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 mounting brackets are on the rail (4, 5). Gear retracted Mounting bracket Mounting bracket Fig. 6. Putting the carriage on a straight track Rail Runner 2 – Operator’s Manual... - Page 15 Move the carriage slightly back and forth to make sure that there is a backlash. 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
Then, tighten the screws (1) and use the knob (4) to engage the gear with the rack as described in “Positioning on a straight track”. 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 ena- ble the arc for a while. Rail Runner 2 – Operator’s Manual... -
Page 19: Operating
Operating mode Direction switch Oscillation switch (Forward/O/Backward) (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 [step: 0.05/0.02] From –2.5 to +2.5 cm Torch height (when the From –1 to +1 in vertical slide is con- Rotate [step: 0.02/0.01] nected). 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 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 direction switch to ‘O’. After the work is finished, use the power switch to turn off the carriage. 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 moves 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
Controller failure or no communication. Contact service center for check and repair. Motor overload. Adjust the position of the cables so that they do not block the carriage. Remove obstacles that block the car- riage or the drive gear. Rail Runner 2 – Operator’s Manual... -
Page 31: Maintenance
Each month: 1. Make sure that the knobs and the switches work as intended. Replace if they are loose or damaged. 2. Examine cables and cords, and 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: Hi-Flex Track
If you need to use more units, use narrow magnetic units. Part number (rail): TRO-0673-00-00-00-0 Part number (rollers for hi-flex track): ZSP-0673-07-00-00-0 Use the 13 mm flat wrench to remove the standard rollers and install the rollers for hi- flex track. Rail Runner 2 – Operator’s Manual... -
Page 35: Semi-Flex 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 5.8. Rack adjustment tool Removes the clearance between the racks of two semi-flex rails that are put on a curve. Part number: PKT-0341-13-00-00-0 Rail Runner 2 – Operator’s Manual... -
Page 36: Contact Block
Use two blocks to close the track and limit the travel path to a section. Part number Part number (for semi-flex and rigid track): (for hi-flex track): ZDR-0523-76-00-00-0 ZDR-0673-08-00-00-0 Rail Runner 2 – Operator’s Manual... -
Page 37: Magnetic Units
75% (900 N) 80°C (176°F) 75% (900 N) 50% (600 N) 120°C (248°F) 50% (600 N) Use the 4 mm hex wrench to attach the unit to the tracks as shown in the figures. Rail Runner 2 – Operator’s Manual... - Page 38 Rail Runner 2 M6x16 M6x16 M6x20 M6x20 M6x35 M6x16 Rail Runner 2 – Operator’s Manual...
- Page 39 80°C (176°F) 50% (600 N) 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 40 50% (600 N) 120°C (248°F) Install the unit in the same way as the magnetic unit is installed. To adjust the spac- ing, use the 5 mm hex wrench and loosen four side screws. Rail Runner 2 – Operator’s Manual...
- Page 41 20°C (68°F) 75% (750 N) 80°C (176°F) 50% (500 N) 120°C (248°F) Use the 4 mm hex wrench to attach the unit to the tracks as shown in the figures. M6x16 M6x16 M6x16 M6x16 Rail Runner 2 – Operator’s Manual...
- Page 42 5.11. Semi-flex track support Allows supporting a semi-flex track by using the support instead of a magnetic unit or narrow magnetic unit. Use the 4 mm hex wrench to attach the support. Part number: WSP-0523-12-01-00-1 M6x16 Rail Runner 2 – Operator’s Manual...
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Page 43: Vacuum Track System
Allows clamping a hi-flex, semi-flex, or rigid 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 44: Ring Tracks
Min. Max. [mm] [mm] TRO-0523-14-00-00-0 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 Rail Runner 2 – Operator’s Manual... - Page 45 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 46: Ring Track Supports And Bracket
5.14. Ring track supports and bracket Ring track support with bolts Part number: WSP-0523-14-02-00-0 Ring track support with plastic feet Part number: WSP-0523-14-11-00-0 Ring track support with magnets Part number: WSP-0523-14-12-00-0 Ring track bracket Part number: DYS-0523-14-14-00-0 Rail Runner 2 – Operator’s Manual... -
Page 47: Torch Holders, Clamps, And Rods
Short low rod torch holder with clip 16–22 mm Part number: UCW-0476-06-00-00-0 Long rod torch holder with clamp 16–22 mm Part number: UCW-0466-04-00-00-0 Long rod torch holder with clip 16–22 mm Part number: UCW-0466-22-00-00-0 Rail Runner 2 – Operator’s Manual... - Page 48 Rail Runner 2 Torch clamp 16–22 mm Part number: ZRZ-0466-04-01-00-0 Torch clip 16–22 mm Part number: ZCS-0476-06-01-00-0 Torch clamp 22–35 mm Part number: ZRZ-0466-19-00-00-0 Short rod Part number: WLK-0476-20-01-00-0 Long rod Part number: WLK-0466-04-10-00-0 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). Use the 80 mm (3″) rod to put the oscillator onto the carriage (2). Next, set the switch to the middle 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...
- Page 55 Rail Runner 2 Rail Runner 2 – Operator’s Manual...
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Page 56: 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 57 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 58 Rail Runner 2 Rail Runner 2 – Operator’s Manual...
- Page 59 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 60 HEX SOCKET HEAD CAP SCREW M4x8 PLY-0523-02-17-00-0 INTERMEDIATE PLATE OSL-0523-02-05-00-0 OSCILLATOR COVER ASSY SRB-000262 HEX SOCKET LOW HEAD BOLT M6x25 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 61 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 62 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 63 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 64 SRB-000310 HEX SOCKET HEAD CAP SCREW M3x10 RDT-0523-01-09-04-0 RADIATOR 2 PDK-0523-01-11-00-0 THERMAL WASHER SRB-000142 HEX SOCKET HEAD CAP SCREW M8x16 BZP-000084 SLOW BLOW FUSE 5x20, 5A T5A CERAMIC * not shown in the drawing Rail Runner 2 – Operator’s Manual...
- Page 65 Rail Runner 2 ITEM PART NUMBER DESCRIPTION Q-TY WZK-0523-09-10-00-0 LED WIRE WKR-000147 CROSS RECESSED COUNTERSUNK HEAD SCREW M3x12 UCW-0523-09-03-00-0 POWER SUPPLY HANDLE NKR-000015 HEX NUT M5 PDK-000044 SPRING WASHER 5.1 PDK-000017 ROUND WASHER 5.3 Rail Runner 2 – Operator’s Manual...
- Page 66 STP-000005 BRACKET 20 PWD-0461-17-00-00-0 POWER CORD - 230V PWD-0461-17-00-00-1 POWER CORD - 115V WZK-0523-09-06-03-0 PRIMARY SIDE WIRE SET - 42V DLW-000007 CABLE GLAND WITH STRAIN RELIEF PG11 SRB-000075 HEX SOCKET HEAD CAP SCREW M5x10 Rail Runner 2 – Operator’s Manual...
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Page 67: Declaration Of Conformity
• EN 60974-10 and satisfies 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, Poland Białystok, 17 December 2015 ___________________________ Marek Siergiej Rail Runner 2 – Operator’s Manual... -
Page 68: 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 workman- ship under normal use for a period of 12 months from the date of sale.
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