ESAB Railtrac BV1000 Instruction Manual
  1. Manuals
  2. Brands
  3. ESAB Manuals
  4. Welding System
  5. Railtrac BV1000
  6. Instruction manual
ESAB Railtrac BV1000 Instruction Manual

ESAB Railtrac BV1000 Instruction Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Railtrac
BV1000/BVR1000
104
Instruction manual
0777 169
001
2011- -09- -21
Valid for Serial NO 948 XXX- -XXXX

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Railtrac BV1000 and is the answer not in the manual?

Questions and answers

Related Manuals for ESAB Railtrac BV1000

Summary of Contents for ESAB Railtrac BV1000

  • Page 1 Railtrac BV1000/BVR1000 Instruction manual 0777 169 2011- -09- -21 Valid for Serial NO 948 XXX- -XXXX...
  • Page 2 ENGLISH ..........Rights reserved to alter specifications without notice.

  • Page 3: Table Of Contents

    ENGLISH 1 DIRECTIVE ............2 SAFETY .

  • Page 4: Directive

    DIRECTIVE DECLARATION OF CONFORMITY ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that auto- matic welding machine Railtrac BV1000/BVR1000 from serial number 948 (1999 w.48) complies with standard EN 12100--2 and EN 60204--1, in accordance with the requirements of directive (98/37/EEC) and with standard EN 61000--6--2 and also EN 61000--6--3, in accordance with the requirements of directive (2004/108/EEC).
  • Page 5 WARNING ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU- TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS’ 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.

  • Page 6: Introduction

    INTRODUCTION General Railtrac BV1000 (with weaving unit) and Railtrac BVR1000 (with weaving unit and adjustable start, stop and return facilities) are two machines designed for repair welding and cladding of rail sections. The welding can be performed by way of weaving across the rail, longitudinal welding or frame welding.

  • Page 7: Technical Data

    By way of the remote control unit the operator can start and stop the carriage (with or without welding), set the travel direction and the travel length, start the weaving and select increasing/decreasing welding width for the start and stop distances. It is also possible to adjust the width of the weaving and the 0--line in the course of welding.

  • Page 8: Installation

    INSTALLATION General The installation shall be executed by a professional. Connections Wire feed unit MED304/MEH44 Adaptation set 0443 341 880 Control cable 5m 0457 360 883 Universal 230 V Transformer 0457 467 880 Control cable 5m 0457 360 881 - - 8 - - fta3i1ea...

  • Page 9: Assembly

    Assembly For the assembly of the rail brackets, the carriage, the welding torch attachment and for the connection of the control box, please follow the instructions below. Mount the rail brackets on the aluminium rail. Fit the brackets across the rail and secure. Adjust the aluminium rail by way of the gauges.
  • Page 10 Tighten the lock screw. Fit the attachment of the torch. Connect the remote control unit, the carriage and the voltage supply cable to the control box. Press the 0--line button for automatic positioning. Fit the welding torch. Select a program. Start welding.

  • Page 11: Operation

    OPERATION General General safety regulations for the handling of the equipment appear from page 4. Read through before you start using the equipment! Frontpanel- -Travelcarriage Program selection: BV contains four different programs (P1--P4) and BVR six ones (P1--P6). Menu selector: For the programming of basic values (to be done by a service technician).

  • Page 12: Front Panel -- Weaving Unit

    Front Panel - - Weaving Unit The desired length of the start section in cm (program 3). Length: Menu selector: Programming of basic values (to be done by a service techni- cian). Weaving width: The desired weaving width in mm (P1--P3); in P4, the dis- tance between the longitudinal joints.

  • Page 13: Line Adjustment

    0- -line Adjustment The 0--line can start either from the inner or from the outer side of the rail. The 0--line must be adjusted each time the voltage is switched on (green LED in button (2) flashes). Inner 0- - line The red lamp (1) must be off.

  • Page 14: Program

    Program The BV version offers four program selections (P1- - P4) and the BVR six ones (P1- -P6). The programs 1--3 are made for welding with weaving motion, 4 and 6 for longitudinal welding. Program 5 is for frame welding and is to be programmed before program 6.
  • Page 15 Program 2 = P2 Select termination angle: 90° , 45° or 22° (see pos. 4 on page 12) Normal weaving Start angle: 45° (in P2 the angle of the start distance always is 45° ) 1. Program the weaving width in mm. 2.
  • Page 16 Program 4 = P4 Longitudinal welding Program the welding speed in cm/min Red lamp is to light. Program the distance between the runs in mm. Program P5 and P6 (for BVR) Program 5 = P5 Before start the travel carriage must be positioned on the starting point (indicated by a red lamp).
  • Page 17 Program 6 = P6 Program 6 is for filling the frame. The welding stops when the frame is filled up. Frame welding Program the welding speed in cm/min. Program the distance between the runs in mm. Program the width in mm. Red lamp is to light.

  • Page 18: Remote Control Unit

    Remote Control Unit For travel in the direction of the arrow: For travel in the direction of the arrow: Click START SPEED+ once. Click START SPEED- - once. For rapid transport: Hold down for two For rapid transport: Hold down for two seconds.
  • Page 19 For increase or decrease of the advancing speed in the course of welding. 0- -line displacement Changing the weaving width To step up by one program: To step down by one program: Hold down NEXT. Then click SPEED+. Hold down NEXT. Then click SPEED- - . Remote control of the welding volt- Remote control of the welding cur- rent...
  • Page 20 Changing from normal weaving width Changing from normal weaving width to decreasing width to the left: to decreasing width to the right: Double- - click on +. Double- - click on - - . Going over from rapid transport to welding: Double- - click (Applies only to program 4) Welding transport (welding OFF).

  • Page 21: Maintenance

    ORDERING OF SPARE PARTS Spare parts are ordered through your nearest ESAB representative, see back cover. When ordering spare parts, please state machine type and number as well as desig- nation and spare part number as shown in the spare parts list on page 23.
  • Page 22 - - 22 - - sida...

  • Page 23: Spare Parts List

    Spare parts list Edition 2000- -02- -09 - - 23 - - fta3rfram...
  • Page 24 Item Ordering no. Denomination Notes Carriage 0398145501 Plastic cover 0398145509 Motor box BV 0398145503 Cable release 0398145525 Motor cable 0398145290 Inductive sensor (BVR) 0398145506 Torch cable release 0398145507 Cable bracket 0398145508 Drive wheel bracket 0398145510 Distance with screw 0398145511 Locking arm 0398145512 Lock screw 0398145513...
  • Page 25 Item Ordering no. Denomination Notes Weaving unit 0398145631 Alu cover 0398145632 Backplate 0398145606 Time belt 0398145607 Motor w. belt wheel 0398145633 Weaving guide 0398145610 Inductive sensor 0398145611 Frontplate 0398145612 Guide bracket 0398145634 Steering bars 0398145635 Outer guide 0398145636 Bottom plate - - 25 - - fta3s11a...
  • Page 26 Item Ordering no. Denomination Notes Slide 0398145801 Slide bracket 0398145802 Bushing 0417855009 Lever 0398145803 0398145804 Slide house 0417855001 Knob 0398145805 Disc 0398145806 Straight slide bracket 0398145807 Bracket plate 0398145808 Intermediate bracket 0398145101 Torch holder PSF 0398145100 Torch holder Universal - - 26 - - fta3s11a...
  • Page 27 Item Ordering no. Denomination Notes 0398145177 Control box complete BV 1000 0398145180 Control box complete BVR 1000 0398146901 Controlbox cabinet 0398145903 Magnet box 0417855010 Stop button 0398145909 19--pin female chassis 0398145908 12--pin male chassis 0398145906 12--pin female chassis 0398145926 Control unit carriage BV 1000 0398145928 Control unit carriage...
  • Page 28 Item Ordering no. Denomination Notes 0398145190 Rail bracket complete (Item no. 1- -6) 0398145401 Knob 0398145402 Alu--bracket 0398145403 Guide 0398145404 Rail bracket 0398145405 Screw 0398145406 Locking screw 0398145122 BV--rail 2m 0398145115 Start/stop bracket (2 pcs) - - 28 - - fta3s11a...
  • Page 29 - - 29 - - sida...
  • Page 30 ESAB Romania Trading SRL ESAB VAMBERK s.r.o. SOUTH AFRICA ESAB Mexico S.A. Bucharest Vamberk ESAB Africa Welding & Cutting Ltd Monterrey Tel: +40 316 900 600 Tel: +420 2 819 40 885 Durbanvill 7570 - Cape Town Tel: +52 8 350 5959...

This manual is also suitable for:

Railtrac bvr1000

Table of Contents