SteelMax Rail Runner 2 Manual de usuario

The tools of innovation.

15335 E. Fremont Drive, Centennial, CO 80112

1–87STEELMAX, FAX 303–690–9172

www.steelmax.com sales@steelmax.com

OPERATOR’S MANUAL

WELDING CARRIAGE

Contents 
 
GENERAL INFORMATION............................................................................................... 3 
1. Application................................................................................................................. 3 
2. Technical data............................................................................................................ 4 
3. Equipment included ................................................................................................... 5 
4. Dimensions................................................................................................................ 6 
5. Design ....................................................................................................................... 7 
SAFETY PRECAUTIONS.................................................................................................. 8 
STARTUP AND OPERATION..........................................................................................10 
1. Assembling the semi-flexible or rigid track ................................................................10 
2. Assembling the ring track..........................................................................................12 
3. Positioning on a straight track...................................................................................14 
4. Positioning on a curved track....................................................................................16 
5. Preparing and connecting.........................................................................................17 
6. Connecting to the welding circuits.............................................................................18 
7. Operating..................................................................................................................19 
8. Adjusting the pressure of rollers................................................................................25 
9. Adapting for seam tracking (option)...........................................................................26 
10. Troubleshooting ......................................................................................................30 
MAINTENANCE...............................................................................................................31 
ACCESSORIES...............................................................................................................32 
1. Seam tracking attachment.........................................................................................32 
2. Tracking sensor tips..................................................................................................32 
3. Motorized vertical slide..............................................................................................33 
4. 0.5 m (1.5 ft) signal cable..........................................................................................33 
5. Semi-flexible track.....................................................................................................34 
6. Rigid track.................................................................................................................34 
7. Rack adjustment tool.................................................................................................34 
8. Contact block............................................................................................................35 
9. Magnetic units...........................................................................................................36 
10. Semi-flexible track support......................................................................................40 
11. Vacuum track system..............................................................................................41 
12. Ring tracks..............................................................................................................42 
13. Ring track supports.................................................................................................44 
14. Torch clamps ..........................................................................................................45 
15. Rods .......................................................................................................................46 
16. Torch holders..........................................................................................................47 
17. Transport attachment..............................................................................................49 
18. Pendulum oscillator.................................................................................................49 
WIRING DIAGRAM..........................................................................................................52 
EXPLODED DRAWINGS AND PARTS LIST....................................................................55 
DECLARATION OF CONFORMITY.................................................................................66 
WARRANTY CARD..........................................................................................................67 

Rail Runner 2

Rail Runner 2 –Operator’s Manual

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.

Accessories allow, for example, using torches with a larger diameter, guiding

the carriage on a semi-flexible, rigid, or ring track, and tracking the welding seam.

Using a vacuum track system allows the track to be clamped to surfaces that are

non-ferromagnetic.

Two intended configurations are shown in the figure that follows.

Basic configuration

Configuration with seam tracking in two

axes (requires an optional tracking

attachment and a motorized vertical slide)

Travel direction

Rail Runner 2

Rail Runner 2 –Operator’s Manual

1.2. Technical data

Voltage

1~ 230 V, 50–60 Hz

1~ 115 V, 50–60 Hz

1~ 42 V, 50–60 Hz (60 V DC)

Power

120 W

Welding position

(according to EN ISO 6947 and

AWS/ASME)

Horizontal

PA / 1F / 1G

PB / 2F

PC / 2G

PD / 4F

PE / 4G

Vertical

PF / 3G

PG / 3F (contact your dealer)

PG / 3G

Outer diameter

of round workpiece

Ring tracks

200 mm (8″) – 3 m (10 ft)

Custom rolled tracks

3 m (10 ft) –10 m (32 ft)

(contact your dealer)

Semi-flexible tracks

Minimum 10 m (32 ft)

Torch type

MIG/MAG, oxy-fuel, plasma

MIG/MAG torch diameter

16–22 mm (0.63–0.87″)

Minimum workpiece thickness for magnetic clamping

5 mm (0.2″)

Horizontal pulling force

400 N (88 lbs)

Vertical pulling force

300 N (66 lbs)

Horizontal speed

0–300 cm/min (0–120 in/min)

Vertical speed

0–300 cm/min (0–120 in/min)

Oscillation type

Linear

Weld path

Straight, triangle, trapezoid, square

Oscillation width

0.2–11.8 cm (0.1–4.5″)

Oscillation speed

10–300 cm/min (5–120 in/min)

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

80%

Protection level

IP 23

Weight

10 kg (22 lbs)

Rail Runner 2

Rail Runner 2 –Operator’s Manual

1.3. Equipment included

Carriage

1 unit

Plastic box

1 unit

Remote control

1 unit

Contact block

1 unit

300 mm (12″) rod

1 unit

300 mm (12″) rack with 180 mm (7″) adjustment

1 unit

Rack holder

1 unit

Clamping block with levers

1 unit

Short rod torch holder with clip

1 unit

Cable anchor

1 unit

6 mm hex wrench

1 unit

6.5 m (21 ft) arc ignition cable

1 unit

5 m (17 ft) power cable

1 unit

3 m (10 ft) remote control cable

1 unit

Power supply*

1 unit

–

Operator’s Manual

1 unit

* 230 V, 115 V, or 42 V depending on the order

Rail Runner 2

Rail Runner 2 –Operator’s Manual

1.4. Dimensions

470 mm (18.5″)

195 mm (7.7″)

318 mm (12.5″)

267 mm (10.5″)

350 mm (13.8″)

73 mm (2.9″)

131 mm (5.2″)

354 mm (13.9″)

121 mm (4.8″)

Rail Runner 2

Rail Runner 2 –Operator’s Manual

1.5. Design

Arc ignition socket

Carrying handle

Power cord

Rod holder

Passive roller

Knob to attach the remote

control to the carriage

Power switch

Carriage / 3 m (10 ft) remote

control cable connection

Remote control / 3 m (10 ft) remote control cable /

tracking sensor / motorized vertical slide connection

5 m (17 ft) power cable connection

Drive clutch knob

Pressing lever (pressing

rollers are loose in this position)

Pressing roller

Limit switch

Drive gear

Install bracket

Display guard

Rail Runner 2

Rail Runner 2 –Operator’s Manual

2. SAFETY PRECAUTIONS

1. Before you start, read this Operator’s Manual and complete occupational safety

and health training.

2. Use the carriage, power supply, remote control, and other equipment only in

applications specified in this Operator’s Manual.

3. Make sure that the carriage, power supply, remote control, and other equipment

have all parts. Make sure that all parts are genuine and not damaged.

4. Make sure that the specifications of the power source are the same as those

specified on the rating plate.

5. Connect the carriage to the power supply by using the power cable. Connect the

power supply to a correctly grounded power source.

6. Do not carry the carriage, remote control, and other equipment by cords or cables.

Do not pull the cords or cables. This can cause damage and electric shock.

7. Keep untrained bystanders away from the carriage.

8. Before you start, ensure the correct condition of the carriage, power supply, remote

control, and other equipment, power source, cords and cables, connections, rollers,

and gear.

9. Keep the carriage, power supply, remote control, and other equipment dry. Do not

expose them to rain, snow, or frost.

10. Keep the work area well lit, clean, and free of obstacles.

11. Do not use near flammable materials, or in explosive environments.

12. Transport and position the carriage by using the carrying handles.

13. Install the carriage only on the supplied track.

14. Make sure that the gear and rollers are clean.

15. Plug the cords and cables into sockets only after you set the power switch to ‘O’.

16. Keep the sockets clean. Do not use high pressure during cleaning.

17. Install only torches whose diameter matches the diameter of the torch holder.

18. Hang the cables to decrease the load of the carriage.

19. Do not bend the semi-flexible track to a radius less than 5 m (16 ft).

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

Rail Runner 2 –Operator’s Manual

flexible or rigid track to a stable structure. To protect the carriage, attach a chain

to a carrying handle. Make sure that the chains are not loose.

22. Do not stay below the carriage or the track that is put at heights.

23. Use eye protection (helmet, shield, and screen), hearing protection, gloves, and

protective clothing during work. Do not use loose clothing.

24. Before each use, make sure that the carriage is not damaged and no part is

cracked or loose. Make sure to maintain correct conditions that can have an

effect on the operation of the carriage.

25. Do not try to stop the travel by hand. To stop, set the travel direction switch to ‘O’.

26. Maintain only after you unplug the carriage from the power source.

27. Repair only in a service center appointed by the seller.

28. If the carriage falls from any height, is wet, or has any damage, stop the work and

promptly send the carriage to the service center for check and repair.

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

Rail Runner 2 –Operator’s Manual

3. STARTUP AND OPERATION

3.1. Assembling the semi-flexible or rigid track

Connect magnetic units to the rail, and put it on the workpiece. Use the 4 mm hex

wrench to attach more rails (1, Fig. 1). Then, set the levers of the magnetic units to ‘I’

(2). This will clamp the track to the surface.

When working in PC/2G welding position, put the track so that the teeth of the

racks point down.

Fig. 1. Connecting the rails and clamping the magnetic units to the surface

If a semi-flexible rail is put on a curve, before you attach more rails use the 4 mm hex

wrench to loosen the screws of the connecting plates (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

left (4) to remove the gap (5) between the racks. Then, tighten the leftmost screw and

the rightmost screw of each rack (2).

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