SteelMax Rail Runner 2 Manual de usuario

The tools of innovation.

15335 E. Freemont Drive, Centennial, CO 80112

1–87STEELMAX, FAX 303 –690 –9172

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 hi-flex, semi-flex, and 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. Hi-flex track...............................................................................................................34 
6. Semi-flex track..........................................................................................................35 
7. Rigid track.................................................................................................................35 
8. Rack adjustment tool.................................................................................................35 
9. Contact block............................................................................................................36 
10. Magnetic units........................................................... Error! Bookmark not defined. 
11. Semi-flex track support............................................................................................37 
12. Vacuum track system..............................................................................................43 
13. Ring tracks..............................................................................................................44 
14. Ring track supports and bracket..............................................................................46 
15. Torch holders, clamps, and rods.............................................................................47 
16. Transport attachment..............................................................................................49 
17. Pendulum oscillator.................................................................................................49 
WIRING DIAGRAM..........................................................................................................52 
EXPLODED DRAWINGS AND PARTS LIST....................................................................56 
DECLARATION OF CONFORMITY.................................................................................67 
WARRANTY CARD..........................................................................................................68 

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 using torches with a larger diameter, guiding the carriage on a

hi-flex, semi-flex, 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

Diameter

of round workpiece

Ring tracks (OD)

200 mm (8″) – 3 m (10 ft)

Hi-flex tracks (OD)

Minimum 1.5 m (5 ft)

Hi-flex tracks (ID)

Minimum 3.4 m (11 ft)

Custom rolled tracks (OD)

3–10 m (10–32 ft)

(contact your dealer)

Semi-flex tracks (OD)

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 conden-

sation

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 roll-

ers are loose in this position)

Pressing roller

Limit switch

Drive gear

Mounting bracket

Display guard

Rail Runner 2

Rail Runner 2 –Operator’s Manual

2. SAFETY PRECAUTIONS

1. Before use, read this Operator’s Manual and complete a training in occupational

safety and health.

2. Use 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 spec-

ified 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 each use, ensure the correct condition of the carriage, power supply, re-

mote control, and other equipment, power source, cords, cables, connections, roll-

ers, and gear.

9. Before each use, make sure that no part is cracked or loose. Make sure to main-

tain correct conditions that can have an effect on the operation of the carriage.

10. Keep the carriage, power supply, remote control, and other equipment dry. Do

not expose them to rain, snow, or frost.

11. Keep the worksite well lit, clean, and free of obstacles.

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

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

14. Install the carriage only on the supplied track.

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

16. Connect the cords and cables only after you set the power switch to ‘O’.

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

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

19. Hang the cables to decrease the load applied on the carriage.

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

Rail Runner 2 –Operator’s Manual

23. 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 hi-flex,

semi-flex 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.

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

25. Use eye protection (helmet, shield, and screen), ear protection, gloves, and pro-

tective clothing. Do not use loose clothing.

26. Do not stop the carriage by hand. To stop, set the direction switch to ‘O’.

27. Do the maintenance only after you unplug the carriage from the power source.

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

29. If the carriage falls, is wet, or has any damage, stop the work and promptly send

the carriage to the service center for check and repair.

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

Rail Runner 2 –Operator’s Manual

3. STARTUP AND OPERATION

3.1. Assembling the hi-flex, semi-flex, and rigid track

Attach magnetic units to the rail, and put it on the workpiece. Use the 4 mm or 5 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-flex 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

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