ESAB Railtrac BV2000 Instruction manual

Railtrac™ BV2000

Instruction manual

0463 629 001 GB 20181029

Valid for: serialno.1801xxxx

TABLE OF CONTENTS

1

SAFETY ....................................................................................................... 4

1.1 Meaning of symbols ............................................................................... 4

1.2 Safety precautions ................................................................................. 4

2

INTRODUCTION.......................................................................................... 7

3

TECHNICAL DATA ...................................................................................... 11

4

INSTALLATION............................................................................................ 12

5

OPERATION ................................................................................................ 14

5.1 Electronic – Carriage ............................................................................. 14

5.2 Programs................................................................................................. 16

5.3 Remote control ....................................................................................... 17

5.3.1 Remote control functions...................................................................... 17

5.4 Preheat .................................................................................................... 18

5.5 Remote control for digital wire feeder.................................................. 19

5.6 Installation of wire feeder ...................................................................... 19

6

MAINTENANCE........................................................................................... 20

7

ORDERING SPARE PARTS........................................................................ 21

DIAGRAM ............................................................................................................ 22

ORDERING NUMBERS ....................................................................................... 23

ACCESSORIES ................................................................................................... 24

Rights reserved to alter specifications without notice.

0463 629 001 © ESAB AB 2018

1 SAFETY

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!
Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!
Means potential hazards which could result in personal injury or loss of

life.

CAUTION!
Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

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1 SAFETY

4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to
EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

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NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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1 SAFETY

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.

NOTE!
Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation
in accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be
disposed of at a recycling facility.

As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

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© ESAB AB 2018

2 INTRODUCTION

2 INTRODUCTION

Railtrac™ BV2000 is a system of components that can be configured to create the optimal
solution for a mechanized welding application. Railtrac™ BV2000 is designed for horizontal
use and it covers most proven and globally applied welding patterns for repair of rail and rail
components in all steel types and casting grades. To minimise problems associated with
harsh environments, most mechanical parts are constructed in aluminum and stainless steel.

Equipment

The welding tractor Railtrac™ BV2000 is supplied with:

• Remote control

• Slides and torch holder

• 1x 2 m rail BV2000

• 2x Rail Bracket

• 2x Alignment brackets

• Storage box

Features Railtrac™ BV2000

• 42VAC or battery driven with standard Makita® 18V system.

• High speed and low speed in one unit.

• Micro process controlled electronics package in a single onboard housing.

• Stepper motor both for drive and weaving function.

• Only one cable to the wire feeder (not needed if using the battery) and one cable to the
remote control (if used) but can be run without any remote control.

• The unit can be programmed and run directly from the controls on the Railtrac™
BV2000 if the remote control is lost-damaged or not preferred.

• Dual high-visibility screens for easy viewing in any orientation.

• The remote control is programmable for weave patterns and travel speed and is
capable of controlling voltage and wire feed speed in up to 6 standard programs.

• IP44 environmental rating on both the Railtrac™ and the remote control.

• Choose between welding on left side or right side for remote control to correspond to
carriage movement.

Direct connection to all new modern ESAB wire feeders

Railtrac™ BV2000 can be easily connected to most ESAB wire feeders with no major
modification. Remote adapters have to be mounted in wire feeders (Aristo®Feed3004,
Aristo®Feed4804, Origo™Feed304, Origo™Feed484 and Warrior™Feed304).

Six programs can easily be stored

As many as six different programs can be stored. Each program is individual and can be
retrieved from the control on the main unit or the remote control.

Remote control of welding parameters and immediate program shift

Both welding current (wire-feed speed) and voltage can be adjusted (in %) during welding.
Stepping up or down between the alternative motion programs is also easy, depending on
welding position.

Resilient programming units with great potential

Straightforward, logically-designed programming units are used to set the values for six
different programs. All speeds are calibrated in millimetre (mm), for the greatest possible
precision and welding quality.

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2 INTRODUCTION

Remote control for the harshest environments

Using the robust and lightweight remote control that comes with the Railtrac™ BV2000, the
operator can access and control every function without lifting the welding visor. Individually
shaped buttons for:

• Start and stop

• Shift program

• Travel or welding direction (cutting direction)

• Travel or welding speed (cutting speed)

• Weaving width

• Zero-line displacement

• Welding current (wire-feed speed)

• Welding voltage

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2 INTRODUCTION

1. Slide height adjustment 7. Locking wheel

2. Support wheel holder 8. Locking screw

3. Bracket for coarse adjustment in/out and

9. Electronics

height

4. Universal torch holder 10. Battery holder

5. Protection plate 11. Weaving movement

6. Drive wheel ×2 12. Weaving movement connection

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2 INTRODUCTION

Dimensions

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3 TECHNICAL DATA

3 TECHNICAL DATA

Railtrac™BV2000, Valid from serial no. 1801xxxx

Supply voltage 24–60VDC

20–50VAC

18 V battery

Power consumption max 50W

Battery running time 3–4h

Weight 8 kg (17.6lb)

Carriage measurements (L×W×H) 210×350×267mm (8.27×13.78×10.51in.)

Length running rail 2m (2x 1m) (6ft7in.)

Max temp. Carriage
Carriage with battery

80°C (176°F)
60°C (140°F)

Max pay load 10 kg (22 lb)

Height adjustment slide ± 45mm (± 1.77 in.)

Speed carriage 2–150 cm/min (0.79–4ft 11in./min)

Rapid speed carriage 15cm/min (5.91in./min)

Weaving speed 5–40mm/s (0.2–1.57in.)

Weaving width 0–60mm (0–2.36in.)

0-line adjustment ±30mm* (1.18in.*)

Mechanical adj. in/out ±40mm (±1.57in.)

Tot. movement weaver 80mm (3.15in.)

Programs 6

Remote control Wire Feed Speed and V

ESAB 0–10V

(separate adj. on each program)

Safety class DIN40050

Enclosure class IP44

*Depending on weaving width. Max workspace = 80mm (3.15in.)

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© ESAB AB 2018

4 INSTALLATION

4 INSTALLATION

The installation must be carried out by a professional.

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.

1. Mount the rail brackets on the aluminium
rail.

2. Fit the brackets across the rail and
secure.

3. Adjust the aluminium rail by way of the
gauges.

4. Mount the carriage on the rail.

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4 INSTALLATION

5. Tighten the lock screw.
Fit the attachment of the torch.

6. Connect the remote control unit to the
carriage.
Then connect the voltage supply cable to
the carriage and wire feed unit.

7. Press the 0-line in or 0-line out button for
positioning.

8. Fit the welding torch.

9. Select a program.

10. Start welding.

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5 OPERATION

5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!

5.1 Electronic – Carriage

One press: Start left without welding

1 Start left

2 Menu/Stop

3 Start right

Menus

Program P0 to P5, Railtrac™BV2000 has 6 different welding programs.

Weaving width 0–60 mm (0–2.3in.)

Double press: Start left with welding

Press 2 seconds: Start with fast move left

One press after start: Speed carriage -

Before start: Selector for programming
parameters. Blinking display indicates
progamming modus. Adjust parameters using
the + and - buttons.

After start: Stop carriage and welding.

If function Length: Press for 3 seconds to set
start position. Display shows 0.

One press: Start right without welding

Double press: Start right with welding

Press 2 seconds: Start with fast move right

One press after start: Speed carriage +

Space weaving
strings

Speed weaving 5–40 mm/s (0.20–1.6in./s)

Length 1–200 cm (0.39–79) length in program 3

Speed carriage 20–1500 mm/s (0.79–59in./s)

0-line adjustment In steps of 0.5mm (0.020in.)

WFS Wire Feed Speed 1–99% (only for Esab wire feeders)

Volt 1 – 99% (only for Esab wire feeders)

1.0–10.0 mm (0.039–0.39in.)

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5 OPERATION

1. Software version / Running hours 9. Menu 4: Weaving width

2. Connected wire feeder 10. Menu 5: Weaving pattern

3. 4 settings. Use button Start right to select 11. Menu 6: Weaving hold time (hold out)

4. Default: Program number / RS = welding

12. Menu 7: Weaving hold time (hold in)

on right side

5. Default: Speed Carriage / Weaving width,

13. Menu 8: Wire feed speed

Weaving speed

6. Menu 1: Program number 14. Menu 9: Volt

7. Menu 2: Speed carriage 15. Menu 10: Welding length. 0mm >

length/auto return off

8. Menu 3: Speed weaving

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5 OPERATION

5.2 Programs

Menu

Weaving

Width

Space

(D)

Weaving

Speed

Length

(L)

Speed

Carriage

P0 X

P1 X X X

P2 X X X

P3 X X X X

P4 X

P5 X X

D = Distance between pulses
L = Length

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5 OPERATION

5.3 Remote control

1 Shift

2 Stop

3 Weaving width- Wire Feed Speed -

Start left

4

After start: Speed+

Volt+

Press 2seconds for fast move.

5 0-line in

Start right

6

After start: Speed-

Volt -

Press 2seconds for fast move.

7 Program -

8 Program+ Menu+

9 0-line out

10 Weaving width+ Wire Feed Speed+

5.3.1 Remote control functions

45 degrees ending in
P1–P3

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5 OPERATION

After start: SPEED + After start: SPEED -

Arm in Arm out

Decrease weaving width Increase weaving width

Stop with 45° termination
angle Fast speed return

Turn point string welding

5.4 Preheat

The first menu in service is Preheat. Start delay carriage after start welding.

WFS = Wire Feed Speed

1. Press Stop for 6 seconds for access to
service menu A.

2. Release Stop when the display shows
Service Menu A .
The electronics will stay in the service menu
5 seconds after last button press.

3. The default setting is 300 ms.
Press + or - to adjust the setting.

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5 OPERATION

5.5 Remote control for digital wire feeder

It is possible to adjust the maximum value on the remote control output (0-10 V) both for wire
feed speed and voltage. The maximum value is 0.5V lower than Vin(10V) due to the

voltage drop in the opto driver.

Set Wire Feed Speed (WFS)

1. Press Menu once.
The display shows: DigF max WFS

2. Press + or - to adjust the setting.
Scale value: 1 - 40
Higher value gives higher output.

Set Voltage (V)

1. Press Menu until DigF max V is shown in the
display.

2. Press + or - to adjust.
Scale value: 1 - 40
Higher value gives higher output.

5.6 Installation of wire feeder

The installation must be carried out by a professional.

Railtrac™BV2000 can be connected to one of the following wire feed units:
Aristo®Feed3004, Aristo®Feed4804, Origo™Feed304, Origo™Feed484 and
Warrior™Feed304.

For necessary adaptation between Railtrac™BV2000 and the used wire feed unit (including
choice of control cable), see the "ACCESSORIES" appendix to this manual.

Universal feeder connection

For the operation of Railtrac™BV2000 from other wire feeders (none ESAB), use
transformer unit and control cable according to the "ACCESSORIES" appendix.

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© ESAB AB 2018

6 MAINTENANCE

6 MAINTENANCE

NOTE!

All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the unit during the warranty period.

Daily

• Check that all cables and plugs are intact.

• Clean the magnet, vacuum cups and air hoses and check for damage.

• Check that the rail is not damaged.

• Clean the carriage and the torch holder.

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© ESAB AB 2018

7 ORDERING SPARE PARTS

7 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.

Railtrac™BV2000 is designed and tested in accordance with the international and
European standard IEC/EN60974-10 Class A. It is the obligation of the service unit which
has carried out the service or repair work to make sure that the product still conforms to the
mentioned standards.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see

esab.com. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.

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DIAGRAM

DIAGRAM

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ORDERING NUMBERS

ORDERING NUMBERS

Ordering no. Denomination Product Notes

0459 990 644 Welding tractor Railtrac™BV2000

0463 631 001 Spare parts list Railtrac™BV2000

Technical documentation is available on the Internet at: www.esab.com

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© ESAB AB 2018

ACCESSORIES

ACCESSORIES

1. 0457 360 880 Control cable (12p- 23p) Railtrac™ - MEK

2. 0457 360 886 Universal connection cable 12-pin plug

3. 0457 467 880 Transformer 230/36 VAC with 12-pin plug

0457 467 882 Transformer 115VAC

0398 145 106 Torch holder universal Ø15-30 mm

System features different torch holders for
different torches and applications. Railtrac™
BV2000 comes with a universal torch holder
(Ø10-22 mm) and adjusters as standard.

0398 145 101 Torch holder for ESAB PSF torches

0398 145 202 Tilt bracket Railtrac™

The tilt bracket enables the Railtrac™ to
weave when welding fillet joints. It is mounted
between drive and weaving unit. The weaving
unit can be tilted from 0 to 60 degrees.

0398 145 203 Turning bracket B42

The turning bracket is used to change the
angle of the weaving unit at ±22 degrees from
travel direction.

0457 467 880 Transformer 230 VAC

0457 467 882 Transformer 115 VAC

0457 360 880 Connection cable ESAB, 12 + 23-pin

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© ESAB AB 2018

ACCESSORIES

0457 360 886 Connection cable universal, for start/stop

wire feeder, only with 12-pin

0398 146 120 Quick-extension bracket for flexible rail

The quick-extension bracket facilitates rapid
mounting and dismounting when using two
rails.

0457 468 074 Battery 18 V / 5 Ah Makita®

0457 468 072 Battery charger 230 VAC Makita®

For local purchase at hardware store Makita®

196673-6 BL1850

18 V

18 V 5.0 Ah Li-ion.

195585-0 DC18RC

14,4 V - 18 V

Charger for 14,4 V-18 V batteries.

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ACCESSORIES

Cable key function diagram B42V and BV2000

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© ESAB AB 2018

ACCESSORIES

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© ESAB AB 2018

ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone [phone]

http://manuals.esab.com

For contact information visit esab.com