SteelMax Rail Runner, Operator'S Manual

Page 1: ...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 R Ra ai il l R Ru un nn ne er r WELDING CARRIAGE ...

Page 2: ...ubleshooting 18 4 MAINTENANCE 19 5 ACCESSORIES 20 5 1 Semi flexible track 20 5 2 Rigid track 20 5 3 Rack adjustment tool 20 5 4 Magnetic units 21 5 5 Semi flexible track support Error Bookmark not defined 5 6 Transport attachment 25 5 7 76 mm cross slide 26 5 8 Vacuum track system 27 5 9 Torch clamps 28 5 10 Rods 29 5 11 Torch holders 30 6 115 230 V WIRING DIAGRAM 32 7 42 V WIRING DIAGRAM 33 8 115...

Page 3: ...can work in the following welding positions PA 1F 1G PB 2F PC 2G PD 4F PE 4G PF 3G and PG 3F 3G The track is fixed by using magnetic units to ferromagnetic surfaces that are flat or curved with a radius of at least 5 m 16 ft Accessories allow for instance using torches with the handle diameter larger than 22 mm 0 87 and guiding the carriage on a semi flexible or rigid track Using a vacuum track sy...

Page 4: ...lamping 5 mm 0 2 Horizontal pulling force 350 N 77 lbs Vertical pulling force 150 N 33 lbs Cross slide adjustment range 0 35 mm 0 1 38 up down left right Horizontal speed 0 120 cm min 0 47 2 in min Vertical speed 0 110 cm min 0 43 3 in min Oscillation type Linear Oscillation path Trapezoid triangle straight line Oscillator arm stroke 0 100 mm 0 3 9 Oscillation width 0 50 mm 0 1 9 Oscillation speed...

Page 5: ...1 Carriage 1 unit 2 Metal box 1 unit 3 Cross slide assembly 1 unit 4 Long rod torch holder with clip 1 unit 5 3 m 10 ft power cord 1 unit 6 6 5 m 21 ft arc ignition cable 1 unit 7 3 mm hex wrench 1 unit 8 4 mm hex wrench 1 unit Operator s Manual 1 unit 1 2 3 4 5 6 7 8 ...

Page 6: ...Rail Runner Rail Runner Operator s Manual 6 1 4 Dimensions 362 mm 14 3 644 mm 25 4 441 mm 17 4 ...

Page 7: ... Forward O Backward Oscillation offset knob arm stroke Travel speed knob Left oscillation position dwell knob Right oscillation position dwell knob Center oscillation position dwell knob Pressing lever Control panel Oscillator arm Cable anchor Cross slide Power switch Arc ignition socket Drive clutch knob Display Carrying handle Clamping block Long rod ...

Page 8: ...10 Keep the work area well lit clean and free of obstacles 11 Never use near flammable liquids or gases 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 and not damaged 15 Plug the cords and arc ignition cable into sockets only when the power switch i...

Page 9: ... of the carriage 25 Never try to manually stop the travel To stop set the travel direction switch to O 26 Maintain only when the carriage is unplugged 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 other damage that could affect the technical state of the carriage stop the work and promptly send the carria...

Page 10: ...the teeth of the racks are directed downward Fig 1 Connecting the rails and clamping the magnetic units to the surface Before attaching additional rails to a semi flexible rail placed on a curve 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 Place the rack adjustmen...

Page 11: ...Rail Runner Rail Runner Operator s Manual 11 Fig 2 Removing the gap between the racks of a semi flexible track 1 2 5 3 4 ...

Page 12: ...0 screws as shown in Fig 3 The parts shown can be assembled in many ways to form different configurations However note that the oscillator moves in and out during startup Thus to allow proper startup install the torch holder and the cross slide so that they will not collide with the carriage side or obstacles Fig 3 Sample method of assembling the torch holder ...

Page 13: ...rc ignition switch and travel direction switch to O Next set the pressing lever to OFF 1 Fig 4 and loosen the drive clutch knob fully 2 Then set the carriage onto the track 3 so that the back rollers are placed in the groove 4 Fig 4 Positioning the carriage on the track 1 2 3 4 7 6 5 ...

Page 14: ...xt insert the torch cable into the cable anchor secure with knobs and then fix the anchor in the required position with levers 3 4 Connecting to the welding circuits The carriage can control two torches by using the arc ignition cable plugged into the arc ignition socket To do this according to the diagram shown in Fig 5 connect any blue jacketed wire to any terminal of the welding circuit Then co...

Page 15: ...l time in right position of the oscillation 0 5 cm 0 2 in step 0 1 cm 0 02 in Oscillation width Set to weld without oscillation 0 100 step 1 Relative oscillation speed 100 to 100 step 1 Oscillation offset If exceeds the value of the parameter the parameter is recalculated automatically 0 5 140 cm min 2 55 in min Carriage speed Setting to during travel stops the main motor Then the oscillator goes ...

Page 16: ...y time by rotating the knobs The produced welds form a shape similar to that shown in Fig 6 Fig 6 Graphic description of the oscillation parameters from Tab 1 To stop the travel and save the values shown on the display set the travel direction switch to O After the work is finished use the power switch to turn off the power Then unplug the carriage from the power source If the arc ignition switch ...

Page 17: ... Fig 7 Fig 7 Changing the unit of measure When the jumper cap connects the top and center pin the measurement system will be metric after restart When the jumper cap connects the center and bottom pin the system will be imperial Set the jumper cap in the position matching to the required unit Use the 2 5 hex wrench not included to loosen the fixing screws and access the back side of the control pa...

Page 18: ...nction of the main motor encoder Contact service center for check and repair Oscillator move blocked or power not supplied to the oscillator motor Remove obstacles blocking the move of the oscillator If this message still appears contact service center for check and repair Malfunction of the oscillator motor encoder or the controller Contact service center for check and repair Malfunction of the o...

Page 19: ... and the rack of each rail 2 Clean the rollers and make sure that they rotate freely 3 Clean the torch nozzle Replace if damaged Monthly 1 Check whether the knobs and switches work as intended Replace if loose or damaged 2 Inspect cables cords and hoses Replace if damaged 3 Tighten screws if loose ...

Page 20: ...ingle rail is 2 m 6 5 ft 5 2 Rigid track Allows guiding the carriage along a straight line The length of a single rail is 2 m 6 5 ft 5 3 Rack adjustment tool Removes the clearance between the racks of two semi flexible rails that are put on a curve Part number PRW 0482 15 05 00 0 Part number PKT 0341 13 00 00 0 Part number PRW 0482 47 00 00 0 ...

Page 21: ...00 N 265 lbs 20 C 68 F 20 C 68 F 75 900 N 200 lbs 80 C 176 F 160 C 320 F 50 600 N 130 lbs 120 C 248 F 200 C 392 F Use the 4 mm hex wrench to attach the unit to a semi flexible or rigid track as shown in the figures Part number bracket for semi flexible track DYS 0482 19 00 00 0 Part number bracket for rigid track DYS 0482 21 00 00 0 Part number ZSP 0475 44 00 00 0 magnetic unit ZSP 0475 44 00 00 1...

Page 22: ... in height up to 80 mm 3 1 Holding force on a 5 mm 0 2 thick surface Temperature 100 1200 N 265 lbs 20 C 68 F 75 900 N 200 lbs 80 C 176 F 50 600 N 130 lbs 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 Part number ZSP 0475 85 00 00 0 Part number bracket for semi flexible track DYS 0482 19 00 00 ...

Page 23: ...mm 6 7 9 1 Holding force on a 5 mm 0 2 thick surface Temperature 100 1200 N 265 lbs 20 C 68 F 75 900 N 200 lbs 80 C 176 F 50 600 N 130 lbs 120 C 248 F Install the unit in the same way as the magnetic unit is installed To adjust the spacing use the 5 mm hex wrench and loosen four side screws Part number ZSP 0523 19 00 00 0 Part number bracket for semi flexible track DYS 0482 19 00 00 0 Part number ...

Page 24: ...re 100 1000 N 220 lbs 20 C 68 F 75 750 N 165 lbs 80 C 176 F 50 500 N 110 lbs 120 C 248 F Use the 4 mm hex wrench to attach the unit to a semi flexible or rigid track as shown in the figures To clamp the unit to the surface use the 17 mm flat wrench not included and set the side screw to ON Part number PDS 0582 10 00 02 0 Part number bracket for semi flexible track DYS 0582 10 00 00 0 M6x35 M6x16 M...

Page 25: ...s supporting a semi flexible track by using the support instead of a magnetic unit Use the 4 mm hex wrench to attach the support to a semi flexible track 5 6 Transport attachment Allows transporting the wire feeder Part number PEP 0482 18 00 00 0 Part number WSP 0523 12 01 00 1 M6x16 ...

Page 26: ...26 5 7 76 mm cross slide Extends either up down or left right adjustment range from 0 35 mm 0 1 38 to 0 76 mm 0 3 Install in place of the standard cross slide after unscrewing four screws with the 4 mm hex wrench Part number ZSP 0466 46 00 00 1 ...

Page 27: ... 8 Vacuum track system Dedicated to fixing the 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 separate manual ...

Page 28: ... 87 5 9 2 16 22 mm torch clip The clip allows using a torch with the handle diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip 5 9 3 22 35 mm torch clamp Allows using a torch with the handle diameter of 22 35 mm 0 87 1 38 Part number ZRZ 0466 19 00 00 0 Part number ZRZ 0466 04 01 00 0 Part number ZCS 0476 06 01 00 0 ...

Page 29: ...l Runner Rail Runner Operator s Manual 29 5 10 Rods 5 10 1 Short rod Provides a 120 mm 4 7 reach 5 10 2 Long rod Provides a 240 mm 9 4 reach Part number WLK 0476 20 01 00 0 Part number WLK 0466 04 10 00 0 ...

Page 30: ...p The holder allows using a torch with the handle diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip 5 11 3 Short rod low torch holder with clip The holder allows using a torch with the handle diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip Part number UCW 0476 20 00 00 0 Part number UCW 0476 27 00 00 0 Part number UCW 04...

Page 31: ...ng a torch with the handle diameter of 16 22 mm 0 63 0 87 5 11 5 Long rod torch holder with clip The holder allows using a torch with the handle diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip Part number UCW 0466 22 00 00 0 Part number UCW 0466 04 00 00 0 ...

Page 32: ...Rail Runner Rail Runner Operator s Manual 32 6 115 230 V WIRING DIAGRAM ...

Page 33: ...Rail Runner Rail Runner Operator s Manual 33 7 42 V WIRING DIAGRAM ...

Page 34: ...07 4 MM HEX WRENCH 1 8 UCW 0466 22 00 00 0 LONG ROD TORCH HOLDER WITH CLIP ASSY 1 9 WLK 0482 04 10 00 0 LONG ROD WITHOUT SLEEVE ASSY 1 10 KST 0482 11 01 00 0 CLAMPING BLOCK I 1 11 KST 0482 11 02 00 0 CLAMPING BLOCK II 1 12 RKJ 000043 HANDLEVER M6 25 1 13 RKJ 000036 HANDLEVER M6 32 2 14 SRB 000086 HEX SOCKET HEAD CAP SCREW M5x20 4 15 ZSP 0466 03 00 00 1 CROSS SLIDE ASSY 1 16 WLK 0466 04 10 00 0 LON...

Page 35: ...0 52 44 79 1 21 54 87 35 62 86 41 83 85 42 82 84 120 118 64 109 114 22 72 73 74 77 8 58 120 18 80 108 71 119 18 2 16 11 115 43 39 45 6 13 66 20 5 22 57 111 4 92 19 24 63 23 100 104 81 78 76 67 95 36 38 33 60 46 26 25 97 90 34 3 75 110 105 117 88 89 91 107 116 113 103 96 102 93 103 99 70 106 68 101 59 88 94 100 56 69 98 38 12 49 10 31 47 55 65 61 9 7 17 48 29 28 32 27 51 45 15 38 30 40 50 52 44 79 ...

Page 36: ...0103 HEX SOCKET HEAD CAP SCREW M6x12 4 24 WKR 000143 HEX SOCKET COUNTERSUNK HEAD SCREW M6x20 6 25 KOL 0341 02 01 09 0 DRIVE GEAR z14 1 26 WPS 0341 02 01 10 0 KEY 1 27 PDK 0233 01 21 00 0 DISTANCE WASHER 12 1x19x3 1 28 KOL 0456 01 05 00 1 IDLE GEAR WHEEL ASSY z25 1 29 KRP 0482 02 01 00 1 MOTOR BODY 1 30 KOL 0482 02 02 00 0 GEAR z22 1 31 WLK 0482 02 03 00 0 DRIVE GEAR SHAFT 1 32 KOL 0482 02 04 00 0 ...

Page 37: ...04 02 04 0 MAIN MODULE 1 75 MSK 0482 04 02 10 1 PANEL MASKING COVER WITH OSCILLATION ASSY 1 76 PDK 000058 EXTERNAL TOOTH LOCK WASHER 3 4 77 PKT 000028 POTENTIOMETER KNOB 23 2 78 TLJ 000051 HEX SLEEVE 4 79 WKR 000058 HEX SOCKET SET SCREW WITH FLAT POINT M6x8 1 80 PKT 000015 POTENTIOMETER KNOB K85 6D 5 81 WKR 000181 CROSS RECESSED PAN HEAD SCREW M3x6 4 82 MDL 0476 02 02 22 2 DISPLAY 1 83 MDL 0482 04...

Page 38: ... 0482 04 01 00 1 BODY 1 110 PNL 0482 04 02 00 1 CONTROL PANEL WITH OSCILLATION ASSY 1 111 WYS 0482 04 03 00 1 DISPLAY ASSY 1 112 WZK 0482 04 04 00 0 POWER SWITCH WIRE SET 1 113 PWD 0482 04 05 00 0 CONTROL PANEL GROUNDING WIRE ASSY 1 114 NKR 000013 HEX NUT M4 2 115 DLW 000007 CABLE GLAND WITH STRAIN RELIEF PG11 1 116 PDK 000060 EXTERNAL TOOTH LOCK WASHER 4 3 2 117 PNK 000026 LEVER SWITCH 641 H3 1 1...

Page 39: ...ITH CLIP ASSY 1 9 WLK 0482 04 10 00 0 LONG ROD WITHOUT SLEEVE ASSY 1 10 KST 0482 11 01 00 0 CLAMPING BLOCK I 1 11 KST 0482 11 02 00 0 CLAMPING BLOCK II 1 12 RKJ 000043 HANDLEVER M6 25 1 13 RKJ 000036 HANDLEVER M6 32 2 14 SRB 000086 HEX SOCKET HEAD CAP SCREW M5x20 4 15 ZSP 0466 03 00 00 1 CROSS SLIDE ASSY 1 16 WLK 0466 04 10 00 0 LONG ROD ASSY 1 17 ZCS 0476 06 01 00 0 TORCH CLIP ASSY 1 18 RKJ 00003...

Page 40: ...0 52 44 79 1 21 54 87 35 62 86 41 83 85 42 82 84 120 118 64 109 114 22 72 73 74 77 8 58 120 18 80 108 71 119 18 2 16 11 115 43 39 45 6 13 66 20 5 22 57 111 4 92 19 24 63 23 100 104 81 78 76 67 95 36 38 33 60 46 26 25 97 90 34 3 75 110 105 117 88 89 91 107 116 113 103 96 102 93 103 99 70 106 68 101 59 88 94 100 56 69 98 38 12 49 10 31 47 55 65 61 9 7 17 48 29 28 32 27 51 45 15 38 30 40 50 52 44 79 ...

Page 41: ...SCREW M5x16 7 23 SRB 000103 HEX SOCKET HEAD CAP SCREW M6x12 4 24 WKR 000143 HEX SOCKET COUNTERSUNK HEAD SCREW M6x20 6 25 KOL 0341 02 01 09 0 DRIVE GEAR z14 1 26 WPS 0341 02 01 10 0 KEY 1 27 PDK 0233 01 21 00 0 DISTANCE WASHER 12 1x19x3 1 28 KOL 0456 01 05 00 1 IDLE GEAR WHEEL ASSY z25 1 29 KRP 0482 02 01 00 1 MOTOR BODY 1 30 KOL 0482 02 02 00 0 GEAR z22 1 31 WLK 0482 02 03 00 0 DRIVE GEAR SHAFT 1 ...

Page 42: ...DL 0482 04 02 03 0 ENCODER MODULE 1 74 MDL 0482 04 02 04 0 MAIN MODULE 1 75 MSK 0482 04 02 10 1 PANEL MASKING COVER WITH OSCILLATION ASSY 1 76 PDK 000058 EXTERNAL TOOTH LOCK WASHER 3 4 77 PKT 000028 POTENTIOMETER KNOB 23 2 78 TLJ 000051 HEX SLEEVE 4 79 WKR 000058 HEX SOCKET SET SCREW WITH FLAT POINT M6x8 1 80 PKT 000015 POTENTIOMETER KNOB K85 6D 5 81 WKR 000181 CROSS RECESSED PAN HEAD SCREW M3x6 4...

Page 43: ...2 04 00 0 ARC IGNITION SOCKET WIRE SET 1 109 KRP 0482 04 01 00 1 BODY 1 110 PNL 0482 04 02 00 1 CONTROL PANEL WITH OSCILLATION ASSY 1 111 WYS 0482 04 03 00 1 DISPLAY ASSY 1 113 PWD 0482 04 05 00 0 CONTROL PANEL GROUNDING WIRE ASSY 1 114 NKR 000013 HEX NUT M4 2 115 DLW 000007 CABLE GLAND WITH STRAIN RELIEF PG11 1 116 PDK 000060 EXTERNAL TOOTH LOCK WASHER 4 3 2 117 PNK 000026 LEVER SWITCH 641 H 3 1 ...

Page 44: ...responsibility that Rail Runner Welding Carriage is manufactured in accordance with the following standards EN 50144 1 EN 60974 10 and satisfies safety 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 Białystok 22 February 2013 ___________________________ Marek Siergiej CEO ...

Page 45: ...ol card Rail Runner Welding Carriage 115 230 V 42 V Serial number Electric test Type of test Result Name of tester Insulation electrical strength test 1000 V 50 Hz Date Continuity test of the protective earth system Ω Signature Quality control Adjustments inspections Quality control ...

Page 46: ...hip under normal use for a period of 12 months from the date of sale This warranty does not cover rollers as well as damage or wear that arise from misuse accident tempering or any other causes not related to defects in workmanship or material Date of production Serial number Date of sale Signature of seller 2 15 8 November 2018 WE RESERVE THE RIGHT TO MAKE CHANGES IN THIS MANUAL WITHOUT NOTICE ...