ESAB Railtrac BV2000 User manual

Instruction manual
0463 629 001 GB 20181029 Valid for: serialno.1801xxxx
Railtrac™ BV2000

TABLE OF CONTENTS
0463 629 001 © ESAB AB 2018
1SAFETY ....................................................................................................... 4
1.1 Meaning of symbols ............................................................................... 4
1.2 Safety precautions ................................................................................. 4
2INTRODUCTION.......................................................................................... 7
3TECHNICAL DATA ...................................................................................... 11
4INSTALLATION............................................................................................ 12
5OPERATION ................................................................................................ 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
6MAINTENANCE........................................................................................... 20
7ORDERING SPARE PARTS ........................................................................ 21
DIAGRAM ............................................................................................................ 22
ORDERING NUMBERS....................................................................................... 23
ACCESSORIES ................................................................................................... 24
Rights reserved to alter specifications without notice.

1 SAFETY
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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

1 SAFETY
0463 629 001 -5- © ESAB AB 2018
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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0463 629 001 -6- © ESAB AB 2018
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.

2 INTRODUCTION
0463 629 001 -7- © ESAB AB 2018
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.

2 INTRODUCTION
0463 629 001 -8- © ESAB AB 2018
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

2 INTRODUCTION
0463 629 001 -9- © ESAB AB 2018
1. Slide height adjustment 7. Locking wheel
2. Support wheel holder 8. Locking screw
3. Bracket for coarse adjustment in/out and
height
9. Electronics
4. Universal torch holder 10. Battery holder
5. Protection plate 11. Weaving movement
6. Drive wheel ×2 12. Weaving movement connection

2 INTRODUCTION
0463 629 001 - 10 - © ESAB AB 2018
Dimensions

3 TECHNICAL DATA
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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
(separate adj. on each program)
ESAB 0–10V
Safety class DIN40050
Enclosure class IP44
*Depending on weaving width. Max workspace = 80mm (3.15in.)

4 INSTALLATION
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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.

4 INSTALLATION
0463 629 001 - 13 - © ESAB AB 2018
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.

5 OPERATION
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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
1 Start left
One press: Start left without welding
Double press: Start left with welding
Press 2 seconds: Start with fast move left
One press after start: Speed carriage -
2 Menu/Stop
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.
3 Start right
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 +
Menus
Program P0 to P5, Railtrac™BV2000 has 6 different welding programs.
Weaving width 0–60 mm (0–2.3in.)
Space weaving
strings
1.0–10.0 mm (0.039–0.39in.)
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)

5 OPERATION
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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
on right side
12. Menu 7: Weaving hold time (hold in)
5. Default: Speed Carriage / Weaving width,
Weaving speed
13. Menu 8: Wire feed 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

5 OPERATION
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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

5 OPERATION
0463 629 001 - 17 - © ESAB AB 2018
5.3 Remote control
1 Shift
2 Stop
3 Weaving width-Wire Feed Speed -
4
Start left
After start: Speed+
Press 2seconds for fast move.
Volt+
5 0-line in
6
Start right
After start: Speed-
Press 2seconds for fast move.
Volt -
7 Program -45 degrees ending in
P1–P3
8 Program+Menu+
9 0-line out
10 Weaving width+Wire Feed Speed+
5.3.1 Remote control functions

5 OPERATION
0463 629 001 - 18 - © ESAB AB 2018
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.

5 OPERATION
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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.

6 MAINTENANCE
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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.