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
0463 629 001 -4- © ESAB AB 2018
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
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Dimensions