Itm RAIL TITAN User manual

BEFORE USE, ENSURE EVERYONE USING THIS MACHINE READS AND UNDERSTANDS
ALL SAFETY AND OPERATING INSTRUCTIONS IN THIS MANUAL .
Serial #............................................ Date of Purchase............................
OPERATOR’S MANUAL
RAIL TITAN
WELDING CARRIAGE
Ver: 1.01 07/12/2021
ul. Elewatorska 23/1, 15-620 Białystok, Poland
Phone: [phone], Fax: [phone]
www.promotech.eu e-mail: [e-mail]
OPERATOR’S MANUAL
WELDING CARRIAGE
R
Ra ai il l T Ti it ta an n

RAIL TITAN OPERATOR’S MANUAL
2www.itmtools.com.au
LIMITED WARRANTY
Industrial Tool & Machinery Sales (hereinafter referred to as ITMS) will, within twelve (12) months from the original date of purchase, repair
or replace any goods found to be defective in materials or workmanship.
This warranty is void if the item has been damaged by accident, neglect, improper service or other causes not arising out of defects in
materials or workmanship. This warranty does not apply to machines and/or components which have been altered, changed, or modified in
any way, or subjected to overloading or use beyond recommended capacities and specifications. Worn componentry due to normal wear
and tear is not a warranty claim. Goods returned defective shall be returned prepaid freight to ITMS or agreed repair agent, which shall
be the buyer’s sole and exclusive remedy for defective goods. ITMS accepts no additional liability pursuant to this guarantee for the costs
of travelling or transportation of the product or parts to and from ITMS or the service agent or dealer, such costs are not included in this
warranty.
Our goods come with guarantees which cannot be excluded under the Australian Consumer Law. You are entitled to replacement or refund
for a major failure and to compensation for other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or
replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
THE MANUFACTURER RESERVES THE RIGHT TO MAKE IMPROVEMENTS AND MODIFICATIONS TO
DESIGN WITHOUT PRIOR NOTICE.
PRODUCTS IMPORTED AND DISTRIBUTED NATIONALLY BY:
INDUSTRIAL TOOL & MACHINERY SALES
18 BUSINESS ST, YATALA QLD 4207
T: 07 3287 1114 E: [email protected]
F: 07 3287 1115 W: www.industrialtool.com.au
Contents
1. GENERAL INFORMATION ............................................................................................... 3
1.1. Application ................................................................................................................. 3
1.2. Technical data............................................................................................................ 4
1.3. Equipment included ................................................................................................... 5
1.4. Dimensions ................................................................................................................ 6
1.5. Design ....................................................................................................................... 7
2. SAFETY PRECAUTIONS.................................................................................................. 8
3. STARTUP AND OPERATION ..........................................................................................10
3.1. Assembling the hi-flex, semi-flex, or rigid track..........................................................10
3.2. Assembling the ring track..........................................................................................12
3.3. Positioning on a straight track ...................................................................................14
3.4. Positioning on a curved track ....................................................................................16
3.5. Preparing and connecting .........................................................................................17
3.6. Connecting to the welding circuits.............................................................................18
3.7. Operating ..................................................................................................................19
3.8. Adjusting the pressure of rollers................................................................................25
3.9. Adapting for seam tracking (option)...........................................................................26
3.10. Troubleshooting ......................................................................................................30
4. MAINTENANCE ...............................................................................................................31
5. ACCESSORIES ...............................................................................................................32
5.1. Seam tracking attachment.........................................................................................32
5.2. Tracking sensor tips ..................................................................................................32
5.3. Motorized vertical slide..............................................................................................33
5.4. Cables ......................................................................................................................33
5.5. Hi-flex track...............................................................................................................34
5.6. Semi-flex track ..........................................................................................................35
5.7. Rigid track.................................................................................................................35
5.8. Rack adjustment tool.................................................................................................35
5.9. Contact block ............................................................................................................36
5.10. Magnetic units.........................................................................................................37
5.11. Semi-flex track support............................................................................................42
5.12. Vacuum track system..............................................................................................43
5.13. Ring tracks ..............................................................................................................44
5.14. Ring track supports and bracket..............................................................................46
5.15. Torch holders, clamps, and rods .............................................................................47
5.16. Transport attachment ..............................................................................................49
5.17. Pendulum oscillator.................................................................................................50
6. PARTS BREAKDOWN.....................................................................................................52
7. ELECTRICAL DIAGRAM..................................................................................................60

RAIL TITAN OPERATOR’S MANUAL
3
www.itmtools.com.au
Rail Titan
This document is protected by copyrights.
Copying, using, or distributing without permission of PROMOTECH is prohibited.
3
1. GENERAL INFORMATION
1.1. Application
The Rail Titan is a track carriage designed to make butt and fillet welds with or without
oscillation and to cut. The carriage allows MIG/MAG, TIG, 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.
Basic configuration
Configuration with seam tracking in two axes
(requires an optional tracking attachment and
a motorized vertical slide)
Travel direction

RAIL TITAN OPERATOR’S MANUAL
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Rail Titan
This document is protected by copyrights.
Copying, using, or distributing without permission of PROMOTECH is prohibited.
4
1.2. Technical data
Voltage
1~ 100–240 V, 50–60 Hz
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, TIG, 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
Vertical pulling force
315 N
Horizontal speed
0–250 cm/min (0–98 in/min)
Vertical speed
0–250 cm/min (0–98 in/min)
Oscillation type
Linear
Weld path
Straight, triangle, trapezoid, square
Oscillation width
0.1–11.8 cm (0.04–4.5″)
Oscillation speed
10–200 cm/min (5–78 in/min)
Oscillation dwell time at center and on ends
0–5 s
Maximum oscillator pulling force
100 N
Required ambient temperature
0–50°C (32–122°F)
Maximum allowed ambient humidity non-condensing
80%
Protection level
IP 20
Weight with remote control
13 kg (29 lbs)

RAIL TITAN OPERATOR’S MANUAL
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www.itmtools.com.au
Rail Titan
This document is protected by copyrights.
Copying, using, or distributing without permission of PROMOTECH is prohibited.
5
1.3. Equipment included
1
Carriage
1 unit
2
Plastic box
1 unit
3
Remote control
1 unit
4
Contact block
1 unit
5
Rod 300mm (12″)
1 unit
6
Rack 300mm (12″) with 180mm (7″) adjustment
1 unit
7
Rack holder
1 unit
8
Clamping block with levers
1 unit
9
Short rod torch holder with clamp
1 unit
10
Cable anchor
1 unit
11
Hex wrench 6mm
1 unit
12
Arc ignition cable 6.5 m (21 ft)
1 unit
13
Power cord 3m (10 ft)
1 unit
14
Cable 0.5m (1.5 ft)
1 unit
15
Cable 3m (10 ft)
1 unit
16
Cable 5m (16.5 ft)
1 unit
–
Operator’s Manual
1 unit
12
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