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

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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

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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

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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)

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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
1
3
4
7
8
9
10
11
13
5
6
2
14
16
15

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1.4. Dimensions
510 mm (20″)
195 mm (7.7″)
350 mm (13.8″)
267 mm (10.5″)
73 mm(2.9″)
400 mm (15.7″)

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1.5. Design
Drive clutch knob
Pressing lever (pressing rollers are loose in
this position)
Pressing roller
Limit switch
Drive gear
Mounting bracket
Knob to attach the remote control to the carriage
Display guard
Carriage/cable connection
Power switch
Remote control / cable / tracking sensor /
motorized vertical slide connection
Arc ignition socket
Power cord
Carrying handle
Rod holder
Passive roller
Front cover

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2. SAFETY PRECAUTIONS
1. Before use, read this Operator’s Manual and complete a training in occupational
safety and health.
2. Use only in applications specified in this Operator’s Manual.
3. Make sure that the carriage, remote control, and other equipment have all parts.
Make sure that all parts are genuine and not damaged.
4. Make sure that the specifications of the power source are the same as those
specified on the rating plate.
5. Do not carry the carriage, remote control, and other equipment by cables. Do not
pull the cables. This can cause damage and electric shock.
6. Keep untrained bystanders away from the carriage.
7. Before each use, ensure the correct condition of the carriage, power supply,
remote control, and other equipment, power source, cables, connections, rollers,
and gear.
8. Before each use, make sure that no part is cracked or loose. Make sure to main-
tain correct conditions that can have an effect on the operation of the carriage.
9. Keep the carriage, remote control, and other equipment dry. Do not expose them
to rain, snow, or frost.
10. Keep the worksite well lit, clean, and free of obstacles.
11. Do not use near flammable materials, 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.
15. Connect the cables only after you set the power switch to ‘O’.
16. Keep the sockets clean. Do not use high pressure during cleaning.
17. Install only torches whose diameter matches the diameter of the torch holder.
18. Hang the cables to decrease the load applied on the carriage.
19. Do not bend the hi-flex track to a radius less than 0.75 m (2.5 ft).
20. Do not bend the semi-flex track to a radius less than 5 m (16.5 ft).
21. Use the rigid track only on flat surfaces.
22. At heights, protect the carriage and the track from falling. To do this, use chains
(not included) to attach the leftmost and rightmost magnetic units of the hi-flex,

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semi-flex or rigid track to a stable structure. To protect the carriage, attach a
chain to a carrying handle. Make sure that the chains are not loose.
23. Do not stay below the carriage or the track that is put at heights.
24. Use eye protection (helmet, shield, and screen), ear protection, gloves, and
protective clothing. Do not use loose clothing.
25. Do not stop the carriage by hand. To stop, set the direction switch to ‘O’.
26. Do not touch moving parts, and do not put fingers in the front cover holes.
27. Do the maintenance only after you unplug the carriage from the power source.
28. Repair only in a service center appointed by the seller.
29. If the carriage falls, is wet, or has any damage, stop the work and immediately
send the carriage to the service center for check and repair.
30. Do not leave the carriage unattended during work.
31. If you are not going to use the carriage, remove it from the worksite and keep in a
safe and dry place.

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3. STARTUP AND OPERATION
3.1. Assembling the hi-flex, semi-flex, or rigid track
Attach magnetic units to the rail, and put it on the workpiece. Use the 4 mm or 5 mm
hex wrench to attach more rails (1). Then, set the levers of the magnetic units to ‘I’
(2). This will clamp the rails to the surface.
When working in PC/2G welding position, put the rails so that the teeth of the
racks point down.
1
2

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If a semi-flex rail is put on a curve, before you attach more rails use the 4 mm hex
wrench to loosen the screws of the connecting plates (1) and of the racks (2). Next,
attach the rails, clamp them with levers, and then tighten the connecting plates. Put
the rack adjustment tool (not included) into the hole (3), and rotate the tool to the left
(4) to remove the gap (5) between the racks. Then, tighten the leftmost screw and
the rightmost screw of each rack (2).
1
2
5
3
4

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3.2. Assembling the ring track
Select the track that matches the outer diameter of the round workpiece. Use the
4 mm hex wrench to attach the supports to the rails (1). Next, on all supports, move
back the bolts (2, or screws) as much as possible. To clamp the track to the work-
piece with a smaller diameter, you can use brackets (3). But this will decrease the
stiffness of the clamping.
Put the workpiece vertically, and then put the rails onto the workpiece so that the
teeth of the racks point down. Next, for all rails, use the 12 mm hex wrench to set the
hinge as shown. Then, put the lock pin through the holes (1), and then rotate the
wrench (2) to connect the rails.
1
2
2
Screw with plastic foot
25 mm (1″) adjustment range
Bolt
25 mm (1″) adjustment range
Screw with magnet
25 mm (1″) adjustment range
3

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Use the 13 mm flat wrench to adjust the bolts (or the screws by hand) until they are
in contact with the workpiece (1). Adjust each support equally to make the track
concentric to the workpiece. Lock the supports with the nuts (2) or levers.
1
2
2
1

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3.3. Positioning on a straight track
Set the power switch, arc ignition switch, oscillation switch, and direction switch to
‘O’. Pull the lever lock (1). Next, set the lever to OFF (2), and loosen the knob (3) fully
to move back the gear (4). Then, put the carriage so that the mounting brackets are
on the rail (5, 6).
3
4
Gear moved back
5
Mounting bracket
Mounting bracket
6
1
2

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Set the lever to ON (1) to put the rollers into the grooves (2). Tighten the knob (3) to
engage the gear of the carriage with the rack of the rail (4). Keep a small backlash
between the gear and the rack. Move the carriage slightly back and forth to make
sure that there is a backlash.
3
Not engaged
×
Engaged
✓
1
2
2
4

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3.4. Positioning on a curved track
Use the 6 mm hex wrench to loosen four screws (1), and then put the carriage on the
track. Rotate two roller brackets (2) to put the rollers into the grooves, and then set
the levers to ON (3). Next, move the carriage back and forth to make sure that it
moves smoothly. Then, tighten the screws (1) and use the knob (4) to engage the
gear with the rack as described in “Positioning on a straight track”.
1
2
2
4
3

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3.5. Preparing and connecting
At heights, protect the carriage and the track from falling. To do this, use chains
(not included) to attach the leftmost and rightmost magnetic units of the hi-flex, semi-
flex or rigid track to a stable structure. To protect the carriage, attach a chain to a
carrying handle. Make sure that the chains are not loose.
Use the 0.5 m (1.5 ft) cable to connect the remote control to the carriage (1), if
the remote control will be put onto the carriage, or use the 3 m (10 ft) / 5 m (16.5 ft)
cable (2). Then, connect the carriage to the power source and put the torch and
torch cables into the holders.
Make sure that the cables are correctly connected. Connect the plugs
marked in red to the socket marked in red.
INCORRECT
×
CORRECT ✓
3 m (10 ft) cable
1
2
2
1
0.5 m (1.5 ft)
cable

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3.6. Connecting to the welding circuits
Before connecting, read the operator’s manual of the welding source. Connect the
arc ignition cable only to the remote control socket of the welding source.
Do not connect the carriage to sockets other than the remote
control socket.
The carriage can control two torches by using the arc ignition cable plugged into
the arc ignition socket. To do this, refer to the diagram and connect one blue-
jacketed wire to one terminal of the welding circuit. Then, connect the other blue-
jacketed wire to the other terminal of the same circuit. To control the second torch,
connect the green-jacketed wires to the terminals of the second welding circuit.
Make sure that the arc ignition cable is connected correctly. To do this, turn on the
power of the carriage, and then set the arc ignition switch to TEST. This should
enable the arc for a while.
Blue
Blue
Green
Green
Welding circuit 2
Welding circuit 1

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3.7. Operating
Set the power switch to ‘I’ to turn on the carriage. To pause loading to check the
firmware version, press and hold one of the navigation buttons. After you release the
button, the control system loads and the main screen shows.
Operating mode
Arc ignition switch
(TEST/O/I)
Direction switch
(Forward/O/Backward)
F1
F3
F2
Oscillation switch
(TEST/O/I)
Navigation button 2
Navigation button 1

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Tab. 1 explains the symbols shown on the right of the main screen.
Tab. 1. Symbols of connected modules
Symbol
Description
Motorized vertical slide (option).
Tracking sensor (option).
Use the knobs to set the required parameters (Tab. 2). Rotate to the right to increase
the value of the parameter. Rotate to the left to decrease the value.
Tab. 2. Parameters shown on the main screen
Parameter
Value
Description
Method of control
0–5 s [step: 0.1]
(with tracking off)
0.2–5 s [step: 0.1]
(with tracking on)
Oscillation dwell time
in left position. Press and hold and rotate
0–5 s
[step: 0.1]
Oscillation dwell time
in center position. Press and hold and rotate
0–5 s [step: 0.1]
(with tracking off)
0.2–5 s [step: 0.1]
(with tracking on)
Oscillation dwell time
in right position. Press and hold and rotate
0.1–11.8 cm
0.04–4.5 in
[step: 0.1/0.01]
Oscillation width.
Press and release (activates
) and rotate
10–200 cm/min
5–78 in/min
[step: 5/1]
Oscillation speed
(when the vertical
slide is not connect-
ed).
Rotate
Oscillation speed
(when the vertical
slide is connected).
Press and release (activates
) and rotate
0–250 cm/min
0–98 in/min
[step: 1/0.5]
Carriage speed.
Rotate
Travel the carriage
with the maximum
speed in the direction
set by the direction
switch.
Press and hold when the
arc ignition switch is set to ‘O’
From –9.9 to +9.9
cm
From –3.9 to +3.9 in
[step: 0.05/0.02]
Oscillation offset.
Rotate
From –2.5 to +2.5
cm
From –1 to +1 in
[step: 0.02/0.01]
Torch height
(when the vertical
slide is connected).
Rotate