Promotech Rail Bull User manual

ul. Elewatorska 23/1, 15-620 Białystok, Poland
Phone: [phone], Fax: [phone]
www.promotech.eu e-mail: [e-mail]
OPERATOR’S MANUAL
R
Ra ai il l B Bu ul ll l
WELDING AND CUTTING
CARRIAGE

Contents
1. GENERAL INFORMATION............................................................................................... 3
1.1. Application................................................................................................................. 3
1.2. Technical data............................................................................................................ 3
1.3. Design ....................................................................................................................... 5
1.4. Equipment included ................................................................................................... 6
2. SAFETY PRECAUTIONS.................................................................................................. 7
3. STARTUP AND OPERATION........................................................................................... 9
3.1. Assembling the track.................................................................................................. 9
3.2. Assembling the holder...............................................................................................11
3.3. Positioning................................................................................................................12
3.4. Connecting to the welding or plasma cutting circuits.................................................13
3.5. Adapting for cutting...................................................................................................14
3.6. Operating..................................................................................................................15
3.7. Changing the unit of measure...................................................................................16
3.8. Troubleshooting........................................................................................................17
4. MAINTENANCE...............................................................................................................18
5. ACCESSORIES...............................................................................................................19
5.1. Semi-flexible track.....................................................................................................19
5.2. Rigid track.................................................................................................................19
5.3. Gear rack adjustment tool.........................................................................................19
5.4. Dual magnetic unit....................................................................................................20
5.5. Narrow magnetic unit................................................................................................21
5.6. Angle-adjustable dual magnetic unit..........................................................................22
5.7. Spacing-adjustable dual magnetic unit......................................................................23
5.8. Semi-flexible track support........................................................................................23
5.9. Geared rack..............................................................................................................24
5.10. Transport attachment..............................................................................................24
5.11. Cutting torch holder.................................................................................................25
5.12. Rod (for cutting) ......................................................................................................27
5.13. Gas manifold (for oxy-fuel cutting)...........................................................................27
5.14. Vacuum track fixing system.....................................................................................29
5.15. 16–22 mm torch clamp............................................................................................30
5.16. 16–22 mm torch clip................................................................................................30
5.17. 22–35 mm torch clamp............................................................................................30
5.18. Short rod.................................................................................................................31
5.19. Long rod..................................................................................................................31
5.20. Short rod torch holder with clamp............................................................................31
5.21. Short rod torch holder with clip................................................................................32
5.22. Short rod low torch holder with clip..........................................................................32
5.23. Long rod torch holder with clamp ............................................................................32
5.24. Long rod torch holder with clip.................................................................................33
6. WIRING DIAGRAM..........................................................................................................34
7. DECLARATION OF CONFORMITY.................................................................................35
8. QUALITY CERTIFICATE..................................................................................................36
9. WARRANTY CARD..........................................................................................................37

Rail Bull
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1. GENERAL INFORMATION
1.1. Application
The Rail Bull welding and cutting carriage is a track carriage designed to produce butt
and fillet welds by using MIG/MAG torches with the handle diameter of 16–22 mm
(0.63–0.87’’), and can cut steel by using oxy-fuel or plasma torches. The carriage can
work in the following welding positions: PA/1F/1G, PB/2F, PC/2G, PD/4F, PE/4G, and
PG/3F/3G. It travels on a track fixed by using dual 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 a welding torch 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 fixing system allows the track to be fixed to surfaces that are
non-ferromagnetic.
1.2. Technical data
Voltage
1~ 115–230 V, 50–60 Hz
Power
100 W
Welding position
(according to EN ISO 6947
and AWS/ASME)
horizontal
PA / 1F / 1G
PB / 2F
PC / 2G
PD / 4F
PE / 4G
vertical
PG / 3F / 3G (contact your dealer)
Minimum curvature radius of a semi-flexible track
5 m (16 ft)
Torch type
MIG/MAG
oxy-fuel/plasma cutting torch
Torch diameter
16–22 mm (0.63–0.87’’)
Minimum workpiece thickness
5 mm (0.2’’)
Horizontal pulling force
350 N
Vertical pulling force
150 N
Horizontal speed
0–120 cm/min (0–47.2 in/min)
Vertical speed
0–110 cm/min (0–43.3 in/min)
Geared rack stroke
0–190 mm (0–7.5’’)
Maximum permitted ambient temperature
50°C (122°F)
Maximum permitted ambient humidity
85%
Weight
18 kg (40 lbs)

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358 mm (14.1’’)
635 mm (25.0’’)
484 mm (19.1’’)

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1.3. Design
The Rail Bull carriage consists of a chassis, a drive system, a controller, a 540 mm
(21’’) geared rack, acable anchor, aslide, a300 mm (12’’) vertical geared rack, and a
torch holder. Acam mechanism enables the carriage to be installed on a track, onto
which dual magnetic units may be attached to allow the track to be fixed to the surface.
The drive system incorporates a gear-motor that drives a gear wheel cooperating
with the gear rack of the track. The position of the 540 mm geared rack is adjusted by
using the knob, and the slide with the vertical geared rack enables the adjustment of
the vertical position of the torch holder. Additionally, connecting the arc ignition cable
will enable the carriage to ignite an arc when selecting a travel direction.
Fig. 1. View of the Rail Bull
Arc ignition socket
Pressing lever
Control panel
540 mm geared rack
Levers securing
the geared rack
position
Torch holder with clamp
Power switch
Drive clutch knob
Display
Carrying handle
Geared rack position
adjustment knob
Cable anchor
300 mm vertical geared rack
Slide
Clamping block

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Fig. 2. View of the control panel
1.4. Equipment included
The Rail Bull is supplied including the following elements.
Carriage
1 unit
Metal box
1 unit
540 mm (21’’) geared rack
1 unit
Slide
1 unit
300 mm (12’’) geared rack
1 unit
Short rod torch holder with clamp
1 unit
Clamping block
1 unit
Cable anchor
1 unit
3 m (10 ft) power cord
1 unit
6.5 m (21 ft) arc ignition cable
1 unit
Gas manifold bracket
1 unit
3 mm hex wrench
1 unit
4 mm hex wrench
1 unit
Operator’s Manual
1 unit
Arc ignition switch (TEST / O / I)
Travel direction switch (forward / O / backward)
Travel speed knob

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2. SAFETY PRECAUTIONS
1. Before beginning, read this Operator’s Manual and complete proper occupational
safety and health training.
2. Use the carriage only in applications specified in this Operator’s Manual.
3. The carriage must be complete and all parts must be genuine and fully operational.
4. The specifications of the power source must conform to those specified on the
rating plate.
5. Connect the carriage into a properly grounded power source.
6. Never carry the carriage by the cords or arc ignition cable and never pull them as
this may damage them and result in electric shock.
7. Untrained bystanders must not be present near the carriage.
8. Before beginning, make sure that the correct is the condition of the carriage, power
source,cords, arcignition cable, plugs, control panel, guiding rollers, and gear wheel.
9. Keep the carriage dry. Exposure to rain, snow, or frost is prohibited.
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 wheel and guiding rollers are clean and not damaged.
15. Plug the cords and arc ignition cable into sockets only when the power switch is
set to the position ‘O’.
16. Keep the sockets clean. Do not use compressed air for cleaning.
17. Install only MIG/MAG welding torches or oxy-fuel/plasma cutting torches with the
handle diameter corresponding to the torch holder in use.
18. Suspend cables to reduce the load of the carriage.
19. Do not bend the semi-flexible track to a radius less than 5 m (16 ft).
20. Use the rigid track only on flat surfaces.
21. When operating at heights, protect the carriage and the track from falling. To do
this, fasten the track to a fixed structure with chains attached to the leftmost and
rightmost dual magnetic units. Protect the carriage by attaching a chain to a
carrying handle. The chains must not be loose.
22. Do not stay below the carriage or the track placed at heights.

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23. Always use eye protection (helmet, shield, and screen), hearing protection, gloves,
and protective clothing during operation. Do not wear loose clothing.
24. Before every use, inspect the carriage to ensure it is not damaged. Check whether
any part is cracked or improperly fitted. Make sure to maintain proper conditions
that may affect the operation of the carriage.
25. Never try to manually stop the motion of the carriage. To stop, set the travel
direction switch to the position ‘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 operation and immediately
send the carriage to the service center for inspection and repair.
29. Never leave the carriage unattended during operation.
30. Remove from the worksite and store in a secure and dry location when not in use.

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3. STARTUP AND OPERATION
3.1. Assembling the track
Connect dual magnetic units to the rail, and position it on the workpiece. Use the
4 mm hex wrench to attach additional rails (1, Fig. 3), and then switch the levers of
the magnetic units to the position ‘I’, which will clamp the track to the surface.
When working in PC/2G welding position, place the track so that the teeth of the
gear racks are directed downward.
Fig. 3. Interconnecting the rails and clamping the magnetic units to the surface
Before attaching additional rails to a semi-flexible rail placed on a curvature, use the
4 mm hex wrench to loosen the screws of the connecting plates (1, Fig. 4) and of
the gear racks (2). Next, attach the rails, clamp them with levers, and then tighten the
connecting plates. Place the gear rack adjustment tool (not included) into the hole (3),
rotate the tool to the left (4) to remove the gap (5) between the gear racks, and then
tighten the leftmost screw and the rightmost screw of each gear rack (2).
1
2

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Fig. 4. Removing the gap between the gear racks of a semi-flexible track
1
2
5
3
4

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3.2. Assembling the holder
Assemble the vertical geared rack with the slide as shown in Fig. 5 and attach the
slidetothe540mmgearedrack.Then,assemblethetorchholderwiththeclampingblock
and attach the block to the vertical geared rack. Secure with levers. The slide, clamping
block, and torch holder can be assembled in many ways to form different configurations.
Fig. 5. Sample methods of assembling the vertical geared rack with the torch holder
540 mm
geared rack
300 mm vertical geared rack
Clamping block
Slide
Torch holder

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3.3. Positioning
Set the power switch, arc ignition switch, and travel direction switch to the position ‘O’.
Next, with the pressing lever in the position OFF (1, Fig. 6) loosen the drive clutch knob
fully (2), and then set the carriage onto the track (3) so that the back rollers are placed
in the groove (4).
Fig. 6. Positioning the carriage on the track
1
2
3
4
7
6
5

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Set the pressing lever to the position ON (5) to press the front rollers to the track.
Slide the carriage to the required position (6), and fully tighten the drive clutch knob (7)
to engage the gear wheel of the carriage with the gear rack of the track. Then, loosen
the knob by 1/4 rotation.
When operating at heights, protect the carriage and the track from falling. To do
this, fasten the track to a fixed structure with chains attached to the leftmost and
rightmost dual magnetic units. Protect the carriage by attaching a chain to a carrying
handle. The chains (not included) must not be loose.
Plug the power cord into the power source, and then insert the torch into the torch
holder and secure with the knob. Next, 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 or plasma cutting circuits
The carriage can control two torches by using the arc ignition cable plugged into the arc
ignition socket. To do this, connect any blue-jacketed wire to any terminalof the welding
/plasma cutting circuit, and then connect the second blue-jacketed wire to the second
terminal of the same circuit, according to the diagram shown in Fig. 7. To control the
second torch, connect the green-jacketed wires to the terminals of the second circuit.
Fig. 7. Connecting the arc ignition cable to welding / plasma cutting circuits
To make sure that the arc ignition cable is connected correctly, turn on the power
of the carriage, and set the arc ignition switch to the position TEST, which should
enable the arc for a while.
blue blue
Circuit 1
green green
Circuit 2

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3.5. Adapting for cutting
To adapt the carriage for oxy-fuel or plasma cutting, remove the welding torch holder,
and install a rod for cutting and a cutting torch holder (Fig. 8).
For oxy-fuel cutting, use the 3 mm hex wrench to unscrew three screws fixing the
cable anchor, and use the same screws in the same position to secure the bracket of
the gas manifold. Then, use the 4 mm hex wrench to attach agas manifold to the
bracket with the M5x45 screw.
Fig. 8. Installing a cutting torch holder, gas manifold, and arc ignition cable
For plasma-cutting, use the arc ignition cable to connect the carriage to the
cutting circuits as shown in Fig. 7.
Plasma cutting
Oxy-fuel cutting
Oxy-fuel/plasma
cutting
Gas manifold
(optional)
oxy-fuel cutting
Cutting torch holder (optional)
Rod for cutting
(optional)

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3.6. Operating
Set the power switch to the position ‘I’, to turn on the carriage and start the
initialization of the control system. If the message appears on the display,
set the travel direction switch to the position ‘O’. Then, use the travel speed knob to
set the required speed of the carriage.
If the carriage is to control the torch, set the arc ignition switch to the position ‘I’.
Use the travel direction switch to select a direction of motion, which will start the
movement of the carriage with the speed shown on the display. The speed can be
adjusted at any time.
To stop the motion, set the travel direction switch to the position ‘O’.
After the work is finished, turn off the power with the power switch and unplug the
carriage from the power source.
If the arc ignition switch is set to the position ‘I’, the torch starts welding
/ plasma cutting immediately after selecting a travel direction.

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3.7. Changing the unit of measure
To change the unit of measure from centimeters to inches, or vice versa, unplug the
power cord from the power source and follow the steps shown in Fig. 9.
Fig. 9. Changing the unit of measure
With the jumper cap connecting the top and center pin, the measurement system
will be metric after the carriage is restarted. With the jumper cap connecting the
center and bottom pin, the system will be imperial.
The 2.5 mm hex wrench needed to unscrew the control panel is not included in
standard equipment.
Set the jumper cap in the position
corresponding to the required unit.
inch
cm
Use the 2.5 mm hex wrench to loosen
the fixing screws to access the back
side of the control panel.

Rail Bull
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3.8. Troubleshooting
Problem
Cause
Solution
Travel direction switch not in the position
‘O’ when powering.
Set the travel direction switch
to the position ‘O’.
Malfunction of the travel direction switch
wire set or the controller.
Contact service center for
inspection and repair.
Power not supplied to the main motor.
Contact service center for
inspection and repair.
Malfunction of the main motor
encoder or the controller.
Contact service center for
inspection and repair.
Malfunction of the encoder board.
Contact service center for
inspection and repair.

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4. MAINTENANCE
Daily:
1. Clean the gear wheel of the carriage chassis and the gear rack of each rail.
2. Clean the guiding rollers and make sure that they rotate freely.
3. Clean the torch nozzle. Replace if damaged.
Monthly:
1. Check whether the knob and the switches operate as intended. Replace if loose
or damaged.
2. Inspect cables, cords, and hoses. Replace if damaged.
3. Tighten screws if loose.

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5. ACCESSORIES
5.1. Semi-flexible track
Allows guiding the carriage along acurvature. The length of asingle rail is 2m(6.5 ft).
5.2. Rigid track
Allows guidingthe carriage along astraight line. The length of asingle rail is 2m(6.5 ft).
5.3. Gear rack adjustment tool
Allows removing the clearance between the gear racks of two semi-flexible rails
placed on a curvature.
Part number:
PRW-0482-15-05-00-0
Part number:
PRW-0482-47-00-00-0
Part number:
PKT-0341-13-00-00-0

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5.4. Dual magnetic unit
Allows clamping asemi-flexible track (by using abracket) or rigid track to ferromagnetic
surfaces.Theholding force on a5mm (0.2’’) thick surface is 1200 N up to atemperature
of 100°C(212°F).At 180°C(356°F) the force decreasesto 720 N.
Attach the unit to a semi-flexible rail as shown in the left figure: use the 5 mm hex
wrench to tighten the bracket to the unit with M6x20 screws and 6.4 mm washers,
and then tighten the bracket to the rail with M6x16 screws and 6.4 mm washers.
Attach the unit to a rigid rail as shown in the right figure: use the 5 mm hex
wrench to tighten the unit with M6x40 screws and 6.4 mm washers.
Part number:
ZSP-0475-44-00-00-0
Part number (bracket):
DYS-0482-19-00-00-0
Part number (bracket):
DYS-0482-21-00-00-0
(required only when the
rigid track is used with dual
and narrow magnetic units
at the same time)
M6x20
M6x16