SteelMax ARC Runner Operator'S Manual Download

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The tools of innovation.

112 Inverness Circle East Suite F Englewood, CO 80112

–

87STEELMAX, FAX 303

–

690

–

9172

www.steelmax.com

[email protected]

OPERATOR’S MANUAL

WELDING CARRIAGE

Summary of Contents for ARC Runner

Page 1: ...e tools of innovation 112 Inverness Circle East Suite F Englewood CO 80112 1 87STEELMAX FAX 303 690 9172 www steelmax com sales steelmax com OPERATOR S MANUAL A AR RC C R Ru un nn ne er r WELDING CARRIAGE ...

Page 2: ... 9 Troubleshooting 21 4 MAINTENANCE 22 5 ACCESSORIES 23 5 1 Oscillator 23 5 2 Torch clamps 25 5 3 Rods 26 5 4 Torch holders 27 5 5 Torch extension arm 29 5 6 Guide arms 30 5 7 Dual torch mount 35 5 8 Flexible guide set 36 5 9 Guide adjustment tool 38 5 10 76 mm cross slide 39 5 11 Display protection shield 40 5 12 Fall arrester 40 5 13 Stainless steel wheels 41 6 115 230 V EXPLODED VIEWS AND PARTS...

Page 3: ...dle diameter of 16 22 mm 0 63 0 87 It is fixed by permanent magnets and can work in the following welding positions PA 1F 1G PB 2F PC 2G PD 4F and PE 4G Accessories allow for instance welding with oscillation using torches with the handle diameter larger than 22 mm using two torches at the same time and guiding the carriage along outside edges lap joints and templates walls low or with holes and o...

Page 4: ...orch type MIG MAG Torch diameter 16 22 mm 0 63 0 87 Maximum torch reach 80 mm 3 15 Maximum allowed cable weight Horizontal work 12 kg 27 lbs Vertical work 8 kg 18 lbs Minimum workpiece thickness 5 mm 0 20 Ground clearance 5 mm 0 20 Horizontal pulling force 220 N 48 lbs Vertical pulling force 150 N 33 lbs Cross slide adjustment range 0 35 mm 0 1 38 up down left right Guide arm adjustment range 0 75...

Page 5: ...ncluded 1 Carriage 1 unit 2 Foam filled cardboard box 1 unit 3 Cable anchor 1 unit 4 Short rod torch holder with clip 1 unit 5 3 m 10 ft power cord 1 unit 6 6 5 m 21 ft arc ignition cable 1 unit 7 4 mm hex wrench 1 unit Operator s Manual 1 unit 1 2 3 4 5 6 7 ...

Page 6: ...ARC Runner ARC Runner Operator s Manual 6 1 4 Dimensions 411 mm 16 2 368 mm 14 5 447 mm 17 6 ...

Page 7: ...g for fall arrester Arc ignition socket Control panel Cross slide Oscillation socket Guide arm Power switch Limit switch Magnet ON OFF lever LCD display Knob F1 Knob F2 Arc ignition switch TEST O I Travel direction switch Left O Right Speed adjustment knob ...

Page 8: ...se near flammable liquids or gases or in explosive environments 12 Make sure that the rubber of the wheels is clean and not damaged 13 Never remove the cover of the wheels 14 Remove objects attracted to the chassis by the magnet 15 Transport and position the carriage by using the carrying handle and only when the magnet ON OFF lever is set to O 16 Position the carriage on the ferromagnetic workpie...

Page 9: ...ted Make sure to maintain proper conditions that may affect the operation of the carriage 27 Never try to manually stop the travel To stop set the travel direction switch to O 28 Maintain only when the carriage is unplugged from the power source 29 Repair only in a service center appointed by the seller 30 If the carriage falls from any height is wet or has any other damage that could affect the t...

Page 10: ... the power source insert the torch into the torch holder and then secure it with the screws with the 4 mm hex wrench Next insert the torch cable into the cable anchor secure it with the knobs and then fix the anchor in the required position with the lever Precise torch position adjustment knobs Knobs securing the cable in the anchor Lever securing the cable anchor Screws securing the torch in the ...

Page 11: ...Then connect the second blue jacketed wire to the second terminal of the same circuit To control the second torch connect the green jacketed wires to the terminals of the second welding circuit Fig 2 Connecting the arc ignition cable to welding circuits To make sure that the arc ignition cable is connected correctly turn on the power of the carriage and then set the arc ignition switch to the posi...

Page 12: ...rriage travels to the left use the 4 mm hex wrench to loosen the screws securing the right guide arm Next move out the right arm about 10 mm 0 4 or one groove more than the left arm Fig 3 and then retighten the screws Fig 3 Proper positioning of the guide arms The roller assemblies may be installed at the other end of the guide arms Interval adjustment Travel direction Continuous adjustment Swap t...

Page 13: ...FF lever from left O to right I This will change the clamping force from minimum to maximum Loosen the levers to adjust the position and angle of the torch Use two knobs at the cross slide to precisely set the torch position At heights attach a fall arrester not included to a lug Fig 3 to prevent the carriage from falling This will avoid possible injury to the operator in case the carriage loses t...

Page 14: ...out 3 seconds to go into the configuration menu and set the welding parameters 3 5 Programming The ARC Runner welding carriage allows defining up to 40 welding programs After going into the configuration menu proceed as described in Fig 5 to move among the parameters from Tab 1 Fig 5 Configuration menu Current operating state Program number Unit of speed Value of speed Name of parameter Rotate the...

Page 15: ...he crater must be set higher or equal to the time of the current lowering that is set at the welding source 0 2 cm 0 2 in step 0 1 Length of the backweld Shorter or equal to weld length Inactive if skip set to zero which is indicated by the sign 0 1000 cm 0 400 in infinity step 10 or 1 Longer or equal to the sum of weld length and skip If set to infinity the program executes until the carriage is ...

Page 16: ...If the chosen parameters are not saved they will be active only until the current program number is changed in the main menu 3 6 Welding procedure Fig 6 shows a graphic description of the welding procedure that starts with the speed value shown in the main menu when selecting a travel direction The first stage involves producing the weld after which the carriage fills the crater stage 2 for the ch...

Page 17: ...travel The carriage will start moving according to the chosen program parameters The indication of the current operating mode will show on the display during program execution The carriage speed can be changed during work with the speed adjustment knob The new speed will be saved only if the current program does not change in the meantime The carriage stops after reaching the total length and mess...

Page 18: ...e the torch holder plate 2 by unscrewing screws 3 with 4 mm hex wrench Unscrew the cap 4 Fix the arm 5 to the oscillator 6 Fix the oscillator 6 to the bracket 7 with two M5x20 screws 8 Fix the bracket 7 to the cross slide 10 with two M5x16 screws 9 Fix the oscillator plug 11 to the oscillation socket 12 Fix the low torch holder 13 to the oscillator arm 5 4 2 3 1 8 7 9 12 10 6 11 5 13 ...

Page 19: ...Description 0 100 step 10 or 1 Relative amplitude of the oscillation 0 100 step 10 or 1 Relative speed of the oscillation The higher the speed the shorter the oscillation period 0 5 s step 1 or 0 1 Dwell time in the top position of the oscillation 0 5 s step 1 or 0 1 Dwell time in the bottom position of the oscillation YES NO Choosing YES locks the capability of changing dwell times during welding...

Page 20: ...ob F1 or F2 during work will not trigger any action Otherwise the delay parameters will show on the display and can be adjusted online Fig 9 Fig 9 Menu for changing the oscillator dwell times Rotation of the knob F1 changes the oscillation amplitude by 1 Rotation of the knob F2 changes the oscillation speed by 1 Rotation of the knob F2 changes the delay 2 by 0 1 s Pressing the F2 switches from sho...

Page 21: ...e obstacle at the front Remove the obstacle blocking the travel or choose the opposite travel direction Carriage reached the obstacle at the rear Remove the obstacle blocking the travel or choose the opposite travel direction Too fast switching between left and right travel direction Set the travel direction switch to O 1 Travel direction switch not set to O when powering 2 Displayed during travel...

Page 22: ...Clean the rollers of the guide arms and make sure that the rollers rotate freely 3 Clean the torch nozzle Replace if damaged Monthly 1 Check whether the knobs and the switches work as intended Replace if loose or damaged 2 Inspect cables cords and hoses Replace if damaged 3 Tighten screws if loose ...

Page 23: ...pe Pendulum maximum 11 Oscillation amplitude at r 150 mm 5 9 1 30 mm 1 100 Oscillation speed at oscillation amplitude of 10 mm 0 4 and zero dwell time on ends 7 164 cycles min 1 100 Dwell time on ends 0 5 s Maximum torque 5 Nm 3 7 lb ft Power 12 W Weight 2 6 kg 5 7 lbs To obtain the proper shape of oscillation the axis of the oscillator s output shaft must cross with the axis of the torch Part num...

Page 24: ...ARC Runner ARC Runner Operator s Manual 24 ...

Page 25: ...63 0 87 5 2 2 16 22 mm torch clip Allows using a torch with the handle diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip 5 2 3 22 35 mm torch clamp Allows using a torch with the handle diameter of 22 35 mm 0 87 1 38 Part number ZRZ 0466 19 00 00 0 Part number ZRZ 0466 04 01 00 0 Part number ZCS 0476 06 01 00 0 ...

Page 26: ...RC Runner ARC Runner Operator s Manual 26 5 3 Rods 5 3 1 Short rod Provides a 120 mm 4 72 reach 5 3 2 Long rod Provides a 240 mm 9 45 reach Part number WLK 0476 20 01 00 0 Part number WLK 0466 04 10 00 0 ...

Page 27: ... with clip Allows using a torch with the handle diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip 5 4 3 Short rod low torch holder with clip Allows using a torch with the handle diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip Part number UCW 0476 20 00 00 0 Part number UCW 0476 27 00 00 0 Part number UCW 0476 06 00 00 0 ...

Page 28: ...s using a torch with the handle diameter of 16 22 mm 0 63 0 87 5 4 5 Long rod torch holder with clip Allows using a torch with the handle diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip Part number UCW 0466 22 00 00 0 Part number UCW 0466 04 00 00 0 ...

Page 29: ...0 00 0 5 5 Torch extension arm Extends the reach of the torch Use the 4 mm hex wrench to unscrew the M5x10 screws fixing the cross slide Next use the same screws to fix the cross slide at the end of the arm as shown in the figure Then use M5x16 screws to fix the arm to the carriage ...

Page 30: ... Manual 30 5 6 Guide arms 5 6 1 Edge following guide arms Allow guiding the carriage along outside edges Use the 4 mm hex wrench to unscrew the standard guide arms and install the new guide arms Part number 2 units PRW 0476 21 00 00 1 ...

Page 31: ...or s Manual 31 5 6 2 Adjustable guide arms Allow guiding the carriage along lap joints and templates Use the 4 mm hex wrench to unscrew the standard guide arms and install the new guide arms Part number 2 units PRW 0476 22 00 00 1 ...

Page 32: ...nner Operator s Manual 32 5 6 3 Magnet guide arms Allow guiding the carriage on ceilings Use the 4 mm hex wrench to unscrew the standard guide arms and install the new guide arms Part number 2 units PRW 0476 52 00 00 1 ...

Page 33: ...the 4 mm hex wrench to unscrew the standard guide arms and install the new guide arms To position the carriage closer to the workpiece use the 3 mm hex wrench to unscrew the roller assemblies Next install them at the other end of the guide arms and then swap the guide arms Part number 2 units PRW 0476 54 00 00 1 ...

Page 34: ... Operator s Manual 34 5 6 5 High guide arms Allow guiding the carriage along walls with holes Use the 4 mm hex wrench to unscrew the standard guide arms and install the new guide arms Part number 2 units PRW 0476 55 00 00 1 ...

Page 35: ...5 5 7 Dual torch mount Allows using a second torch Use the 5 mm hex wrench to unscrew the M6x20 screws and washers fixing the carrying handle Next use the same screws and washers to fix the mount to the carriage Part number PDT 0466 40 00 00 1 ...

Page 36: ...thick ferromagnetic surface is 90 N 20 lbs up to a temperature of 100 C 212 F At 180 C 356 F the force decreases to 54 N 12 lbs Connect two guides with the 3 mm hex wrench and M5x16 screws to form a butt or lap joint Next use the 4 mm hex wrench to remove the standard guide arms and install the new guide arms Flexible guide 1 unit PRW 0466 50 01 01 0 Magnet block set BLO 0466 68 00 00 0 includes 1...

Page 37: ...ARC Runner ARC Runner Operator s Manual 37 ...

Page 38: ...long the direction of welding Loosen the levers and put the tool onto the first magnet resting the side of the pilot pin on an outside edge or placing the tip of the pilot pin in a groove Then lock the levers in this position and pull the further part of the guide off the workpiece 1 Next start moving the tool along the guide 2 to clamp the successive magnets to the workpiece Part number UST 0466 ...

Page 39: ...l 39 5 10 76 mm cross slide Extends either up down or left right adjustment range from 0 35 mm 0 1 38 to 0 76 mm 0 3 Use the 4 mm hex wrench to remove the standard cross slide and install the new cross slide Part number ZSP 0466 46 00 00 1 ...

Page 40: ...Protects the display from dirt Use the 2 5 mm hex wrench to unscrew the top screws of the panel and use them to tighten the shield 5 12 Fall arrester Protects the carriage from falling The length of the line is 10 m 33 ft Part number OSL 0476 23 00 00 0 Part number URZ 000001 ...

Page 41: ...ss steel wheels Allow working in horizontal position on a preheated plate As shown in the figure use the 2 5 mm hex wrench to remove the cover and use the 3 mm hex wrench to remove four wheels Install in reverse order Part number 1 unit KOL 0476 57 00 00 0 ...

Page 42: ...ner ARC Runner Operator s Manual 42 6 115 230 V EXPLODED VIEWS AND PARTS LIST 4 3 12 5 11 13 14 6 24 21 2 22 25 8 20 19 18 17 16 23 15 10 7 9 1 4 3 12 5 11 13 14 6 24 21 2 22 25 8 20 19 18 17 16 23 15 10 7 9 1 ...

Page 43: ...7 TRM 0219 06 16 00 0 CLAMP PLATE I 1 8 KST 0466 55 01 00 0 ANCHOR CLAMPING BLOCK 1 9 NKR 000121 KNURLED NUT M6 2 10 RKJ 000036 HANDLEVER M6 32 1 11 ZCS 0476 06 01 00 0 TORCH CLIP ASSY 1 12 WLK 0476 20 01 00 0 SHORT ROD ASSY 1 13 TLJ 0419 04 02 03 0 INSULATION SLEEVE 1 14 RKJ 000036 HANDLEVER M6 32 1 15 SRB 000177 HEX SOCKET HEAD CAP SCREW M5x22 2 16 PDK 000036 ROUND WASHER 5 5 4 17 OSL 0466 06 02...

Page 44: ... 7 3 43 26 57 14 53 51 75 58 68 73 39 21 66 76 86 83 81 8 9 89 77 44 82 30 32 73 24 59 35 64 22 61 20 10 38 56 34 27 50 48 1 16 20 55 54 31 12 60 11 47 72 19 45 46 23 29 36 80 78 88 33 41 79 42 85 87 84 49 25 63 18 28 37 4 5 52 62 74 6 2 68 67 69 71 70 92 ...

Page 45: ... HEX SOCKET HEAD CAP SCREW M5x16 4 23 WPS 0170 00 22 00 1 KEY 3x5x13 1 24 KRZ 0233 01 16 00 0 CAM 2 25 PDK 0233 01 21 00 0 DISTANCE WASHER 12 1x19x3 4 26 PDK 0233 01 23 00 0 WASHER 6 4x12x1 6 1 27 TLJ 0233 01 27 00 0 SLEEVE BEARING 9x16x10 1 28 TLJ 0233 01 28 00 0 SLEEVE BEARING 12x16x10 1 29 ZSP 0476 01 16 00 0 LIMIT SWITCH ASSY 1 30 KOL 0466 01 08 00 0 BEVEL GEAR z30 1 31 KRP 0476 01 01 00 1 BOD...

Page 46: ...02 02 30 1 ENCODER MODULE 1 68 PDK 000058 EXTERNAL TOOTH LOCK WASHER 3 2 7 69 WZK 0476 02 02 02 0 TRAVEL DIRECTION AND ARC IGNITION WIRE SET 1 70 OSL 000036 LEVER SWITCH COVER 2 71 PKT 000016 POTENTIOMETER KNOB 3 72 WZK 0476 02 07 00 0 POWER SWITCH WIRE SET 1 73 WKR 000181 CROSS RECESSED PAN HEAD SCREW M3x6 7 74 MDL 0476 02 02 22 2 DISPLAY MODULE 1 75 WZK 0466 02 09 00 0 POWER WIRE SET 1 76 PKR 04...

Page 47: ...ARC Runner ARC Runner Operator s Manual 47 7 42 V EXPLODED VIEWS AND PARTS LIST 2 4 3 12 5 11 13 14 6 24 21 22 25 8 20 19 18 17 16 23 15 10 7 9 1 ...

Page 48: ...NURLED NUT M6 2 10 RKJ 000036 HANDLEVER M6 32 1 11 ZCS 0476 06 01 00 0 TORCH CLIP ASSY 1 12 WLK 0476 20 01 00 0 SHORT ROD ASSY 1 13 TLJ 0419 04 02 03 0 INSULATION SLEEVE 1 14 RKJ 000036 HANDLEVER M6 32 1 15 SRB 000177 HEX SOCKET HEAD CAP SCREW M5x22 2 16 PDK 000036 ROUND WASHER 5 5 4 17 OSL 0466 06 02 00 0 ROLLER COVER 2 18 RLK 0221 01 19 00 0 GUIDE ARM ROLLER 2 19 TLJ 0419 06 03 00 0 ROLLER SLEEV...

Page 49: ...2 19 45 46 23 29 36 80 78 88 33 41 79 42 85 87 84 49 25 63 18 28 37 4 5 52 62 74 6 2 68 67 69 71 70 ITEM PART NUMBER DESCRIPTION Q TY 1 ZSP 0466 03 00 00 1 CROSS SLIDE ASSY 1 2 KUL 0466 13 00 00 0 LEVER BALL 1 3 ZSP 0623 01 00 00 0 DRIVE SYSTEM 42V 1 4 GLK 0476 01 11 00 0 LEVER HOLDER 1 5 DZW 0476 01 12 00 0 LEVER 1 6 RKJ 0476 01 13 00 0 CARRYING HANDLE 1 7 PKR 0623 02 00 00 0 CONTROLLER HOUSING A...

Page 50: ...EL GEAR z30 1 31 KRP 0476 01 01 00 1 BODY 1 32 WLK 0476 01 02 00 0 FRONT DRIVE SHAFT ASSY 1 33 WLK 0476 01 03 00 0 BACK DRIVE SHAFT ASSY 1 34 BLO 0476 01 04 00 0 MAGNET BLOCK ASSY 1 35 NPN 0476 01 05 00 0 CHAIN TENSIONER 1 36 RDK 0476 01 06 00 0 GEARBOX ASSY 1 37 KOL 0476 01 07 00 0 DRIVE WHEEL 4 38 OSL 0476 01 08 00 0 WHEEL GUARD RIGHT 1 39 OSL 0476 01 09 00 0 WHEEL GUARD LEFT 1 40 OSK 0476 01 10...

Page 51: ...OTENTIOMETER KNOB 3 73 WKR 000181 CROSS RECESSED PAN HEAD SCREW M3x6 7 74 MDL 0476 02 02 22 2 DISPLAY MODULE 1 75 WZK 0621 01 02 00 0 POWER WIRE SET 42V 1 76 PKR 0476 02 01 00 1 CONTROLLER HOUSING 1 77 DLW 000007 CABLE GLAND WITH STRAIN RELIEF PG11 1 78 SZP 0476 02 03 00 0 PIN 4 79 WZK 0476 02 04 00 0 ARC IGNITION SOCKET WIRE SET 1 80 WZK 0476 02 06 00 0 OSCILLATION SOCKET WIRE SET 1 81 NKR 000013...

Page 52: ...ARC Runner ARC Runner Operator s Manual 52 8 115 230 V WIRING DIAGRAM ...

Page 53: ...ARC Runner ARC Runner Operator s Manual 53 9 42 V WIRING DIAGRAM ...

Page 54: ...ponsibility that ARC RUNNER WELDING CARRIAGE is manufactured in accordance with the following standards EN 12100 EN 60745 1 EN 60974 10 and satisfies safety regulations of the guidelines 2004 108 EC 2006 95 EC 2006 42 EC Person authorized to compile the technical file Marek Siergiej ul Elewatorska 23 1 15 620 Białystok Białystok 4 March 2015 ___________________________ Marek Siergiej CEO ...

Page 55: ...l card ARC RUNNER WELDING CARRIAGE 115 230 V 42 V Serial number Electric test Type of test Result Name of tester Insulation electrical strength test 1000 V 50 Hz Date Continuity test of the protective earth system Ω Signature Quality control Adjustments inspections Quality control ...

Page 56: ...p under normal use for a period of 12 months from the date of sale This warranty does not cover wheels as well as damage or wear that arise from misuse accident tempering or any other causes not related to defects in workmanship or material Date of production Serial number Date of sale Signature of seller 2 13 29 November 2017 WE RESERVE THE RIGHT TO MAKE CHANGES IN THIS MANUAL WITHOUT NOTICE ...

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