Buyer: Delivery:

Brasil

Brasil

Schlieren, 14. October 2016

SP / Mpe

Technical Specifications no -H
GAAS80 serial no. 2145.31713.
Ref.: P.O. 55747-00 dd. 13/10/2016 (ref. customer: 4920104839)

DC Rectifier Flash Butt Welding and

Burr Removing Machine type GAAS 80

Contents Page
1. Application and production ...................................................................7
2. Technical data ......................................................................................9
3. Connection & consumption data ........................................................11
4. Main features .....................................................................................12
5. Description of the installation .............................................................14

Acknowledgement of order -H page 6 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
1. Application and production
1.1. Application
The Schlatter Direct Current (DC) Rail Flash Butt Welding Machine is designed
for indoor welding of rails for the production of continuous rails. Rail alignment,
welding and burr removal of new and used rails takes place in one work cycle.
The machine is easy to operate and well maintainable. Rail alignment can be
done easily and quickly by the operator. The welding quality is stable from the
first to the last weld. The integrated automatic burr removing device cuts the
burr around the whole rail profile (head, web and base) directly after the welding
process while both rail ends remain clamped.

1.2. Rail Length

Short rails, non-welded from 6 m to 120 m

1.3. Rail profiles

Equipped for 4 profiles UIC 60 kg/m
(other profiles on request) TR45
TR57
TR68

1.4. Welding range

General working range: 45 kg/m up to 75 kg/m
Weldable rail section up to ~ 12'000 mm²

1.5. Material specification

Normal quality 700 - 900 N/mm²
Special wear resisting quality 900 - 1100 N/mm²
High wear resisting quality 1100 - 1300 N/mm²
Heat-treated rail

1.6. Aligning accuracy

Aligning accuracy on running edge ± 0,3 mm
Aligning accuracy on rail head ± 0,3 mm

1.7. Production Capacity

No of welds per hour, thermically admissible, burr-removal included (without
reheating), on rail types:
60 kg/m up to 20 welds per hour
75 kg/m up to 15 welds per hour

Acknowledgement of order -H page 7 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
1.8. Production sequence
Transport of the rail to the machine inlet side (left)
Rough aligning
The rails to be welded can be entered from both sides of the machine.

Left machine side

Approach of the upper electrode
Approach of the centering arms for the rail head.
Approach of the lower electrode
Horizontal clamping of the centering arms
Vertical crown alignment
Clamping over the rail web
Entering the short rail, (right hand side)

Right machine side

Clamping and aligning of the short rail as described for the left side.

Start of welding process

automatic performance of welding program:
- Flashing-even
- Preheating
- Flashing
- Upsetting
- Post-heating (as far as necessary)
Opening of the right-side electrode assembly and the horizontal centering
arms
Automatic deburring
Opening of the remaining clamping elements
Ongoing transport of the welded and deburred rail

Manual operation of the GAAS 80:

All machine functions can also be selected individually and executed step by
step.

Acknowledgement of order -H page 8 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
2. Technical data
2.1. Mechanical
Upset force max. 800 kN
Upsetting travel, total 50 mm
Stroke of back up and crown rolls 50 mm
Gap between electrode dies 200 - 250 mm
Upsetting speed > 40 mm/s
Main clamping force on web max. 1'500 kN
(separate from electrode system)
Burr-removing force max. 600 kN
Number of adjustable blades 4
Clamping force of electrodes 400 KN
(separate from rail clamping system)
Clamping force of horizontal aligning device 60 kN
Horizontal adjustment ± 7.5 mm
Preselectable on center line, running edge right or left yes
Vertical adjustment ± 10.0 mm
The indicated force values are max. values.

2.2. Electrical
Max. welding power (with preheating) 660 kVA
Welding power for continuous flashing 370 kVA
Secondary DC-welding current up to 80 kA
Secondary open-circuit voltage 6.3 V
Power factor cos. phi 0,85
Nominal mains voltage 3 x 400 V, 60 Hz *
Electronic voltage compensation capability during +/- 10 %
welding

* Remark: other mains voltages need a separate 3-phase autotransformer

(not part of the supply)

Acknowledgement of order -H page 9 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
2.3. Layout, Dimensions and Weights
Documentation
Layout with protective fence no. 1042700
Dimension sketch no. 820660

Weights:
Machine ca. 30'000 kg
Hydraulic aggregate (without oil) ca. 950 kg
Connection and control cabinet ca. 850 kg
Cooling water recooling unit Sigma 104 ca. 810 kg
(without water)

Dimensions:
Machine L x W x H * ca. 6'200 x 2'050 x 2'500 mm
Control cabinet ca. 2'400 x 600 x 2.100 mm
Hydraulic-Aggregate ca. 1'800 x 950 x 1'600 mm
Cooling unit Sigma 104 ca. mm
* without protection fence

Colours
Blue RAL 5017 Machine socket
Grey RAL 7035 Machine casing
Yellow RAL 1007 Moveable parts

Acknowledgement of order -H page 10 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
3. Connection & consumption data
3.1. Electrical
Electric energy three-phase current, AC * 3 x 380 V, 60 Cycles
* Deviating mains voltage to be adapted by auto-transformer (Buyer's supply).

Mains transformer
Mains transformer capacity required 630 kVA
Impedance voltage max. 5 %
Limitation of voltage drop max. 10 %
Lead-in cable, cross sectional area per phase 3 x 150 mm²
Earth lead cable 2 x 150 mm²
Length of lead-in cable max. 70 m
Fusing according to local regulations

3.2. Cooling water

Lead-in temperature max. 25° C
Temperate increase 7° C
Heat dissipation ca. kcal/h
Water pressure min. 4 bar
max. 6 bar
Flow rate for rectifier groups, current leads,
electrodes, hydraulic unit total 150 l/min.
Filtering 100 µm
dH-value not above 8 °
pH-value 7 - 8,5
Only clean, neutral to slightly alkaline water may be used.
A separate cooling water recooling device with closed circuit is recommended.

3.3. Atmospheric Conditions

Ambient temperature (indoor, in operation) + 5 to +40 °C
Relative air humidity, at 20°C max. 90 %
at 40°C max. 50 %
Admissible operation altitude (m. above sea level) 1'500 m
Oher conditions on request

Acknowledgement of order -H page 11 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
4. Main features
4.1. Closed frame machine body
Sturdy closed machine frame prevents deformations of the frame during
clamping and upsetting.
The design of the upsetting slide based on the patented Schlatter hinged sheet
principle is practically free of friction and without play. This allows to maintain a
constantly high weld quality. The hinged sheet principle is insensitive to smoke
and overheat. It does not need neither lubrication nor other maintenance, a
great advantage for a smooth operation of the machine

4.2. Automatic alignment of the rail ends

Rails, also with horizontal and vertical deviations on the rail ends, are
automatically aligned in the range of 1 m. Alignment to the running edge or
profile center are pre-selectable, A vertical alignment unit puts the rails
automatically in a pre-selectable crown position. Also rails with torsions can be
aligned.
This automatic alignment unit grants for constant alignment accuracy and offers
a considerable time saving.
An additional manual alignment by means of push-buttons is also possible.

4.3. Web clamping system

The major part of the clamping force is transmitted to the rail web. There are no
marks on the rail head and rail base, which could lead to a fatigue break of the
rail.

4.4. Symmetrical set-up of the upsetting presses

The upsetting force is spread evenly over the entire rail section.

4.5. Automatic deburring in the welding machine

Immediately after completion of the welding process the burr is removed on the
entire rail profile circumferential to a residual height of approx. 1 mm.
The two rail ends remain clamped during this operation. Deburring at optimum
temperatures prevents heat cracks on the rail surface.

4.6. Six-phase rectification of the secondary current

The rectified weld current grants for an even heat distribution over the rail
section. This results in an even heat affected zone.

4.7. Optimised mains connection conditions

Absolutely symmetrical loading of the three mains phases. Reduced peak
loads, reduced harmonic distortion to the mains.

Acknowledgement of order -H page 12 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
4.8. Good power factor
Because the symmetrical 3-phase connection and insignificant reactive power
the connected load is lower. Consequently the necessary mains transformer
and the lead cross sections can be dimensioned smaller, in particular no
reactive power compensation is required.

4.9. Combined regulation of current, force and travel

The welding process is sub-divided into different stages and, depending on the
stage, either current, force or travel-regulated. By this, a constant welding
quality as well as a high dimensional accuracy of the welded components by
regulated end positions is achieved.

4.10. Weld process monitoring and documentation system

The Schlatter Weld Analyzer Program displays in real time on the Screen the
three most important parameters of the flash butt welding process:
Weld force
Weld current
Travel
The weld parameters are in parallel stored on the hard disk for later retrieval.

4.11. Power breaker

Located in the mains cabinet power breakers serve for a selective protection of
the electrical equipment. The transformer / rectifier group is individually
protected with a power breaker with thermal and magnetic release.

4.12. Hydraulic equipment

The hydraulic unit is placed beside the machine and works with a regulation
pump. During idle operation it is pressure released. The hydraulic oil is water
cooled by means of a heat exchanger.

Acknowledgement of order -H page 13 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
5. Description of the installation
The machine is consisting of

5.1. Flash Butt Welding Machine Type GAAS 80 *

Sturdy machine body as a frame type welded structure
Hydraulically operated clamping mechanism working on the rail web.
Current leads to the electrodes
Hydraulically operated height adjustment
Hydraulically operated lateral adjustment
Hydraulically operated upsetting unit
Thyristor contactors, with three water cooled power thyristors, control the
welding current on the primary side. Setting of the welding current is
effected by means of phase shift on the control unit.
Welding transformer group, with three single phase transformers with
water-cooled secondary windings. Each transformer is thermally protected
against overheating. On the primary side, the transformers are connected
in star connection.
Rectification of the welding current on the secondary side of the welding
transformers by means of water cooled high current diodes.
Operating elements: The operating elements for the machine are
concentrated on an adjustable hinged control box.
Spatter guard.
Safety fence

5.2. Hydraulic unit **

A separate hydraulic unit, type Rexroth, is supplied to operate the welding plant.
* Pressure of pump 140 bar
* Tank capacity 400 lt
* Hydraulic oil type HVLP Z ISO 46

5.3. Machine control ***

Machine control incorporated into a free standing control cabinet, comprising:

5.3.1. Function Control Siemens S7

Memory-programmable microprocessor control type Siemens S7 for the
automatic working sequence of the machine, incorporated in control unit.

5.3.2. Operation
Control buttons for operating and set-up functions.
Siemens OPxx control panel

Acknowledgement of order -H page 14 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
 Emergency cut-out button

Operating language
The machine control is set-up as far as possible by language-neutral symbols
(pictograms)
Advice and warning labels are in the language of the country (as available)
The language of the man machine interface of the PLC, the WeldAnalyzer, etc.
can be selected out of the available languages as stipulated in the interface
documents.
Language chosen for that project: Brazilian / English

5.3.3. Weld Processor regulating Unit Type SWEP 20

for control and management of the complete weld process
Sensors for the detection of the weld current, weld force and stroke
Self-calibrating electronic, all modules are identical and ready to
operate after the auto calibration process
Phase control with voltage compensation: Weld current within ± 2 % for
voltage variations of ± 10 %.
The weld process is freely programmable. A weld program can contain
up to 12 process steps.

Example:
Step 1 Preparations for the welding
Step 2 Flashing even
Step 3 Preheating
Step 4 Flashing
Step 5 Upsetting
Step 6 Post heating

Programming, storage, documentation and data management of the

weld programs with Personal Computer (Profile Studio).
Wide selection of diagnostic functions within the Profile Studio
Failures while clamping the rail (slipping or too large initial gap) will be
detected and indicated before welding.
While booting, errors within the SWEP20 are detected and indicated
Password protection for weld programs

Acknowledgement of order -H page 15 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
5.3.4. Schlatter Weld Analyzer System
The Schlatter WeldAnalyzer System records, analyzes and monitors the three
most important parameters of a flash butt welding process and plots the
information in real-time on a high resolution graphic display while the welding
process is running. The three parameters are:
Welding Force [kN]
Welding Current [kA]
Travel [mm]
At the end of the welding process, the complete data recording and the
currently valid weld specifications, along with additional information about the
welding job, customer, date and time, welding machine, operator, user
specific information and comments about the current job, current rail and
current welding etc. are saved in the so-called Weld-File.
Weld-Files can be automatically saved to two different drives/directories at
the same time. These can be local internal or external drives or network
drives.
After the weld data has been saved, weld characteristics such as mean
values, RMS values and maximum values of current and force, cycle
duration, velocities, number of preheats/postheats, flashing travel, upset
travel and so on are calculated and displayed together with the weld graph.
WeldAnalyzer also recognizes and graphically distinguishes each cycle of
the weld process (Flash Even, Pre Heating, Final Flash, Upset Current,
Upset Hold, and Post Heating) with different background colour shades.
Weld specifications to certain critical areas can be predefined and are
displayed within the weld graph. Each weld is checked for compliance to
these specifications. Critical areas of a weld found to be non-compliant are
highlighted and the out of tolerance value is displayed. If any specification
limit is violated, this will also be transmitted to the machine control system
(PLC) and needs to be approved before further welding is possible.
When rating welds at a later date, the user can choose whether the
recordings should be analyzed on the basis of the specifications saved in the
Weld-Files (being valid at the time of welding) or on the basis of the currently
valid limits.
As the experience gained in the process of analyzing welding parameter
recordings is increasing with time, the second version allows analyzing of
earlier recordings based on the latest know-how.
Additional Functions:
Printing of weld graph, weld report, specification limits, rail or part list,
WeldAnalyzer settings to a printer or into PDF files.
Logbook function into a CSV file.
Weld data export for data base or spreadsheet programs.
Marking devices can be automatically controlled for marking welds via a
serial interface.
Acknowledgement of order -H page 16 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
 Zoom function for the weld graph.

5.3.5. Software (programs)

WINDOWS operating system, licensed version
Norton Ghost, licensed version
Schlatter Weld Analyzer Software, licensed version
Schlatter Profile Studio to create and manage weld programs
Schlatter Weld Viewer Software, optimized for office PC

Not included in the extent of supply:

Network (LAN) integration as far as additional hardware, software or
integration work is involved.
Printer for text and graphic output.
Remote support service (*)
(*)
helpline services outside the regular remedial support during
warranty period are subject to special support conditions.
For regular helpline support please request

5.4. External Water Cooling Device type Sigma 104

The cooling unit is connected to the cooling water circuit of the welding
machine and the heat exchanger of the hydraulic unit.
Specifications :
3/PE 380-415
Connecting voltage 10 %
50/60Hz VAC
Control voltage 50/60Hz* 24V AC
Ambient temperature -20°C min 40°C max*
Water inlet temperature 25°C
Digital temperature indication
Coolant medium (free of chloride) R410A
Water with 30% Glycol addictive
Air capacity 2*15'000 m³/h
Water tank content 400 l
Tube connection, inlet and outlet IG 2 "
Tube connection, fresh water feeder IG 3/8 "
General alarm shown on Schlatter interface

Dimensions L x W x H 2216 x 990 x 1998 mm

Weight (without water) 810 kg

Acknowledgement of order -H page 17 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
 Typical operating data :

Ambient temperature 40°C

Water inlet temperature 25°C
Cooling power
Power consumption max. 41.1kW
Current consumption max. 71.7A

Ambient temperature 50°C

Water inlet temperature 25°C
Cooling power
Power consumption max. 38.4kW
Current consumption max. 63.2A

Remark:

Water pipes for the connection between cooling unit and welding
machine, power groups and hydraulic unit are not included in the
scope of supply.
We recommend to organise a local specialist to carry out these
connections.

5.5. Operating Instructions

Language Brazilian / English
Quantity 1 set on paper 1 set on USB (pdf format)
Contents:
Introduction, security instructions
Description, technical Data
Transport, setting up and connecting
Operation
Maintenance
Troubleshooting
Electric diagram
*Drawings and Parts lists

*Drawings and Part lists only in English language.

Acknowledgement of order -H page 18 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com
5.6. Pre-acceptance in Schlieren
Before delivery of the machine a joint (Buyer and Seller) pre-acceptance test
verifying the agreed technical specifications and test welds will take place in
Schlieren.

Acceptance conditions for the welding machine:

3 consecutive successful welds with bend test according to following
arrangement:

Profile 60 E1 R260 E1 / E2
Bend test force min. 1'600 kN
Deflection min. 20 mm

The necessary local homologation procedures for the welding machine / flash
butt welding process is in the responsibility of the Buyer and not included in the
basic scope of supply of the machine.
Any support from the Seller in this respect shall be reimbursed according to the
real effort and according to the actual rates for Schlatter service personnel.

Duration: 1 to 2 days

Acknowledgement of order -H page 19 of 20

Brandstrasse 24 T +41 44 732 71 11 info@schlatter grou p.com

8952 Schl ieren | Sw itzerl and F +41 44 7 32 45 50 ww w.schlattergroup. com