GB
Tramtrac
t
II
Instruction manual
Valid for serial no. 06470460 231 001 GB 2008--04--24
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that
L
automatic welding machine TramtractII from serial number 0647 complies with standard
EN 12100--2 and EN 60204--1, in accordance with the requirements of directive (73/27/EEC) and with
standard EN 61000--6--2 and also EN 61000--6--3, in accordance with the requirements of directive
(89/336/EEC).
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -----------------------------------axå 2006--12--21
Kent Eimbrodt
Global Director
ESAB AB, Welding Equipment
SE--695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721
DECLARATION OF CONFORMITY
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1SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
2.1 General 6..................................................................
2.2 Technical data 7............................................................
3 INSTALLATION 8....................................................
3.1 General 8..................................................................
4 OPERATION 10.......................................................
4.1 General 10..................................................................
4.2 Handling 10.................................................................
5 MAINTENANCE 11....................................................
5.1 General 11..................................................................
5.2 Daily 11.....................................................................
5.3 As necessary 11.............................................................
6 ACCESSORIES 11....................................................
7 ORDERING OF SP ARE P ARTS 11......................................
DIMENSION DRAWING 12................................................
DIAGRAM 13............................................................
SPARE PARTS LIST 15...................................................
Rights reserved to alter specifications without notice.
TOCe
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GB
1SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from draughts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
SafE
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GB
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS -- Can injure eyes and burn skin.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
SafE
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GB
2 INTRODUCTION
2.1 General
Tramtrac II is a welding carriage designed for surfacing of embedded tram rails. It is
provided with a built-- in wire feed unit, a welding gun and a holder for the wire reel.
The welding carriage only needs to be completed by a welding power source.
The welding gun mount can be adjusted for horizontal or vertical welding, forehand
or backhand. A meniscal sledge allows the gun angle to be adjusted stepplessly
without changing the position of the wire in the joint.
To ensure stable advancement 2 electric motors drive each one wheel set. The
wheels are spiny in order to guarantee good friction against the rail. The carriage is
controlled by two spring--loaded wheels at the bottom of the rail.
The connection to the power source is done by way of a prepared control cable at
the wire feed terminal, where the power supply and the start/stop functions are
included, and a welding cable for the welding current.
The control of Tramtrac II is done from a built--in control panel, from where welding
direction, travel speed , wire feed speed, welding on/off, high--speed transport,
inching and reversing of the wire are controlled.
1. Wire feed
2. Wir reel
3. Weight
4. Guide wheel
5. Drive wheels (4 pcs.)
6. Welding gun
7. Adjusting the gun angle
8. Horizontal slide
9. Vertical slide
10. Wire conduit
1 1. Control panel
12. Lifting handle
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GB
2.2 Technical data
Tramtrac II
Supply voltage 36 -- 46 VAC
Power 90 W
Welding speed 30 -- 1100 mm/min
Dimensions ( l x w x h ) 600x300x150 mm
Weight (without wire reel) 12 kg
Track gauge, carriage 100mm
Max. difference in altitude, bottom rail 10mm
Wire feed speed 6--12 m/min
Wire diameter Ø1,2--1,6 mm
Max. current, start relay 2A
Connection Burndy, 12 stift
Enclosure class IP 23
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.
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