ESAB Miggytrac 3000 Instruction manual / Spare parts list (Replacement parts)

Miggytrac 3000

Instruction manual

Valid for serial no. 06450449 453 101 GB 2008--03--20

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that auto-

matic welding machine Miggytrac 3000 from serial number 0341 (2003 w.41) complies with standard EN 12100--2 and EN 60204--1, in accordance with the requirements of directive (98/37/EEC) and with standard EN 61000--6--2 and also EN 61000--6--3, in accordance with the requirements of directive (2004/108/EEC).

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axå 2007--05--23

Kent Eimbrodt Global Director Equipment and Automation

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..................................................................

3.2 Connection of Welding Carriage 8.............................................

4 OPERATION 9.......................................................

4.1 General 9..................................................................

4.2 Front Panel -- Carriage 10.....................................................

4.3 Front Panel -- Wire Feed 1 1...................................................

5 MAINTENANCE 12....................................................

5.1 General 12..................................................................

5.2 Daily 12.....................................................................

5.3 As necessary 12.............................................................

6 ACCESSORIES 12....................................................

7 ORDERING OF SP ARE P ARTS 12......................................

DIMENSION DRAWING 13................................................

DIAGRAM 14............................................................

LIST OF COMPONENTS 15...............................................

SPARE PARTS LIST 17...................................................

Rights reserved to alter specifications without notice.

TOCe

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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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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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2 INTRODUCTION

2.1 General

Miggytrac 3000 is a welding carriage with integrated wire feed and welding torch, designed for horizontal MIG/MAG welding of plates and beams.

All connections (electricity, gas and water) are placed so as to permit the use of ESAB standard cables.

The carriage is provided with a potentiometer for remote control of the welding voltage. All electric communication with the carriage (operating voltage 42V, start and stop signals to the power source and the potentiometer connection) are collected in a 23--pole Burndy contact.

Miggytrac 3000 is provided with four--wheel drive. The carriage follows the weld joint by means of one front and one rear guide wheel. The wheels are adjusted so as to make the carriage travel diagonally towards the flange or stiffener to be welded.

Miggytrac 3000 is provided with two different electronic units, one for the carriage motion and one for the wire feed unit. The parameters are set by way of the plus and minus buttons on the front panel. The set value is indicated o n the display. The carriage also has a function for intermittent welding. The length of the beads and the distance between them are set in cm (1--99 cm). For optimal efficiency the distance between the beads is run at transport speed (250 cm/min).

If the power source has no crater--fill function, the backfill function can be programmed on the carriage. This means that the carriage goes backwards for a selected number of mm in order to fill the crater formed at the end of the bead. The carriage can be programmed with a wa iting time for finishing the cra ter--filling. (Applies to power sources with crater--fill function.) This facility can also be used for creating a cooling pause before the backfill process is executed.

By way of separate electronics the following wire feed parameters can be programmed: Wire feed speed (Welding current), time for Gas pre--flow, Gas post-- flow and Burnback. All the settings are to be done on the front panel. The welding torch can also be provided with a water--cooled gas cup. The carriage is dimensioned for wire reelsupto20kg.

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2.2 Technical Data

Wire dimensions (mm):

Miggytrac 3000

Unalloyed steel

Stainless steel

Cored wire

Connection voltage 36 -- 46 VAC Power 80 W ( max ) Welding speed 15 -- 150 cm/min Transport speed 250 cm/min Lengths at intermittent welding 1--99cm Crater--fill time 0--9.9s Backfill 0--9.9cm Wire feed speed 2--25m/min Gas pre--flow / post --flow 0--9.9s Burnback 0--9.9s Filler wire reel 12” Dimensions (lxwxh) 370 x 400--530 x 520 mm Weight excl. wire reel 17 kg

1.0--1.4

Slide adjustment +/-- 17 mm Remote control terminal Volt Remote control, max. values 2,5 k Max. current over the start relay 5A Connection 23--pin Burndy Enclosure class IP23

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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3 INSTALLATION

3.1 General

The installation must be executed by a professional.

3.2 Connection of Welding Carriage

12--pin Burndy

Welding current (1):

The connection of incoming welding current is done over an OKC connector.

The 42 V connection for start/stop functions and remote control of the welding voltage is done over a 23--pole Burndy contact.

Water (2):

The hoses are provided with quick-- couplings.

Gas (3):

Quick--coupling connections are placed at the back of the tower.

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4 OPERATION

4.1 General

Caution:

Have you read and understood the safety information ? You must not operate the machine before then !

General safety regulations for the handling of the equipment can be found on page 4. Read through before you start using the equipment!

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4.2 Front Panel -- Carriage

Stop

Start

1 Welding speed Programming the welding speed. Displayed in cm/minute. At speeds over

100 cm/min, a comma is lighting after the last figure.

2 Menu selector Switching between the menus for the programming of intermittent welding,

craterfill time and backfill.

3 Bead length Programming the bead length in cm for intermittent welding. 4 Distance betwe-

en the beads

5 Crater--fill time Programming the pause time of the carriage during the craterfilling. Can

6 Backfill Programming the reversing length of the carriage to fill the crater at the

7 Intermittent weld-

ing

8 Direction Switch for selecting the direction of the carriage motion. The selection shall

9 Welding Start/stop switch for the power source connected. 10 Pot. Remote control of the welding voltage (Volt)

Programming the distance in cm between the beads for intermittent welding.

also be used for programming the pause/cooling time before the carriage executes the backfill.

end of the bead. Programming in mm.

Switch for the selection of intermittent welding. Green LED indicates continuous welding.

be done before start.

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4.3 Front Panel -- Wire Feed

1 Wire feed speed Shows the speed in m/min. 2 Display Shows the programmed values. The top window continuously shows

the wire feed speed in cm/min, whereas the bottom window shows the value in steps of 0,1 m/min.

3 Times +/– For programming of the selected function. Only possible when welding

is not going on.

4 LEDs Shows the function marked by way of the menu selector. 5 Menu selector Selecting between three functions: Gas pre--flow, Gas post--flow and

Burnback. Functions only when welding is not going on.

6 Reverse Reversed wire feed. 7 Manual wire feed Wire feed without starting the power source.

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5 MAINTENANCE

5.1 General

Note:

All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period.

5.2 Daily

S Check that all cables and connections are intact.

S Clean the guide wheels.

S Check and clean the wire feed rollers.

5.3 As necessary

S Replace the O--rings of the drive wheels.

S Lubricate the hubs of the guide wheels using thin oil.

6 ACCESSORIES

See separate market leaflet.

7 ORDERING OF SPARE PARTS

Spare parts are ordered through your nearest ESAB representative, see back cover. When ordering spare parts, please state machine type and number as well as designation and spare part number as shown in the spare parts list on page 17. This will simplify dispatch and ensure you get the right part.

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Dimension drawing

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Diagram

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List of components

No. Description

A Filter, voltage supply

D Control unit, welding carriage

E Control unit, wire feeder

D1 Protection diode

D2 Protection diode

F Relay

G Gas Valve

M1 DC--Motor, welding carriage

M2 DC--Motor, wire feeder

R1 Potentiometer 2.5k

SW1 Switch -- “Start/stop”

XP01 Connector 23--pin male

XP02 Connector wire feeder

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sida

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Spare parts list

Edition 2007--03--07

Miggytrac 3000

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Item

Qty Ordering no. Denomination Notes

no.

1 0457357080 Drive wheel

2 0457357090 O--ring

3 0449 901005 Chain protection

4 0449901002 Chain

5 Chain tightener

6 0449901018 Side cover

7 0449901016 Cyl. nut

8 0449901001 Axes with sprocket

9 Counterweight

10 0417855009 Lever

11 0449901012 Arm

12 0449901013 Guide wheel

13 Chassis (empty)

14 0449901015 Motor with gear

15 0449901014 Spatter protection

16 0449902016 Stearing (4 pcs.)

17 0417855001 Slide wheel

18 0449901006 Slide screw, cpl.

19 0449901007 Front tower support

20 0449901008 Horizontal slide nut

21 0449901009 Guides (2 pcs.)

22 0449901011 Rear tower support

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Item

Qty Ordering no. Denomination Notes

no.

1 0398145912 Top cover switch, double

2 0449901036 Top cover

3 0398145913 Switch, double

4 0449902431 Remote control knob

5 0449902432 Label, potentiometer

6 0449902430 Spring-- loaded potentiometer 2.5k

7a 0449902401 Carriage electronics

7b 0449902421 Front label, carriage

8 0449902108 Front frame

9a 0449902411 Electronic wire feed unit

9b 0449902422 Front label, wire feed unit

10 0398146905 Power filter

11 0449902441 Start relay

12 0449902303 Solenoid valve

13 0449902113 Hub

14 Tower (empty)

15 Bracket, hub

16 0398145603 Relief bushing

17 0449902301 Gas connection, male

18 0449902302 Gas connection, female

19 0449902019 Hose support

20 0449902020 Chain

21 0449902451 Cable complete 42 V, 23--pin Burndy

22 0449902453 Chassis plug, male 23--pin

23 Chassis plug with cable 2-- pin

24 0417855009 Locking lever

25 0449902125 Handle

26 Slide base, vertical

27 Pole, hose package

28 0449902208 Slide support, vertical

29 0449902209 Vertical slide

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Item

Qty Ordering no. Denomination Notes

no.

1 0160360882 OKC 95 connection

2 0449903401 Current cable

3 0417855040 Plug motor

4 0449903402 Motorcablewithplug

5a 0365803012 Water Connection (blue)

5b 0365803011 Water Connection (red)

6 0449903201 Water hoses in/out, 2 pcs.

7 0449903202 Water hoses, block--gas nozzle

8a 0365803016 Water Connection small (red)

8b 0365803017 Water Connection small (blue)

9 0365803001 Water connection (male)

10 0449903203 Water hoses, gas cap 2 pcs.

12 0398145603 Relief bushing

13 0449903005 Motor protection

14 0449903410 Motor with gear

15 0449903211 Gas hose

16 0365803001 Gas nipple

17 0449903009 Wire inlet

18 0449903010 Wire inlet support

19 0449903011 Wire feed housing

20 0449903027 Pressure spring

21 0449903028 Pressure screw

22 0449903029 Pressure screw with locking nut

23 0449903013 Hub for feed roller

24 0449903014 Wire feed roller

25 0449903012 Pressure roller support

26 0449903015 Cover

27 0449903016 Allen screw cover

28 0449903017 Insulation (big + small)

29 0449903020 Heat shield

30 0449903019 Distribution block

31 0449903018 Sleeve

32 0449903026 Swan--neck locking screw

33 0449903021 Plate for swan-- neck

34 0449903022 Wire guide

35a 0449903100 Front part 0_

35b 0449903115 Front part 15_

35c 0449903130 Front part 30_

36 0366394002 Adapter

37 0449903101 Gas nozzle, water--cooled

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1 234 5 6 9 810

17 2523 24

1918

2726

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Item

Qty Ordering no. Denomination Notes

no.

1 0449902211 Bar

2 0449902212 Tilting attachment spring

3 0449902213 Tilting arm

4 0449902214 Insulating bushing

5 0417855009 Locking lever

6 0449902216 Fork attachment

7 0417855001 Hand wheel, M8

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ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H Vienna--Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V. Brussels Tel: +32 2 745 11 00 Fax: +32 2 745 11 28

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB Herlev Tel:+4536300111 Fax:+4536304003

FINLAND

ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

FRANCE

ESAB France S.A. Cergy Pontoise Tel:+33130755500 Fax:+33130755524

GERMANY

ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03

ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft Budapest Tel:+3612044182 Fax:+3612044186

ITALY

ESAB Saldatura S.p.A. Mesero (Mi) Tel:+3902979681 Fax:+390297289181

THE NETHERLANDS

ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44

NORWAY

AS ESAB Larvik Tel:+4733121000 Fax:+4733115203

POLAND

ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277

SLOVAKIA

ESAB Slovakia s.r.o. Bratislava Tel:+421744882426 Fax:+421744888741

SPAIN

ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB Gothenburg Tel:+4631509500 Fax:+4631509222

ESAB international AB Gothenburg Tel:+4631509000 Fax:+4631509360

SWITZERLAND

ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

North and South America

ARGENTINA

CONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A. Contagem--MG Tel: +55 31 2191 4333 Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc. Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 57 48

Asia/Pacific

CHINA

Shanghai ESAB A/P Shanghai Tel: +86 21 5308 9922 Fax: +86 21 6566 6622

INDIA

ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama Jakarta Tel: +62 21 460 0188 Fax: +62 21 461 2929

JAPAN

ESAB Japan Tokyo Tel: +81 3 5296 7371 Fax:+81352968080

MALAYSIA

ESAB (Malaysia) Snd Bhd Selangor Tel: +60 3 8027 9869 Fax:+60380274754

SINGAPORE

ESAB Asia/Pacific Pte Ltd Singapore Tel:+6568614322 Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63

Representative offices

BULGARIA

ESAB Representative Office Sofia Tel/Fax: +359 2 974 42 88

EGYPT

ESAB Egypt Dokki--Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13

ROMANIA

ESAB Representative Office Bucharest Tel/Fax: +40 1 322 36 74

RUSSIA

LLC ESAB Moscow Tel: +7 095 543 9281 Fax: +7 095 543 9280

LLC ESAB St Petersburg Tel: +7 812 336 7080 Fax: +7 812 336 7060

Distributors

For addresses and phone numbers to our distributors in other countries, please visit our home page

www.esab.com

ESAB AB SE-- 695 81 LAXÅ SWEDEN Phone +46 584 81 000

www.esab.com

070514

ESAB Miggytrac 3000 Instruction manual / Spare parts list (Replacement parts)

Specifications and Main Features

Frequently Asked Questions

User Manual