GB
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-
L
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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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
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
1.0--1.4
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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