ESAB Miggytrac 3000 Instruction manual

Miggytrac 3000

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Valid for serial no. 0411--xxx--xxxx0449 453 001 2006--01--10

SVENSKA 5..............................................

DANSK 15................................................

NORSK 25................................................

SUOMI 35................................................

ENGLISH 45..............................................

DEUTSCH 55.............................................

FRANÇAIS 65.............................................

NEDERLANDS 75.........................................

ESPAÑOL 85..............................................

ITALIANO 95..............................................

PORTUGUÊS 105..........................................

ЕЛЛЗНЙКБ 115.............................................

POLSKI 125.................................................

Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.

ДйбфзсеЯфбй фп дйкбЯщмб фспрпрпЯзузт рспдйбгсбцюн ЧщсЯт рспейдпрпЯзуз.

Zastrzegamy sobie prawo do wprowadzenia zmian.

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ESAB AB, Welding Automation, SE--695 81 Laxå, Sverige, försäkrar under eget ansvar att svetsauto­mat Miggytrac 3000 från serienummer 341 är i överensstämmelse med standard IEC/EN 60292 och
IEC/EN 60204--1 enligt villkoren i direktiv (98/37/EG) och standard EN 50199 enligt villkoren i direktiv
(89/336/EEG).

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FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

ESAB AB, Welding Automation, SE--695 81 Laxå, Sverige, erklærer på eget ansvar, at svejseautomat
Miggytrac 3000 fra serienummer 341 er i overensstemmelse med standarden IEC/EN 60292 og IEC/
EN 60204--1 ifølge betingelserne i direktiv (98/37/EØF) og standarden EN 50199 ifølge betingelserne
i direktiv (89/336/EØF).

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Esab Welding Equipment AB, SE--695 81 Laxå, Sverige, forsikrer på eget ansvar at sveiseautomat
Miggytrac 3000 fra serienummer 341 er i overensstemmelse med standard EN 60292 og EN
60204--1 i følge vilkårene i direktiv (98/37/EF) og standard EN 50199 i følge vilkårene i direktiv
(89/336/EF).

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ESAB AB, Welding Automation, SE--695 81 Laxå, Ruotsi, vakuuttaa omalla vastuullaan, että
hitsausautomaatti Miggytrac 3000 alkaen sarjanumerosta 341 täyttää standardin IEC/EN 60292 ja
IEC/EN 60204--1 vaatimukset direktiivin (98/37/ETY) ehtojen mukaisesti sekä standardin EN 50199
vaatimukset direktiivin (89/336/ETY).

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ESAB AB, Welding Automation, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that
automatic welding machine Miggytrac 3000 from serial number 341 complies with standard
IEC/EN 60292 and IEC/EN 60204--1, in accordance with the requirements of directive (98/37/EEC)
and with standard EN 50199, in accordance with the requirements of directive (89/336/EEC).

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ESAB AB, Welding Automation, SE--695 81 Laxå Schweden, bestätigt hiermit in Eigenverantwortung,
daß der Schweißautomat Miggytrac 3000 ab Seriennummer 341 dem Standard IEC/EN 60292 und
IEC/EN 60204--1 gemäß den Bedingungen der Direktive (98/37/EEG) und dem Standard EN 50199
gemäß den Bedingungen der Direktive (89/336/EEG).

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OVERENSSTEMMELSEERKLÆRING

FORSIKRING OM SAMSVAR

VAATIMUSTENMUKAISUUSVAKUUTUS

DECLARATION OF CONFORMITY

ZULASSUNGSNACHWEIS

ESAB AB, Welding Automation, SE--695 81 Laxå, Suède, certifie que la appareil de soudage
automatique Miggytrac 3000 à partir du numéro de série 341 est conforme à la norme IEC/EN 60292
et IEC/EN 60204--1 selon les conditions de la directive (98/37/CEE) et à la norme EN 50199 selon les
conditions de la directive (89/336/CEE).

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ESAB AB, Welding Automation, SE--695 81 Laxå Zweden, verklaart geheel onder eigen verantwoor­delijkheid dat lasautomaat Miggytrac 3000 van het serienummer 341 in overeenstemming is met
norm IEC/EN 60292 en IEC/EN 60204--1 conform de bepalingen in richtlijn (98/37/EEG) en met norm
EN 50199 conform de bespalingen in richtlijn (89/336/EEG).

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ESAB AB, Welding Automation, SE--695 81 Laxå, Suecia, garantiza bajo propia responsabilidad que
la equipo para soldadura automática Miggytrac 3000 a partir del número de serie 341 concuerda con
la norma IEC/EN 60292 y IEC/EN 60204--1 conforme a la directiva (98/37/CEE) y con la norma EN
50199 según los requisitos de la directiva (89/336/CEE).

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ESAB AB, Welding Automation, SE--695 81 Laxå Svezia, dichiara sotto la propria responsabilità che
la saldatrice automatica Miggytrac 3000 con numero di serie a partire da 341 è conforme alla norma
IEC/EN 60292 e IEC/EN 60204--1 come previsto dalla direttiva (98/37/CEE) ed alla norma EN 50199
come previsto dalla direttiva (89/336/CEE).

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CERTIFICAT DE CONFORMITÉ

VERKLARING VAN OVEREENSTEMMING

-----------------------------------

DECLARACIÓN DE CONFORMIDAD

DICHIARAZIONE DI CONFORMITA

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ESAB AB, Welding Automation, SE--695 81 Laxå Suécia, garante sob responsabilidade própria que,
o equipamento automático para soldadura Miggytrac 3000 a partir do número de série 341 está em
conformidade com a norma IEC/EN 60292 e IEC/EN 60204--1 segundo os requisitos da directiva
(98/37/CEE) e com a norma EN 50199 segundo os requisitos da directiva (89/336/CEE).

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DECLARAÇÃO DE CONFORMIDADE

ЗефбйсеЯбESAB AB, Welding Automation, SE--695 81 Laxе, УпхздЯб, дзлюней ьфй фб мзчбнЮмбфб
бхфьмбфт ухгкпллзфЮт Miggytrac 3000 брь фпн бсйимь уейсЬт 341 кбй Эрейфб, ухммпсцюнпнфбй
ме фп рсьфхрп IEC/EN 60292 êáé IEC/EN 60204--1 уэмцщнб ме фйт брбйфЮуейт фзт пдзгЯбт

(98/37/EEG) кбй фп рсьфхрп EN 50199 уэмцщнб ме фйт брбйфЮуейт фзт п дзгЯбт (89/336/EEG).

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Firma ESAB AB, Welding Automation, SE-695 81 Laxå, Szwecja, gwarantuje pod rygorem
odpowiedzialno¶ci, ¿e automat spawalniczy Miggytrac 3000 od numeru seryjnego 341 spe³nia wymagania
normy IEC/EN 60292 i IEC/EN 60204-1 wed³ug dyrektywy (98/37/EG) oraz normy EN 50199 wed³ug
dyrektywy (89/336/EEG).

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Henry Selenius
Managing Director
ESAB AB, Welding Automation
SE--695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721

ДЗЛЩУЗ УХММПСЦЩУЗУ

CERTYFIKAT ZGODNO¦CI

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ENGLISH

1SAFETY 46...........................................................

2 INTRODUCTION 48...................................................

2.1 General 48..................................................................

2.2 Technical Data 49............................................................

3 INSTALLATION 50....................................................

3.1 General 50..................................................................

3.2 Connection of Welding Carriage 50.............................................

4 OPERATION 51.......................................................

4.1 General 51..................................................................

4.2 Front Panel -- Carriage 52.....................................................

4.3 Front Panel -- Wire Feed 53...................................................

5 MAINTENANCE 54....................................................

5.1 General 54..................................................................

5.2 Daily 54.....................................................................

5.3 As necessary 54.............................................................

6 ACCESSORIES 54....................................................

7 ORDERING OF SPARE PARTS 54......................................

DIMENSION DRAWING 135................................................

DIAGRAM 136............................................................

LIST OF COMPONENTS 137...............................................

SPARE PARTS LIST 139...................................................

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 on the display. T he
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 waiting time for finishing the crater--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.

fhb8d1ea

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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.

fhb8d1ea

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GB

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.

fhb8i1ea

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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 46. Read through before you start using the equipment!

fhb8o1ea

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4.2 Front Panel -- Carriage

StartStop

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 conti-

nuous 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.

fhb8o1ea

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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 139.
This will simplify dispatch and ensure you get the right part.

fhb8m1ea

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ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna-- Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V .
Brussels
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Prague
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Copenhagen--Valby
Tel:[phone]
Fax:[phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]

ITALY

ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]

THE NETHERLANDS

ESAB Nederland B.V.
Utrecht
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel:[phone]
Fax:[phone]

POLAND

ESAB Sp.z.o.o
Warszaw
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]

SPAIN

ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]

ESAB International AB
Gothenburg
Tel:[phone]
Fax:[phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. Esabindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Singapore Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyung--Nam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East
Dubai
Tel: [phone]
Fax: [phone]

Representative offices

BULGARIA

ESAB Representative Office
Sofia
Tel/Fax: [phone]

EGYPT

ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Representative Office
Bucharest
Tel/Fax: [phone]

RUSSIA--CIS

ESAB Representative Office
Moscow
Tel:[phone]
Fax: [phone]

ESAB Representative Office
St Petersburg
Tel:[phone]
Fax: [phone]

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 [phone]

www.esab.com

031021