ESAB Miggytrac 3000 User manual

Brand: ESAB

Model: Miggytrac 3000

Category: Welding System

Type: User manual

ESAB Miggytrac 3000 is a welding carriage with integrated wire feed and welding torch, designed for horizontal MIG/MAG welding of plates and beams. Four-wheel drive ensures precise movement along the weld joint, while the adjustable guide wheels allow for welding on various surfaces. The carriage features a user-friendly front panel with a display and buttons for setting welding parameters, including welding speed, wire feed speed, and gas pre/post-flow. Additionally, intermittent welding, crater-fill, and backfill functions enhance welding efficiency and quality.

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

Miggytrac 3000

Instruction manual

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DECLARATION OF CONFORMITY

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).

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

Kent Eimbrodt

Global Director

Equipment and Automation

axå 2007--05--23

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TOCe

Rights reserved to alter specifications without notice.

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 11...................................................

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

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

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

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

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

7 ORDERING OF SPARE PARTS 12......................................

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

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

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

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

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SafE

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 recommen-

dations 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.

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SafE

WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERAT ING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS 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 s tandards.

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 y our 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 y our ears. Use earmuffs or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

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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. T he 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. 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. T he

carria ge 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.

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2.2 Technical Data

Miggytrac 3000

Wire dimensions (mm):

Unalloyed steel

Stainless steel

Cored wire

1.0--1.4

Connection voltage 36 -- 46 VAC

Power 80 W ( max )

Welding speed 15 -- 150 cm/min

T ransport 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

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 installatio n must be executed by a p rofessional.

3.2 Connection of Welding Carriage

12--pin Burndy

Welding cu rrent (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

Start

Stop

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

Programming the distance in cm between the beads for intermittent weld-

ing.

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

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

executes the backfill.

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

end of the bead. Programming in mm.

7 Intermittent weld-

ing

Switch for the selection of intermittent welding. Green LED indicates conti-

nuous welding.

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

be done before start.

9 Welding Start/stop switch for the power source connected.

10 Pot. Remote control of the welding voltage (Volt)

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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 desig-

nation 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.

Dimension drawing

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fhb8dim

Diagram

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fhb8diag

List of components

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fhb8comp

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

-- 1 6 --

sida

Spare parts list

-- 1 7 --

Miggytrac 3000

Edition 2007--03--07

-- 1 8 --

fhb8Chassi

Item

no.

Qty Ordering no. Denomination Notes

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

-- 1 9 --

fhb8Chassi

-- 2 0 --

fhb8torn

Item

no.

Qty Ordering no. Denomination Notes

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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ESAB Miggytrac 3000 User manual

Brand: ESAB

Model: Miggytrac 3000

Category: Welding System

Type: User manual

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ESAB Miggytrac 3000 User manual

ESAB Miggytrac 3000 User manual

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