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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).
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Kent Eimbrodt
Global Director
Equipment and Automation
L
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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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
1.0--1.4
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.
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Dimension drawing
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Diagram
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List of components
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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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Spare parts list
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Miggytrac 3000
Edition 2007--03--07
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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
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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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