ESAB Miggytrac 2000 User manual

Brand: ESAB

Model: Miggytrac 2000

Category: Welding System

Type: User manual

Valid for serial no. 739--xxx--xxxx0449 310 001 2009--03--11

Miggytrac 2000

104

Instruction manual

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DECLARATION OF CONFORMITY

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

automatic welding machine Miggytrac 2000 from serial number 739 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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Henry Selenius

Managing Director

ESAB AB, Welding Automation

SE--695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721

Laxå 2004--04--16

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TOCe

Rights reserved to alter specifications without notice.

1SAFETY 4...........................................................

2 INTRODUCTION 6...................................................

2.1 General 6..................................................................

2.2 Equipment 7................................................................

2.3 Technical Data 7............................................................

3 INSTALLATION 8....................................................

3.1 General 8..................................................................

3.2 Other connections 9.........................................................

4 OPERATION 19.......................................................

4.1 General 19..................................................................

4.2 Front panel 20...............................................................

5 MAINTENANCE 21....................................................

5.1 General 21..................................................................

5.2 Daily 21.....................................................................

5.3 As necessary 21.............................................................

6 ACCESSORIES 21....................................................

6.1 Connection, alternative 1: ESAB 21.............................................

6.2 Connection, alternative 2: Universal 21.........................................

7 ORDERING OF SPARE PARTS 21......................................

DIMENSION DRAWING 22................................................

SCHEMATIC DRAWING 23................................................

SPARE PARTS LIST 25...................................................

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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 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 2000 is a welding carriage designed for horizontal MIG/MAG welding of

plates and beams.

The carriage is powered by an electric motor and is prepared for connection to the

remote control socket on the ESAB wire feed unit MEK 4 (23--pin Burndy).

By the connection of a special cable kit to the wire feed unit, the power supply

(42VAC), the start/stop functions of the arc and the co ntrol of voltage and current will

take place over the same cable and the same connection.

The four driving wheels together with a powerful permanent magnet integrated in the

chassis of the carriage guarantee smooth an r egular operation. The m agnet keeps

the carriage in the r ight position on the plate even in the case of welding on bent

plates, or if a long hose bundle is used.

The carriage follows the joint by means of two guide wheels, one at each end of the

carriage. T he wheels are adjusted in such a way as to make the carriage travel

diagonally towards the flange or stiffener to be welded. The permanent magnet can

be disconnected using a hand wheel on the welding carriage in case the carriage is

to be cleaned or displaced without welding. The magnet is activated with the same

hand wheel.

Miggytrac 2000 is provided with digital control electronics for the programming of

the welding speed in cm/minute. For intermittent welding the length of the beads and

the distance between them can be programmed in cm (1--99 cm).

For optimal efficiency the distance between the beads is run at transport speed (250

cm/min). If wire feed units without craterfill function are used, the so--called backfill

function can be programmed. This means that the carriage goes backwards the

selected number of mm in order to fill the crater formed at the end of the bead.

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2.2 Equipment

1. Switch, Start/Stop

2. Adjustment,

torch angle

3. Vertical slide

4. Welding torch holder

5. Magnet disconnection lever

6. Guide wheel

7. Arm

8. Magnet wheel

9. Driving wheel

10. Horizontal slide

11. Electric connection

12. Electronics

13. Remote control, volt/amp.

2.3 Technical Data

Miggytrac 2000

Supply voltage: 36 -- 46 VAC

Power: 40 W ( max )

Welding speed: 15 -- 150 cm/min

Accelerated motion: 250 cm/min

Bead length, chain intermittent weld: 1--99cm

Craterfill time: 0--9.9s

Backfill: 0--9.9cm

Dimensions ( LxWxH ): 33 x 26 x 36 cm

Weight: 9.5 kg

Slide adjustment: +/-- 17 mm

Remote--control parameters: Volt and ampere (wire feed)

Max. data, remote control: 10 kohm, 0.1 W

Max. current, start relay: 0.5 A

Connection: Burndy, 12--pin

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.

MIGGYTRAC 2000 can be connected to one of the wire feed units MEK 4, MEK

4SP, MEK 4C, MEK 44C, MED 44A, MEH 30, MEH 44, MED 302, MED 304, MED

44B or MEK 2. In the case of welding at a great distance from the feed unit an

intermediate wire feed unit (MEK 25) can be connected.

For necessary adaptation of these units, see side 9.

MIGGYTRAC 2000 can also be powered by other power sources via a transformer

unit, see side 17.

For connection of the wire feed unit to MIGGYTRAC 2000, use control cable

according to “Accessories”, see on page 21.

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3.2 Other connections

MEK 4 / MEK 4SP ! MIGGYTRAC 2000

Accessories: cables A, B, F and G, terminal block E, {.

S Remove the cover, |.

S Unscrew the sleeve socket, }.

S Cut off the cables E1 and E2, ~.

S Connect the two cables to terminal block E and cables F and G, .

S Connect the cables A and B between the terminal block, G1 and G2, and the

sleeve socket, pins A and B, .

S Connect the cables F and G to the sleeve socket, pins F and G .

S Fasten the sleeve socket , }.

S Fit the cover, |.

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MEK 4C ! MIGGYTRAC 2000

Accessories: The cables A, B, F, G and terminal block E, {.

S Remove the cover, |.

S Unscrew the sleeve socket, }.

S Cut off the cables E1 and E2, ~.

S Connect the two cables to terminal block E and cables F and G, .

S Connect the cables A and B between the terminal block, J1 and J2, and the

sleeve socket, pins A and B, .

S Connect the cables F and G to the sleeve socket, pins F and G, .

S Fasten the sleeve socket, }.

S Fit the cover, ⎯|.

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MEK 44C ! MIGGYTRAC 2000

Accessories: The cables C, D, J, K and terminal block E.

S Remove the cover (1).

S Unscrew the sleeve socket (2), 23--pol.

S Connect the cables J and K between the terminal block, J1 and J2, on circuit

card AP01 (3) and sleeve socket (2), pins A and B.

S Cut off the cables E1 and E2.

S Connect the two cables to terminal block E and cables C and D.

S Connect the cables C and D to the sleeve socket (2), pins G and F.

S Fasten the sleeve socket , ( 2).

S Fit the cover, (1).

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MED 44A ! MIGGYTRAC 2000

Accessories: The cables C, D, J, K and terminal block E.

S Remove the cover, (1).

S Unscrew the sleeve socket (2), 23--pol.

S Connect cable C between terminal block M7 (5) screw no. 10 and sleeve socket

(2), pin A.

S Connect cable D between terminal block M7 (5) screw no. 11 and sleeve socket

(2), pin B.

S Cut off the cables 093 and 094.

S Connect the two cables to terminal block E and cables J and K.

S Connect the cables J and K to sleeve socket (2), pins G and F.

S Fasten the sleeve socket, (2).

S Fit the cover, (1).

Diagram MEK 4, MEK 4SP, MEK 4C, MEK 44C, MED 44A ! MIGGYTRAC 2000

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MEH 30 / MEH 44 ! MIGGYTRAC 2000

Cable set 0443 341 880 consists of a 4--pole Amphenol sleeve socket to be fitted in

the prepared hole (2). By using a separate contact for MIGGYTRAC 2000 the possi-

bility of using a remote control unit remains.

S Remove the side plate.

S Unscrew the sleeve socket, (2).

S Connect cable A (600 mm) between terminal block B (1) no. 1 on the circuit card,

parallel to the pink cable and sleeve socket (2), pin A.

S Connect cable B (600 mm) between terminal block B (1) no. 2 on the circuit card,

parallel to the grey cable and sleeve socket (2), pin B.

S Connect cable C (160 mm) ) between the flat-- pin connection on the connection

plate parallel to cable 011 (4) and sleeve socket (2), pin C.

Pull the insulating hose (Elcotherm) over the 110 mm cable.

S Connect cable D (160 mm) between the flat--pin connection on the connection

plate parallel to cable 012 (3) and sleeve socket (2), pin D.

Pull the insulating hose (Elcotherm) over the 110 mm cable.

S Fasten the sleeve socket, (2).

S Fit the side plate.

S Connect the 12--pole Burndy contact to the sleeve socket, (5).

Diagram M EH 30, MEH 44 ! MIGGYTRAC 2000

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MED 302 / M ED 304 ! MIGGYTRAC 2000

Cable set 0443 341 880 consists of a 4--pole Amphenol sleeve socket to be fitted in

the prepared hole (2). By using a separate contact for MIGGYTRAC 2000 the possi-

bility of using a remote control unit remains.

S Remove the side plate.

S Remove the plug, (2).

S Connect cable A between terminal block M7 ( 1) no. 1 on the circuit card, and

sleeve socket (2), pin A.

S Connect cable B between terminal block M7 ( 1) no. 2 on the circuit card, and

sleeve socket (2), pin B.

S Connect cable C between the flat--pin connection on the connection plate

parallel to cable 047 (4) and sleeve socket (2), pin C.

S Connect cable D between the flat--pin connection on the connection plate

parallel to cable 045 (3) and sleeve socket (2), pin D.

S Fit the side plate.

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MED 44B ! MIGGYTRAC 2000

Cable set 0443 341 880 consists of a 4--pole Amphenol sleeve socket to be fitted in

the prepared hole (2). By using a separate contact for MIGGYTRAC 2000 the possi-

bility of using a remote control unit remains.

S Remove the side plate.

S Remove the plug, (2).

S Connect the cable between terminal block M7 (5) no. 10 on the circuit card, and

sleeve socket (2), pin A.

S Connect the cable between terminal block M7 (5) no. 11 on the circuit card, and

sleeve socket (2), pin B.

S Connect the cable between the flat--pin connection on the connection plate

parallel to cable 066 (4) and sleeve socket (2), pin C.

S Connect the cable between the flat--pin connection on the connection plate

parallel to cable 062 (3) and sleeve socket (2), pin D.

S Fit the side plate.

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MEK 2 ! MIGGYTRAC 2000

Cable set 0443 341 880 consists of a 4--pole Amphenol sleeve socket to be fitted in

the prepared hole (2). By using a separate contact for MIGGYTRAC 2000 the possi-

bility of using a remote control unit remains.

S Open the cover, (6).

S Remove the side plate, |.

S Remove the plug, (7).

S Cut off the cables E1 and E2, ~.

S Connect the two cables to terminal block E and cables C

and D, and to the sleeve socket, pins C and D, .

S Connect the cables A and B to the terminal block, H01

and H02, and the sleeve socket, pins A and B, .

S Fasten the sleeve socket, (7).

S Fit the side plate, |.

S Close the cover, (6).

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Diagram MED 302, MED 304, MED 33B, MEK 2 ! MIGGYTRAC 2000

Intermediate wire feed unit MEK 25

Prepare MEK 25 as follows:

Accessories: cables C, D, J and K acc. to {.

S Open the wire feed unit, see |.

S Unscrew the sleeve socket.

S Connect the cables J and K to the terminal block already existing on the cables

024 and 025 and to the sleeve socket.

S Connect the cables C and D between the sleeve socket and the existing terminal

block, |.

For connection of MEK 25 to MIGGYTRAC 2000, see Accessories, see page 21.

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Universal

For the operation of MIGGYTRAC 2000 from other power sources, use transformer

unit and control cable acc. to Accessories, see page 21.

1 Control cable for other power sources

2 Transformer unit

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4OPERATION

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!

S Place Miggytrac 2000 near the joint to be welded.

S Adjust the distance and the direction by way of the guide wheels, which shall

press slightly against the flange during operation and by that guide the carriage.

When the magnet is activated the friction between the driving wheels and the

plate is increased and the risk of spinning diminishes. The magnet is activated

by way of the welding start switch.

S Strike the arc using the switch and start welding in the selected direction.

A lamp indicates power ON. The speed of the carriage, the arc voltage and the

welding current (wire feed speed) are adjusted on the front panel.

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4.2 Front panel

1 Welding speed: Program the weld speed in cm/minute. For speeds over 100 cm/min a com-

ma is lighting after the last figure.

2 Menu selector: Switch between the menus for the programming of chain intermittent weld-

ing, craterfill time and backfill.

3 Bead length: Program the length of the bead in cm for chain intermittent welding.

4 Bead distance: Program the distance between the beads for chain intermittent welding.

5 Craterfill time: Program the standstill time of the carriage during the craterfilling. Can also

be used for programming the pause/cooling time before the carriage is to

execute a backfill.

6 Backfill: Program the reversing length of the carriage to fill a crater at the end of a

bead.

7 Chain intermit-

tent welding:

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

continuous 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 Voltage poten-

tiometer:

Potentiometer for remote control of welding voltage.

11 Wire feed po-

tentiometer:

Potentiometer for remote control of wire feed speed (welding current).

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ESAB Miggytrac 2000 User manual

Brand: ESAB

Model: Miggytrac 2000

Category: Welding System

Type: User manual

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ESAB Miggytrac 2000 User manual

ESAB Miggytrac 2000 User manual

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