ESAB Miggytrac 2000 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:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding

2. The operator must ensure that:

Sno unauthorised person is stationed within the working area of the equipment when it is

started up.

Sno--one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from draughts

4. Personal safety equipment

SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

SDo not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication 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 OPERATING.

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

SInstall and earth the welding unit in accordance with applicable standards.

SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

SKeep your head out of the fumes.

SUse 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.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FIRE HAZARD

SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn 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 control 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 regular operation. The magnet keeps

the carriage in the right 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. The 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, {.

SRemove the cover, |.

SUnscrew the sleeve socket, }.

SCut off the cables E1 and E2, ~.

SConnect the two cables to terminal block E and cables F and G, .

SConnect the cables A and B between the terminal block, G1 and G2, and the

sleeve socket, pins A and B, .

SConnect the cables F and G to the sleeve socket, pins F and G .

SFasten the sleeve socket , }.

SFit the cover, |.

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MEK 4C !MIGGYTRAC 2000

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

SRemove the cover, |.

SUnscrew the sleeve socket, }.

SCut off the cables E1 and E2, ~.

SConnect the two cables to terminal block E and cables F and G, .

SConnect the cables A and B between the terminal block, J1 and J2, and the

sleeve socket, pins A and B, .

SConnect the cables F and G to the sleeve socket, pins F and G, .

SFasten the sleeve socket, }.

SFit the cover, ⎯|.

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