GB

Valid for serial no. 05360449 476 001 GB 2008--03--20

Miggytrac 1001

Instruction manual

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DECLARATION OF CONFORMITYESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that auto-matic welding machine Miggytrac 1001 from serial number 0536 (2005 w.36) complies with standardEN 12100--2 and EN 60204--1, in accordance with the requirements of directive (98/37/EEC) and withstandard EN 61000--6--2 and also EN 61000--6--3, in accordance with the requirements of directive(2004/108/EEC).------------------------------------------------------------------------------------------------------------------------------------------------------------------

Kent EimbrodtGlobal DirectorEquipment and Automation

Laxå 2007--05--23

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Rights reserved to alter specifications without notice.

1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 INTRODUcTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Technical data 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 General 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Other connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 OPERATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 General 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Start / stop of carriage 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Welding 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 Magnet 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 MAINTENANCE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 General 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Daily 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 As necessary 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 ACCESSORIES 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 ORDERING OF SPARE PARTS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIMENSION DRAWING 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPARE PARTS LIST 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone whoworks on or near the equipment observes all the relevant safety precautions. Safety precautionsmust 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 weldingequipment. Incorrect operation of the equipment may lead to hazardous situations which can resultin injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:S its operationS location of emergency stopsS its functionS relevant safety precautionsS 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 purposeS be free from draughts

4. Personal safety equipmentS 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 precautionsS 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 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 BEBASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can killS 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 healthS 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 HAZARDS Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.NOISE -- Excessive noise can damage hearingS 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.

PROTECT YOURSELF AND OTHERS!

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2 INTRODUCTION

2.1 General

Miggytrac 1001 is designed for MIG/MAG welding of plates and beams.

It is a compact motor--driven carriage, where in one single operation you can fit astandard welding gun.

The welding carriage is powered by an electric motor. It is provided with a 12--pinBurndy socket for connection to a corresponding 23--pin socket on the wire feedunits for remote control of the wire feed.

The connection is done by way of two prepared control cables, which are pluggeddirectly into the ESAB feed unit. The advantage of this is that you get power supplyfor the carriage, start and stop functions for the feed unit as well as the possibility ofremote control of current and voltage in one and the same cable. No external poweris necessary.

Miggytrac 1001 is a small compact motor--driven carriage on which an ESABstandard welding gun can easily be fitted. The four driving wheels together with apowerful electro--magnet which is integrated in the chassis of the carriage guaranteesmooth and regular operation.The magnet keeps the carriage in the right position in proportion to the foundation,even if you weld on bent plates or use long cable bundles.The magnet is protected behind the stainless steel plate and can be switched off byway of a grip on top of the chassis, when the carriage is going to be moved orcleaned. The carriage follows the weld joint by way of two guide wheels, which areadjusted so as to make the carriage drive diagonally towards the edge of the plate.

The carriage is easy to operate with one switch for the travel direction and one knobfor the speed. There are separate potentiometers for the remote control.

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1. Slide

2. Connection

3. Electro--magnet ON/OFF

4. Driving wheels

5. Electro--magnet

6. Adjustable arm

7. Support wheels

8. Height adjustment

9. Gun bracket

10. Angle adjustment

11. Gun angle adjustment

12. Remote control (Volt/ Amp)

13. Direction Start/stop

14. Travel speed

2.2 Technical data

Miggytrac 1001

Supply voltage 36 -- 46 VAC

Power 20 W

Welding speed 150 -- 1200 mm/min

Dimensions ( l x w x h ) 266x257x261 mm

Weight 7 kg

Slide adjustment +/-- 20 mm

Remote control socket Volt and ampere (wire feed)

Max. values, remote control 1 kohm, 0.1 W

Max. current, start relay 2 A

Connection Burndy, 12 --pin

Enclosure class IP 23

Enclosure classThe IP code indicates the enclosure class, i. e. the degree of protection against penetration by solidobjects 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 1001 can be connected to most of ESAB’s feed units.For connection to older feed units, please contact your nearest ESAB retailer.

In the case of welding at a great distance from the feed unit an intermediate wirefeed unit (MEK 25) can be connected.

Miggytrac 1001 can also be powered by other welding power sources via aseparate transformer, see page 12.

For connection of the wire feed unit to Miggytrac 1001, use control cable acc. toAccessories, on page 15.

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3.2 Other connections

MIGGYTRAC 1001! ESABFeed

Miggytrac 1001 is to be connected directly to the remote control socket.No intervention in the feed unit is necessary.

ESABFeed 30--2 with control panel M11.

Miggytrac 1001 cannot be connected to this feed unit.

ESABFeed 30--4 och 48--4 with M12 control panel.

It is not possible to adjust the voltagefrom Miggytrac 1001.

ESABFeed 30--4 och 48--4 with M13 and M14 control panels.

It is possible to adjust both voltage and wire feed from Miggytrac 1001.

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MIGGYTRAC 1001! AristoFeed with control panel fitted

S Dismount the door and fit the sticker (1).

S Mount the switch with the cabling (2).

S Open the socket for remote control connection (3).

S Fit the cabling (4).

S Fit the remote control socket on the front panel (5).

S Connect the cabling with the printed circuit boards (6).

S Fit the printed circuit board at the bottom and then fit the door (7).

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MIGGYTRAC 1001! AristoFeed with U8

S Dismount the door (1).

S Open the socket for remote control connection (2).

S Fit the cabling (3).

S Fit the remote control socket on the front panel (4).

S Mount the switch with the cabling on the printed circuit board (5).

S Connect the cabling with the printed circuit boards (6).

S Fit the printed circuit board at the bottom and then fit the door (7).

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Miggytrac 1001! other feed unit makes

When connecting Miggytrac 1001 to other feed units, use the transformer and thecontrol cable you find under Accessories on page 15.

10 kohm

F – G = Start / Stop function

J = Reference +

K = Reference welding voltage

L = Reference 0

M = Reference wire feed speed

A – B = Voltage feed

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4 OPERATION

4.1 General

General safety regulations for the handling of the equipment can be found onpage 4. Read through before you start using the equipment!

S Place Miggytrac 1001 at the weld joint.

S Adjust the arms so that the carriage runs diagonally towards the edge of theplate.

S When the magnet is activated the friction between the drive wheels and thefoundation increases, resulting in a more stable carraiage, despite its low weight.The magnet is switched On/Off using a twist grip on top of the chassis.

4.2 Start / stop of carriage

Travel direction, left Stop Travel direction, Right

4.3 Welding

Selection whether to start/stop the connected feed unit with the switch on thecarriage or not.

On Off

4.4 Magnet

On OffTwist grip switching the built--in magnet On/Off (raising and lowering). When thecarriage is not in use the magnet should be switched off.

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5 MAINTENANCE

5.1 General

Note:All warranty undertakings given by the supplier cease to apply if the customerattempts to rectify any faults on the machine during the warranty period.

5.2 Daily

S Check that all cables and plugs are in good condition.

S Switch off the magnet and clean the bottom of the carriage.

S Clean the guide wheels.

5.3 As necessary

S Replace the O--rings ( 8 pcs. ) on the driving wheels.

S Lubricate the guide wheels using thin oil.

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6 ACCESSORIES

ESABFeed 30--4 M12ESABFeed 30--4 M13ESABFeed 30--4 M14

ESABFeed 48--4 M12ESABFeed 48--4 M13ESABFeed 48--4 M14

AristoFeedwith adapter

Control cable23--p0457 360 880

x x x

MEK 4 MEK 4SP MEK 4C MEK 44C MED 44A

Control cable 23--p0457 360 880

x x x x x

Cable kit,remote control socket23--p0457 462 880

x x x x x

MEH 30 MEH 44 MED44B MEK 2 Universal

Control cable 4--p, 12--p0457 360 883

x x

Cable kit0443 341 880

x x x x

Control cable 4--p0457 360 882

x x

Control cable0457 360 881

x

Transformer0457 467 880

x

Welding screen 0457 463 880

Bracket for water--cooled PSF 0457 357 251

7 ORDERING OF SPARE PARTS

Miggytrac 1001 is designed and tested in accordance with the international and Euro-pean standards IEC/EN 60204--1, ISO/EN 12100--2 and IEC/EN 60974--10 .It is the obligation of the service unit which has carried out the service or repair workto make sure that the product still conforms to the said standard.

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

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Dimension drawing

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Diagram

SW1

SW2

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Spare parts list

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Edition 2008--01--18

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Itemno. Qty Ordering no. Denomination Notes

Miggytrac 1001

1 8 0457357090 O--ring

2 0457357080 Wheel

3 0457357051 Axes with sprocket

4 0457357201 Slide screw with knob

5 0457357021 Switch box

6a 0457468031 Knob

6b 0457468041 Potentiometer speed

6c 0457468021 Label, speed

7 0457468051 Switch, direction

8 0457468052 Switch, welding

9 0457468031 Potentiometer knob

10 0457357241 Vertical slide house

11 0398145808 Intermediate bracket

12 0417855009 Lever

13 0457357272 Knob, slides

14 Magnetic lifting device

15 0457357003 Chassis 1001

16 0457357111 Bottom cover

17 0457357150 Nut

18 0457357304 El. motor with gear

19 0457357161 Guide arm

20 0457468003 PC board 1001

21 0457469881 Magnet unit complete

22 0457357063 Chain tightener

23 0457357064 Chain

24 0457357202 Arm

25 0457357181 Guide wheel

26 0457357251 Welding gun bracket

27 0457357101 Spatter screen

28 0457468061 Chassis plug 12--pol

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www.esab.com

070514

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