ESAB Miggytrac 1001 User manual

GB
Valid for serial no. 05360449 476 001 GB 2011--08--16
Miggytrac 1001
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 1001 from serial number 0536 (2005 w.36) 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
Laxå 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 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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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:
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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2INTRODUCTION
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 a
standard welding gun.
The welding carriage is powered by an electric motor. It is provided with a 12--pin
Burndy socket for connection to a corresponding 23--pin socket on the wire feed
units for remote control of the wire feed.
The connection is done by way of two prepared control cables, which are plugged
directly into the ESAB feed unit. The advantage of this is that you get power supply
for the carriage, start and stop functions for the feed unit as well as the possibility of
remote control of current and voltage in one and the same cable. No external power
is necessary.
Miggytrac 1001 is a small compact motor--driven carriage on which an ESAB
standard welding gun can easily be fitted. The four driving wheels together with a
powerful magnet which is integrated in the chassis of the carriage guarantee smooth
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 by
way of a grip on top of the chassis, when the carriage is going to be moved or
cleaned. The carriage follows the weld joint by way of two guide wheels, which are
adjusted 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 knob
for the speed. There are separate potentiometers for the remote control.
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1. Slide
2. Connection
3. Magnet ON/OFF
4. Driving wheels
5. 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 7kg
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 2A
Connection Burndy, 12 --pin
Enclosure class IP 23
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 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 wire
feed unit (MEK 25) can be connected.
Miggytrac 1001 can also be powered by other welding power sources via a
separate transformer, see page 12.
For connection of the wire feed unit to Miggytrac 1001, use control cable acc. to
Accessories, 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 voltage
from 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
SDismount the door and fit the sticker (1).
SMount the switch with the cabling (2).
SOpen the socket for remote control connection (3).
SFit the cabling (4).
SFit the remote control socket on the front panel (5).
SConnect the cabling with the printed circuit boards (6).
SFit the printed circuit board at the bottom and then fit the door (7).
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MIGGYTRAC 1001 !AristoFeed with U8
SDismount the door (1).
SOpen the socket for remote control connection (2).
SFit the cabling (3).
SFit the remote control socket on the front panel (4).
SMount the switch with the cabling on the printed circuit board (5).
SConnect the cabling with the printed circuit boards (6).
SFit 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 the
control 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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4OPERATION
4.1 General
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
SPlace Miggytrac 1001 at the weld joint.
SAdjust the arms so that the carriage runs diagonally towards the edge of the
plate.
SWhen the magnet is activated the friction between the drive wheels and the
foundation 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 the
carriage or not.
On Off
4.4 Magnet
On Off
Twist grip switching the built--in magnet On/Off (raising and lowering). When the
carriage 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 customer
attempts to rectify any faults on the machine during the warranty period.
5.2 Daily
SCheck that all cables and plugs are in good condition.
SSwitch off the magnet and clean the bottom of the carriage.
SClean the guide wheels.
5.3 As necessary
SReplace the O--rings ( 8 pcs. ) on the driving wheels.
SLubricate the guide wheels using thin oil.
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6 ACCESSORIES
ESABFeed 30--4 M12
ESABFeed 30--4 M13
ESABFeed 30--4 M14
ESABFeed 48--4 M12
ESABFeed 48--4 M13
ESABFeed 48--4 M14
AristoFeed
with adapter
Control cable
23--p
0457 360 880
xxx
MEK 4 MEK 4SP MEK 4C MEK 44C MED 44A
Control cable 23--p
0457 360 880 xxxxx
Cable kit,
remote control socket
23--p
0457 462 880
xxxxx
MEH 30 MEH 44 MED44B MEK 2 Universal
Control cable 4--p, 12--p
0457 360 883 x x
Cable kit
0443 341 880 x x x x
Control cable 4--p
0457 360 882 x x
Control cable
0457 360 881 x
Transformer
0457 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 work
to 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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fhc1dim

Diagram
SW1
SW2
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fhc1diag

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sida

Spare parts list
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spare
Edition 2011--08--16

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miggy1001
Item
no. Qty Ordering no. Denomination Notes
Miggytrac 1001
1 8 0457357090 O--ring
20457357080 Wheel
30457357051 Axes with sprocket
40457357201 Slide screw with knob
50457357021 Switch box
6a 0457468031 Knob
6b 0457468041 Potentiometer speed
6c 0457468021 Label, speed
70457468051 Switch, direction
80457468052 Switch, welding
90457468031 Potentiometer knob
10 0457357241 Vertical slide house
11 0398145808 Intermediate bracket
12 0417855009 Lever
13 0457357272 Knob, slides
14 0457357130 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