GB

Miggytrac 1001

Instruction manual

0449 476 001 GB 2008--03--20 Valid for serial no. 0536

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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Laxå 2007--05--23

Kent Eimbrodt
Global Director
Equipment and Automation

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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

Rights reserved to alter specifications without notice.

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1 SAFETY
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
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 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 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 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 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 your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

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 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 electro--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 6. Adjustable arm 11. Gun angle adjustment

2. Connection 7. Support wheels 12. Remote control (Volt/ Amp)
3. Electro--magnet ON/OFF 8. Height adjustment 13. Direction Start/stop
4. Driving wheels 9. Gun bracket 14. Travel speed
5. Electro--magnet 10. Angle adjustment

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 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

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 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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4 OPERATION

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!
S Place Miggytrac 1001 at the weld joint.
S Adjust the arms so that the carriage runs diagonally towards the edge of the
plate.
S When 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
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 M12 ESABFeed 48--4 M12 AristoFeed
ESABFeed 30--4 M13 ESABFeed 48--4 M13 with adapter
ESABFeed 30--4 M14 ESABFeed 48--4 M14
Control cable x x x
23--p
0457 360 880

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

Control cable 23--p x x x x x
0457 360 880
Cable kit, x x x x x
remote control socket
23--p
0457 462 880

MEH 30 MEH 44 MED44B MEK 2 Universal

Control cable 4--p, 12--p x x
0457 360 883
Cable kit x x x x
0443 341 880
Control cable 4--p x x
0457 360 882
Control cable x
0457 360 881
Transformer x
0457 467 880

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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Diagram

SW1

SW2

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sida
Spare parts list

Edition 2008--01--18

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spare
Item
Qty Ordering no. Denomination Notes
no.

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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ESAB subsidiaries and representative offices

Europe NORWAY Asia/Pacific Representative offices

AUSTRIA AS ESAB BULGARIA
CHINA
ESAB Ges.m.b.H Larvik ESAB Representative Office
Tel: +47 33 12 10 00 Shanghai ESAB A/P
Vienna--Liesing Shanghai Sofia
Tel: +43 1 888 25 11 Fax: +47 33 11 52 03 Tel/Fax: +359 2 974 42 88
Tel: +86 21 5308 9922
Fax: +43 1 888 25 11 85 Fax: +86 21 6566 6622
POLAND EGYPT
BELGIUM ESAB Sp.zo.o. INDIA ESAB Egypt
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Brussels Tel: +48 32 351 11 00 Calcutta Tel: +20 2 390 96 69
Tel: +32 2 745 11 00 Fax: +48 32 351 11 20 Tel: +91 33 478 45 17 Fax: +20 2 393 32 13
Fax: +32 2 745 11 28 Fax: +91 33 468 18 80
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THE CZECH REPUBLIC ESAB Lda INDONESIA ESAB Representative Office
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Vamberk Tel: +351 8 310 960 Jakarta Tel/Fax: +40 1 322 36 74
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SLOVAKIA LLC ESAB
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Tel: +45 36 30 01 11 Fax: +421 7 44 88 87 41 Tel: +81 3 5296 7371
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Tel: +358 9 547 761 Fax: +34 91 802 3461 Tel: +60 3 8027 9869
Fax: +358 9 547 77 71 Fax: +60 3 8027 4754 Distributors
SWEDEN For addresses and phone
FRANCE ESAB Sverige AB SINGAPORE numbers to our distributors in
ESAB France S.A. Gothenburg ESAB Asia/Pacific Pte Ltd other countries, please visit our
Cergy Pontoise Tel: +46 31 50 95 00 Singapore home page
Tel: +33 1 30 75 55 00 Fax: +46 31 50 92 22 Tel: +65 6861 43 22
www.esab.com
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Gothenburg
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Solingen Kyungnam
Tel: +49 212 298 0 SWITZERLAND Tel: +82 55 269 8170
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Dietikon
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Tel: +44 1992 76 85 15 North and South America Tel: +971 4 887 21 11
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Andover Buenos Aires
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Budapest
Tel: +55 31 2191 4333
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Tel: +39 02 97 96 81 Fax: +1 905 670 48 79
Fax: +39 02 97 28 91 81
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THE NETHERLANDS ESAB Mexico S.A.
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Amersfoort Tel: +52 8 350 5959
Tel: +31 33 422 35 55 Fax: +52 8 350 7554
Fax: +31 33 422 35 44
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ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48

ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000

www.esab.com

070514