Miggytrac 1000
SERVICE MANUAL
Ver. GB1.0 2003-02-20
Miggytrac 1000 service manual
08.04.05
1
ver. GB1.0
Miggytrac 1000
3.1 Connector 14
3.2 Cable 14
3.3 Accessories 14
Notes 15
3
INSTALLATION
2.1 Block diagram 6
2.2 Technical data 11
2.3 Dismantling / reassembly 11
2.4 Component circuit board 12
2.5 Speed adjustment 13
2.6 Spare parts
13
2
ELECTRONIC
1.1 Motor & Gear 2
1.2 Chain 2
1.3 Chain tensioner 2
1.4 Shaft 2
1.5 Wheel 3
1.6 Limit switch 3
1.7 Magnet unit 3
1.8 Maintenance 3
1.9 Spare parts 4
CHASSIS
1
page
page
side
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CHASSIS
(pos.no. in the spare parts drawing)
1.1
Motor & Gear (pos. 3)
The Miggytrac 100 is equipped with a 24VDC motor. The motor, gearbox and sprocket is sold
as one unit and should never been dismantled.
Replacing the motor:
Remember, when working on the carriage always disconnect the power supply!
Remove the front side drive wheels (see cpt. 1.5) and the chain cover.
Remove the electronic unit (one screw on the top) and disconnect cable “1” and “2” on the on
the terminal block.
Unscrew the 4 bolts on the bottom side of the carriage and place the ”electronic tower” carefully
to one of the sides.
Remove the chain adjuster and pull off the chain.
Remove the nuts, which are locking the motor and gear to the chassis and pull the whole unit
out.
1.2
Chain (pos. 21)
The carriage use one chain between the gearbox and the two shafts. It’s a permanent 4-wheel
drive. The chain has an ordinary chain joint.
After installing a new chain, let the carriage run for few minutes before mounting back the chain
cover and make sure that the chain is running correct.
The chain is lubricated with thin oil.
1.3
Chain tensioner
Miggytrac 1000 use an eccentric wheel as a chain tensioner. By turning the wheel it is possible
to loosen or tighten the chain.
When pressing the chain with your finger it should bee about 5mm gap from the edge of the
chassis to the chain (see fig).
1.4
Drive shaft (pos. 20)
Miggytrac 1000 use two drive shafts. Both with sprockets locked to the shafts with a splint. The
drive shaft and the sprocket is a complete unit. Each shaft rotates in two bearings (pos. 23).
Replacing the drive shafts:
Remove the spatter shield (pos. 26) and the chain cover (pos. 27, see cpt. 1.5), then the chain
tensioner and chain. Pull out the drive shaft carefully.
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1.5 Wheel (pos. 24 + 25)
The carriage has 4 wheels, each with two O-rings that make the friction to the surface.
Replacing the wheels:
Remove the outer side O-ring. Each wheel has a locking bolt (2,5mm socket headed hex bolt)
thru the wheel and the shaft.
1.6
Limit switch (pos. 2)
On each end of the carriage a limit switch is located. The switch stop both the movement of the
carriage and the welding process if a wire feeder is connected to the Burndy connector on the
front panel. The switch is “NO” (normally open).
Replacing the switch:
The limit switch is mounted into a threaded bore in the chassis. Unscrew the switch carefully.
The electrical connections are soldered (conn. “1” and “2”).
1.7
Magnet unit (pos. 33)
To make a light carriage as the Miggytrac 1000 stable, it’s equipped with an electro magnet in
the bottom of the chassis. To get the magnet source to the ground without loosing power and a
minimum of friction the magnet unit has 2 wheels. The magnet field is running in a loop between
one of the wheels – the plate/surface and back to the other wheel. Another advantages of this
system are no magnet field that influence on the welding process. The whole magnet unit is
spring loaded to make sure the carriage is moving as soft as possible.
The magnet unit is powered by a simple unregulated DC voltage (cpt. 2.1.C). The operator can
turn the magnet on/off with a switch on the front panel.
Removing the magnet unit:
The magnet unit is always a complete unit. Never try to dismantle it. Disconnect the power
supply. Place the carriage on the side. Remove the electronic unit (one screw on the top) and
disconnect the two cables “M” on the on the terminal block. Cut off the cable terminators (“M”)
on the end of the cable. Unscrew the 4 bolts on the bottom side of the carriage and place the
”electronic tower” carefully to one of the sides. Unscrew the 4 bolts on the top of the magnet
unit. Carefully pull the unit out and at the same time make sure that the cables are not blocked.
Magnet unit reassembly:
Try to slide the cables thru the hole in the bottom of the chassis and at the same time place the
new magnet unit in its position. Use a small portion of glume to lock the 4 bolts. Connect the
new cables back in the “M” position on the terminal block. Make a function test.
1.8
Maintenance
On each service remember to check:
Cleaning the wheels on the magnet unit.
Check the chain and lubricate with thin oil.
Check the O-rings, if necessary replace them.
Lubricate the guide wheels.
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1.9 Spare parts chassis
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1.9 Spare parts list
Pos Text Order no.
1 Chassis 457 357-002
from ser.no. -> 837xxxx
2 Limit switch 457 357-401
3a El-motor with gear 457 357-302
from 749xxxx to 827xxxx
3b El-motor with gear 457 357-303
from ser.no. ->837xxxx
4 Motor casing 457 357-010
5 Slide screw with knob 457 357-200
6 Front slide bracket 457 357-210
7 Slide nut 457 357-220
8 Guide 457 357-230
9 Guide extension 457 357-231
10 Rear slide bracket 457 357-211
11 Vertical slide bracket 457 357-240
12 Box 457 357-020
13 Top cover 457 357-030
14 Electronics, complete 457 468-881
15 Bolt 457 357-260
16 Welding gun bracket 457 357-250
17 Knob 457 357-270
18 Knob, locking arm 457 357-271
19 Locking arm 457 357-280
20 Shaft with sprocket 457 357-050
21a Chain 457 357-060
to ser.no. -> 7470060
21b Chain 457 357-061
from ser.no. -> 7490061
21c Chain 457 357-062
from ser.no. -> 837xxxx
22 Spacing ring 457 357-070
23 Bearing 457 357-071
24 Wheel 457 357-080
25 O-ring 457 357-090
26 Spatter shield 457 357-100
27 Chain cover 457 357-110
28 Nut 457 357-150
29 Guide wheel arm 457 357-160
30 Guide wheel bracket 457 357-170
31 Guide wheel 457 357-180
32 Guide wheel shaft 457 357-190
33 Magnet unit, complete 457 469-880
34 Sleeve 457 357-261
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ELECTRONIC
2.1. Block diagram
No. Description Type
A Power
B Start / stop welding Relay 24 VDC
C Power electro magnet
D Motor driver
E Stop input
EM1 Electro magnet TPS
M1 Motor SAYAMA 24 VDC
RP2 Potentiometer (welding voltage) 10 kOhm, 0,1W
RP3 Potentiometer (welding current) 10 kOhm, 0,1W
SW4 On / off switch (welding start)
SW5 On / off switch (magnet)
SW6 Limit switch (stop)
SW7 Limit switch (stop)
XP1 Chassis plug Burndy 12-pin male
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2.1.A Power
42VAC is supplied to the electronic via pin “A” and “B” on the 12-pin Burndy connector on
the front panel. From the backside run 2 cables into a 4-pin AMP connector “K3” for
connection to the main board.
The electronic is protected by a 0,5A PTC (temperature) fuse (RV1). If the electronic is
overloaded and the PTC-fuse turns off, you have to disconnect the power supply and wait
few seconds before turning it on again.
A 10 ohm NTC resistor (RV2, see cpt. 2.4). limits the current when the power supply is
switched on.
RV3 is a varistor that protects the electronic against a high voltage input. The varistor short-
circuits at voltages above 50VAC. By a very high over voltage the varistor may be damaged
and permanently short circuit. The varistor is easily replaced by cutting the legs close to the
casing, then unsoldering the legs individually.
RV4 and RV5 are not in use.
The diode bridge (D1) rectifies the input voltage, which is around 60VDC at 42VAC, and
filtered by L1 and C1/C2.
No. Name Type
C1 Capacitors 220 uF / 63V
C2 Capacitors 100 nF / 63V
D1 Rectifier 2A / 100V
K3 Connector 4-pin AMP MTA100 male
L1 Lowpass filter Murata
No. Name Type
RV1 PTC-fuse 0,5 A
RV2 NTC 10 ohm / 3,6 W
RV3 Varistor 35V
RV4 not in use
RV5 not in use
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2.1.B Start / Stop welding
The Start / stop signal to the wire feeder is a simple relay connection between pin “F” and
“G” on the 12-pin Burndy. The relay (RL4, see cpt. 2.4) is placed on the main board, and is
secured by a 1,1A PTC fuse (F2). It’s possible to turn on/off the start/stop function with a
switch on the front panel.
The relay turns on/off as the carriage is started / stopped.
2.1.C Power electro magnet
The magnet unit is powered by a simple unregulated DC voltage (D11). The operator can
turn the magnet on/off with a switch (SW5) on the front panel.
The power supply is secured by a 1,1A PTC fuse (F1).
No. Name Type
F2 PTC-fuse 1.1 A
K1 Connector 8-pin
K6 Connector 2-pin AMP MTA100 male
RL4 Relay Max 2 A
SW4 Panel Switch Single pole
XP1 Chassis plug Burndy 12-pin male
No. Name Type
D11 Rectifier 2A / 100V
EM1 Electro magnet TPS
F1 PTC-fuse 1.1 A
K1 Connector 8-pin
K3 Connector 4-pin AMP MTA100 male
K5 Connector 2-pin AMP MTA100 male
SW5 Panel Switch Single pole
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2.1.D Motordriver
Miggytrac 1000 uses an analog electronic for speed control. The motor driver is a step down
switching regulator (IC1) operating at 100 kHz. Adjusting the voltage feedback with a
potentiometer R7, placed on the front panel, controls the regulators output. The L2 and
C4/C5 filtering the output to a smooth DC voltage.
Speed adjustment
R6 is a trim pot. (placed in the centre of the main board, see cpt. 2.4) for a simple speed
adjustment. From the factory this trim pot. is adjusted for 6V output at minimum speed. On
maximum speed the output is about 33-34V.
Running direction
The running direction is controlled by two relays (RL1 and RL2). Left direction relay 2 is on;
right direction relay 1 is on. In stop mode both relays are off and make a short circuit across
the motor for maximum braking force.
Motor filter
The varistor RV6 is working as an over voltage protection, and the C6 and C7 as a high
frequency filter.
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2.1.E Start / Stop carriage
From the front panel the carriage can be started in the desired direction with “<” or “>” key
(SW3 or SW1) and stopped with the “STOP” key (SW2).
Start right:
Switch 1 activates relay 1, right direction, and makes a self-hold via diode D10. The coil
current is controlled by R8 to 0V. All the relays are with 24VDC coils. The relay is released
thru the stop switch and D5 by placing +60V on the 0V input. D3 is working as a protection
diode across the relay coil.
Start left:
Switch 3 activates relay 2, left direction, and makes a self-hold via diode D12. The coil
current is controlled by R9 to 0V. The relay is released thru the stop switch and D6 by
placing +60V on the 0V input. D4 is working as a protection diode across the relay coil.
On / off welding relay:
Relay 4 is activated via RL1 and D7 or RL2 and D8 (depending on which direction). The coil
current is controlled by R10 to 0V. The relay turns off when RL1 and RL2 are off. D9 is
working as a protection diode across the relay coil.
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2.2 Technical data
2.3.1 Exchange the electronic unit
Remember, when working on the carriage always disconnect the power supply!
Unscrew the socket-headed screw (3mm) on top of the front panel. Carefully pull the
electronic unit up and out.
Disconnect cable marked “1, 2, 6, 13, M and M”, and put the electronic in an anti static bag.
If returned to a service office, it’s important to make a note what’s the problem / defect with
the unit.
2.3.2 Exchange the main board
Remove the electronic unit as described in cpt. 2.3.1.
Disconnect all the cables on the terminal block and pull out the small AMP-connectors.
Remove the speed knob on the front panel (small grub-screw).
Remove the 4 nuts, which secure the main board to the front panel and pull it out.
Remember to fit the isolating washers on hole “H3” and “H4” (back- and front side), metal
washers on “H1” and “H2” (see cpt. 2.4).
Supply voltage 36 – 46 VAC
Power with / without magnet 60 / 10 W
Welding speed 150 – 1200 mm/min
Dimensions (L x W x H) 262 x 268 x 324 mm
Weight 8 kg
Slide adjustment +/- 20 mm
Remote control socket Volt & Ampere (wire feed)
Max. values, remote control 10 kohm / 0,1 W
Max. current, start relay 2 A
Connection Burndy, 12-pin male
Enclosure class IP 23
1
2
4
5
9
10
F
G
1
2
4
5
13
6
M
M
F
G
Old ver. New ver.
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2.4 Component cicuit board
2.5 Speed adjustment
R6 is a trim pot. (placed in the centre of the main board, see cpt. 2.4) for a simple speed
adjustment. From the factory this trim pot. is adjusted for 6V output at minimum speed. On
maximum speed the output is about 33-34V.
Let the carriage run for about 5 minutes before adjustment to make sure the electronic got
the correct operating temp.
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2.6 Spareparts electronic
1
2
3
4
5
6
7
Pos. Description Order no.
1 Circuit card 0457 468-002
2 Front folio 0457 468-020
3 Front alum-panel incl. folio 0457 468-010
4 Knob speed 0457 468-031
5a Knob remote 0457 468-032
5b Potentiometer remote 0457 468-040
6 Panel-Switch 0457 468-050
7 Chassis connector 12-pin incl. Cable 0457 468-060
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3.1 Connector
3.2 Control cable
See cpt. 4 in the instruction manual!
The Miggytrac 1000 uses the same type of control cables as the Railtrac 1000 system.
3.3 Accessories
See cpt. 7 in the instruction manual.
A
Red
B Blue
F Black
G
White
J
Green
K Yellow
L
Brown
M
Violet
Red
Blue
Black
White
Green
Yellow
Brown
Violet
Screen
Power (42 VAC)
Start / Stop welding
Ref. Voltage
+15V
0V
Ref. Wirefeed
Gnd.
REMOTE
CONTROL
INSTALLATION
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NOTES
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1
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2
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3
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4
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5
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6
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7
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8
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9
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