ESAB Miggytrac™ B5001 User manual

Brand: ESAB

Model: Miggytrac™ B5001

Type: User manual

This manual is also suitable for

Miggytrac™ B501

Service manual

0463 406 001 GB 20181030

Valid for: B501:serialno.1501xxxx,1525xxxx,1847xxxx

B5001:serialno.1847xxxx

Miggytrac™B501,

Miggytrac™B5001

TABLE OF CONTENTS

0463 406 001 © ESAB AB 2018

READ THIS FIRST.................................................................................... 3

INTRODUCTION....................................................................................... 4

Assembly ................................................................................................ 4

TECHNICAL DATA ................................................................................... 5

WIRING DIAGRAM................................................................................... 7

Miggytrac™B501, Only valid for approx. the 50 first units

delivered..................................................................................................

Miggytrac™ B501, Valid after approx. the 50 first units delivered .... 8

Miggytrac™B5001 ................................................................................. 9

ELECTRICAL DESCRIPTION .................................................................. 10

Miggytrac™B501 ................................................................................... 10

Component positions of electronics in Miggytrac™B501 .................... 10

Miggytrac™B5001 ................................................................................. 11

Component positions of electronics in Miggytrac™B5001 .................. 11

12-pin connector................................................................................... 11

Switch board with display ..................................................................... 12

FAULT INDICATIONS ............................................................................... 13

TROUBLESHOOTING .............................................................................. 14

Miggytrac™B501 ................................................................................... 14

Miggytrac™B5001 ................................................................................. 15

Checking the external supply voltage................................................... 16

Ckecking the battery voltage ................................................................ 17

Checking the ouput signal for wire feed ............................................... 17

SERVICE INSTRUCTIONS....................................................................... 18

What is ESD? .......................................................................................... 18

Service aid .............................................................................................. 18

Replacing the electronic unit in the Miggytrac™B501....................... 19

Replacing the control unit in the Miggytrac™B5001 ......................... 20

Replacing the motor driver in the Miggytrac™ B501 .......................... 21

Adjustment of the drive chain ............................................................... 22

Replacing the drive wheels ................................................................... 22

SPARE PARTS AND ACCESSORIES ..................................................... 23

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 406 001

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READ THIS FIRST

Maintenance and repair work must be performed by an experienced person, and electrical

work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault-tracing and repair.

Use the wiring diagram as a form of index for the description of operation. The circuit boards

are divided into numbered blocks, which are described individually in more detail in the

description of operation. Component names in the wiring diagram are listed in the

component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS AND

ACCESSORIES" chapter in this manual.

This manual contains details of design changes that have been made up to and including

October 2018.

The manual is valid for:

Miggytrac™ B501/ordering no. 0457 357 882 /serialno.1501xxxx, 1525xxxx and1847xxxx

Miggytrac™B5001/ordering no. 0459 990 645/serial no. 1847xxxx

NOTE!

The unit is tested by ESAB in a general set-up. The responsibility for safety and

function, of the specific set-up, lies with the integrator.

CAUTION!

Read and understand the instruction manual before

installing or operating.

The Miggytrac™B501 and Miggytrac™B5001 are designed and tested in accordance with

the standards stated in the instruction manual. On completion of service or repair work, it is

the responsibility of the person(s) performing the work to ensure that the product still

complies with the requirements of the involved standards.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see

esab.com. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures

correct delivery.

INTRODUCTION

0463 406 001

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INTRODUCTION

The Miggytrac™B501 and Miggytrac™B5001 are designed for MIG/MAG welding of plates

and beams.

The Miggytrac™B501 and Miggytrac™B5001 are compact tractors on which a welding

torch can be fitted. Both tractors can be powered with 18VDC from a lithium-ion battery. The

Miggytrac™B5001 can also be powered with 42VAC from a welding power source. The

tractors are equipped with four wheel drive for good traction and a high torque stepper motor

for stable welding speed. The Miggytrac™ is intended for welding with 4-stroke control mode.

As an option there is an easy fit magnet kit. The magnet kit can be attached at the bottom of

the tractor to further stabilize the movement when welding slopes up to 45°.

A battery and a battery charger are not included in the delivery, refer to the "ACCESSORIES"

chapter in the Instruction manual.

Assembly

1. Knob, horisontal adjustment 6. Handle

2. Adjustable arm 7. Control panel

3. Guide wheel support 8. Battery

4. Knob, vertical adjustment 9. Driving wheels

5. Connection, welding torch

NOTE!

The graphic above shows the Miggytrac™ B501 tractor. However assembly and

adjustments are performed in the same way on the Miggytrac™ B5001 tractor.

TECHNICAL DATA

0463 406 001

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TECHNICAL DATA

Miggytrac™ B501, Serial no. 1501 xxxx and 1525 xxxx

Miggytrac™ B501

Battery voltage (lithium-ion) 18 V DC

Battery operating time 8 hours

Motor type Stepper motor

Welding speed

10–130cm/min

(4–51in./min)

Mechanical adjustments:

Horizontal slide ±32 mm (±1.3in.)

Vertical slide ±40mm (±1.6in.)

Guide wheel arms ±40mm (±1.6in.)

Maximum operating temperature:

Battery +60°C (140°F)

Carriage +80°C (176°F)

Of surface where the tractor is operated, at standstill +70 °C (158°F)

Of surface where the tractor is operated, with moving wheels +150°C (302°F)

Horizontal tensile force:

Without magnets 12kg (26lb)

With magnets 25kg (55lb)

Vertical tensile force at 45° with magnet 11kg (24lb)

Maximum drive angle with magnet kit 45°

Dimensions (l×w×h)

310×290×250mm

(12.2×11.4×9.84in.)

Weight 12kg (26lb)

Miggytrac™ B501 and Miggytrac™ B5001, from serial no. 1847xxxx

Miggytrac™ B501 Miggytrac™ B5001

Battery voltage (lithium-ion) 18 V DC

External supply voltage –

20–50 V AC

24–70 V DC

Battery operating time 6–8 hours 4–6 hours

Motor type Stepper motor

Welding speed

10–130cm/min

(4–51in./min)

2–170cm/min

(1–66in./min)

Travel speed step welding –

250cm/min

(99in./min)

Length step welding –

1–99cm

(0.1–19.9in.)

Crater pause – 0–5.0 s

Backfill – 0–50mm (0–2.0in.)

Preheat – 0–5.0s

TECHNICAL DATA

0463 406 001

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Miggytrac™ B501 and Miggytrac™ B5001, from serial no. 1847xxxx

Miggytrac™ B501 Miggytrac™ B5001

Remote volt and wire feed speed – 10–95%

Mechanical adjustments:

Horizontal slide ±32 mm (±1.3in.)

Vertical slide ±40mm (±1.6in.)

Guide wheel arms ±40mm (±1.6in.)

Maximum operating temperature:

Battery +60°C (140°F)

Carriage +80°C (176°F)

Drive wheels +150°C (302°F)

Horizontal tensile force:

Without magnets 12kg (26lb)

With magnets 25kg (55lb)

Vertical tensile force at 45° with magnet 11kg (24lb)

Maximum drive angle with magnet kit 45°

Dimensions (l×w×h)

310×290×250mm

(12.2×11.4×9.84in.)

310×290×340mm

(12.2×11.4×13.4in.)

Weight 12kg (26lb) 13kg (29lb)

WIRING DIAGRAM

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WIRING DIAGRAM

Miggytrac™B501, Only valid for approx. the 50 first units delivered

B1 Battery 18V

D1 LED Battery indicator

E1 Motor driver

F1 Fuse PTC 1.1 A

M Stepper motor

R1 Potentiometer speed 10 kΩ

R2 Resistor max speed

R3 Resistor min speed

R4 Resistor LED

R5 Resistor LED

SW1 Switch 3-pos. Direction

WIRING DIAGRAM

0463 406 001

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Miggytrac™ B501, Valid after approx. the 50 first units delivered

B1 Battery 18V

D1 Zener diode 5.6V

D2 LED Battery indicator

D3–D4 TVS Diode 30V / 600W P6KE30CA

E1 Motor driver

F1 Fuse PTC 1.1A

M Stepper motor

R1 Potentiometer speed 10kΩ

R2 Resistor max speed

R3 Resistor min speed

SW1 Switch 3-pos. Left–Stop–Right

WIRING DIAGRAM

0463 406 001

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Miggytrac™B5001

ELECTRICAL DESCRIPTION

0463 406 001

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ELECTRICAL DESCRIPTION

Miggytrac™B501

Component positions of electronics in Miggytrac™B501

1. Switch On/Off direction 4. Potentiometer speed

2. Front panel 5. Battery indicator

3. Motor control 6. Knob speed

ELECTRICAL DESCRIPTION

0463 406 001

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Miggytrac™B5001

Component positions of electronics in Miggytrac™B5001

1. 12-pin connector 3. Power board

2. Switch board 4. Main board

12-pin connector

ELECTRICAL DESCRIPTION

0463 406 001

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Switch board with display

FAULT INDICATIONS

0463 406 001

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FAULT INDICATIONS

Indication Charge level

Green light 100%

Yellow light 60%

Yellow blinking light 30%

Red light 15%

Red blinking light 7%

Red rapidly blinking light 0%

TROUBLESHOOTING

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TROUBLESHOOTING

Miggytrac™B501

Battery Switch Electronics Motor

1 Is the battery OK? When the battery is

charged, the green LED on the front

panel should be lit when the switch is in

ON position.

Change

2 Open the electronic unit (see

"Replacing the electronic unit in the

Miggytrac™B501", page19).

3 Turn the switch ON. Check the blue

LED on the motor driver and measure

the voltage V+.

V+should be in the interval 18–20V.

Check Check

4 If there is no voltage between V+ and

ground:

Change

5 If the voltage between V+ and ground is

18–20V but the blue LED is not lit:

Change

6 When the switch is ON, measure the

voltage between the "SPD" pin on the

motor driver and Ground.

The voltage should be in the interval

0.16–2.5V.

Change

7 If the driver is OK: Change

TROUBLESHOOTING

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Miggytrac™B5001

TROUBLESHOOTING

0463 406 001

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Checking the external supply voltage

1. Connect the tractor via the 12-pin connector to the rated external supply voltage

(20–50VAC or 24–70VDC).

2. Measure the voltage between pins3 and4 of connectorJ1 on the power board

using a multimeter. The voltage should be in the interval 20–50VAC or

24–70VDC dependent on supply voltage used.

TROUBLESHOOTING

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Ckecking the battery voltage

1. Insert an 18V lithium-ion battery into the battery compartment.

2. Measure the voltage between pins2 and4 of connectorJ2 on the power board

using a multimeter. The voltage should be in the interval 18.0–20.7VDC.

Checking the ouput signal for wire feed

1. Set the wire feed to Off in the front panel user interface.

2. Measure the resistance between pins1 and2 of connector J1 on the power board

using a multimeter. The resistance should be >10MΩ (meaning that the relay

contact is open).

3. Start wire feed, using the front panel user interface.

4. Measure the resistance between pins1 and2 of connector J1 on the power board

using a multimeter. The resistance should be <1Ω (meaning that the relay contact

is closed).

SERVICE INSTRUCTIONS

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SERVICE INSTRUCTIONS

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

What is ESD?

A sudden transfer or discharge of static electricity from one object to another. ESD stands

for Electrostatic Discharge.

How does ESD damage occur?

ESD can cause damage to sensitive electrical components, but is not dangerous to people.

ESD damage occurs when an ungrounded person or object with a static charge comes into

contact with a component or assembly that is grounded. A rapid discharge can occur,

causing damage. This damage can take the form of immediate failure, but it is more likely

that system performance will be affected and the component will fail prematurely.

How do we prevent ESD damage?

ESD damage can be prevented by awareness. If static electricity is prevented from building

up on you or on anything at your work station, then there cannot be any static discharges.

Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static

charge, so you should not bring unnecessary nonconductive items into the work area. It is

obviously difficult to avoid all such items, so various means are used to drain off any static

discharge from persons to prevent the risk of ESD damage. This is done by simple devices:

wrist straps, connected to ground, and conductive shoes.

Work surfaces, carts and containers must be conductive and grounded. Use only antistatic

packaging materials. Overall, handling of ESD-sensitive devices should be minimized to

prevent damage.

Service aid

ESAB can offer a number of service tools that will simplify the service.

Antistatic service kit

Ordering no. 0740 511 001

The kit makes it easier to protect sensitive

components from electrostatic discharge.

Contents:

• A conductive mat (size 610×610mm /

24×24in)

• A 1.5m (3.28ft) long ground cable with

a crocodile clip

• An adjustable wrist strap and cable with

a built-in protective resistor

Antistatic service kit

SERVICE INSTRUCTIONS

0463 406 001

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Replacing the electronic unit in the Miggytrac™B501

1. Remove the battery.

2. Remove the 3 screws from the back of the control unit as illustrated below.

3. Pull the electronic unit slightly up and disconnect the electrical cables from the battery

and the motor.

4. Remove the electronic unit.

Install the new electronic unit in the reverse order.

SERVICE INSTRUCTIONS

0463 406 001

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Replacing the control unit in the Miggytrac™B5001

1. Remove the battery.

2. Unscrew the ten M5 screws to remove the side plates, the three M5 pipes, the front

panel and the B5001 control unit.

Reassemble in the reverse order.

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ESAB Miggytrac™ B5001 User manual

Brand: ESAB

Model: Miggytrac™ B5001

Type: User manual

This manual is also suitable for

Miggytrac™ B501

Download PDF

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ESAB Miggytrac™ B5001 User manual

This manual is also suitable for

ESAB Miggytrac™ B5001 User manual

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