ESAB Origo Mig 4002c User manual

Origo™
Instruction manual
0463 264 001 GB 20170310 Valid for: serial no. 136-, 740-, 745-, 801-, 806-xxx-xxxx
Mig4002c
Mig5002c
Mig 6502c

TABLE OF CONTENTS
0463 264 001 © ESAB AB 2017
1SAFETY ......................................................................................................... 4
1.1 Meaning of symbols ................................................................................. 4
1.2 Safety precautions ................................................................................... 4
2INTRODUCTION............................................................................................ 7
2.1 Equipment ................................................................................................. 7
3TECHNICAL DATA ........................................................................................ 8
4INSTALLATION.............................................................................................. 12
4.1 Location..................................................................................................... 12
4.2 Assembly of components........................................................................ 13
4.3 Mains power supply ................................................................................. 14
5OPERATION .................................................................................................. 16
5.1 Connections and control devices ........................................................... 17
5.2 Overheating protection ............................................................................ 17
5.3 Water connection ..................................................................................... 17
5.4 Water flow guard ...................................................................................... 18
5.5 MIG/MAG and FCAW-S welding .............................................................. 18
5.6 MMA welding............................................................................................. 18
5.7 TIG welding ............................................................................................... 18
6MAINTENANCE............................................................................................. 19
6.1 Inspection and cleaning........................................................................... 19
6.1.1 Power source ......................................................................................... 19
6.1.2 Welding torch.......................................................................................... 19
6.2 Topping up the coolant ............................................................................ 19
7FAULT TRACING........................................................................................... 20
8ORDERING SPARE PARTS .......................................................................... 21
CLEANING............................................................................................................ 22
DIAGRAM ............................................................................................................. 23
CONNECTION INSTRUCTION............................................................................. 26
ORDER NUMBERS .............................................................................................. 28
ACCESSORIES .................................................................................................... 29
Rights reserved to alter specifications without notice.

1 SAFETY
0463 264 001 -4- © ESAB AB 2017
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of
life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and Safety
Data Sheets (SDSs).
1.2 Safety precautions
Users of ESAB 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 equipment. The following
recommendations 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
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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0463 264 001 -5- © ESAB AB 2017
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• 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
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0463 264 001 -6- © ESAB AB 2017
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of class
A equipment in those locations, due to conducted as well
as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation
in accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be
disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
0463 264 001 -7- © ESAB AB 2017
2 INTRODUCTION
The Mig 4002c, Mig 5002c and Mig 6502c are welding power sources intended for
MIG/MAG welding, as well as for welding with powder filled cored wire (FCAW-S), Live TIG
welding (only with some of the control panels) and for welding with coated and cellulosic
electrodes (MMA).
The power sources are intended for use with the following wire feed units:
• Feed 3004/4804
• MobileFeed 300
• YardFeed 2000
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The power source is supplied with:
• Return cable 5m with return clamp
• Shelf for gas cylinder
• Attachment chain for gas cylinder
• Guide pin for wire feed unit
• Cooling unit (if applicable)
• Instruction manual

3 TECHNICAL DATA
0463 264 001 -8- © ESAB AB 2017
3 TECHNICAL DATA
Mig 4002c
Mains voltage 380/400 - 415 V, +/-10%, 3~ 50/60 Hz
230/400 - 415/440 - 460/500 V, +/-10%, 3~ 50/60 Hz
Permissible load at MIG/MAG
60% duty cycle 400 A / 34.0 V
100% duty cycle 310 A / 30.0 V
Permissible load at MMA
60% duty cycle 400 A / 36.0 V
100% duty cycle 310 A / 33.0 V
Welding range 1)
MIG/MAG 20 A / 15 V - 400 A / 34.0 V
MMA 20 A / 20.8 V - 400 A / 36.0 V
Open circuit voltage
MIG/MAG without VRD function 3) 68.0 V
MMA without VRD function 3) 62.0 V
VRD function deactivated 4) 56.0 V
VRD function activated 4) < 35.0 V
Open circuit power 500 W
with cooling unit 700 W
in energy saving mode (15 min
after last welding) 2)
60 W
Power factor at maximum current
MMA
0.88
Efficiency at maximum current
MMA
70%
Control voltage 42.0 V, 50/60 Hz
Dimensions l × w × h 830 × 640 × 835 mm (32.7 × 25.2 × 32.9 in.)
Weight 149 kg (328.5 lb)
with cooling unit 163 kg (359.4 lb)
Operating temperature -10 to +40° C (+14 to +104 °F)
Transportation temperature -20 to +55° C (-4 to +131 °F)
Enclosure class IP 23
Application classification
1) Welding ranges are different to the possible setting range on the panel.
2) Power saving mode works only in MIG/MAG.
3) Valid for power sources without VRD specification on the rating plate.
4) Valid for power sources with VRD specification on the rating plate. The VRD function is
explained in the instruction manual for the control panel.

3 TECHNICAL DATA
0463 264 001 -9- © ESAB AB 2017
Mig 5002c
Mains voltage 380/400 - 415 V, +/-10%, 3~ 50/60 Hz
230/400 - 415/440 - 460/500 V, +/-10%, 3~ 50/60 Hz
Permissible load at MIG/MAG
60% duty cycle 500 A / 39.0 V
100% duty cycle 400 A / 34.0 V
Permissible load at MMA
60% duty cycle 500 A / 40.0 V
100% duty cycle 400 A / 36.0 V
Welding range 1)
MIG/MAG 20 A / 15.0 V - 500 A / 39.0 V
MMA 20 A / 20.8 V - 500 A / 40.0 V
Open circuit voltage
MIG/MAG without VRD function 3) 68.0 V
MMA without VRD function 3) 62.0 V
VRD function deactivated 4) 56.0 V
VRD function activated 4) < 35.0 V
Open circuit power 550 W
with cooling unit 750 W
in energy saving mode (15 min
after last welding) 2)
60 W
Power factor at maximum current
MMA
0.90
Efficiency at maximum current
MMA
72%
Control voltage 42.0 V, 50/60 Hz
Dimensions l × w × h 830 × 640 × 835 mm (32.7 × 25.2 × 32.9 in.)
Weight 185 kg (407.9 lb)
with cooling unit 199 kg (438.7 lb)
Operating temperature -10 to +40° C (+14 to +104 °F)
Transportation temperature -20 to +55° C (-4 to +131 °F)
Enclosure class IP 23
Application classification
1) Welding ranges are different to the possible setting range on the panel.
2) Power saving mode works only in MIG/MAG.
3) Valid for power sources without VRD specification on the rating plate.
4) Valid for power sources with VRD specification on the rating plate. The VRD function is
explained in the instruction manual for the control panel.

3 TECHNICAL DATA
0463 264 001 - 10 - © ESAB AB 2017
Mig 6502c
Mains voltage 380/400 - 415 V, +/-10%, 3~ 50/60 Hz
230/400 - 415/440 - 460/500 V, +/-10%, 3~ 50/60 Hz
Permissible load at MIG/MAG
60% duty cycle 650 A / 44.0 V
100% duty cycle 500 A / 39.0 V
Permissible load at MMA
60% duty cycle 650 A / 44.0 V
100% duty cycle 500 A / 40.0 V
Welding range 1)
MIG/MAG 20 A / 15.0 V - 650 A / 39.0 V
MMA 20 A / 20.8 V - 650 A / 40.0 V
Open circuit voltage
MIG/MAG without VRD function 3) 68.0 V
MMA without VRD function 3) 62.0 V
VRD function deactivated 4) 56.0 V
VRD function activated 4) < 35.0 V
Open circuit power 670 W
with cooling unit 870 W
in energy saving mode (15 min
after last welding) 2)
60 W
Power factor at maximum current
MMA
0.90
Efficiency at maximum current
MMA
76%
Control voltage 42.0 V, 50/60 Hz
Dimensions l × w × h 830 × 640 × 835 mm (32.7 × 25.2 × 32.9 in.)
Weight 222 kg (489.4 lb)
with cooling unit 236 kg (520.3 lb)
Operating temperature -10 to +40° C (+14 to +104 °F)
Transportation temperature -20 to +55° C (-4 to +131 °F)
Enclosure class IP 23
Application classification
1) Welding ranges are different to the possible setting range on the panel.
2) Power saving mode works only in MIG/MAG.
3) Valid for power sources without VRD specification on the rating plate.
4) Valid for power sources with VRD specification on the rating plate. The VRD function is
explained in the instruction manual for the control panel.