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.

3 TECHNICAL DATA
0463 264 001 - 11 - © ESAB AB 2017
Cooling unit
Cooling power 1.0 kW at 25° C (77 °F) and flow 1.0 l/min (0.26
gpm)
Coolant ESAB's ready mixed coolant
Coolant quantity 5 l (1.45 gal)
Maximum flow 2.1 l/min (0.55 gpm)
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23 is intended for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

4 INSTALLATION
0463 264 001 - 12 - © ESAB AB 2017
4 INSTALLATION
The installation must be carried out by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment this product
may cause radio interference. It is the user's responsibility to take adequate
precautions.
WARNING!
Straps must be used when lifting the
power source. The handle is only
intended for pulling it.
4.1 Location
Position the welding power source so that its cooling air inlets and outlets are not obstructed.

4 INSTALLATION
0463 264 001 - 13 - © ESAB AB 2017
4.2 Assembly of components
WARNING!
During transport, the rear wheels of the power source are in their forward
position. Before use, place the wheels in their rear position.

4 INSTALLATION
0463 264 001 - 14 - © ESAB AB 2017
4.3 Mains power supply
Check that the welding power source is connected
to the correct mains power supply voltage, and that
it is protected by the correct fuse size. A protective
earth connection must be made in accordance with
regulations.
The primary side of the transformers must be
connected according to the chapter "Connection
instruction".
• T1 Main transformer
• TC1 Auxiliary transformer
• TC2 CO2 heater (option)
Rating plate with supply connection data
Recommended fuse sizes and minimum cable areas
3~ 50/60 Hz Mig 4002c
Mains voltage 230 V 380 V 400-415 V 440-460 V 500 V
Primary current
60% duty cycle 56 A 34 A (45 A*) 32 A (43 A*) 29 A (39 A*) 26 A (35 A*)
100% duty cycle 43 A 26 A 25 A 23 A 20 A
Mains cable area 4 G 10 mm24G4mm24G4mm24G4mm24G4mm2
Fuse anti-surge 35 A 25 A ( 50 A*) 25 A ( 50 A*) 25 A ( 50 A*) 20 A ( 50 A*)
3~ 50/60 Hz Mig 5002c
Mains voltage 230 V 380 V 400-415 V 440-460 V 500 V
Primary current
60% duty cycle 75 A 45 A (53 A*) 43 A (50 A*) 39 A (48 A*) 34 A (42 A*)
100% duty cycle 57 A 35 A 33 A 30 A 26 A
Mains cable area 4 G 16 mm24G6mm24G6mm24G6mm24G6mm2
Fuse anti-surge 63 A 35 A ( 50 A*) 35 A ( 50 A*) 35 A ( 50 A*) 35 A ( 50 A*)
3~ 50/60 Hz Mig 6052c
Mains voltage 230 V 380 V 400-415 V 440-460 V 500 V
Primary current
60% duty cycle 103A 62 A (68 A*) 59 A (65 A*) 53 A (69 A*) 47 A (52 A*)
100% duty cycle 80 A 48 A 46 A 42 A 37 A

4 INSTALLATION
0463 264 001 - 15 - © ESAB AB 2017
3~ 50/60 Hz Mig 6052c
Mains cable area 4 G 25 mm24 G 10 mm24 G 10 mm24 G 10 mm24 G 10 mm2
Fuse anti-surge 80 A 50 A ( 63 A*) 50 A ( 63 A*) 50 A ( 63 A*) 50 A ( 63 A*)
* AAG (Arc Air Gouging)
NOTE!
The mains cable areas and fuse sizes as shown above are in accordance with
Swedish regulations. For other regions, supply cables must be suitable for the
application and meet local and national regulations.

5 OPERATION
0463 264 001 - 16 - © ESAB AB 2017
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
WARNING!
Secure the equipment - particularly if
the ground is uneven or sloping.

5 OPERATION
0463 264 001 - 17 - © ESAB AB 2017
5.1 Connections and control devices
1Mains supply switch 0 / 1 6Connection RED for cooling water from
the wire feed unit
2Indicating lamp, power supply ON 7Connection BLUE for cooling water to
the wire feed unit
3Indicating lamp, overheating / fault 8Connection for welding current cable (+)
4Connection for welding current cable (+) 9Control cable socket (from / to wire feed
unit)
5Connection for welding current cable (-)
5.2 Overheating protection
The power source has one thermal overload trip that operates if the internal temperature
becomes too high. When this occurs the welding current is interrupted and the orange
indicator lamp will light on the front of the power source.
The thermal overload trip resets automatically when the temperature has fallen and the
indicator lamp will go out.
5.3 Water connection
The wire feed unit is equipped with a detection system ELP, (ESAB Logic Pump), which
checks that the water hoses for the welding torch are connected. When a water cooled
welding torch is connected, the water pump starts.
When connecting the cooling water hoses to/from the wire feed unit, the mains ON/OFF
switch of the power source must be in the OFF position.
NOTE!
If a water cooled welding torch is used when the pump is inactive, the welding
torch might be damaged, therefore it is not recommended to use wire feed units
without ELP.

5 OPERATION
0463 264 001 - 18 - © ESAB AB 2017
5.4 Water flow guard
The water flow guard interrupts the welding current in the event of loss of coolant and an
orange indicator lamp on the front of the power source lights up.
The water flow guard is an accessory. Ordering number see in chapter "ACCESSORIES".
5.5 MIG/MAG and FCAW-S welding
An arc melts a continuously supplied wire. The weld pool is protected by shielding gas. For
MIG/MAG and FCAW-S welding, the power source is supplemented with:
• wire feed unit
• welding torch
• connection cable between power source and wire feed unit
• shielding gas bottle
5.6 MMA welding
MMA welding may also be referred to as welding with coated electrodes. Striking the arc
melts the electrode and its coating forms protective slag.
For welding with coated and cellulosic electrodes, the power source is supplemented with:
• welding cable with electrode clamp.
5.7 TIG welding
TIG welding melts the metal of the workpiece, using the arc struck from a tungsten electrode,
which does not melt itself. The weld pool and the electrode are protected by shielding gas.
For TIG welding, the welding power source is supplemented with:
• TIG torch with tungsten electrode and gas valve
• argon gas bottle
• argon gas regulator
"Live TIG-start"
At a "Live TIG-start" the tungsten electrode must touch the workpiece. When the electrode is
then lifted away from workpiece, the arc is struck with the set current value.

6 MAINTENANCE
0463 264 001 - 19 - © ESAB AB 2017
6 MAINTENANCE
NOTE!
Regular maintenance is important for safe and reliable operation.
Only those persons who have appropriate electrical knowledge (authorised personnel) may
remove the safety plates to connect or carry out service, maintenance or repair work on
welding equipment.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.1 Inspection and cleaning
6.1.1 Power source
Check regularly that the power source is free from dirt.
The power source should be regularly blown clean using dry compressed air at reduced
pressure, see chapter "CLEANING". This should be done more frequently in dirty
environments.
Otherwise the air inlet/outlet may become blocked and cause overheating. To avoid this you
can use an air filter.
The air filter is an accessory. Ordering number can be found in chapter "ACCESSORIES".
6.1.2 Welding torch
Wear parts should be cleaned and replaced at regular intervals in order to achieve
trouble-free welding.
6.2 Topping up the coolant
Coolant
Use ESAB approved coolant only. Non-approved coolants
might damage the equipment and jeopardize product
safety. For ordering information, see the "ACCESSORIES"
chapter in the instruction manual.
• Fill with coolant.
(The fluid level must not exceed the upper marking but
neither must it be below the lower marking).
• Disconnect the coolant hose for outgoing water
(welding torch blue connection) in order to bleed any
trapped air.
• Connect the coolant hose again.
NOTE!
Coolant must be topped up if connecting a welding torch or connection cables
that are 5 meters in length or longer. When adjusting the water level by topping
up,the coolant hose does not need to be disconnected.
CAUTION!
The coolant must be handled as chemical waste.

7 FAULT TRACING
0463 264 001 - 20 - © ESAB AB 2017
7 FAULT TRACING
Try these recommended checks and inspections before sending for an authorized service
technician.
Type of fault Actions
No arc. • Check that the mains power supply switch is turned on.
• Check that the welding current supply and return cables
are correctly connected.
• Check that the correct current value is set.
Welding current is
interrupted during welding.
• Check whether the thermal overload trip has operated
(indicated by the orange lamp on the front).
• Check the main power supply fuses.
The thermal overload trips
operate frequently.
• Check to see whether the air filters are clogged.
• Make sure that you are not exceeding the rated data for
the power source (i.e. that the unit is not being
overloaded).
Poor welding performance. • Check that the welding current supply and return cables
are correctly connected.
• Check that the correct current value is set.
• Check that the correct welding wires are being used.
• Check the main power supply fuses.