ESAB Origo Mig 4002cw User manual

Valid for serial no.
740,743,741,744,742,745,801,802,803,804,806,805
0349 301 143 080904
Mig 4002cw, Mig 4002c
Mig 5002cw, Mig 5002c
Mig 6502cw, Mig 6502c
Origo
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
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Instruction manual

ENGLISH
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TOCe
1 DIR CTIV 3........................................................
2 SAF TY 3...........................................................
3 INTRODUCTION 5...................................................
3.1 Equipment 5................................................................
4 T CHNICALDATA 5.................................................
5 INSTALLATION 7....................................................
5.1 Placing 7...................................................................
5.2 Assem lyofcomponents 8...................................................
5.3 Electricalinstallation 9.......................................................
5.4 Mainspowersupply 9........................................................
6 OP RATION 10.......................................................
6.1 Connectionsandcontroldevices 10............................................
6.2 Overheatingprotection 10.....................................................
6.3 Waterconnection 11..........................................................
6.4 Waterflowguard 11..........................................................
7 MAINT NANC 11....................................................
7.1 Inspectionandcleaning 11....................................................
7.2 Toppingupthecoolant 12.....................................................
8 FAULTTRACING 12...................................................
9 ORD RINGOFSPAR PARTS 12......................................
DIAGRAM 14............................................................
? 230V / 400---415V / 440---460V / 500V ? 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACC SSORI S 25.......................................................

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1 DIR CTIV
D CLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-
ing power source OrigoTM Mig 4002cw, Mig 4002c, Mig 5002cw, Mig 5002c, Mig 6502cw, Mig 6502c
from serial num er 740, 743, 741, 744, 742, 745 are constructed and tested in compliance with the
standard EN 60974--1 and EN 60974--10 in accordance with the requirements of directive
(2006/95/EC) and (2004/108/EEC).
------------------------------------------------------------------------------------------------------------------------------------
Kent Eim rodt
Glo al Director
Equipment and Automation
Laxå 2007--10--01
2 SAF TY
Users of ESAB welding equipment have the ultimate responsi ility for ensuring that anyone who
works on or near the equipment o serves all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen-
dations should e o served in addition to the standard regulations that apply to the workplace.
All work must e carried out y 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 e familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorised person is stationed within the working area of the equipment when it is
started up.
Sno--one is unprotected when the arc is struck
3. The workplace must:
Se suita le for the purpose
Se free from draughts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
SDo not wear loose--fitting items, such as scarves, racelets, rings, etc., which could ecome
trapped or cause urns.
5. General precautions
SMake sure the return ca le is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must e clearly marked and close at hand.
SLu rication and maintenance must not e carried out on the equipment during operation.
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WARNING!
Read and understand the instruction manual
efore installing or operating.
WARNING
R AD AND UND RSTAND TH INSTRUCTION MANUAL B FOR INSTALLING OR OP RATING.
ARC W LDING AND CUTTING CAN B INJURIOUS TO YOURS LF AND OTH RS. TAK PR CAU-
TIONS WH N W LDING. ASK FOR YOUR MPLOY R’S SAF TY PRACTIC S WHICH SHOULD B
BAS D ON MANUFACTUR RS’ HAZARD DATA.
L CTRIC SHOCK -- Can kill
SInstall and earth the welding unit in accordance with applica le standards.
SDo not touch live electrical parts or electrodes with are skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUM S AND GAS S -- Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or oth, to take fumes and gases away from your reathing zone
and the general area.
ARC RAYS -- Can injure eyes and burn skin.
SProtect your eyes and ody. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect ystanders with suita le screens or curtains.
FIR HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflamma le materials near y.
NOIS -- xcessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn ystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROT CT YOURS LF AND OTH RS!
SAB can provide you with all necessary welding protection and accessories.
Do not use the power source for thawing frozen pipes.
WARNING!
This product is solely intended for arc welding.
Do not dispose of electrical equipment together with normal waste!
In o servance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must e collected separately and returned to an
environmentally compati le recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human health!
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3 INTRODUCTION
The OrigoTM Mig 4002cw, Mig 5002cw, Mig 6502cw are MIG/MAG welding power
sources, which can also e used for MMA welding.
There are two variants of the power sources:
SOrigoTM Mig xx02c without cooling unit
SOrigoTM Mig xx02cw with cooling unit
The power sources are intended for use with the AristoTM/OrigoTM Feed 3004,
AristoTM/OrigoTM Feed 4804 or AristoTM/OrigoTM YardFeed 2000 wire feed units.
All settings are made from the wire feed unit.
SAB’s accessories for the product can be found on page 24.
3.1 quipment
The power source is supplied with:
SReturn ca le 5m with return clamp
SShelf for gas cylinder
SAttachment chain for gas cylinder
SGuide pin for wire feed unit
SInstruction manual
4 T CHNICAL DATA
OrigoTM Mig 4002cw
Mains voltage 230/400--415/500 V 3∼50 Hz
230/440--460 V 3∼60 Hz
Permissible load at
60 % duty cycle
100% duty cycle
Mig/Mag: 400 A / 34 V; MMA: 400 A / 36 V
Mig/Mag: 310 A / 30 V; MMA: 310 A / 33 V
Setting range (DC) MIG/MAG
MMA Mig/Mag: 16A / 8V--400 A / 34 V MMA: 16A / 8V--400 A / 36 V
Open circuit voltage Mig/Mag: 62V; MMA: 68V
Open circuit power
with cooling unit
in energy saving mode
(15 min after last welding)
500 W
700 W
60W
Power factor at maximum current 0,88
fficiency at maximum current 70 %
Control voltage 42 V, 50/60 Hz
Dimensions lxwxh 830 x 640 x 835 mm
Weight
with cooling unit
149 kg
163 kg
Operating temperature --10 to +40˚C
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nclosure class IP 23
Application classification
OrigoTM Mig 5002cw
Mains voltage 230/400--415/500 V 3∼50 Hz
230/440--460 V 3∼60 Hz
Permissible load at
60 % duty cycle
100% duty cycle
Mig/Mag: 500 A / 39 V; MMA: 500 A / 40 V
Mig/Mag: 400 A / 34 V; MMA: 400 A / 36 V
Setting range (DC) MIG/MAG
MMA Mig/Mag: 16A / 8V--500 A / 39 V MMA: 16A / 8V--500 A / 40 V
Open circuit voltage Mig/Mag: 62V; MMA: 68V
Open circuit power
with cooling unit
in energy saving mode
(15 min after last welding)
550 W
750 W
60W
Power factor at maximum current 0,90
fficiency at maximum current 72 %
Control voltage 42 V, 50/60 Hz
Dimensions lxwxh 830 x 640 x 835 mm
Weight
with cooling unit
185 kg
199 kg
Operating temperature --10 to +40˚C
nclosure class IP 23
Application classification
OrigoTM Mig 6502cw
Mains voltage 230/400--415/500 V 3∼50 Hz
230/440--460 V 3∼60 Hz
Permissible load at
60 % duty cycle
100% duty cycle
Mig/Mag: 650 A / 44 V; MMA: 650 A / 44 V
Mig/Mag: 500 A / 39 V; MMA: 500 A / 40 V
Setting range (DC) MIG/MAG
MMA Mig/Mag: 16A / 8V--650 A / 44 V MMA: 16A / 8V--650 A / 44 V
Open circuit voltage Mig/Mag: 62V; MMA: 68V
Open circuit power
with cooling unit
in energy saving mode
(15 min after last welding)
670 W
870 W
60W
Power factor at maximum current 0,90
fficiency at maximum current 76 %
Control voltage 42 V, 50/60 Hz
Dimensions lxwxh 830 x 640 x 835 mm
Weight
with cooling unit
222 kg
236 kg
Operating temperature --10 to +40˚C
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nclosure class IP 23
Application classification
Cooling unit
Cooling power 2500 W at40˚C temp. difference and flow
1,5l/min
Coolant 50 % water / 50% glycol
Coolant quantity 5,5 l
Maximum water flow 2,0 l/min
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
nclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration y solid
o jects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The sym ol indicates that the power source is designed for use in areas with increased
electrical hazard.
5 INSTALLATION
The installation must be executed by a professional.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsi ility to take adequate precautions.
The power supply should e lifted y means of its lifting
eye. The handle is only intended for pulling it along the
ground.
Lifting instructions
5.1 Placing
Position the welding power source such way that its cooling air inlets and outlets are not o structed.
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5.2 Assembly of components
During transport, the rear wheels of the power source are in their forward position.
Before use, place the wheels in their rear position.
WARNING!
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5.3 lectrical installation
5.4 Mains power supply
Check that the unit is connected to the correct mains power supply voltage, and that
it is protected y the correct fuse size. A protective earth connection must e made,
in accordance with regulations.
Rating plate with supply connection data
Recommended fuse sizes and minimum cable areas
50Hz Mig 4002cw, 4002c Mig 5002cw, 5002c Mig 6502cw, 6502c
Mains voltage 230/400--415/500 V 230/400--415/500 V 230/400--415/500 V
Primary current
60% duty cycle
100% duty cycle
56/32(43*)/26 A
43/25/20 A
75/43(50*)/34 A
57/33/26 A
103/59(65*)/47
80/46/37 A
Mains cable area (4x) 10/4/4 mm216/6/6 mm225/10/10 mm2
Fuse anti--surge 35/25(50*)/20 A 63/35(50*)/35 A 80/50(63*)/50 A
60Hz Mig 4002cw, 4002c Mig 5002cw, 5002c Mig 6502cw, 6502c
Mains voltage 230/440--460 V 230/440--460 V 230/440--460 V
Primary current
60% duty cycle
100% duty cycle
56/32(43*)/26 A
43/25/20 A
75/43(50*)/34 A
57/33/26 A
103/59(65*)/47
80/46/37 A
Mains cable area (4x) 10/4/4 mm216/6/6 mm225/10/10 mm2
Fuse anti--surge 35/25(50*)/20 A 63/35(50*)/35 A 80/50(63*)/50 A
* AAG (Arc Air Gouging)
B: The mains cable areas and fuse sizes as shown above are in accordance with Swedish
regulations. They may not be applicable in other countries: make sure that the cable area and fuse
sizes comply with the relevant national regulations.
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6 OP RATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
WARNING -- TIPPING RISK!
Fasten the equipment -- particularly if the ground is uneven or sloping.
6.1 Connections and control devices
1Mains supply switch 6Control ca le socket (from / to wire feeder)
2Indicating lamp, power supply ON 7Connection for weldng current ca le (+)
3Indicating lamp, overheating / fault 8Connection BLUE for cooling water to the
wire feed unit
4Connection for weldng current ca le (+) 9Connection RED for cooling water from
the wire feed unit
5Connection for weldng current ca le (--)
6.2 Overheating protection
The power source has one thermal overload trip which operates if the internal
temperature ecomes too high, interrupting the welding current and lighting the
orange indicating lamp on the front of the unit. It resets automatically when the
temperature has fallen and the indicating lamp will go out.
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6.3 Water connection
The AristoTM/OrigoTM Feed has a sensor LP,SAB Logic Pump, that senses if the
water hoses of the welding gun are connected. When a water cooled welding gun is
connected, the water pump starts.
When connecting the cooling water hoses to/from the Feed wire feed unit, the mains
ON/OFF switch of the OrigoTM Mig must e in the OFF position.
Note, if a water cooled welding gun is used when the pump is inactive, the welding
gun might e damaged, therefore it is not recommended to use wire feeders not
equipped with ELP.
6.4 Water flow guard
The water flow guard interrupts the welding current in the event of loss of coolant
and an orange indicating lamp on the front of the power source lights up.
The water flow guard is an accessory. Ordering num er see on page 25.
7 MAINT NANC
Regular maintenance is important for safe, reliable operation.
Maintenance must be executed by a professional.
nly those persons who have appropriate electrical knowledge (authorised
personnel) may remove the safety plates.
ote!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
7.1 Inspection and cleaning
Check regularly that the power source is free from dirt.
The power source should e regularly lown clean using dry compressed air at
reduced pressure. More frequently in dirty environments.
Otherwise the air inlet/outlet may ecome locked and cause overheating. To avoid
this you can use an airfilter.
The airfilter is an accessory. Ordering num er on page 25.
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7.2 Topping up the coolant
We recommend a 50/50 % mixture of water and ethylene glycol.
8 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised
service technican.
Type of fault Actions
No arc. SCheck that the mains power supply switch is turned on.
SCheck that the welding current supply and return ca les are
correctly connected.
SCheck that the correct current value is set.
Welding current is interrupted
during welding
SCheck whether the thermal overload trip has operated
(indicated y the orange lamp on the front)
SCheck the main power supply fuses.
The thermal overload trips
operate frequently
SCheck to see whether the air filters are clogged.
SMake sure that you are not exceeding the rated data for the
power source (i.e. that the unit is not eing overloaded).
Poor welding performance. SCheck that the welding current supply and return ca les are
correctly connected.
SCheck that the correct current value is set.
SCheck that the correct welding wires are eing used.
SCheck the main power supply fuses.
9 ORD RING OF SPAR PARTS
OrigoTM Mig 4002cw, Mig 4002c, Mig 5002cw, Mig 5002c, Mig 6502cw, Mig 6502c is de-
signed and tested in accordance with the international and uropean standards I C/
N 60974--1 and N 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 may e ordered through your nearest ESAB dealer, see the last page of
this pu lication.
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document

Diagram
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Mig 4002cw, 5002cw, 6502cw, 400 -- 415 V

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dmxx02cw
Mig 4002cw, 5002cw, 6502cw, 400 -- 415 V

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Mig 4002c, 5002c, 6502c, 400 -- 415 V

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Mig 4002c, 5002c, 6502c, 400 -- 415 V

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Mig 4002cw, 5002cw, 6502cw, 230 -- 550 V

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Mig 4002cw, 5002cw, 6502cw, 230 -- 550 V

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Mig 4002c, 5002c, 6502c, 230 -- 550 V