ESAB Origo Mig 4002cw User manual

0349 300 080 Valid for serial no.
740,743,741,744,742,745,801,802,803,804,806,805--xxx--xxxx
101229
Mig 4002cw, Mig 4002c
Mig 5002cw, Mig 5002c
Mig 6502cw, Mig 6502c
Origo 
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-- 2 -- TOCe
R ADTHISFIRST 4.................................................................
INTRODUCTION 4...................................................................
T CHNICALDATA 5.................................................................
WIRINGDIAGRAM 8.................................................................
Componentdescription 8..........................................................
OrigoTM Mig 4002c / 5002c / 6502c block diagram 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
?230V/400--415V/440--460V/500V? 18............................................
Burndy23 <--> Amphenol19 19....................................................
D SCRIPTIONOFOP RATION 20.....................................................
CB0Controlcircuitboard 20........................................................
CB0:1Circuitboardidentity 20........................................................
CB0:2Powersupply 20..............................................................
CB0:3TheCANbus 21..............................................................
Terminatin resistors 22..............................................................
CB0:4Temperaturemonitorin 22.....................................................
CB0:5Currentsensor 23.............................................................
CB0:5.1 Calibratin the current sensor si nal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CB0:6Arcvolta einputMi /Ma 25...................................................
CB0:6.1 Calibration of the arc volta e feedback 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CB0:7Arcvolta einputinMMAprocess 28............................................
CB0Componentspositions 29........................................................
ACH10Driver/relaysboard 30.......................................................
ACH10:1Circuitdia ram 30..........................................................
ACH10:2Powersupply 30............................................................
ACH10:3PWMdriver 31.............................................................
ACH10:4Prechar in volta esense 32...............................................
ACH10:5 Mains contactor circuit, ener y savin 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACH10:6Coolin fan 33.............................................................
ACH10:7Coolin liquidpump 34......................................................
ACH10:8Flow uard 34..............................................................
ACH10Componentspositions 35.....................................................
PF20Suppressioncircuitboard 36..................................................
PF20:1Circuitdia ram 36............................................................
PF20:2Componentspositions 36.....................................................
R MOT CONTROLS 36..............................................................
FAULTCOD S 37....................................................................
Faultlo 37........................................................................
Faultcodedescription,powersource 38................................................
S RVIC INSTRUCTIONS 41..........................................................
Whatis SD? 41...................................................................
Serviceaid 42......................................................................
ESABAdministrationTool(ESAT) 42..................................................
CANsupplyservicekit 42............................................................
Antistaticservicekit 43...............................................................
Checkin PWMsi nal 43.............................................................
Checkin thermalcutout 46...........................................................
Checkin Flow uard
(onlymachineswithFlowGuardsensor) 47.............................................
Checkin prechar in circuit 48......................................................
Checkin FanCircuit 48..............................................................
Checkin liquidpumpcircuit 49.......................................................
Checkin the LED Indicators on board CB0 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checkin chopperblockV0 51........................................................
Overviewtest 53....................................................................
Rectifiertest 53.....................................................................
Checkin ofoutputsta e 54..........................................................
Replacin ofdama edtransistors 55..................................................
High current aluminum leads maintenance 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-- 3 -- TOCe
INSTRUCTIONS 56...................................................................
SAF TY 56..........................................................................
INSTALLATION 57....................................................................
Placing 57.........................................................................
Assemblyofcomponents 58........................................................
Mainspowersupply 59.............................................................
OP RATION 60.......................................................................
Connectionsandcontroldevices 60.................................................
Overheatingprotection 60..........................................................
Waterconnection 61...............................................................
Waterflowguard 61................................................................
MAINT NANC 61....................................................................
Inspectionandcleaning 61.........................................................
Toppingupthecoolant 61..........................................................
FAULTTRACING 62..................................................................
ORD RINGOFSPAR PARTS 62......................................................
NOT S 63...........................................................................

-- 4 --
1sxx02cw
R AD THIS FIRST
Maintenance and repair work should 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 trainin for
help in connection with fault--tracin and repair.
Use the wirin dia ram as a form of index for the description of operation. The circuit
board is divided into numbered blocks, which are described individually in more detail in
the description of operation. All component names in the wirin dia ram are listed in the
component description.
This manual contains details of all desi n chan es that have been made up to and
includin December 2010.
The Origo
TM
Mig 4002cw, Mig 4002c, Mig 5002cw, Mig 5002c, Mig 6502cw, Mig 6502c
are designed and tested in accordance with uropean standard N 60974--1 and N
60974--10.
On completion of service or repair work, it is the responsibility of the person(s) etc.
performing the work to ensure that the product does not depart from the requirements
of the above standard.
WARNING
Many parts of the power unit are at mains voltage.
INTRODUCTION
The Ori o
TM
Mi 4002cw, Mi 5002cw, Mi 6502cw are MIG/MAG weldin power
sources, which can also be used for MMA weldin .
There are two variants of the power sources:
SOri o
TM
Mi xx02c without coolin unit
SOri o
TM
Mi xx02cw with coolin unit
The power sources are intended for use with the Aristo
TM
Feed 3004 or Aristo
TM
Feed 4804 wire feed units.
All the settin s are made from the wire feed unit.

-- 5 -- 1sxx02cw
T CHNICAL DATA
Origo
TM
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
Mi /Ma : 400 A / 34 V; MMA: 400 A / 36 V
Mi /Ma : 310 A / 30 V; MMA: 310 A / 33 V
Setting range (DC) MIG/MAG
MMA Mi /Ma : 16A / 8V--400 A / 34 V MMA: 16A / 8V--400 A / 36 V
Open circuit voltage Mi /Ma : 62V; MMA: 68V
Open circuit power
with coolin unit
in ener y savin mode
(15 min after last weldin )
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 coolin unit
149 k
163 k
Operating temperature --10 to +40˚C
nclosure class IP 23
Application classification
Origo
TM
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
Mi /Ma : 500 A / 39 V; MMA: 500 A / 40 V
Mi /Ma : 400 A / 34 V; MMA: 400 A / 36 V
Setting range (DC) MIG/MAG
MMA Mi /Ma : 16A / 8V--500 A / 39 V MMA: 16A / 8V--500 A / 40 V
Open circuit voltage Mi /Ma : 62V; MMA: 68V
Open circuit power
with coolin unit
in ener y savin mode
(15 min after last weldin )
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 coolin unit
185 k
199 k
Operating temperature --10 to +40˚C

-- 6 --
1sxx02cw
nclosure class IP 23
Application classification
Origo
TM
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
Mi /Ma : 650 A / 44 V; MMA: 650 A / 44 V
Mi /Ma : 500 A / 39 V; MMA: 500 A / 40 V
Setting range (DC) MIG/MAG
MMA Mi /Ma : 16A / 8V--650 A / 44 V MMA: 16A / 8V--650 A / 44 V
Open circuit voltage Mi /Ma : 62V; MMA: 68V
Open circuit power
with coolin unit
in ener y savin mode
(15 min after last weldin )
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 coolin unit
222 k
236 k
Operating temperature --10 to +40˚C
nclosure class IP 23
Application classification
Cooling unit
Coolin power 2500 W at40˚C temp. difference and flow
1,5l/min
Coolant 50 % water / 50% lycol
Coolant quantity 5,5 l
Maximum water flow 2,0 l/min
Duty cycle
The duty cycle refers to the time as a percenta e of a ten--minute period that you can weld at a cer-
tain load without overloadin .
nclosure class
The IP code indicates the enclosure class, i. e. the de ree of protection a ainst penetration by solid
objects or water. Equipment marked IP 23 is desi ned for indoor and outdoor use.
Application class
The symbol indicates that the power source is desi ned for use in areas with increased
electrical hazard.

-- 7 -- 1sxx02cw
This pa e is left blank intentionally.

-- 8 --
1sxx02cw
WIRING DIAGRAM
WARNING !
STATIC L CTRICITY can damage circuit
boards and electronic components.
S
SS
SObserve precautions for handling electrostatic
sensitive devices.
S
SS
SUse proper static--proof bags and boxes.
SD
Component description
XT1 9 pole terminal block
PF20 Suppression circuit board
Q01 Main ON/OFF switch
K1 Main contactor
M1 Fan 230V 50Hz
M2 Pump motor, 230V 50Hz 0.2kW. Only machines with water cooler
C1 Capacitor, 6uF 250V, for reducin the speed of fan motor M1
C2 Capacitor, 3uF 400V. Start and run capacitor for fan motor M1
C3 -- C7 Suppression capacitors, 0,1uF 250V
C8 Snubber for K1 coil
H2 Oran e indicatin lamp, Error,overheatin
H4 White indicatin lamp, power supply ON
T1 Main transformer
TC1 Control power transformer
TC2 Transformer for CO2 heater. (an accessory, see an accessories listed in
user manual)
VB1 Rectifier
B1 Thermal switch. Protects the main transformer a ainst excessive
temperature
B2 Thermal switch. Protects the chopper block a ainst excessive temperature
B3 Thermal switch. Controls the speed of fan motor M1
CS Current sensor
R1 Resistor (pre--char in )
L1 Inductor
CB0 Control circuit board

-- 9 -- 1sxx02cw
ACH10 Driver/relays circuit board
V0 Chopper module
X02 Connector, r Amphenol 10 pole or Burndy 12 pole (obsolete). For connection
to/from the wire feed unit
Origo
TM
Mig 4002c / 5002c / 6502c block diagram

-- 10 --
1sxx02cw
Mig 4002cw, 5002cw, 6502cw, 400 -- 415 V

-- 11 -- 1sxx02cw
Mig 4002cw, 5002cw, 6502cw, 400 -- 415 V

-- 12 --
1sxx02cw
Mig 4002c, 5002c, 6502c, 400 -- 415 V

-- 13 -- 1sxx02cw
Mig 4002c, 5002c, 6502c, 400 -- 415 V

-- 14 --
1sxx02cw
Mig 4002cw, 5002cw, 6502cw, 230 -- 500 V

-- 15 -- 1sxx02cw
Mig 4002cw, 5002cw, 6502cw, 230 -- 500 V

-- 16 --
1sxx02cw
Mig 4002c, 5002c, 6502c, 230 -- 500 V

-- 17 -- 1sxx02cw
Mig 4002c, 5002c, 6502c, 230 -- 500 V

-- 18 --
1sxx02cw
? 230V / 400--415V / 440--460V / 500V ?

-- 19 -- 1sxx02cw
Burndy 23 <--> Amphenol 19
Burndy 23 Amphenol 19 Signals
A A 42V
B B 42V
C
D D 12V
E E 0V
F F Start contact
G G Artificial round
H H Arc volta e
J J +15VB
K K Ref
L L 0VB
M
N
P
R
S
T T Data display
U U Clock display
V V Load display
W M Crater fill
X R Water connection monitorin
Y S Water connection monitorin
Z

-- 20 --
1sxx02cw
D SCRIPTION OF OP RATION
CB0 Control circuit board
The processor on the control board monitors and controls the various functions of the power
source. It obtains information on weldin data and weldin processes from the weldin data
board in the MMC control panel.
CB0:1 Circuit board identity
The control board has a machine ID, a hardware ID and a unit type number. To
read this you need the ESAT service kit. The machine ID defines which type of
power source the board is intended for. The hardware ID shows desi n and type of
circuit board. The unit type is used for identification on the CAN bus.
The ID numbers of the machines :
SOri o
TM
Mi 4002c/cw: 38
SOri o
TM
Mi 5002c/cw: 39
SOri o
TM
Mi 6502c/cw: 40
CB0:2 Power supply
+24 V Power supply to relay board CB0
+15 V Internal power supply on CB0
--15 V Internal power supply on CB0
+5 V Internal power supply on CB0