ESAB Origo Mig 4002cw Bedienungsanleitung

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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