ESAB Mig 4002c, Mig 5002c, Mig 6502c Instruction manual

Origo™

Mig 4002c, Mig 5002c, Mig 6502c

Instruction manual

0463 337 131 US 20170427

Valid for: 850-, 851-xxx-xxxx

TABLE OF CONTENTS

1

SAFETY ......................................................................................................... 3

1.1 Meaning of symbols ................................................................................. 3

1.2 Safety precautions ................................................................................... 3

1.3 User responsibility ................................................................................... 7

2

INTRODUCTION............................................................................................ 10

2.1 EQUIPMENT .............................................................................................. 10

3

TECHNICAL DATA ........................................................................................ 11

4

INSTALLATION.............................................................................................. 15

4.1 Location..................................................................................................... 15

4.2 Assembly of components........................................................................ 16

4.3 Mains power supply ................................................................................. 16

5

OPERATION .................................................................................................. 18

5.1 Connections and control devices ........................................................... 18

5.2 Overheating protection ............................................................................ 19

5.3 Water connection ..................................................................................... 19

5.4 Water flow guard ...................................................................................... 19

6

MAINTENANCE............................................................................................. 20

6.1 Inspection and cleaning........................................................................... 20

6.2 Topping up the coolant ............................................................................ 20

7

TROUBLESHOOTING ................................................................................... 21

8

ORDERING SPARE PARTS.......................................................................... 22

CLEANING............................................................................................................ 23

SCHEMATIC DIAGRAM ....................................................................................... 24

CONNECTION INSTRUCTION............................................................................. 26

ORDERING NUMBER .......................................................................................... 27

ACCESSORIES .................................................................................................... 28

Rights reserved to alter specifications without notice.

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1 SAFETY

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

WARNING!

These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in the Additional Safety Information section.
Before performing any installation or operating procedures, be sure to read and
follow the safety precautions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe the Safety Precautions could
result in injury or death.

PROTECT YOURSELF AND OTHERS

Some welding, cutting and gouging processes are noisy and require
hearing protection. The arc, like the sun, emits ultraviolet (UV) and
other radiation and can injure the skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes and equipment is
essential to prevent accidents. Therefore:

1. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes
when welding or watching.

2. Always wear safety glasses with side shields in any work area, even if welding
helmets, face shields and goggles are also required.

3. Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to look at the arc and not to expose themselves to
the rays of the electric-arc or hot metal.

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1 SAFETY

4. Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants,
high-topped shoes, and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.

5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of the
clothing.

6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.

7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be
hot and can fly for long distances. Bystanders should also wear goggles over safety
glasses.

FIRES AND EXPLOSIONS

The heat from flames and arcs can start fires. Hot slag or sparks can
also cause fires and explosions. Therefore:

1. Protect yourself and others from flying sparks and hot metal.

2. Move all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints, and coating paper, etc.

3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.

4. Do not weld, cut, or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not perform hot work on closed containers, they may
explode.

5. Have fire extinguishing equipment handy for instant use, such as a garden hose,
water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its
use.

6. Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.

7. After completing work, inspect the work area to make sure there are no hot sparks or
hot metal that could cause a fire later. Use fire watchers when necessary.

ELECTRICAL SHOCK

Contact between live electrical parts and earth can cause severe injury
or death. DO NOT use AC welding current in damp areas, if movement
is confined, or if there is danger of falling. Therefore:

1. Be sure the power source frame (chassis) is connected to the earth system of the
input power.

2. Connect the workpiece to a good electrical earth.

3. Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.

6. Make sure that all parts of your body are insulated from both the work piece and from
the ground.

7. Do not stand directly on metal or the ground while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

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1 SAFETY

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power, before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for a earth cable.

ELECTRIC AND MAGNETIC FIELDS

May be dangerous. Electric current flowing through any conductor
causes localised Electric and Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables and welding
machines. Therefore:

1. Welders with pacemakers fitted should consult their doctor before welding. EMF may
interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimise exposure to EMF:

a) Route the electrode and work cables together. Secure them with tape when

possible.
b) Never coil the torch or work cable around your body.
c) Do not place your body between the torch and work cables. Route cables on

the same side of your body.
d) Connect the work cable to the workpiece as close as possible to the area being

welded.
e) Keep the welding power source and cables as far away from your body as

possible.

FUMES AND GASES

Fumes and gases, can cause discomfort or harm, particularly in
confined spaces. Shielding gases can cause asphyxiation. Therefore:

1. Keep your head out of the fumes. Do not breathe the fumes and gases.

2. Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe in the fumes from these materials.

3. Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other
irritant gases.

4. If you develop momentary eye, nose or throat irritation while operating, this is an
indication that the ventilation is not adequate. Stop work and take the necessary steps
to improve ventilation in the work area. Do not continue to operate if physical
discomfort persists.

5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.

6. WARNING: This product when used for welding or cutting, produces fumes or gases
that contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)

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CYLINDER HANDLING

Cylinders, if mishandled, can rupture and violently release gas. A
sudden rupture of cylinder valve or relief device can injure or kill.
Therefore:

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1 SAFETY

1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.

2. Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adapters. Maintain
hoses and fittings in good condition. Follow the manufacturer's operating instructions
for mounting a regulator to a compressed gas cylinder.

3. Always secure cylinders in an upright position, by chain or strap, to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.

4. When not in use, keep cylinder valves closed. Have valve protection cap in place if
regulator is not connected. Secure and move cylinders by using suitable hand trucks.

MOVING PARTS

Moving parts, such as fans, rotors and belts can cause
injury. Therefore:

1. Keep all doors, panels, guards, and covers closed and securely in place.

2. Stop the engine or drive systems before installing or connecting a unit.

3. Have only qualified people remove covers for maintenance and troubleshooting as
necessary

4. To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.

5. Keep hands, hair, loose clothing and tools away from moving parts.

6. Reinstall panels or covers and close doors when service is finished and before starting
engine.

WARNING!
FALLING EQUIPMENT CAN INJURE

• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or
any other accessories.

• Use equipment of adequate capacity to lift and support unit.

• If using lift forks to move unit, be sure forks are long enough to extend
beyond opposite side of unit.

• Keep cables and cords away from moving vehicles when working from
an aerial location.

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1 SAFETY

WARNING!
EQUIPMENT MAINTENANCE

Faulty or improperly maintained equipment can cause injury or death.
Therefore:

1. Always have qualified personnel perform the installation, troubleshooting

and maintenance work. Do not perform any electrical work unless you
are qualified to perform such work.

2. Before performing any maintenance work inside a power source,

disconnect the power source from the incoming electrical power.

3. Maintain cables, earthing wire, connections, power cord and power

supply in safe working order. Do not operate any equipment in faulty
condition.

4. Do not abuse any equipment or accessories. Keep equipment away from

heat sources such as furnaces, wet conditions such as water puddles, oil
or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any

manner.

CAUTION!
ADDITIONAL SAFETY INFORMATION

For more information on safe practices for electric arc welding and cutting
equipment, ask your supplier for a copy of “Precautions and Safe Practices
for Arc Welding, Cutting and Gouging.” Form 52-529.

The following publications are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding"

3. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"

4. AWS SP - "Safe Practices" - Reprint, Welding Handbook

5. ANSI/AWS F4.1 - "Recommended Safe Practices for Welding and

Cutting of Containers That Have Held Hazardous Substances"

6. OSHA 29 CFR 1910 - "Safety and Health Standards"

7. CSA W117.2 - "Code for Safety in Welding and Cutting"

8. NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and

Other Hot Work"

9. CGA Standard P-1, “Precautions for Safe Handling of Compressed

Gases in Cylinders”

10.ANSI Z87.1, "Occupational and Educational Personal Eye and Face

Protection Devices"

1.3 User responsibility

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
could result in injury to the operator and damage to the equipment.

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1 SAFETY

1. Anyone who uses the equipment must be familiar with:
○ its operation
○ the location of emergency stops
○ its function
○ the relevant safety precautions
○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:
○ no unauthorized person is 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

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 may cause injury 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 - Pose health risks

• Welders with pacemakers fitted should consult their doctor 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 the 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.

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1 SAFETY

FUMES AND GASES - Can be dangerous to your 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 ear defenders or other hearing protection.

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 a fire. Make sure 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!

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

This product is solely intended for arc welding.

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.

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2 INTRODUCTION

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 some of the control panels) and for welding with coated and cellulosic electrodes
(MMA).

These 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 delivered with:

• Return 5 m cable with return clamp

• Shelf for gas cylinder

• Attachment chain for gas cylinder

• Guide pin for wire feed unit

• Cooling unit (if applicable)

• Instruction manual

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3 TECHNICAL DATA

3 TECHNICAL DATA

Mig 4002c

Mains voltage 230/400-415/440-460/500/575 V 3~ 50/60 Hz

Permissible load at GMAW (MIG)

60 % duty cycle 400 A / 34 V

100 % duty cycle 310 A / 30 V

Permissible load at SMAW (MMA)

60 % duty cycle 400 A / 36 V

100 % duty cycle 310 A / 33 V

Welding range

GMAW (MIG) 20 A / 15 V - 400 A /34 V

SMAW (MMA) 20 A / 20.8 V - 400 A /36 V

Open circuit voltage

1)

without VRD function3)GMAW (MIG)

without VRD function3)SMAW (MMA)

VRD function deactivated

VRD function activated

4)

4)

68 V

62 V

56 V

< 35 V

Open circuit power

without cooling unit 500 W

with cooling unit 700 W

in energy-saving mode (15 min after last
welding)

2)

Power factorat maximum current SMAW

60 W

0.88

(MMA)

Efficiencyat maximum current SMAW

70 %

(MMA)

Control voltage 42 V, 50/60 Hz

Dimension l × w × h 32.7 × 25.2 × 32.9" (830 × 6740 × 835 mm)

Weight

without cooling unit 328.5 lbs (149 kg)

with cooling unit 359.3 lbs (163 kg)

Operating temperature -50 to 104° F (-10 to +40° C)

Transportation temperature -50 to 104° F (-20 to +55° C)

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 specifications on the rating plate.

4)

Valid for power sources with VRD specifications on the rating plate. The VRD function is

explained in the instruction manual for the control panel.

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3 TECHNICAL DATA

Mig 5002c

Mains voltage 230/400-415/440-460/500/575 V 3~ 50/60 Hz

Permissible load at GMAW (MIG)

60 % duty cycle 500 A / 39 V

100% duty cycle 400 A / 34 V

Permissible load at SMAW (MMA)

60 % duty cycle 500 A / 40 V

100% duty cycle 400 A / 36 V

Welding range

1)

GMAW (MIG) 20 A / 15 V - 500 A / 39 V

SMAW (MMA) 20 A / 20.8 V - 500 A / 40 V

Open circuit voltage

without VRD function3)GMAW (MIG)

without VRD function3)SMAW (MMA)

VRD function deactivated

VRD function activated

4)

4)

68 V

62 V

56 V

< 35 V

Open circuit power

without cooling unit 550 W

with cooling unit 750 W

in energy-saving mode (15 min after last
welding)

2)

Power factorat maximum current SMAW

60 W

0.90

(MMA)

Efficiencyat maximum current SMAW

72 %

(MMA)

Control voltage 42 V, 50/60 Hz

Dimensions l × w × h 32.7 × 25.2 × 32.9” (830 × 640 × 835 mm)

Weight

without cooling unit 407.8 lbs (185 kg)

with cooling unit 438.7 lbs (199 kg)

Operating temperature -50 to 104° F (-10 to +40° C)

Transportation temperature -50 to 104° F (-20 to +55° C)

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 specifications on the rating plate.

4)

Valid for power sources with VRD specifications on the rating plate. The VRD function is

explained in the instruction manual for the control panel.



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3 TECHNICAL DATA

Mig 6502c

Mains voltage 230/400-415/440-460/500/575 V 3~ 50/60 Hz

Permissible load at GMAW (MIG)

60 % duty cycle 650 A / 44 V

100% duty cycle 500 A / 39 V

Permissible load at SMAW (MMA)

60 % duty cycle 650 A / 44 V

100% duty cycle 500 A / 40 V

Welding range

1)

GMAW (MIG) 20 A / 15 V - 650 A / 39 V

SMAW (MMA) 20 A / 20.8 V - 650 A / 40 V

Open circuit voltage

without VRD function3)GMAW (MIG)

without VRD function3)SMAW (MMA)

VRD function deactivated

VRD function activated

4)

4)

68 V

62 V

56 V

< 35 V

Open circuit power

without cooling unit 670 W

with cooling unit 870 W

in energy-saving mode (15 min after last
welding)

2)

Power factorat maximum current SMAW

60 W

0.90

(MMA)

Efficiencyat maximum current SMAW

76%

(MMA)

Control voltage 42 V, 50/60 Hz

Dimensions l × w × h 32.7 × 25.2 × 32.9" (830 × 640 × 835 mm)

Weight

without cooling unit 489.4 lbs (222 kg)

with cooling unit 520.3 lbs (236 kg)

Operating temperature -50 to 104°F (-10 to +40°C)

Transportation temperature -50 to 104°F (-20 to +55°C)

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 specifications on the rating plate.

4)

Valid for power sources with VRD specifications on the rating plate. The VRD function is

explained in the instruction manual for the control panel.

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3 TECHNICAL DATA

Cooling unit

Cooling power 1.0 kW at 77°F and flow 0.3 US gallon/min

(1l/min)

Coolant ESAB's ready-mixed coolant

Coolant quantity 1.3 US gallon (5 l)

Maximum flow 0.5 US gallon/min (2.1 l/min)

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 104°F (40°C) 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.

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4 INSTALLATION

4 INSTALLATION

The installation must be carried out by a professional.

WARNING!

Straps must be used when lifting the
power source. The handle is only
intended for pulling it.

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.

4.1 Location

Position the welding power source such way that its cooling air inlets and outlets are not
obstructed.

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4 INSTALLATION

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.

4.3 Mains power supply

Check that the unit is connected to the correct mains power supply voltage, and that it is
protected by the correct fuse size. A protective ground connection must be made, in
accordance with regulations.

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4 INSTALLATION

Rating plate with supply connection data

Recommended fuse sizes and minimum cable areas

3~ 50/60Hz Mig 4002c

Mains voltage 230 V 400-415 V 440-460 V 500 V 575 V

Primary current

60% duty cycle 55 A 32 A (43 A*) 29 A (39 A*) 26 A (35 A*) 22 A (32 A*)

100% duty cycle 43 A 25 A 23 A 20 A 17 A

Mains cable area

4 G 10 mm24 G 4 mm

2

4 G 4 mm

2

4 G 4 mm

2

4 G 4 mm

2

Fuse anti-surge 35 A 25 A (50 A*) 25 A (50 A*) 20 A (50 A*) 20 A (50 A*)

3~ 50/60Hz Mig 5002c

Mains voltage 230 V 400-415 V 440-460 500 V 575 V

Primary current

60% duty cycle 75 A 43 A (50 A*) 39 A (48 A*) 35 A (42 A*) 30 A (38 A*)

100% duty cycle 58 A 33 A 30 A 27 A 23 A

Mains cable area

4 G 16 mm24 G 6 mm

2

4 G 6 mm

2

4 G 6 mm

2

4 G 6 mm

2

Fuse anti-surge 63 A 35 A (50 A*) 35 A (50 A*) 35 A (50 A*) 35 A (50 A*)

3~ 50/60Hz Mig 6052c

Mains voltage 230 V 400-415 V 440-460 V 500 V 575 V

Primary current

60% duty cycle 103 A 59 A (65 A*) 54 A (59 A*) 48 A (52 A*) 44 A (50 A*)

100% duty cycle 80 A 46 A 40 A 37 A 34 A

Mains cable area

4 G 25 mm24 G 10 mm24 G 10 mm24 G 10 mm24 G 10 mm

2

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.

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5 OPERATION

5 OPERATION

General safety regulations for handling the equipment can be found on page 4. Read
through before you start using the equipment!

WARNING!

Secure the equipment - particularly if
the ground is uneven or sloping.

5.1 Connections and control devices

1. Mains supply switch 6. Control cable socket (from/to wire feeder)

2. Indicating lamp, power supply ON 7. Connection for welding current cable (+)

3. Indicating lamp, overheating/fault 8. Connection BLUE for cooling water to the

wire feed unit

4. Connection for welding current cable (+) 9. Connection RED for cooling water from the

wire feed unit

5. Connection for welding current cable (-)

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5 OPERATION

5.2 Overheating protection

The power source has one thermal overload trip which operates if the internal temperature
becomes 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.

5.3 Water connection

The Feed has a sensor ELP (ESAB 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 Mig must be in the OFF position.

Note, if a water cooled welding gun is used when the pump is inactive, the welding gun might
be damaged, therefore it is not recommended to use wire feeders that are not equipped with
ELP.

5.4 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, see the "ACCESSORIES" chapter.

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6 MAINTENANCE

6 MAINTENANCE

NOTE!

Regular maintenance is important for safe and reliable operation.

Only individuals with the 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

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. More frequently in dirty environments, see the "CLEANING" chapter.

Clogged or blocked air inlets and outlets will otherwise result in overheating. To avoid this
you can use an air filter.

The air filter is an accessory, see the "ACCESSORIES" chapter.

6.2 Topping up the coolant

ESAB ready-mixed coolant is recommended for use, see the "ACCESSORIES" chapter.

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7 TROUBLESHOOTING

7 TROUBLESHOOTING

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.

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8 ORDERING SPARE PARTS

8 ORDERING SPARE PARTS

Repair and electrical work should be performed by authorized ESAB service personnel. Use
only ESAB original replacement and wear parts.

When ordering replacement parts, order by part number and part name, as illustrated on the
figure. Always provide the series or serial number on the unit in which the parts will be used.
The serial number is stamped on the rating plate.

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CLEANING

CLEANING

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© ESAB AB 2017

SCHEMATIC DIAGRAM

SCHEMATIC DIAGRAM

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© ESAB AB 2017

SCHEMATIC DIAGRAM

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© ESAB AB 2017

CONNECTION INSTRUCTION

CONNECTION INSTRUCTION

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© ESAB AB 2017

ORDERING NUMBER

ORDERING NUMBER

Ordering no. Denomination Type

0349 311 780

0349 311 810

0349 311 820

0349 312 740

0349 300 544

OrigoTMMig 4002c

OrigoTMMig 5002c

OrigoTMMig 5002cw

OrigoTMMig 6502c

Spare parts list

230V - 575V, 3~50Hz, 3~60Hz

230V - 575V, 3~50Hz, 3~60Hz

230V - 575V, 3~50Hz, 3~60Hz; with water cooler

230 V - 575 V, 3~50Hz, 3~60Hz

Technical documentation is available on the Internet at www.esab.com

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© ESAB AB 2017

ACCESSORIES

ACCESSORIES

Wire feed unit with control panel MA23

0460 526 887

0460 526 897

0460 526 987

0460 526 997

Feed 3004

Feed 3004, with water

Feed 4804

Feed 4804 with water

Wire feed unit with control panel MA24

0460 526 889

0460 526 899

0460 526 989

0460 526 999

Feed 3004

Feed 3004 W, with water

Feed 4804

Feed 4804 W, with water

Wire feed unit with control panel U6

0460 526 886

0460 526 896

Feed 3004

Feed 3004 W, with water

0460 526 986

0460 526 996

Feed 4804

Feed 4804 W, with water

Wire feed unit without control panel, for U8

0460 526 881

0460 526 891

0460 526 981

0460 526 991

Control panel U8

0460 820 880
0460 820 881

Feed 3004

Feed 3004 W, with water

Feed 4804

Feed 4804 W, with water

2

Control panel U8

2

Control panel U82Plus

2

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© ESAB AB 2017

ACCESSORIES

Wire feed unit with control panel MA23

0459 906 887

0459 906 897

YardFeed 2000

YardFeed 2000 with water

Wire feed unit with control panel U6

0459 906 886

0459 906 896

YardFeed 2000

YardFeed 2000 with water

0349 313 055 A24 Control panel kit

0349 302 251 Water flow guard

0465 720 002 ESAB ready mixed coolant (10 l /

2.64 gal)
Use of any other cooling liquid than
the prescribed one might damage
the equipment. In case of such
damage, all warranty undertakings
from ESAB cease to apply.

0349 302 252 Filter

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© ESAB AB 2017

ACCESSORIES

0349 303 362 Holder for welding torch and cables

0349 311 512 Adapter (12 pole to 10 pole)

0349 311 700 Strain relief

Connection set for 400 A power sources, 50mm

0459 528 562

0459 528 563

0459 528 564

0459 528 565

0459 528 566

0459 528 572

0459 528 573

0459 528 574

0459 528 575

0459 528 576

Connection set 10 m

Connection set 15 m

Connection set 25 m

Connection set 35 m

Connection set 50 m

Connection set 10 m, water

Connection set 15 m, water

Connection set 25 m, water

Connection set 35 m, water

Connection set 50 m, water

2

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© ESAB AB 2017

ACCESSORIES

Connection set for 500 A power sources, 70mm

0459 528 780

0459 528 781

0459 528 782

0459 528 783

0459 528 784

0459 528 785

0459 528 790

0459 528 791

0459 528 792

0459 528 793

0459 528 794

0459 528 795

Connection set 1.7 m

Connection set 5 m

Connection set 10 m

Connection set 15 m

Connection set 25 m

Connection set 35 m

Connection set 1.7 m, water

Connection set 5 m, water

Connection set 10 m, water

Connection set 15 m, water

Connection set 25 m, water

Connection set 35 m, water

Connection set for 650 A power sources, 95mm

0459 528 980

0459 528 990

Connection set 1.7 m

Connection set 1.7 m, water

2

2

0459 528 991

0459 528 992

0459 528 993

0459 528 994

Connection set 5 m, water

Connection set 10 m, water

Connection set 15 m, water

Connection set 25 m, water

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© ESAB AB 2017

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna-Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Heist-op-den-Berg
Tel: [phone]
Fax: [phone]

BULGARIA

ESAB Kft Representative Office
Sofia
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Herlev
Tel: [phone]
Fax: [phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel: [phone]
Fax: [phone]

GERMANY

ESAB Welding & Cutting GmbH
Langenfeld
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel: [phone]
Fax: [phone]

ITALY

ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: [phone]
Fax: [phone]

THE NETHERLANDS

ESAB Nederland B.V.
Amersfoort
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel: [phone]
Fax: [phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Romania Trading SRL
Bucharest
Tel: [phone]
Fax: [phone]

RUSSIA

LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel: [phone]
Fax: [phone]

SPAIN

ESAB Ibérica S.A.
San Fernando de Henares
(MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel: [phone]
Fax: [phone]

ESAB International AB
Gothenburg
Tel: [phone]
Fax: [phone]

SWITZERLAND

ESAB Europe GmbH
Baar
Tel: [phone]
Fax: [phone]

UKRAINE

ESAB Ukraine LLC
Kiev
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem-MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting
Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

AUSTRALIA

ESAB South Pacific
Archerfield BC QLD 4108
Tel: [phone]
Fax: [phone]

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

JAPAN

ESAB Japan
Tokyo
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
USJ
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Africa

EGYPT

ESAB Egypt
Dokki-Cairo
Tel: [phone]
Fax: [phone]

SOUTH AFRICA

ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

www.esab.com