ESAB Mig 4002c User manual

Brand: ESAB

Model: Mig 4002c

Category: Welding System

Type: User manual

This manual is also suitable for

ESAB Mig 4002c, Mig 5002c, Mig 6502c welding power sources are designed for MIG/MAG, FCAW-S, Live TIG, and MMA welding. They are suitable for use with ESAB wire feed units like Feed 3004/4804, MobileFeed 300, and YardFeed 2000. These power sources provide precise welding control, ensuring high-quality welds. Their compact and portable design makes them ideal for various applications, including construction, manufacturing, and maintenance. They come equipped with a return cable, gas cylinder shelf, attachment chain, and a guide.

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

SAFETY .........................................................................................................

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

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

INTRODUCTION............................................................................................

2.1 Equipment .................................................................................................

TECHNICAL DATA ........................................................................................

INSTALLATION..............................................................................................

4.1 Location.....................................................................................................

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

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

OPERATION ..................................................................................................

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

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

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

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

5.5 MIG/MAG and FCAW-S welding ..............................................................

5.6 MMA welding.............................................................................................

5.7 TIG welding ...............................................................................................

MAINTENANCE.............................................................................................

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

6.1.1 Power source ......................................................................................... 19

6.1.2 Welding torch.......................................................................................... 19

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

FAULT TRACING...........................................................................................

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

CLEANING............................................................................................................ 22

DIAGRAM ............................................................................................................. 23

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

ORDER NUMBERS .............................................................................................. 28

ACCESSORIES .................................................................................................... 29

Rights reserved to alter specifications without notice.

1 SAFETY

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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

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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

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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

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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

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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

68.0 V

MMA without VRD function

62.0 V

VRD function deactivated

56.0 V

VRD function activated

< 35.0 V

Open circuit power 500 W

with cooling unit 700 W

in energy saving mode (15 min

after last welding)

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

Welding ranges are different to the possible setting range on the panel.

Power saving mode works only in MIG/MAG.

Valid for power sources without VRD specification on the rating plate.

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

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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

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

68.0 V

MMA without VRD function

62.0 V

VRD function deactivated

56.0 V

VRD function activated

< 35.0 V

Open circuit power 550 W

with cooling unit 750 W

in energy saving mode (15 min

after last welding)

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

Welding ranges are different to the possible setting range on the panel.

Power saving mode works only in MIG/MAG.

Valid for power sources without VRD specification on the rating plate.

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

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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

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

68.0 V

MMA without VRD function

62.0 V

VRD function deactivated

56.0 V

VRD function activated

< 35.0 V

Open circuit power 670 W

with cooling unit 870 W

in energy saving mode (15 min

after last welding)

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

Welding ranges are different to the possible setting range on the panel.

Power saving mode works only in MIG/MAG.

Valid for power sources without VRD specification on the rating plate.

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

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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

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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

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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

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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 mm

4 G 4 mm

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 mm

4 G 6 mm

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

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3~ 50/60 Hz Mig 6052c

Mains cable area

4 G 25 mm

4 G 10 mm

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

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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

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5.1 Connections and control devices

1 Mains supply switch 0 / 1 6 Connection RED for cooling water from

the wire feed unit

2 Indicating lamp, power supply ON 7 Connection BLUE for cooling water to

the wire feed unit

3 Indicating lamp, overheating / fault 8 Connection for welding current cable (+)

4 Connection for welding current cable (+) 9 Control cable socket (from / to wire feed

unit)

5 Connection 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

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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

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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

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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.

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ESAB Mig 4002c User manual

Brand: ESAB

Model: Mig 4002c

Category: Welding System

Type: User manual

This manual is also suitable for

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ESAB Mig 4002c User manual

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